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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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30 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Overcoming the thermal conductivity versus oxidation resistance barrier in high-temperature steels

Heat-resistant steels with high chromium additions (≥5 weight percent) are critical for many high temperature energy and manufacturing applications, including heat exchangers, pistons for engines, and dies for metal working and casting. However, while high chromium additions increase oxidation resistance at elevated temperatures, they also compromise thermal conductivity, resulting in a metallurgical trade-off between these two important properties. Here we show that a microstructure with both higher thermal conductivity and improved oxidation resistance at elevated temperatures is achieved in a unique steel with only 1 weight percent chromium, thereby overcoming the long-standing metallurgical trade-off. This is accomplished through a tailored thermal treatment that produces a tempered martensitic matrix with low solute content and a fine dispersion of copper precipitates and molybdenum enriched carbides. A further discovery is that the resultant thermally grown oxide includes an iron-copper-manganese-enriched outer layer that provides high-temperature oxidation protection equivalent to heat-resistant steels with five times the chromium content and 25% lower thermal conductivity.

Pierce, Dean T. [Oak Ridge National Laboratory (OR↗
DOE OSTI2026

Novel approach to general curvilinear coordinates for plasma fluid applications

In general geometry, plasma fluid equations include nonlinear geometric sources associated with fictitious forces, which pose significant challenges to computer simulations. We reformulate the plasma fluid hierarchy to rigorously preserve geometry and conservation properties critical to numerical simulations, while concealing the geometric sources. In their discrete form, the reformulated models conserve mass, angular momentum, and energy naturally, by simple analogy with the continuum equations. These conservation properties have minimal requirements in discrete space, namely, the anti-symmetry of the first derivative and the orthogonality of the scalar and cross products. By decoupling magnetic geometry, coordinate systems, and numerical discretization, this enables maximum flexibility while preserving physics fidelity. As a testbed, we apply the novel representation to the resistive magnetohydrodynamic system, which involves a complete set of curvilinear operations. We verify the correctness of the approach using steady state liquid metal flows and the classic Orszag–Tang vortex.

Halpern, Federico D. [General Atomics, San Diego, ↗
DOE OSTI2025

Predictive turbulence-driven flux model of scrape-off layer widths across confinement regimes in tokamaks

Reliable scrape-off layer (SOL) profile decay lengths predictions are needed to design and operate future tokamaks. The present manuscript describes a new model based on turbulent transport that is able to predict SOL widths for both L-mode and H-mode plasmas. The model is based upon the sheared-spectral filament paradigm (Peret et al (WEST Team) 2022 Phys. Plasmas 29 072306), however, incorporating the effects of thermal transport in order to calculate the parallel heat fluxes. The effects of magnetic shear and ExB shear on the cross-field transport are crucial to explain the shorter SOL decay lengths found in H-mode. The model is validated against a database of thousands of DIII-D L-mode and H-mode SOL profiles. We also calculate SOL decay length predictions in terms of plasma and engineer control parameters, which are in agreement with the multi-machine empirical H-mode scaling (Eich et al (ASDEX Upgrade Team and JET EFDA Contributors) 2013 Nucl. Fusion 53 093031), however, with an additional device geometry dependence. ITER SOL width predictions by the model are 3 times higher than the empirical scaling.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

A kinetic line-driven radiation operator and its application to Gyrokinetics

A velocity dependent, kinetic model for line radiation is developed for continuum kinetic codes. It has been implemented in the full-f gyrokinetic code Gkeyll. The total radiation for a charge state is modeled as an advection in velocity space with a form of $\nabla_v \cdot(v\nu(v)f(v))$, guaranteeing particle conservation. The velocity dependence (in the form of an effective frequency $\nu(v)$) is found through fitting the energy loss of the operator, i.e. the second velocity moment, to the radiation data in the OpenADAS database. Therefore, each individual transition does not need to be evaluated every time step, significantly reducing the computational cost of including line radiation in a kinetic model. The dependence on velocity instead of the usual, temperature, allows the radiation to be computed from non-Maxwellian electron distribution functions: We benchmark the model against a collisional radiative model using isotropic non-Maxwellian distribution functions. A velocity dependent model of radiation can more accurately describe the radiation in the more kinetic regimes expected in reactor-scale devices. The velocity dependence qualitatively captures the quantum mechanical need for a minimum velocity before any radiation occurs.

kinetic↗
DOE OSTI2026

Towards fully predictive gyrokinetic full- f simulations: validation and triangularity studies in TCV

Designing economical magnetic confinement fusion power plants motivates computational tools that can estimate plasma behavior from engineering parameters without direct reliance on experimental measurement of the plasma profiles. In this work, we present full-f global long-wavelength gyrokinetic simulations of edge and scrape-off layer turbulence in tokamaks that use only magnetic geometry, heating power, and particle inventory as inputs. Unlike many modeling approaches that employ free parameters fitted to experimental data, raising uncertainties when extrapolating to reactor scales. This approach directly simulates turbulence and resulting profiles through gyrokinetics without such empirical adjustments. This is achieved via an adaptive sourcing algorithm in Gkeyll that strictly controls energy injection and emulates particle sourcing due to neutral recycling. We show that the simulated kinetic profiles compare reasonably well with Thomson scattering and Langmuir probe data for Tokamak á Configuration Variable (TCV) discharge #65125, and that the simulations reproduce characteristic features such as blob transport and self-organized electric fields. Applying the same framework to study triangularity effects suggests mechanisms contributing to the improved confinement reported for negative triangularity (NT). Simulations of TCV discharges #65125 and #65130 indicate that NT increases the E x B flow shear (by about 20% in these cases), which correlates with reduced turbulent losses and a modest change in the distribution of power exhaust to the vessel wall. While the physical models contain approximations that can be refined in future work, the predictive capability demonstrated here, evolving multiple profile relaxation times with kinetic electron and ion models in hundreds of GPU hours, indicates the feasibility of using Gkeyll to support design studies of fusion devices.

Hoffmann, Antoine Cyril David [Princeton Plasma Ph↗
DOE OSTI2025

X-Ray Imaging and Spectroscopy Mission

The X-Ray Imaging and Spectroscopy Mission (XRISM) is a joint mission between the Japan Aerospace Exploration Agency (JAXA) and the National Aeronautics and Space Administration (NASA) in collaboration with the European Space Agency (ESA). In addition to the three space agencies, universities and research institutes from Japan, North America, and Europe have joined to contribute to developing satellite and onboard instruments, data-processing software, and the scientific observation program. XRISM is the successor to the ASTRO-H (Hitomi) mission, which ended prematurely in 2016. Its primary science goal is to examine astrophysical problems with precise, high-resolution X-ray spectroscopy. XRISM promises to discover new horizons in X-ray astronomy. It carries a 6 × 6 pixelized X-ray microcalorimeter on the focal plane of an X-ray mirror assembly (Resolve) and a co-aligned X-ray CCD camera (Xtend) that covers the same energy band over a large field of view. XRISM utilizes the Hitomi heritage, but all designs were reviewed. The attitude and orbit control system was improved in hardware and software. The spacecraft was launched from the JAXA Tanegashima Space Center on 2023 September 6 (UTC). During the in-orbit commissioning phase, the onboard components were activated. Although the gate valve protecting the Resolve sensor with a thin beryllium X-ray entrance window was not yet opened, scientific observation started in 2024 February with the planned performance verification observation program. The nominal observation program commenced with the following guest observation program beginning in 2024 September.

Astronomy and AstroPhysics↗
DOE OSTI2026

Impacts of Pasture Conversion to Sugarcane on Water Fluxes and Water Use Efficiency in the Southeastern US

The expansion of sugarcane (cane), a high-yielding perennial crop, will likely reshape the bioenergy landscape in the Southeastern US. However, its ecohydrological implications, particularly following conversion from grazed pastures, a dominant land use in the region, remain highly uncertain. We investigated the impact of cane expansion on evapotranspiration (ET) and its partitioning, and the mechanisms influencing both ET components and water use efficiency (WUE) across multiple scales and growth cycles in subtropical Florida. We combined eddy covariance, biometric measurements, and process-based stomatal conductance (g s ) models. ET was 1.7% lower in cane than in improved pasture (IMP) but exceeded that in semi-native pasture (SN) by 21%. Transpiration (T) followed a similar pattern, consistent with lower g s in cane relative to IMP. Cane had more conservative water use and greater sensitivity of g s to vapor pressure deficit (VPD) compared to IMP pasture, suggesting cane may be more tolerant of increasing atmospheric water demand. In contrast, SN showed lower g s and weaker stomatal sensitivity to VPD compared to cane, resulting in lower T. In cane, stomatal regulation and T varied across growth cycles, with stomata becoming less water conservative as stands matured, highlighting the importance of incorporating stand age-dependent stomatal regulation into hydrological models. Evaporation (E) was higher in cane than pastures (19%–26%), partially offsetting WUE gains. Cane exhibited higher intrinsic WUE (GPP/g s ; Gross Primary Productivity), ecosystem WUE (GPP/ET), and harvest WUE (harvest/ET) than both pasture types. Large-scale pasture-to-cane conversion could produce widely contrasting hydrological outcomes. The net regional impact will depend on the proportion of each pasture type converted and on cane's high g s sensitivity to VPD, which triggers tight stomatal regulation and conservative water use, both of which will become increasingly consequential under intensifying atmospheric water demand.

bioenergy↗
DOE OSTI2025

Investigations into the Ternary NaF-KF-UF4 Salt System – Phase A

A knowledge gap exists in the data and understanding of fresh fuel salt and irradiated multicomponent fuel salt systems thermophysical properties. Quantifying these properties is necessary for the design and construction of test reactors, as well as the licensing of future commercial molten-salt reactors. To facilitate thermal property determination on a proposed fuel salt composition for Seaborg Technologies, several samples containing depleted uranium tetrafluoride (UF4), sodium fluoride (NaF), and potassium fluoride (KF) were blended, and a melt temperature analysis was performed. From the melting temperature analysis, it was determined that sample Seaborg-7, a ternary salt composition of 26.4UF4-24.7KF-48.9NaF (mol%), was very near a ternary eutectic point. Therefore, thermal properties such as melting temperature, salt stability, density, heat capacity, thermal diffusivity, and viscosity were experimentally determined on the Seaborg-7 salt. These measurements document the baseline properties of fresh fuel salt as a function of temperature, where future experiments on irradiated fuel salt will provide a holistic perspective on the change of thermophysical properties during reactor operations. Several precision instruments were used to collect property data, and instrument calibrations and data collection were performed and documented in a standardized and reproducible manner with meticulous detail. This process ensured that the measurement procedures and resulting data can readily be duplicated elsewhere. The Seaborg-7 salt was shown to be stable at temperatures up to 900°C, as no mass change was observed upon repeated heating and cooling. The peak melting temperature was determined to be 547°C (557°C endset). The enthalpy of fusion (??H?_fus^o) was determined to be 167.5 ± 2.7 J/g while the enthalpy of crystallization (??H?_c^o) was determined to be -147.8 ± 13.3 J/g. In addition to the eutectic melting peak, upon heating, several pre eutectic peaks were observed, occurring at 470°C (onset) and 499°C (peak). Specific heat capacity measurements showed a slightly increasing trend with respect to temperature in the solid phase, while the liquid-specific heat capacity showed a somewhat flat trend with an average value of 106.1 ± 1.24 J/mol·K between 600 to 800°C. Three independent trials using the Seaborg-7 salt determined the density to be ?(T) = 4.908 – 0.000363·T(°C), validated between 32 to 200°C, and ?(T) = 4.808 – 0.00113·T(°C), validated between ~575 to 850°C. Thermal diffusivity was determined for the liquid state and is represented by the linear equation y = 0.1581 + 0.000207·T(°C) between 550 to 850°C. The viscosity was determined from 600 to 800°C and is represented by the exponential fit equation, ? (mPa·s) = 736.58e^(-0.006·T(°C)). This report documents the conclusion of fuel salt thermophysical property measurements for the Seaborg SPP, Phase A project.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Conceptual Design of a Scaled Voloxidation Apparatus for Testing with Used Nuclear Fuel

This report details the conceptual design overview for Department of Energy (DOE) Level 2 milestone M2FT-25IN030101021 titled “Complete conceptual design of a scaled voloxidation apparatus for testing with used nuclear fuel.” Advanced voloxidation uses high temperature nitrogen dioxide (NO2) gas to oxidize uranium dioxide (UO2) material to triuanium octoxide (U3O8) and ultimately to uranium trioxide (UO3). After consideration of multiple available options and inputs, a rotating advanced voloxidation design was determined to be the best fit for the needs of a full-scale apparatus. The system, which will be deployed in hot cell 4 of the Analytical Research Laboratory (ARL), has been designed to meet the space constraints of the facility while still accommodating at least 100g of used nuclear fuel (UNF). The apparatus consists of three main unit operations, including the gas panel, the custom furnace with reaction vessel, and the liquid scrubber.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Rotary Inertia Friction Welding of Dissimilar High-Strength 422 Martensitic Stainless Steel and 4140 Low Alloy Steel for Heavy-Duty Engine Piston Fabrication

AISI 422 martensitic stainless steel with superior high temperature performance (oxidation resistance and strength) is under evaluation for replacing current heavy-duty piston crown materials, AISI 4140 martensitic steel and micro alloyed steel (MAS) 38MnSiVS5, to fabricate a multimaterial piston. This multimaterial piston concept further improved power density and fuel economy by allowing heavyduty diesel engines to operate at higher temperatures and pressures. Joining AISI 422 steel piston crowns with AISI 4140 steel piston skirts is a key manufacturing step for this multimaterial piston. However, the significant differences in strength, elevated temperature flow stress, alloy chemistry, and temper resistance between these two martensitic steels cause some weldability issues (cracking) and metallurgical challenges (alloying element migration/segregation) when using conventional fusion-based welding processes. Rotary inertia friction welding (RIFW), a solid-state welding process, has been the preferred method to join 4140 crowns to 4140 skirts (and MAS crowns to MAS skirts) in high-volume production of current heavy-duty diesel engine pistons. It has been used to join these two materials with relatively comparable alloy chemistry to fabricate pistons with MAS skirts and 4140 crowns. Meanwhile, RIFW has also been a preferred method of dissimilar metal welding. However, RIFW of dissimilar high-strength martensitic steels has yet to be widely pursued. The interfacial microstructure complexities created by the thermomechanical process and highly nonequilibrium phase transformations during RIFW are a significant challenge for understanding and predicting their joining behavior and have not been reported in detail. Here, in this work, defect-free AISI 422 steel-AISI 4140 multimaterial pistons were successfully fabricated using the RIFW process. The interfacial microstructure and mechanical properties of dissimilar 422/4140 steel RIFW in the as-welded condition were experimentally studied in detail. The results provide critical baseline information for understanding RIFW mechanisms and guiding subsequent postweld heat treatment (PWHT) practice.

36 MATERIALS SCIENCE↗