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All sources NASA NTRS DOE OSTI

DOE OSTI2025

The effect of blue and infrared laser melting frequency on oxide morphology in 304L

Continuous Wave Laser Beam (LB) melting offers control over the localised heating and cooling of melt pools for welding, brazing, additive manufacturing and solidification. Research into laserliquid metal interactions has primarily focused on the heat and mass transport under large thermal gradients imposed by the localised melting conditions. Recent commercial availability of blue (450 nm) wavelength lasers has enabled the printing of material with poor IR (1064) nm attenuation like Cu. However, little research has been conducted into varying input laser frequency and scan rate at fixed absorption to understand the effects of laser light on surface oxide formation and the underlying liquid metal thermodynamic response. Here, this article conducts laser melting of 304L under Blue (450 nm) and Infrared (IR, 1064 nm) laser frequencies and examines their impact on laser oxide thickness, chemistry and coloration. We find that laser frequencies induce changes in the oxide layer thickness and chemistry that cannot be explained using conventional thermal absorption shifts and fluid dynamics. We suggest that light coupling may have thermodynamic implications for the chemical potential of the liquid metal, which may drive the observed phase behaviour. Identifying mechanisms for the tuning of the chemical potential via laser frequency control could enable the ability to control solidification microstructure and atomic ordering in laser welding and additive manufacturing processes.

304L↗

DOE OSTI2024

Interpretative 3D MHD modelling of deuterium SPI into a JET H-mode plasma

Abstract The pre-thermal quench (pre-TQ) dynamics of a pure deuterium ( D 2 ) shattered pellet injection (SPI) into a 3 MA / 7 MJ JET H-mode plasma is studied via 3D non-linear MHD modelling with the JOREK code. The interpretative modelling captures the overall evolution of the measured density and radiated power. The simulations also identify the importance of the drifts of ablation plasmoids towards the tokamak low field side (LFS) and the impurities in the background plasma in fragment penetration, assimilation, radiative cooling and MHD activity in D 2 SPI experiments. It is found that plasmoid drifts lead to an about 70% reduction of the central line-integrated density (compared to a simulation without drifts) in the JET D 2 SPI discharge considered. Impurities that pre-exist before the SPI as well as those from possible impurity influxes related to the SPI are shown to dominate the radiation in the considered discharge. With inputs from JOREK simulations, modelling with the Lagrangian particle-based pellet code PELOTON reproduces the deviation of the SPI fragments in the direction of the major radius as observed by the fast camera. This confirms the role of rocket effects and plasmoid drifts in the considered discharge and reinforces the validity of the JOREK modelling. The limited core density rise due to plasmoid drifts and the strong radiative cooling and MHD activity with impurities (depending on their species and concentration) could limit the effectiveness of LFS D 2 SPI in runaway electron avoidance and are worth considering in the design of the ITER disruption mitigation system.

Physics↗

DOE OSTI2026

Mesh-based multiphysics coupling acceleration for fusion neutronics through clustering for fusion blanket applications

Accurate modeling of particle transport within fusion blankets is essential for predicting performance metrics such as heat deposition and the tritium breeding ratio (TBR). However, high-fidelity coupling of thermal fluids from computational fluid dynamics (CFD) to neutronics simulations often incurs significant computational costs due to the complexity of surface intersection calculations in Monte Carlo codes. This paper presents an accelerated multiphysics coupling method for neutronics that utilizes hierarchical agglomerative clustering to map complex material property distributions to a neutronics model. Implemented within the fusion reactor design and assessment (FREDA) framework, the method leverages existing Python packages to automate the creation of clustered geometries for OpenMC. The approach is demonstrated on a sector model of an ARC-class tokamak with an immersion molten salt blanket, and an simple geometry with varying isotopic concentrations. Results show that the clustering method significantly reduces computational burden without compromising fidelity, providing a foundation for agile iteration of neutronics simulations involving multiple coupled material properties.

Bae, Jin Whan [ORNL] (ORCID:0000000326548907)↗

DOE OSTI2021

A mesoscopic digital twin that bridges length and time scales for control of additively manufactured metal microstructures

We present our recent development of an integrated mesoscale digital twin (DT) framework for relating processing conditions, microstructures, and mechanical responses of additively manufactured (AM) metals. In particular, focusing on the laser powder bed fusion technique, we describe how individual modeling and simulation capabilities are coupled to investigate and control AM microstructural features at multiple length and time scales. We review our prior case studies that demonstrate the integrated modeling schemes, in which high-fidelity melt pool dynamics simulations provide accurate local thermal profiles and histories to subsequent AM microstructure simulations. We also report our new mechanical response modeling results for predicted AM microstructures. In addition, we illustrate how our DT framework has been validated through modeling–experiment integration, as well as how it has been practically utilized to guide and analyze AM experiments. Finally, we share our perspectives on future directions of further development of the DT framework for more efficient, accurate predictions and wider ranges of applications.

36 MATERIALS SCIENCE↗

DOE OSTI2021

ac Sensing Using Nitrogen-Vacancy Centers in a Diamond Anvil Cell up to 6 GPa

Nitrogen-vacancy color centers in diamond have attracted broad attention as quantum sensors for both static and dynamic magnetic, electrical, strain, and thermal fields and are particularly attractive for quantum sensing under pressure in diamond anvil cells. Optically based nuclear magnetic resonance may be possible at pressures greater than a few gigapascals and offers an attractive alternative to conventional Faraday-induction-based detection. In this work, we present ac sensing results and demonstrate synchronized readout up to 6 GPa but find that the sensitivity is reduced due to inhomogeneities of the microwave field and pressure within the sample space. These experiments enable the possibility of all-optical high resolution magnetic resonance of nanoliter sample volumes at high pressures.

58 GEOSCIENCES↗

DOE OSTI2021

Thermal conductivity of CaSiO 3 perovskite at lower mantle conditions

Thermal conductivity (κ) of mantle minerals is key to understanding dynamics in the deep Earth. It controls the style of mantle convection and the timescale of cooling both the mantle and the core. Cubic CaSiO 3 perovskite (CaPv) is the third most abundant mineral in the lower mantle (7 vol %). Despite its importance, no theoretical or experimental estimate of CaPv's κ is available. Theoretical investigations of its properties are challenging because of its strong anharmonicity. Experimental measurements at relevant pressures and temperatures are equally challenging. Here we present ab initio results for CaPv's κ obtained using the phonon quasiparticle approach to address its strong anharmonicity. We also offer experimental measurements of κ up to 67 GPa and 1950 K. Predictions and measurements are in good agreement and reveal a surprisingly large κ for cubic CaPv that can be explained on the basis of its high crystal structure symmetry. Despite its relatively low abundance, CaPv's κ increases the lower mantle κ by ~10 %, if accounted for. κ of mantle regions enriched in subducted crustal materials will be more strongly impacted.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2024

Microphysics of shock-grain interaction for inertial confinement fusion ablators in a fluid approach

Ablator materials used for inertial confinement fusion, such as high-density carbon (HDC) and beryllium, have grain structure which may lead to small-scale density nonuniformity and the generation of perturbations when the materials are shocked and compressed. Here, we use a combination of a linear theory of shock interaction with density nonuniformity [Velikovich et al., Phys. Plasmas 14, 072706 (2007)] and numerical simulations to study shock interaction with a model representation of HDC grains. While the shock-grain interaction is nonlinear, the linear theory shows some key features of the shock-grain interaction, which also hold for the (nonlinear) simulations. The postshock perturbations are made up of sonic reflections off of grain boundaries and vorticity deposition along them, with the latter dominating the perturbed energy content. The mean (per mass) postshock perturbed kinetic energy decreases with increasing grain size, but energy will be deposited at increasing spatial scale. From the perspective of the postshock perturbed energy, the detailed linear theory largely supports a proposed method [S. Davidovits et al., Phys. Plasmas 29, 112708 (2022)] for deresolving the grains (in a similar grains model) that treats the grains statistically. Finally, our simulation results highlight the influence of thermal conduction on the perturbation dynamics at grain scales.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Regulation of Alfvén Eigenmodes by Microturbulence in Fusion Plasmas

Global gyrokinetic simulations of mesoscale reversed shear Alfven eigenmodes (RSAE) excited by energetic particles (EP) in fusion plasmas find that RSAE amplitude and EP transport are much higher than experimental levels at nonlinear saturation, but quickly diminish to very low levels after the saturation when background microturbulence is artificially suppressed. In contrast, in simulations coupling micro-meso scales, the RSAE amplitude and EP transport decrease drastically at the initial saturation but later increases to the experimental levels in the quasi-steady state with bursty dynamics due to regulation by thermal ion temperature gradient (ITG) microturbulence. The quasi-steady state EP transport is larger for a stronger microturbulence. Here, the RSAE amplitude in the quasi-steady state ITG-RSAE turbulence from gyrokinetic simulations, for the first time, agrees very well with experimental measurements.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Laser melting modes in metal powder bed fusion additive manufacturing

In laser powder bed fusion additive manufacturing of metals, extreme thermal conditions create many highly dynamic physical phenomena such as vaporization and recoil, Marangoni convection, and protrusion and keyhole instability. Collectively however, the full set of phenomena is too complicated for practical applications and, in reality, the melting modes are used as a guideline for printing. With increasing local material temperature beyond the boiling point, the mode can change from conduction to keyhole. These mode designations ignore laser-matter interaction details but in many cases are adequate to determine the approximate microstructures and hence the properties of the build. To date, no consistent, common, and coherent definitions have been agreed upon because of historic limitations in melt pool and vapor depression morphology measurements. Here, we distinguish process-based definitions of different melting modes from those based on postmortem evidence. The latter are mainly derived from the transverse cross-sections of the fusion zone, whereas the former come directly from time-resolved x-ray imaging of melt pool and vapor depression morphologies. These process-based definitions are more strict and physically sound, and they offer new guidelines for laser additive manufacturing practices and create new research directions. Further, we highlight the significance of the keyhole, which substantially enhances the laser energy absorption by the melt pool. Recent studies strongly suggest that stable-keyhole laser melting enables efficient, sustainable, and robust additive manufacturing. The realization of this scenario demands the development of multiphysics models, signal translations from morphology to other feasible signals, and in-process metrology across platforms and scales.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2024

Coupled Multiphysics Modeling of Lithium-Ion Batteries for Automotive Crashworthiness Applications

Considerable advances have been made in battery safety models, but achieving predictive accuracy across a wide range of conditions continues to be challenging. Interactions between dynamically evolving mechanical, electrical, and thermal state variables make model prediction difficult during mechanical abuse scenarios. In this study, we develop a physics-based modeling approach that allows for choosing between different mechanical and electrochemical models depending on the required level of analysis. We demonstrate the use of this approach to connect cell-level abuse response to electrode-level and particle-level transport phenomena. A pseudo-two-dimensional model and simplified single-particle models are calibrated to electrical-thermal cycling data and applied to mechanically induced short-circuit scenarios to understand how the choice of electrochemical model affects the model prediction under abuse scenarios. These models are implemented using user-defined subroutines on ls-dyna finite element software and can be coupled with existing automotive crash safety models.

analysis and design of components↗

DOE OSTI2024

Dynamic STEM-EELS for single-atom and defect measurement during electron beam transformations

This study introduces the integration of dynamic computer vision–enabled imaging with electron energy loss spectroscopy (EELS) in scanning transmission electron microscopy (STEM). This approach involves real-time discovery and analysis of atomic structures as they form, allowing us to observe the evolution of material properties at the atomic level, capturing transient states traditional techniques often miss. Rapid object detection and action system enhances the efficiency and accuracy of STEM-EELS by autonomously identifying and targeting only areas of interest. This machine learning (ML)–based approach differs from classical ML in that it must be executed on the fly, not using static data. We apply this technology to V-doped MoS 2 , uncovering insights into defect formation and evolution under electron beam exposure. This approach opens uncharted avenues for exploring and characterizing materials in dynamic states, offering a pathway to increase our understanding of dynamic phenomena in materials under thermal, chemical, and beam stimuli.

47 OTHER INSTRUMENTATION↗

DOE OSTI2020

Dynamic pulse propagation modelling for predictive femtosecond-laser-microbonding of transparent materials

A dynamic pulse propagation modeling for femtosecond laser bonding of Borofloat glass is presented. The temperature evolution and internal modifications are predicted by incorporating the nonlinear electron dynamics along with temperature dependent thermal properties. The modelling predicts the spatial and temporal distribution of absorption coefficient and plasma density that gives quantitative estimations of the heat affected zone and weld geometry. The impact of focusing condition on heat affected zone and weld geometry is investigated, which for the first time to our knowledge allows to numerically determine the desired relative position between the geometrical focus of a femtosecond-laser-pulse and the interface of the two substrates to be welded. The prediction of the modelling on the offset distance is applied to weld Borofloat glass plates having optical contact and can be applied to other dielectric solids.

Sahoo, Pankaj K. (ORCID:0000000209437319)↗

DOE OSTI2025

Hydrology controls thermokarst and alters carbon cycling and methane emissions in peatlands near the southern limit of permafrost: Model Inputs and Outputs

This dataset contains model inputs and simulation outputs associated with the study “Hydrology controls thermokarst and alters carbon cycling and methane emissions in peatlands near the southern limit of permafrost.” The ecosys model was extended to represent thermokarst processes in laterally coupled two-dimensional transects and applied to the Scotty Creek basin (Northwest Territories, Canada). The ecosys model and documentation is available for download at https://github.com/jinyun1tang/ECOSYS. The dataset contains the inputs used to run the model for this study (meteorological forcing data (1950–2018) and site-specific soil and vegetation parameters) and model outputs used to generate Figure 3 and Figure 4 in the paper (simulated ground thermal and hydrologic states, vegetation dynamics, and carbon fluxes).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Design Optimization of A generic Fissile Solution for Mo99 production using Electron Beam-based Neutron Generator using MCNP+CFD

Molybdenum-99 ( 99 Mo) is a medical isotope used in 80% of all medical imaging procedures today. However, 99 Mo is not directly administered to patients for imaging; its decay product, technetium-99m ( 99 mTc), is a metastable isotope with a half-life of ~6 hours. Such a short half-life does not allow for production, separation, and application to a patient before decaying further. Therefore, the solution is to produce the precursor to 99 mTc, 99 Mo. 99 Mo has a half-life of 66 hours, long enough to produce the material and send it to the desired location before it fully decays. Under National Nuclear Security Administration’s (NNSA) highly enriched uranium (HEU) minimization mission, the Material Management and Minimization (M3) office leads the Molybdenum-99 (Mo-99) program. A major goal of the Mo-99 program is to develop methods of producing 99 Mo using low enriched uranium (LEU) opposed to the traditionally used HEU domestically in the U.S. Internationally, LEU is the new standard for use in research reactors and isotope production facility. In this study, we introduce a generic fissile solution system for 99 Mo production facility meeting the design requirement of 1) LEU usage as fissile material and 2) subcritical fissile system coupled with a horizontal electron beam (E-beam) accelerator. The focus of this research is to optimize a fissile solution configuration for maximum 99 Mo production yield using MCNP model, and ultimately implement the optimized design with computational fluid dynamics (CFD) model to understand thermal hydraulic behavior and solution convection characteristic. The report consists of two parts: 1) isotope yield calculation and criticality analysis with a wide range of parametric test matrix, and 2) thermal hydraulic analysis for solution mixing and cooling assessment.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2021

TRUST End-of-Year Report

The objective of the Delivery Environments (DE) Testbeds to Reduce Uncertainties in Simulations and Tests (TRUST) work package is to quantify and help increase confidence in specific areas of computational and experimental capabilities that are applicable to current and future delivery environments. More complete quantification of confidence in experimental and computational capabilities and the sufficient increase of confidence in those capabilities is critical to improving weapons engineering design, qualification, and assessment efforts that are critical to the current and future stockpile. Staff development will include cross-discipline training to provide engineers with experience in both numerical simulations and experimental methods. This work will use and provide feedback on analysis tools and experimental results databases for efficient and responsive engineering which are currently under development: engineering common model framework (ECMF), engineering quantification of margins and uncertainties (EQMU), and the test information management system (TIMS). TRUST includes four testbeds and their associated engineering analysis baseline models (EABMs): 1. contact thermal conductivity (CTC); 2. nonlinear dynamics (ND); 3. sensors in environments for accelerometers (SEA); 4. sensors in environments for fiber optic displacement gages (SEFOD).

42 ENGINEERING↗

DOE OSTI2024

Simultaneous Thermal Analysis of Anion and Cation Exchange Resins

The decomposition reactions of one anion exchange resin (Bio-Rad AG MP-1) and one cerium-loaded cation exchange resin (DOWEX 50W-X8), both in nitrate form, were analyzed using simultaneous thermal analysis methods. Thermogravimetric analysis, dynamic scanning calorimetry, and evolved gas analysis were deployed in combination to probe the temperature profiles, reaction enthalpies, and off-gases from these resins under process-relevant temperature ranges. Analysis indicates that both resins undergo three clear phases during heating. The first is a dehydration step with prominent off-gassing of water, the second is a decomposition step with evolution of several gaseous species, and lastly is a combustion step with a large release of CO 2 . The temperature at which combustion ends varies slightly between AG MP-1 and DOWEX 50W: combustion completed at ~690°C and ~810°C, respectively. For the DOWEX cation resin, the combustion reaction showed greater sensitivity to the availability of oxygen under the test conditions. Both resins displayed broad exotherms during the combustion step of the decomposition, but the DOWEX cation resin demonstrated a 4.5 times higher specific enthalpy than that of the AG MP-1.

36 MATERIALS SCIENCE↗

DOE OSTI2024

TRUST Sensors in Environments: Fiber Optic Displacement (SE-FOD) Report, Release FY24

The objective of the Delivery Environments (DE) Testbeds to Reduce Uncertainty in Simulations and Tests (TRUST) project is to quantify and help increase confidence in specific areas of computational and experimental capabilities that are applicable to the development, on-target assessment, and qualification of current and future delivery environments. More complete quantification of confidence in experimental and computational capabilities and the sufficient increase of confidence in those capabilities is critical to improving weapons engineering design, qualification, and assessment efforts that are critical to the current and future stockpile. This work uses and provides feedback on analysis tools and experimental results databases for efficient and responsive engineering which are currently under development. Under the TRUST work package, there are five testbeds and their associated engineering analysis baseline models (EABMs): 1. Contact Thermal Conductivity (CTC), 2. Nonlinear Dynamics (ND), 3. Sensors in Environments: Accelerometers (SE-A), 4. Sensors in Environments: Fiber Optic Displacement Gauges (SE-FOD), and 5. Sensors in Environments: Thermocouples (SE-TC). The TRUST project uses single-feature testbeds to quantify uncertainties in specific models and experiments and to identify capability development needs that can help to reduce these uncertainties. Each testbed is designed, configured, and tested in collaboration with groups with design and experimental capability: E-14 and MPA-CINT. The complementary simulations are conducted using W-13 analysis tools and stored in model repositories with plans for incremental progress toward EABM requirements. W-13 extends and exercises the testbed simulations in collaboration with experimentalists for uncertainty quantification of current and future materials, geometries, and environments. Additionally, TRUST is intended to provide engineers in W-13 and E-14 with experience in both numerical simulations and experimental methods through cross-discipline collaborations. Following the introduction to the TRUST project, the remainder of this report focuses on experimental, modeling and simulation, and analysis efforts conducted in FY24 relevant to the TRUST Sensors in Environments: Fiber Optic Displacement (SE-FOD) testbed.

42 ENGINEERING↗

DOE OSTI2021

DESIGN AND PROTOYPING OF A FISSILE-BEARING CHLORIDE SALT IRRADIATION EXPERIMENT

Limited data exists on the properties of irradiated fueled chloride-based salts for use in advanced nuclear reactors. The design and prototyping of a salt irradiation experiment is underway. Mechanical design will integrate the experiment into existing assemblies in TRIGA type cores. Neutronics modeling demonstrated how targeted power densities can be reached and provide insight on radionuclide source term generation within the experiment. Thermal-hydraulic and computational fluid dynamics (CFD) analysis indicated that temperature ranges in the salt can satisfy both safety and programmatic requirements. Initial prototyping tests provided confidence in the ability to extract the salt post-irradiation, and in the heater performance. Future planned prototyping will provide an integral assessment of the proposed design prior to insertion in the reactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗