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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 325 records · Page 18
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Activating magnetite ores for aqueous ironmaking at high current densities

Low-temperature electrochemical cells reducing iron oxides to metal in alkaline electrolytes can support fully electrified steelmaking processes. Previous studies on these cells have primarily focused on high-surface-area hematite, Fe 2 O 3 , reactants whereas attempts to reduce suspensions of magnetite, Fe 3 O 4 —one of the two feedstocks for existing ironmaking reactors—have generally been limited to low rates of reaction (<30 mA cm −2 ). Here, in this study, we control the crystalline domain size of Fe 2 O 3 and Fe 3 O 4 particles in 10 M NaOH electrolytes to study how the nanoscale morphology of oxides controls the rate of electrochemical ironmaking. Rotating-ring disk electrode measurements of Fe 2+ , in situ Raman spectroscopy of the electrode surface, and ex situ electron microscopy were consistent with a hypothesized passivation process at Fe 3 O 4 surfaces that may prevent the continuous formation of soluble intermediates. Sufficiently small (<100 nm diameter) oxide particles yielded Fe partial current densities >160 mA cm −2 , a fivefold increase relative to previously reported rates for Fe 3 O 4 suspensions and comparable to active Fe 2 O 3 . Electron microscopy revealed that electrodeposited films were composed of micron-scale crystalline Fe domains with a porous film of Fe 3 O 4 nanoparticles and supports a model where Fe is grown primarily from soluble Fe 2+ intermediates. Based on these insights, inactive blast-furnace-grade iron-oxides were transformed into high surface area nanoparticles (1.6 to 229.2 m 2 g −1 ) via reprecipitation, leading to a ninefold enhancement in faradaic efficiency and an Fe partial current density of 120 mA cm −2 . When integrated with chlor-iron cells producing reagents for reprecipitation, this approach could lead to a cost-competitive process for electrochemical ironmaking from industrially relevant feedstocks.

TEM↗
DOE OSTI2023

Development of low-loss minimal exposure technique for thallium foil fabrication

Despite its availability as a solid bead or ingot, non-isotopic thallium metal is no longer commercially produced as a foil because of its high toxicity. To conduct fundamental studies on the material, the Stable Isotope Materials and Chemistry Group (SIMC) at Oak Ridge National Laboratory (ORNL) was approached to develop a safe method to process thallium and produce 40 non-isotopic thallium foils. The commercially sourced metal was consolidated into an ingot by melting the material in a special tube furnace under a reducing atmosphere. The resulting ingot was cold rolled using a work-hardened, stainless-steel pack and oil lubricant before cutting the final foils to 2.5 × 2.5 cm2 area and thickness of 50–75 mg/cm2. The appropriate safeguards used at each step are outlined to ensure the safe and consistent production of high-quality foils. The low-loss process enables future requests for isotopic thallium and other hazardous and rare materials.

Conner, Jenny↗
DOE OSTI2021

Sublimation temperature sensor for temperature locale

The sublimation temperature sensor (or “sublime sensor”) provides a continuum of measurement locations in which certain maximum temperatures are achieved during a heat up/cool down cycle. A predetermined material is encapsulated within a vacuum-sealed, non-volatile long tube (i.e., both ends capped and L$\gg$ D). This assembly is then inserted and centered into a heated zone, such as a furnace, exhaust pipe, or reactor. As the temperature increases, the material will sublimate (i.e., a process of having both the solid and gaseous states of matter simultaneously present) and will begin to fill the void - moving outward in both directions toward the ends of the tube. Once beyond the elevated temperatures, the gas will de-sublimate (i.e., deposition) onto the inner wall of the tube. The desired result of the sensor is the ring of material that develops over a relatively short period of time. This material deposit can be equated with temperature at an exact location. There is no need to interpolate and/or extrapolate for the desired measurement. Accuracy has been recorded for temperature locations on the range of ±2 mm over a 1 m span. Likewise, the precision of the measurement is ±0.2% the overall sensor domain. Furthermore, individual tubes with unique materials and pressures can be bundled together to provide a complete temperature profile of the heated zone.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Electrical Analysis of Pulsed Laser Annealed Poly-Si: Ga/SiOx Passivating Contacts

In this contribution, we examine Ga hyper-doped poly-Si/SiOx contacts realized by pulsed laser melting (PLM). Here, we use Ga as a novel p-type dopant and B as a conventional dopant to induce non-equilibrium doping using an excimer laser. We perform simulations to visualize the maximum melt depth profiles within the poly-Si, with a goal of distributing dopants close to the tunneling oxide, but at the same time preserving the passivation. Hall measurements show that sheet resistance for B is lower than Ga due to its higher solid solubility limit in Si. After comparing the Hall active dopant concentration with the chemical concentration obtained by SIMS measurement, we show nearly 100% activation B activation reaching 10^21 cm-3, while only ~20% activation for Ga. Nevertheless, we achieve active doping concentrations of Ga in poly-Si six times higher than its solid solubility limit in Si (~10^19 cm-3). We compare our Hall mobilities with values in the literature for c-Si and show that B mobilities in laser-treated poly-Si are close to that of the literature value for B, while Ga mobilities are lower, possibly due to additional scattering channels within grain boundaries and deformed lattice. We also compare our results on PLM samples with conventional furnace annealed samples, and we show much higher percent activation and mobilities. Previously, we showed a low contact resistivity of 35.5 +/- 2.4 m..omega..cm2. Here, we further confirm this result by scanning spreading resistance microscopy and Kelvin force nanoprobe microscopy. We demonstrate that our poly-Si: Ga/nCz contact exhibits large drift and diffusion currents under normal cell operating voltage, which widens the laser processing window for a good metal/poly-Si/c-Si contact.

high-efficiency solar cells↗
DOE OSTI2024

Silicon implantation and annealing in β -Ga 2 O 3 : Role of ambient, temperature, and time

Optimizing thermal anneals of Si-implanted β-Ga 2 O 3 is critical for low resistance contacts and selective area doping. Here we report the impact of annealing ambient, temperature, and time on the activation of room temperature ion-implanted Si in β-Ga 2 O 3 at concentrations from 5 × 10 18 to 1 × 10 20 cm −3 , demonstrating full activation (>80% activation, mobilities >70 cm 2 /V s) with contact resistances below 0.29 Ω mm. Homoepitaxial β-Ga 2 O 3 films, grown by plasma-assisted molecular beam epitaxy on Fe-doped (010) substrates, were implanted at multiple energies to yield 100 nm box profiles of 5 × 10 18 , 5 × 10 19, and 1 × 10 20 cm −3 . Anneals were performed in an ultra-high vacuum-compatible quartz furnace at 1 bar with well-controlled gas compositions. To maintain β-Ga 2 O 3 stability, p O2 must be greater than 10 −9 bar. Anneals up to p O2 = 1 bar achieve full activation at 5 × 10 18 cm −3, while 5 × 10 19 cm −3 must be annealed with p O2 ≤ 10 −4 bar, and 1 × 10 20 cm −3 requires p O2 < 10 −6 bar. Water vapor prevents activation and must be maintained below 10 −8 bar. Activation is achieved for anneal temperatures as low as 850 °C with mobility increasing with anneal temperatures up to 1050 °C, though Si diffusion has been reported above 950 °C. At 950 °C, activation is maximized between 5 and 20 min with longer times resulting in decreased carrier activation (over-annealing). This over-annealing is significant for concentrations above 5 × 10 19 cm −3 and occurs rapidly at 1 × 10 20 cm −3 . Rutherford backscattering spectrometry (channeling) suggests that damage recovery is seeded from remnant aligned β-Ga 2 O 3 that remains after implantation; this conclusion is also supported by scanning transmission electron microscopy showing retention of the β-phase with inclusions that resemble the γ-phase.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

Thermal deflection in neutron scattering sample environments at Oak Ridge National Laboratory

The neutron sources at Oak Ridge National Laboratory use a wide suite of sample environment equipment to deliver extreme conditions for a number of experiments. Much of this instrumentation focuses on extremes of temperature, such as cryostats, closed-cycle refrigerators in both low and high temperature configurations, and radiant heating furnaces. When the temperature is controlled across a large range, thermal deflection effects can notably move the sample and affect its alignment in the beam. Here, we combine these sample environments with neutron imaging and machine vision to determine the motion of a representative sample with respect to the neutron beam. We find vertical sample displacement on the order of 1–2 mm and horizontal displacement that varies from near-negligible to 1.2 mm. While these deflections are not relevant for some of the beamlines at the first target station at the spallation neutron source and the high flux isotope reactor, they will become critical for upcoming instrumentation at the second target station, as well as any instruments targeting sub-mm samples, as neutron sources and optics evolve to smaller and more focused beams. We discuss mitigation protocols and potential modifications to the environment to minimize the effect of misalignment due to thermal deflection.

47 OTHER INSTRUMENTATION↗
DOE OSTI2026

Validation of 266 nm UV Raman thermometry using the alpha-to-beta quartz transition

Ultraviolet Raman scattering is a promising diagnostic for temperature measurements relevant to dynamic compression experiments, where improved signal strength and reduced background are critical. In this work, we experimentally validate Raman thermometry at 266 nm using crystalline quartz heated through the α to β phase transition in a tube furnace. Quartz provides a useful benchmark because of its well-characterized transition temperature near 846 K at ambient pressure. Temperatures inferred from the Stokes to anti-Stokes intensity ratio are compared with thermocouple measurements and with the observed phase transition. Single-shot Raman temperatures track the thermocouple closely, with an empirical single-shot scatter of approximately ±15 K under the present conditions. Temporal averaging reduces shot-to-shot scatter and improves agreement between the Raman temperatures and thermocouple readings to within approximately 8 K, while the transition is identified within 5 K of the accepted value. Measurements are performed using the fourth harmonic of a nanosecond pulsed Nd:YAG laser at 266 nm. The shorter excitation wavelength provides enhanced Raman scattering efficiency and reduced visible background relative to conventional visible excitation. Comparison with 532 nm Raman measurements acquired in the same experimental geometry demonstrates substantially improved signal-to-noise ratio for the UV configuration. These results establish 266 nm Raman thermometry as a reliable and accurate temperature diagnostic under controlled heating conditions and provide a quantitative benchmark for future application in dynamic compression and shock physics experiments.

Chemistry - Chemical explosives↗
DOE OSTI2025

Simulating regional workforce impacts of decarbonizing integrated steelmaking

Global efforts to mitigate climate change are increasing pressure on heavy manufacturing industries to decarbonize production. The iron and steel industry is responsible for 7% of CO 2 emissions globally (2% in the United States) and is often a major employer in the regions where iron and steel is produced. Understanding the future prospects for workers in regions with high CO 2 emitting industries—including impacts of phasing out or evolving such industries—will be critical for informing regional economic and clean energy strategies. We simulate the impact of an “in-place” transition that replaces today’s integrated production with direct reduced iron (DRI) used in electric arc furnaces (EAFs), using Southwest Pennsylvania as an application of our generalizable approach. Our results suggest that the integrated steelmaking workforce today has the skills, knowledge, and abilities (SKAs) to fill over 95% of all jobs required by DRI/EAF facilities, but the number of jobs is only 25% of those at integrated plants. We also find that some occupational groups have greater general transferability into the broader job market, while other groups, such as production workers, are ill-equipped today based on current SKAs to transition out of the iron and steel industry. Our methodology further suggests factors that limit transitions: Around 85% of occupations are more limited by missing skills, while 15% are more limited by insufficient wages. These results may help to improve the design of social policy and the targeting of retraining programs, while the simulation approach can be readily adapted for other regions and industries.

decarbonization↗
DOE OSTI2026

Review of ECCS Acceptance Criteria and Experimental Basis Evolution Toward Fuel Fragmentation, Relocation, and Dispersal Studies

The U.S. nuclear industry is pursuing extensions of light water reactor (LWR) fuel burnup and enrichment limits to approximately 75 GWd/t and 10 wt.% 235 U to achieve economic and operational benefits. A central safety consideration in this effort is the behavior of high burnup (HBu) fuel during loss-of-coolant accidents (LOCAs), particularly fuel fragmentation, relocation, and dispersal (FFRD). Here, this work provides a historical and technical review of U.S. LOCA regulation and experimentation, clarifying how the evolution of Emergency Core Cooling System (ECCS) acceptance criteria in 10 CFR 50.46 has shaped both testing approaches and interpretations of fuel safety. The study revisits the original intent of the ECCS criteria, showing that the peak cladding temperature and equivalent cladding reacted limits were developed as surrogates to preserve a coolable geometry. The explicit inclusion of the coolable geometry criterion in the regulation was intended to emphasize the underlying safety philosophy and as a safeguard against unforeseen failure modes, an intent that remains directly relevant to modern concerns regarding FFRD. The review traces the lineage of HBu LOCA experiments to the Argonne National Laboratory furnace tests, from which subsequent programs at Studsvik, Halden, and Oak Ridge National Laboratory were derived. These tests employed a 5 °C/s heating rate inherited from early embrittlement studies, a stylized temperature history that does not represent actual LWR LOCA thermal-hydraulics. Comparison of these test conditions to pressurized water reactor large break LOCAs and separate effects data indicates that the existing HBu LOCA database may not be fully applicable to all LWR LOCA scenarios, from which a qualitative framework for applicability is proposed.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Conceptual Design for a Blanket Tritium Extraction Test Stand

Future fusion reactors must be able to breed the tritium they will consume. Several breeding and tritium extraction technologies are under investigation internationally. PbLi is of particular interest as a breeder material. A new forced convection PbLi loop, the Tritium Extraction eXperiment (TEX), is being designed and constructed to investigate tritium extraction from PbLi. Specifically, TEX will serve to investigate the extraction efficiency of various vacuum permeator membranes and configurations. The major components of the loop include a moving magnet pump, reverse permeator, furnace test section, analysis chamber, supply tank, and plenum. As significant hazards are present in such experiments, safety is an integral focus of the experimental design.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Infrared thermometry in high temperature materials processing: influence of liquid water and steam

Here, the capability of four infrared thermometry techniques (2-colour and 1-colour pyrometers, Pyrolaser and IR camera) was evaluated with respect to the impact of water or steam in the line of sight to determine temperature from two heat sources (blackbody calibration source and steel block inside the furnace). The influence of liquid water on the temperature readings was minimal when using 2-colour pyrometry due to comparable absorption coefficients of water for the measured wavelengths. The signals measured using both the Pyrolaser and the 1-colour pyrometer were decreased due to the partial absorption and resulted in an apparent temperature lower than the actual. Water readily absorbed the IR signal in the range of the IR camera operation, resulting in no signal whenever liquid water was present in the line of sight. Steam caused the most deviation and fluctuation of temperature readings for all techniques due to the large level of light scattering in addition to the absorption of the radiant energy. A technique was developed to determine the transmissivity (apparent emissivity) when water or steam is in the line of sight of measurement. An approximate correction to the measurements based on Planck’s law is discussed for both 2-colour and 1-colour pyrometers.

2-colour and 1-colour pyrometry↗
DOE OSTI2023

Rooftop unit comparison calculator: a framework for comparing performance of rooftop units with building energy simulation

The applications of building energy simulation (BES) in designing heating, ventilation, and air conditioning (HVAC) systems are limited by the high costs of developing simulation models and the lack of references for determining the model parameters. This paper presents a software framework for selecting designs for rooftop unit HVAC (RTU) systems with BES. Specifically, this framework reduces the cost of using BES by automating the generation of EnergyPlus models. It also employs a systematic method for determining model parameters based on well-accepted datasets. We applied this framework in a comprehensive assessment of an advanced design of RTU systems in which 478 EnergyPlus models were developed without human involvement. The assessment reveals that replacing a constant-speed fan/coil with a multiple-speed fan/coil may not guarantee better overall performance. In conclusion, it also suggests the benefits of replacing furnace coils with heat pumps are subject to utility cost, weather conditions, and heating load profiles.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Optimizing superconducting Nb film cavities by mitigating medium-field Q -slope through annealing

Niobium films are of interest in applications in various superconducting devices, such as superconducting radiofrequency cavities for particle accelerators and superconducting qubits for quantum computing. In this study, we address the persistent medium-field Q-slope issue in Nb film cavities, which, despite their high-quality factor at low RF fields, exhibit a significant Q-slope at medium RF fields compared to bulk Nb cavities. Traditional heat treatments, effective in reducing surface resistance and mitigating the Q-slope in bulk Nb cavities, are challenging for Nb-coated copper cavities. To overcome this challenge, we employed DC bias high-power impulse magnetron sputtering to deposit Nb film onto a 1.3 GHz single-cell elliptical bulk Nb cavity, followed by annealing treatments aimed at modifying the properties of the Nb film. In-situ annealing at 340 °C increased the quench field from 10.0 to 12.5 MV m −1 . Vacuum furnace annealing at 600 °C and 800 °C for 3 h resulted in a quench field increase of 13.5 and 15.3 MV m −1 , respectively. Further annealing at 800 °C for 6 h boosted the quench field to 17.5 MV m −1 . Additionally, the annealing treatments significantly reduced the field dependence of the surface resistance. However, increasing the annealing temperature to 900 °C induced a Q-switch phenomenon in the cavity. The analysis of RF performance and material characterization before and after annealing has provided critical insights into how the microstructure and impurity levels in Nb films influence the evolution of the Q-slope in Nb film cavities. Our findings highlight the significant roles of hydrides, high local misorientation, and lattice and surface defects in driving field-dependent losses. By strategically optimizing film properties and controlling impurity levels, we demonstrate a promising pathway to mitigate the medium-field Q-slope, paving the way for more efficient superconducting RF technologies.

Nb film↗
DOE OSTI2022

3D In-situ Stop Action Study of Recrystallization in Additively Manufactured 316L Stainless Steel: Reconstruction Optimization and Observations

A volume of an additively manufactured 316L stainless steel sample has been tracked during its recrystallization using near-and far-field High Energy Diffraction Microscopy (HEDM) and absorption tomography at Advanced Photon Source beamline 1-ID. A nearfield compatible in situ furnace allows monitoring of Bragg diffraction signals as they evolve out of a weak and diffuse background while the sample temperature is approximate to 1250 degrees C. The sample is rapidly cooled to room temperature after observation of significant signal evolution and ti similar to 0.035 mm(3) is mapped by the near-field method. Four cycles of heat treatment follow the structure from a state of small, isolated grains through impingement of domains to near completion of recyrstallization. Here, the experiment and reconstructions are described, and recrystallized fractions, twin domains, and distributions of grain boundary types are discussed.

Liu, He↗
DOE OSTI2023

Roadmap on energy harvesting materials

Ambient energy harvesting has great potential to contribute to sustainable development and address growing environmental challenges. Converting waste energy from energy-intensive processes and systems (e.g. combustion engines and furnaces) is crucial to reducing their environmental impact and achieving net-zero emissions. Compact energy harvesters will also be key to powering the exponentially growing smart devices ecosystem that is part of the Internet of Things, thus enabling futuristic applications that can improve our quality of life (e.g. smart homes, smart cities, smart manufacturing, and smart healthcare). To achieve these goals, innovative materials are needed to efficiently convert ambient energy into electricity through various physical mechanisms, such as the photovoltaic effect, thermoelectricity, piezoelectricity, triboelectricity, and radiofrequency wireless power transfer. By bringing together the perspectives of experts in various types of energy harvesting materials, this Roadmap provides extensive insights into recent advances and present challenges in the field. Additionally, the Roadmap analyses the key performance metrics of these technologies in relation to their ultimate energy conversion limits. Building on these insights, the Roadmap outlines promising directions for future research to fully harness the potential of energy harvesting materials for green energy anytime, anywhere.

14 SOLAR ENERGY↗
DOE OSTI2023

Abnormal grain growth of 68Cu–16Al–16Zn alloys for elastocaloric cooling via cyclical heat treatments

Abstract Cu-based superelastic shape memory alloys are promising for low-stress elastocaloric cooling. We have synthesized bulk alloys of 68Cu–16Al–16Zn under different conditions in order to promote its grain growth and enhance its elastocaloric properties. High-temperature x-ray diffraction of untreated 68Cu–16Al–16Zn alloy showed that the phase boundary between the α + β mixed phases and the high temperature phase ( β phase) was between 973 K and 1023 K. Based on this result, the 68Cu–16Al–16Zn alloy was heated and cooled in a furnace repeatedly between 773 K and 1173 K. The maximum grain size after heat treatment of the ingot rolled to 67% reached 11.1 mm. The latent heat of the martensitic transformation after grain growth was 6.3 J g −1 , which is higher than the previously reported value for the compound. The stress–strain curve of 68Cu–16Al–16Zn rolled to 67% rolling with cyclical heat treatments showed a maximum stress of 106 MPa at 4.5% strain, with adiabatic temperature change of 5.9 K in heating during stress loading and 5.6 K in cooling in stress removal. Furthermore, no fatigue in the stress–strain behavior was observed up to at least 60 000 mechanical cycles at 2% strain.

36 MATERIALS SCIENCE↗
DOE OSTI2020

High oxygen pressure floating zone growth and crystal structure of the metallic nickelates R4Ni3O10 ( R=La,Pr )

Single crystals of the metallic Ruddlesden-Popper trilayer nickelates R 4 Ni 3 O 10 ( R = La , Pr ) were successfully grown using an optical-image floating zone furnace under oxygen pressure ( p O 2 ) of 20 bar for La 4 Ni 3 O 10 and 140 bar for Pr 4 Ni 3 O 10 . Furthermore, a combination of synchrotron and laboratory x-ray single-crystal diffraction, high-resolution synchrotron x-ray powder diffraction and measurements of physical properties revealed that R 4 Ni 3 O 10 ( R = La , Pr ) crystallizes in the monoclinic P 2 1 / a ( Z = 2 ) space group at room temperature, and that a metastable orthorhombic phase ( Bmab ) can be trapped by postgrowth rapid cooling. Both La 4 Ni 3 O 10 and Pr 4 Ni 3 O 10 crystals undergo a metal-to-metal transition (MMT) below room temperature. In the case of Pr 4 Ni 3 O 10 , the MMT is found at 157.6 K. For La 4 Ni 3 O 10 , the MMT depends on the lattice symmetry: 147.5 K for Bmab vs 138.6 K for P 2 1 / a . Lattice anomalies were found at the MMT that, when considered together with the pronounced dependence of the transition temperature on subtle structural differences between Bmab and P 2 1 / a phases, demonstrate a not insignificant coupling between electronic and lattice degrees of freedom in these trilayer nickelates.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Wireless Interrogation of High Temperature Surface Acoustic Wave Dynamic Strain Sensor

Dynamic strain sensing is necessary for high-temperature harsh-environment applications, including powerplants, oil wells, aerospace, and metal manufacturing. Monitoring dynamic strain is important for structural health monitoring and condition-based maintenance in order to guarantee safety, increase process efficiency, and reduce operation and maintenance costs. Sensing in high-temperature (HT), harsh-environments (HE) comes with challenges including mounting and packaging, sensor stability, and data acquisition and processing. Wireless sensor operation at HT is desirable because it reduces the complexity of the sensor connection, increases reliability, and reduces costs. Surface acoustic wave resonators (SAWRs) are compact, can operate wirelessly and battery-free, and have been shown to operate above 1000°C, making them a potential option for HT HE dynamic strain sensing. This paper presents wirelessly interrogated SAWR dynamic strain sensors operating around 288.8MHz at room temperature and tested up to 400°C. The SAWRs were calibrated with a high-temperature wired commercial strain gauge. The sensors were mounted onto a tapered-type Inconel constant stress beam and the assembly was tested inside a box furnace. The SAWR sensitivity to dynamic strain excitation at 25°C, 100°C, and 400°C was .439 μV/με, 0.363μV/με, and .136 μV/με, respectively. Furthermore, the experimental outcomes verified that inductive coupled wirelessly interrogated SAWRs can be successfully used for dynamic strain sensing up to 400°C.

47 OTHER INSTRUMENTATION↗