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DOE OSTI2024

Multimessenger measurements of the static structure of shock-compressed liquid silicon at 100 GPa

The ionic structure of high-pressure, high-temperature fluids is a challenging theoretical problem with applications to planetary interiors and fusion capsules. Here we report a multimessenger platform using velocimetry and angularly and spectrally resolved x-ray scattering to measure the thermodynamic conditions and ion structure factor of materials at extreme pressures. We document the pressure, density, and temperature of shocked silicon near 100 GPa with uncertainties of 6%, 2%, and 20%, respectively. The measurements are sufficient to distinguish between and rule out some ion screening models. Published by the American Physical Society 2024

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2020

Dependence of Enstrophy Transport and Mixed Mass on Dimensionality and Initial Conditions in the Richtmyer–Meshkov Instability Induced Flows

Here we present a comparative study of the enstrophy budget and mixed mass between two- and three-dimensional flows induced by Richtmyer–Meshkov instability (RMI). Specifically, the individual contributions to the enstrophy budget due to the production from baroclinicity and from vortex stretching (which vanishes in two-dimensional (2D) flow) are delineated. This is enabled by a set of two- and three-dimensional computations at Atwood 0.5 having both narrow- and broad-band perturbations. A further three-dimensional (3D) computation is conducted at Atwood 0.9 using an identical narrowband perturbation to the Atwood 0.5 case to examine the sensitivity to density ratio. The mixed mass is also considered with the goal to obtain insight on how faithfully a simplified calculation performed in two dimensions can capture the mixed mass for an inertial confinement fusion (ICF) or other practical application. It is shown that the late time power law decay of variable density enstrophy is substantially different in two and three dimensions for the narrowband initial perturbation. The baroclinic production term is negligible in three dimensions (aside from the initial shock interaction), as vortex stretching is larger by two orders of magnitude. The lack of vortex stretching considerably reduces the decay rate in both narrowband and broadband perturbations in two dimensions. In terms of mixed mass, the lack of vortex stretching reduces the mixed mass in two dimensions compared to three in all cases. In the broadband cases, the spectral bandwidth in the 2D case is wider; hence, there is a longer time period of sustained linear growth which reduces the normalized mixed mass further.

42 ENGINEERING↗

DOE OSTI2022

High-precision inversion of dynamic radiography using hydrodynamic features

While radiography is routinely used to probe complex, evolving density fields in research areas ranging from materials science to shock physics to inertial confinement fusion and other national security applications, complications resulting from noise, scatter, complex beam dynamics, etc. prevent current methods of reconstructing density from being accurate enough to identify the underlying physics with sufficient confidence. In this work, we show that using only features that are robustly identifiable in radiographs and combining them with the underlying hydrodynamic equations of motion using a machine learning approach of a conditional generative adversarial network (cGAN) provides a new and effective approach to determine density fields from a dynamic sequence of radiographs. In particular, we demonstrate the ability of this method to outperform a traditional, direct radiograph to density reconstruction in the presence of scatter, even when relatively small amounts of scatter are present. Our experiments on synthetic data show that the approach can produce high quality, robust reconstructions. We also show that the distance (in feature space) between a testing radiograph and the training set can serve as a diagnostic of the accuracy of the reconstruction.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2024

Additively Manufactured Molten Salt to Supercritical Carbon Dioxide Heat Exchanger

Design, fabrication, and experimental characterization of the performance of a molten salt (MS)-to-supercritical carbon dioxide (sCO 2 ) heat exchanger (HE) for concentrating solar power (CSP) applications using laser powder bed fusion (LPBF) additive manufacturing (AM) of nickel-based superalloys is presented in this report. The hypothesis is that such additively manufactured HEs will result in a monolithic, compact, low-pressure drop HE that is durable under cyclic operation at high temperature and high pressure in a corrosive salt environment. Two nickel-based superalloys were considered in the project- Haynes 230 (H230) and Haynes 282 (H282). Process windows for LPBF AM were established to provide dense low porosity parts for both alloys. Creep tests results on heat treated AM H230 and H282 samples showed that the AM fabricated specimens were as robust as the wrought specimens and showed no deficit in creep strength at high temperatures. Haynes 282 was down selected for the HE fabrication based on better dimensional tolerance, better corrosion resistance to chloride salt, and higher creep strength.

14 SOLAR ENERGY↗

DOE OSTI2024

Progress and Challenges of Additive Manufacturing of Tungsten and Alloys as Plasma-Facing Materials

Tungsten (W) and W alloys are considered as primary candidates for plasma-facing components (PFCs) that must perform in severe environments in terms of temperature, neutron fluxes, plasma effects, and irradiation bombardment. These materials are notoriously difficult to produce using additive manufacturing (AM) methods due to issues inherent to these techniques. The progress on applying AM techniques to W-based PFC applications is reviewed and the technical issues in selected manufacturing methods are discussed in this review. Specifically, we focus on the recent development and applications of laser powder bed fusion (LPBF), electron beam melting (EBM), and direct energy deposition (DED) in W materials due to their abilities to preserve the properties of W as potential PFCs. Additionally, the existing literature on irradiation effects on W and W alloys is surveyed, with possible solutions to those issues therein addressed. Finally, the gaps in possible future research on additively manufactured W are identified and outlined.

36 MATERIALS SCIENCE↗

DOE OSTI2024

On the Mechanical Behavior of LP-DED C103 Thin-Wall Structures

Laser Powder Directed Energy Deposition (LP-DED) can produce thin-wall features on the order of 1 mm. These features are essential for large structures operating in extreme environments such as regeneratively cooled nozzles and heat exchangers, which often make use of refractory metals. In this work, the mechanical behavior of LP-DED C103 was investigated via quasi-static tensile testing and low cycle fatigue (LCF) testing. The effects of vacuum stress relief (SR) and hot isostatic pressing (HIP) heat treatments were investigated for specimens in the vertical and horizontal build orientations during tensile testing. The AB and SR properties were lower than literature values for wrought and laser powder bed fusion (L-PBF) bulk components but higher than electron beam powder bed fusion (EB-PBF). The application of a HIP cycle improved strength by 7% and ductility by 27% past the initial as-built condition. Fracture images reveal that interlayer stress concentration sites are responsible for fracture in specimens in the vertical orientation. Meanwhile, fracture in the horizontal specimens mainly propagates at a slanted angle typical of plane stress conditions. The LCF results show cycles to failure ranging from 100 cycles to 8000 cycles for max strain levels of 2% and 0.5%, respectively. Fractography on the fatigue specimens reveals an increasing propagation zone as max strain levels are increased. The impact of these findings and future work are discussed in detail.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Roadmap for warm dense matter physics

This roadmap presents the state-of-the-art, current challenges and near future developments anticipated in the thriving field of warm dense matter physics. Originating from strongly coupled plasma physics, high pressure physics and high energy density science, the warm dense matter physics community has recently taken a giant leap forward. This is due to spectacular developments in laser technology, diagnostic capabilities, and computer simulation techniques. Only in the last decade has it become possible to perform accurate enough simulations \& experiments to truly verify theoretical results as well as to reliably design experiments based on predictions. Consequently, this roadmap discusses recent developments and contemporary challenges that are faced by theoretical methods, and experimental techniques needed to create and diagnose warm dense matter. A large part of this roadmap is dedicated to specific warm dense matter systems and applications in astrophysics, inertial confinement fusion and novel material synthesis.

FOS: Physical sciences↗

DOE OSTI2025

Building a new multiphysics workflow in MOOSE: application to tritium migration, trapping and advection in TMAP8

Fusion devices are anticipated to produce and consume several kilograms of tritium per year. This rare fuel resource is both highly mobile and radioactive, making tracking inventories a priority for operation and safety. The fusion safety program at the Idaho National Laboratory has been developing the Tritium Migration and Analysis Program (TMAP), of which the latest version is a MOOSE-based application. TMAP8 is verified against its predecessors and possesses additional multi-dimensional tritium migration modeling capabilities. As we extend its capabilities towards both whole device (in multiple dimensions) and whole plant (with multiple components) simulations, the syntax of inputs must become compact, descriptive, compatible with quality assurance processes, and as error-proof as achievable. The new Physics system developed MOOSE can set up equations and instantiating them on plant components. The system permits the automatic definition of complex discretization with a consistency between object parameters achieved programmatically. The Physics system can currently instantiate the equations for heat conduction and Navier Stokes weakly compressible flow. In MOOSE-terms, it automates the definition of kernels, boundary conditions, and several core and helper materials and fields. As part of this effort, Physics classes were developed for tritium migration, trapping and advection within either a multi-dimensional Navier Stokes fluid dynamics simulation, or a 1D thermal hydraulics piping system. In this presentation, we will showcase the new syntax, its application to several verification and validation cases which were already studied using the classical TMAP8 syntax, and a demonstration of the new coupling capabilities for the migration of tritium into blanket coolant channels and the subsequent advection into the coolant loop.

70 - PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Time-resolved probing of laser-induced nanostructuring processes in liquids

Laser synthesis and processing of colloids (LSPC) in liquids has gained widespread applications in producing nanomaterials of different classes of solids. While the technical processes in different cases of ablation, fragmentation or colloidal fusion may look macroscopically different in each application, the underlying fundamental mechanisms are always the same cascade of laser interaction with matter, non-thermal or thermal energy deposition, phase transitions, and the subsequent structure formation processes. Disentangling these mechanisms represents a veritable challenge, as ultrafast and structurally sensitive experimental methods are required. This review presents a discussion of how state-of-the-art experimental protocols using ultrafast lasers and sensitive structural probes, such as electrons or X-rays are able to address this challenge. In particular, it is possible to investigate LSPC on single objects using single probe pulses and avoid accumulation effects in a heterogeneous sample. The presented results capture structure formation with femtosecond and atomic scale resolution. Ultrafast time-resolved probing approaches are key to revealing the transient states and pathways that govern material transformation in LSPC.

X-ray scattering↗

DOE OSTI2023

The comparative strength and fracture toughness properties of commercial 95W-3.5Ni1.5Fe and 95W-3.5Ni1.5Cu tungsten heavy alloys

Due to the sharp surface cracks resulting from high and cyclic thermal loads, fracture toughness is a crucial property for fusion divertor materials. Tungsten heavy alloys (WHA) have emerged as a leading candidate for plasma facing component applications. Both the WNiFe and WNiCu WHAs have been considered. However, there is no fracture toughness data in the literature on the WNiCu WHA. Therefore, maximum load elastic–plastic fracture toughness (K Jm ) of a commercial 95W-3.5Ni1.5Cu (NiCu) WHA plate is reported here for the first time. The NiCu WHA K Jm is compared to a corresponding K Jm for commercial 95W-3.5Ni1.5Fe (NiFe) WHA, along with comparisons of their respective microstructures, microhardness, and tensile properties. Although their room temperature yield strengths are similar (≈ 600 MPa), the NiFe WHA has higher ultimate stress (818 MPa vs. 642 MPa) and total elongation (8% vs. 1.2%) compared to the NiCu WHA. Most notably, the room temperature elastic–plastic K Jm for the NiFe WHA of ≈ 80 ± 8 MPa$\sqrt{m}$, is nearly twice that of the NiCu WHA at ≈ 47 ± 4 MPa$\sqrt{m}$. Further, while the NiFe WHA experienced stable ductile tearing, the crack propagated unstably (approximately elastically) after reaching the maximum load in the NiCu WHA. The higher K Jm of the NiFe WHA is attributed to its higher flow stress and ductility, along with the energy dissipation and microcrack dilatational stress shielding, provided by a wide distribution of arrested process-zone microcracks, which are largely absent in the NiCu WHA. Since, the 95W-NiFe WHA has distinctly better mechanical properties than 95W-NiCu WHA, it is a more suitable candidate for the fusion reactor application.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

Establishing an acoustic-property relationship in laser powder bed fusion with machine learning

Quality control of Laser Powder Bed Fusion (PBF-LB) additively manufactured parts is an important hurdle inhibiting the technology’s use structural applications. Acoustic monitoring of the laser powder bed fusion process can detect defects in-situ that are known to degrade mechanical properties. However, processing-structure-property (PSP) relationships are required to extrapolate from detected defects to part performance. Here, this study explores how acoustics may be a suitable signature linking processing conditions to properties, thus effectively substituting for structure in the PSP relationship. Establishing such a relationship would enable a part’s mechanical performance to be directly predicted from its acoustic signature, reducing the need for destructive testing or microstructural analysis to ensure a part will meet performance requirements. One hundred CoCrFeMnNi high entropy alloy tensile bars were printed across 13 process conditions in a series of 6 prints. The acoustic signatures of these tensile bars were used to train machine learning models to predict each part’s mechanical properties. By using both process information and acoustic information to predict mechanical properties, yield strength was predicted 18% more accurately and ductility to failure was predicted 10% more accurately than is achieved when using duplicate parts to predict part performance. Finally, individual acoustic frequencies were investigated to determine why acoustic signatures improve mechanical property predictions and the potential physical origins of these signatures. This work demonstrates how blending acoustics, process information, and machine learning can provide in-situ diagnostics of mechanical properties and improve the reliability of the PBF-LB process.

Acoustic emission↗

DOE OSTI2025

Additive Manufacturing of Lattice Structures for Catalyst Applications

Abstract The design and fabrication of Inconel 718 open-pore lattice structures via Laser Powder Bed Fusion (LPBF) has been investigated in this research, focusing on applications such as catalyst supports in jet fuel production. The study explores the impact of laser power and scanning speed on the geometrical resolution of these structures aiming to achieve high porosity (porosity > 60%) and specific pore sizes ranging from 500–1000 μm, intending to serve as catalyst supports, replacing conventionally manufactured foams to reduce costs. Results demonstrate the significant influence of processing parameters on the geometrical aspects of printed lattice structures, with laser power having a more pronounced effect on geometrical accuracy than scanning speed. Additionally, the mechanical properties of the printed lattice structures showed a correlation with the lattice strut sizes, as lattices with less porosity and thicker struts resulted in higher maximum shear stress.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Additive Manufacturing of Lattice Structures for Catalyst Applications

Ghanadi, Nahal [Oregon State University] (ORCID:00↗

DOE OSTI2023

NIMROD Development AND Applications for Advanced Simulations of Tokamak Plasmas

Magnetic fusion experiments have the largest gradients in the world that are in steady state. These gradients lead to instabilities, and thus, most of plasma theory over the past four decades have been devoted to the development of instability theory and their use in interpreting plasma results. Instabilities in tokamaks lead to 3 different phenomenological outcomes: coherent saturation, turbulent saturation, and sudden relaxation (which may include disruptions). For long-wavelength instabilities, the NIMROD extended MHD code has emerged as an important tool for understanding tokamak instabilities. Because of the long history of NIMROD, a new version of it has been started at Tech-X to be able to address multi-species capabilities as well as exploit modern GPU systems. The new version builds on the previous version and improves the workflow by enabling new equilibria from experiments to be resolved. The fundamental formulation of the equations underlying NIMROD has also been explored in multiples ways. First, understanding instabilities in tokamaks through numerical methods is aided by being able to understand the rich history of analytic studies. A paper was published which aid in understanding the literature by simplifying some of the analytic machinery inherent in these studies. Extended MHD, like gyrokinetics, are quasineutral models. From a theoretical point of view, plasma quasineutrality approximation is best understood as the same as the magneto-quasistatic approximation of the Maxwell equations. Finally, the standard model of tokamak theory is that of instability theory. A simple dynamical systems model has been developed to better illustrate the strengths and weaknesses of this model.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Laser-initiated p – 11 B fusion reactions in petawatt high-repetition-rate laser facilities

Driving of the nuclear fusion reaction p + 11 B → 3α + 8.7 MeV under laboratory conditions by interaction between high-power laser pulses and matter has become a popular field of research, owing to its numerous potential applications: as an alternative to deuterium–tritium for fusion energy production, astrophysics studies, and alpha-particle generation for medical treatment. One possible scheme for laser-driven p– 11 B reactions is to direct a beam of laser-accelerated protons onto a boron (B) sample (the so-called “pitcher-catcher” scheme). This technique has been successfully implemented on large high-energy lasers, yielding hundreds of joules per shot at low repetition. We present here a complementary approach, exploiting the high repetition rate of the VEGA III petawatt laser at CLPU (Spain), aiming at accumulating results from many interactions at much lower energy, to provide better control of the parameters and the statistics of the measurements. Despite a moderate energy per pulse, our experiment allowed exploration of the laser-driven fusion process with tens (up to hundreds) of laser shots. The experiment provided a clear signature of the reactions involved and of the fusion products, accumulated over many shots, leading to an improved optimization of the diagnostics for experimental campaigns of this type. In this paper, we discuss the effectiveness of laser-driven p– 11 B fusion in the pitcher–catcher scheme, at a high repetition rate, addressing the challenges of this experimental scheme and highlighting its critical aspects. Our proposed methodology allows evaluation of the performance of this scheme for laser-driven alpha particle production and can be adapted to high-repetition-rate laser facilities with higher energy and intensity.

Alpha particles↗

DOE OSTI2026

First field test of a novel optical gas analyser in the exhaust of Wendelstein 7-X

A novel optical gas analyser, designed for isotope-resolved exhaust composition measurement, was field-tested at Wendelstein 7-X (W7-X) to validate its laboratory-proven concept under operational fusion experiment conditions. The system, Optix, comprises a cold cathode remote plasma generator and a high-resolution Fabry–Perot spectrometer and was deployed in the exhaust line of W7-X during the OP2.3 campaign. The injection of 3 He and 4 He for minority ion-cyclotron heating provided a test case for helium isotope discrimination. Despite limitations due to background gas and low partial pressures of the target species, isotope-resolved spectral signatures were successfully observed, demonstrating the fundamental viability of the Optix approach. Additionally, the spectrometer was evaluated for plasma emission measurements from both core and edge sightlines. While helium line emission was detectable, interpretation was hindered by complex background signals, highlighting the benefits of controlled remote plasma generators for spectroscopy. This first deployment provides critical insight into pressure requirements, spectral resolution, and operational constraints, informing future applications of optical exhaust diagnostics in fusion devices.

magnetic confinement fusion↗

DOE OSTI2023

A Collaboration Website for Muon Catalyzed Fusion and Muon Beam Production

This research initiative establishes a dynamic online platform geared towards supporting the burgeoning Muon Catalyzed Fusion collaboration, focusing on the concurrent development of particle accelerators and transport beamlines for muon beams. The central feature of this endeavor is the creation of a multifaceted website comprising both public facing and private sections to cater to diverse user needs. The public segment is meticulously designed to serve as an educational hub, featuring information pages targeted at the general public alongside private pages exclusively accessible to collaboration members. These pages will host an array of multimedia elements, ranging from images and text animations to video lectures, covering an extensive spectrum of topics integral to the science of Muon Catalyzed Fusion. Encompassing areas such as Acceleration, Applications, Instrumentation, Beamline Design, and beam dynamics design codes, the educational content aims to make complex scientific concepts more accessible to a broader audience. Ensuring seamless accessibility across various devices and operating systems, the website incorporates integration with collaborative tools such as Google Docs for document collaboration, GitHub for code repository management, and WordPress for blogging with interactive commenting features. The bifurcation between public and private sections is a strategic approach to maintaining transparency while safeguarding proprietary research and works in progress. The public pages are strategically crafted to disseminate information, showcasing the latest endeavors and achievements within the NK Labs collaboration, including lectures, published papers, and regular blog posts open to public comments. On the other hand, the private section provides collaboration members with a secure space to share unpublished or nonpublic research, fostering collaborative efforts through integrated Google Docs and Python Plotty for shared graphing work. In essence, this ambitious project endeavors to bridge the gap between complex scientific knowledge and public understanding, enhance collaboration among researchers, and serve as a dynamic and inclusive platform for sharing and advancing the state-of-the-art in Muon Catalyzed Fusion and Accelerators.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2021

Modelling the complex evaporated gas flow and its impact on particle spattering during laser powder bed fusion

The additive manufacturing (AM) of metals is becoming an increasingly important production process with the potential to replace traditional techniques such as casting. Laser Powder Bed Fusion (LPBF) is used in many applications to print metal parts from powder. The metal powder is heated locally with sufficient laser radiation that the liquid melt easily reaches its boiling temperature, which leads to a metallic vapour jet that can entrain both powder bed particles and molten droplets. The small size of laser-matter interaction site makes a detailed experimental analysis of the process challenging. Synchrotron X-ray imaging experiments are one of the few methods which can capture the dynamic melting and solidification processes. Comparing such experiments with computer simulations of the process is an important approach in order to better understand the manufacturing process and to analyse the influence of process parameters on the evaporated gas jet and the subsequent impact on particle ejection, leading to potentially reduced AM component quality. The melting and solidification of the metal powder is simulated using an Eulerian multiphase approach based on a control volume discretization of powder bed and substrate and a volume of liquid separation from melt and gas phase. The gas phase modelled as an ideal gas reaches velocities up to 100 m/s. Lagrangian particle tracking in the simulation demonstrates that the velocity fields calculated by the Eulerian multi-phase approach in combination with a standard drag-force model lead to particle accelerations in good agreement with those measured experimentally. In order to avoid numerical laborious Lagrangian calculations, a direct method to compare an Eulerian multiphase simulation with synchrotron X-ray experiments was introduced and validated. This approach is used to analyse the influence of process parameters including laser power and laser speed on the maximal acceleration of particles from the melt pool area. While the particle acceleration increases linearly with line energy in the conduction mode, a linear decrease of the acceleration with increasing line energy can be found in the transition mode before the accel-eration increases again with line energy in the keyhole mode.

36 MATERIALS SCIENCE↗