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DOE OSTI2020

Wire-Based Additive Manufacturing of Stainless Steel Components

In this work three different wire-fed additive manufacturing (AM) processes were employed to evaluate differences between laser, arc, and electron beam heat sources used for high-deposition-rate AM on the order of 1 kg/h. Optimum weld and build parameters were developed independently to match the characteristics of each heat source using 308L stainless steel welding wire as the feedstock. Laser-wire AM was made with the lowest energy per unit length of weld and had the best control of the melt pool and surface finish. Wire arc-based AM had an intermediate energy per unit length of weld of approximately 5× that of the laser process, while electron beam wire AM had the highest energy per unit length of weld at approximately 10× that of the laser process. Analysis of the parts that were built included evaluation of mechanical properties and microstructures, and these properties are discussed with respect to the difference in input energy and cooling rates. Results show that all three processes build parts with properties that exceed those of annealed 304L wrought stainless steel. However, significant differences exist between the processes, and the results presented here can be used to help select the best wire-fed process for a given high-deposition-rate application.

36 MATERIALS SCIENCE↗

NASA NTRS2013

Potential Impact of Land Use Change on Future Regional Climate in the Southeastern U.S.: Reforestation and Crop Land Conversion

The impact of future land use and land cover changes (LULCC) on regional and global climate is one of the most challenging aspects of understanding anthropogenic climate change. We study the impacts of LULCC on regional climate in the southeastern U.S. by downscaling the NASA Goddard Institute for Space Studies global climate model E to the regional scale using a spectral nudging technique with the Weather Research and Forecasting Model. Climate-relevant meteorological fields are compared for two southeastern U.S. LULCC scenarios to the current land use/cover for four seasons of the year 2050. In this work it is shown that reforestation of cropland in the southeastern U.S. tends to warm surface air by up to 0.5 K, while replacing forested land with cropland tends to cool the surface air by 0.5 K. Processes leading to this response are investigated and sensitivity analyses conducted. The sensitivity analysis shows that results are most sensitive to changes in albedo and the stomatal resistance. Evaporative cooling of croplands also plays an important role in regional climate. Implications of LULCC on air quality are discussed. Summertime warming associated with reforestation of croplands could increase the production of some secondary pollutants, while a higher boundary layer will decrease pollutant concentrations; wintertime warming may decrease emissions from biomass burning from wood stoves

Regional climate change↗

NASA NTRS2001

Vapor Growth of Binary and Ternary Chalcogenides in Preparation for Microgravity Experiments

In the bulk crystal growth of some technologically important semiconducting chalcopyrites, such as ZnTe, CdS, ZnSe and ZnS, vapor growth techniques have significant advantages over melt growth techniques due to the high melting points of these materials. The realization of routine production of high-quality single crystals of these semiconductors requires a fundamental, systematic and in-depth study on the PVT growth process and crystal growth by vapor transport in low gravity offers a set of unique conditions for this study. Previously, two reasons have been put forward to account for this. The first is weight-related reductions in crystal strain and defects. These are thought to be caused by the weight of the crystals during processing at elevated temperatures and retained on cooling, particularly for materials with a low yield strength. The second, and more general, reason is related to the reduction in density-gradient driven convection. The PVT crystal growth process consists of essentially three processes: sublimation of the source material, transport of the vapor species and condensation of the vapor species to form the crystal. The latter two processes can be affected by the convection caused by gravitational accelerations on Earth. Reductions in such convection in low gravity is expected to yield a nearly diffusion-limited growth condition which results in more uniform growth rates (on the microscopic scale) and hence greater crystalline perfection and compositional homogeneity. The reduction of convective contamination by performing flight experiments in a reduced gravity environment will help to understand the relation between fluid phase processes (growth parameters) and defect and impurity incorporation in grown crystals.

Su, C.↗

NASA NTRS2001

Vapor Growth of Binary and Ternary Chalcogenides in Preparation for Microgravity Experiments

Su, Ching-Hua↗

NASA NTRS2000

Does Warming a Lysozyme Solution Cook Ones Data?

Chicken egg white lysozyme has a well characterized thermally driven phase transition. Between pH 4.0 and 5.2, the transition temperature, as defined by the point where the tetragonal and orthorhombic solubility are equal, is a function of the pH, salt (precipitant) type and concentration, and most likely of the buffer concentration as well. This phase transition can be carried out with protein solution alone, prior to the initiation of the crystallization process. We have now measured the kinetics of this process and investigated its reversibility. An aliquot of a stock protein solution is held at a given temperature, and at periodic intervals used to set up batch crystallization experiments. The batch solutions were incubated at 20 C until macroscopic crystals were obtained, at which point the number of crystals in each well were counted. The transition effects increased with temperature, slowly falling off at 30 C with a half time (time to approx. 1/2 the t = 0 number of crystals) of approx. 5 hours, and an estimated half time of approx. 0.5 hours at 43 C. Further, the process was not reversible by simple cooling. After holding a lysozyme solution at 37 C (prior to addition of precipitant) for 16 hours, then cooling and holding it at 4 C, no return to the pre-warmed nucleation kinetics are observed after at least 4 weeks. Thus every thermal excursion above the phase transition point results in a further decrease in the nucleation rate of that solution, the extent being a function of the time and temperature. Orthorhombic lysozyme crystals apparently do not undergo the flow-induced growth cessation of tetragonal lysozyme crystals. We have previously shown that putting the protein in the orthorhombic form does not affect the averaged face growth kinetics, only nucleation, for tetragonal crystals. We may be able to use this differential behavior to elucidate how flow affects tile lysozyme crystal growth process.

Pusey, Marc↗

DOE OSTI2024

Competitiveness Assessment of Decarbonizing Electricity and Process Heat Supply to a Campus with a Small Nuclear Reactor

This paper analyzes the competitiveness of siting a small nuclear reactor to support decarbonization of sites requiring tens of MW of electricity and/or process heat to support centralized heating and cooling system. This paper focuses on campuses as representative of sites with collections of buildings and research facilities with decarbonization needs represented by buildings heating, and electricity consumption by electrical loads which may include cooling via chilled water (e.g., for air conditioning and to cool down computer clusters). A nuclear reactor can be considered to decarbonize a site’s high-temperature steam generation used mostly for building heating needs, climate control, and hot water, by supplying process heat capabilities, while electricity decarbonization would be achieved mostly by the grid. However, a secondary application can be considered to maximize reactor utilization and avoid ramping down the reactor if the steam demand varies significantly throughout the year. Chilled water generation through steam-driven systems was identified as an attractive secondary option for the site analyzed, due to potential for plant design simplification, while electricity generation could be considered as well to reduce electricity purchases for a wider range of site applications. For a campus with peak 60MW thermal power demand, a small nuclear reactor with similar thermal power rating would almost eliminate CO2 emissions from steam generation and reduce electricity imports for chilled water production. A preliminary techno-economic feasibility study shows that a small nuclear reactor design that is optimized to support process heat can represent an economically feasible option when compared with other decarbonization alternatives.

Stauff, Nicolas E.↗

DOE OSTI2022

Manufacturing Science

The Manufacturing Science area of leadership spans the application of fundamental science research and development activities to understand the critical steps in manufacturing processes for the purposes of control and optimization. Although manufacturing is an applied area of research, fundamental science underpins our knowledge of both traditional and transformational manufacturing processes. For example, casting, welding, and many modern additive manufacturing processes that see wide use are broadly classified as solidification processes, with material transitioning from liquid to solid phases upon cooling from higher temperature. However, our understanding of the detailed physics involved in such processes is incomplete, and solidification remains a grand challenge for materials science. To enable adoption of transformative fabrication processes or to accelerate development of traditional ones, it is necessary to develop a detailed mechanistic understanding spanning multiple scales, starting with atomic building blocks (defects, interfaces, composition) and extending all the way up to macroscale performance in moderate and/or extreme environments.

36 MATERIALS SCIENCE↗

DOE OSTI2025

The Ductility of 49Fe-49Co-2V Soft Magnetic Alloy Bar: Surface Effects and Test Methods

The tensile ductility of 49Fe-49Co-2V (Hiperco® 50A) bar was investigated in both as-received and heat-treated conditions. The as-received/machined specimens exhibit very low ductility compared to samples where heat treatment was the final step prior to testing. Microstructural characterization showed that internal residual strain from bar processing and, most importantly, surface machining damage, cause lower elongation in the as-received material. Because fracture of this intermetallic alloy initiates at the surface, it is particularly susceptible to surface machining damage, i.e., the near-surface region has already exhausted most of its ability to accumulate tensile strain. During heat treatment, the internal residual strain and near-surface machining damage are eliminated and ductility is improved, despite a higher degree of crystallographic ordering in the heat-treated condition (which typically lowers ductility). Furthermore, if machining is again performed after heat treatment, the material again exhibits brittle behavior, even with only light touch-up machining passes. Here, in this work, methods of tensile strain measurement were investigated, namely conventional knife-edge extensometry and noncontact digital image correlation (DIC) on heat-treated material. For clip-on knife-edge extensometry, the range of failure strain was 2.5-5.5% for heat-treated Hiperco. For noncontact methods, ductility up to 7% was observed. The results highlight the tendency for the alloy to fail at surface imperfections, even those produced by application of the extensometer itself. Noncontact laser extensometry is recommended for determining the intrinsic ductility of the alloy. A method of laser surface modification was developed which increased ductility by ~ 100% compared to unmodified samples. The high cooling rates achieved during laser surface processing can bypass the ordering reaction and produce a ductile disordered structure at the surface that exhibits ductile fracture characteristics.

EBSD↗

DOE OSTI2025

Analysis of Radioactive Waste and Contamination using 3D Position-Sensitive CdZnTe Detectors

INTRODUCTION The US has surplus plutonium. This material will be diluted in gloveboxes at SRS [Ref 1 and 2]. This process will create holdup. Holdup is material in an unexpected or unwanted location. Because this holdup material is primarily PuO2, it must be accounted for (measured). This measurement is typically done using a liquid-nitrogen cooled, HPGe detector. To enable more rapid processing, advanced holdup technologies are being explored [Ref 3 and 4]. METHODS For the surplus plutonium dilute and dispose program, the traditional detector system could slow down the optimal operational tempo of the program. A multiple-detector system, providing complete glovebox coverage, based on CdZnTe crystals, 3D-positioning electronics, and a coded aperture mask, is in the process of being developed by ORNL and SRNL [Ref 4].

Whiteside, Tad [Savannah River National Laboratory↗

NASA NTRS2003

Uncovering The Properties of Young Neutron Stars and Their Surrounding Supernova A Remnants

In the third year of this program, the following studies have been undertaken in support of this effort: G292.0+1.8: In our previous work on this SNR, we discovered a young neutron star and its associated pulsar wind nebula. Radio observations by Camilo et al. (2002) have identified a young 136 ms pulsar in the direction of G292.0+1.8. We have used Chandra HRC observations of the central source to identify X-ray pulsations at the same period, thus establishing the neutron star as the radio pulsar counterpart. We have also set limits on the cooling of this young neutron star based on the unpulsed component of the X-ray emission. We find that the limit falls slightly below standard cooling models in which the modified Urca process is responsible for the bulk of the interior neutrino emission. A paper summarizing these results is currently being circulated amongst co-authors for review prior to publication. 3c 58: Our Chandra observations of this Crab-like SNR revealed the presence of a young, rapidly rotating pulsar as well as a central compact nebula which we interpret as a toroidal structure associated with the pulsar wind termination shock. Our modeling of this structure has allowed us to establish a temperature upper limit for the neutron star which falls well below predictions from standard cooling models, and implies the presence of exotic particles (such as pion condensates) or other processes that increase the neutrino production rate in the interior. A paper summarizing this work has been published in the Astrophysical Journal (Slane, Helfand, & Murray 2002, ApJ, 571, L45), and the results were the subject of a NASA Space Science Update (4/10/2002) which led to extensive media coverage. Based upon our initial observations, we submitted a successful Chandra Large Project proposal for a 350 ks observation of this young neutron star and its wind nebula. Kes 79: Our Chandra observations of this SNR reveal a compact central source which appears to be the neutron star formed in the explosion that produced the remnant. There is no evidence for a surrounding pulsar wind nebula. The source properties are similar to the central source in Cas A even though the Kes 79 remnant is considerably older. The results have been published in the Astrophysical Journal (Seward, Slane, Smith, and Sun 2003, ApJ, 584,414). Chandra Survey for Compact Objects in Supernova Remnants: We have formed a collaboration to carry out an extensive search for young neutron stars in nearby supernova remnants. Using X-ray observations from an approved Chandra Large Project, as well as from additional approved XMM observations, we are investigating a volume-limited sample of SNRs for which there is currently no evidence of associated neutron stars. We have obtained extensive optical and 1R data to complement the project, and analysis of these data is currently underway.

Slane, Patrick O.↗

NASA NTRS1979

Magnetosphere, ionosphere and atmosphere interactions

In the present review, the general nature of the earth's space environment is discussed with particular reference to the physical processes which link the magnetosphere, the ionosphere, and the upper atmosphere. Recent theoretical and experimental research has revealed the existence of subtle couplings which closely link the electrical and mass properties of these regions. Some of these couplings have been known for many years. Recent discoveries include such couplings as the formation of the plasmasphere through the mutual action of convective electric fields and ionospheric plasma flows. However, there is still insufficient information to define accurately the basic processes associated with space plasma dynamics when cool thermal plasma of ionospheric origin interacts with the neutral atmosphere, the energetic plasma of the ionosphere, and the solar wind. The primary objective of the discussion is to provide a general introduction to the more challenging processes as they are presently known.

Banks, P. M.↗

DOE OSTI2020

Noncontact Flow Rate Using Laser Ultrasonics

Several types of advanced nuclear reactors are cooled with high-temperature liquid metal or molten salt flows. There is a critical need to measure flow velocity in flow channels for test purposes, and eventually in operational reactors. In conventional ultrasonic flow sensors, ultrasonic waves traveling in both the upstream and downstream directions are generated and detected by transducers that must contact the flow channels. A shift in the frequency or transit time between the two ultrasonic waves is measured to determine flow velocity. We describe here an initial effort to apply that sensing concept when the contact transducers are replaced by laser-based generation and detection instrumentation. This noncontact sensing avoids many practical problems associated with contact transducers when implemented on flow channels at high temperature. Laser-based flow monitoring can also be applied to hot-process piping in the geothermal energy, chemical-processing and petroleum-refining industries. Our effort has included theoretical simulation of noncontact laser-based flow monitoring, indicating capability of measuring flow velocities relevant to reactor cooling. It also included a room-temperature experimental demonstration using water as the flow liquid, and indicating capability of measuring flow velocity at a responsivity roughly consistent with simulation predictions. Plans were made for an experimental demonstration at Oregon State University using liquid metal at 110 degrees C.

02 PETROLEUM↗

DOE OSTI2025

Rapid Solidification Effects in Additively Manufactured Si and SiGe Compositions

SiGe alloys have a proven track record as robust high-temperature thermoelectric materials, powering NASA missions like SNAP-10A, LES-9, and Voyager 1 and 2. Enhancing thermoelectric efficiency hinges on minimizing thermal conductivity while preserving electrical conductivity. Rapid solidification via LPBF can generate microstructural features such as subgrain cellular boundaries and twinning, which may help reduce thermal conductivity while preserving semiconducting behavior. Here, this study investigates the potential of laser powder bed fusion (LPBF) additive manufacturing to fabricate nanostructured Si and SiGe thermoelectric materials. High cooling rates (10 5 to 10 7 K/s) rates inherent to the LPBF process are conducive to forming such nanostructures. Moreover, this fabrication technique could also be suitable for fabricating complex geometries needed to achieve improved device level performance. Process mapping of commercial Si powder with irregular morphology was first performed to understand the LPBF processing behavior of this semiconductor material. Subsequent studies included in-house synthesized B-doped (p-type) Si7 8 Ge 22 spherical powder that was produced via ultrasonic atomization. Scan strategies involved multiple laser exposures to mitigate solidification cracking: a high density of >98% was achieved, but solidification cracking could not be fully eliminated. Subsequently, a high electrical resistivity (i.e., low conductivity) was observed, but the measured Seebeck coefficient, ∼230 μV/K @ 500 °C, proved that good semiconductor material was being fabricated. A subgrain cellular structure (5–10 μm) was observed as defined by Ge segregation to the intercellular boundaries. The remelting strategies helped lower the cooling rates in processing SiGe, but this still resulted in high residual stresses, which induced a remarkably high density of twins (78–95%) to accommodate the deformation. This unique grain structure offers an avenue for phonon scattering and potential improvements in thermoelectric performance.

figure of merit↗

NASA NTRS1954

Heat transfer, diffusion, and evaporation

Although it has long been known that the differential equations of the heat-transfer and diffusion processes are identical, application to technical problems has only recently been made. In 1916 it was shown that the speed of oxidation of the carbon in iron ore depends upon the speed with which the oxygen of the combustion air diffuses through the core of gas surrounding the carbon surface. The identity previously referred to was then used to calculate the amount of oxygen diffusing to the carbon surface on the basis of the heat transfer between the gas stream and the carbon surface. Then in 1921, H. Thoma reversed that procedure; he used diffusion experiments to determine heat-transfer coefficients. Recently Lohrisch has extended this work by experiment. A technically very important application of the identity of heat transfer and diffusion is that of the cooling tower, since in this case both processes occur simultaneously.

GASES - DIFFUSION↗

DOE OSTI2024

Raman Sideband Cooling of Molecules in an Optical Tweezer Array to the 3D Motional Ground State

Ultracold polar molecules are promising for quantum information processing and searches for physics beyond the standard model. Laser cooling to ultracold temperatures is an established technique for trapped diatomic and triatomic molecules. Further cooling of the molecules to near the motional ground state is crucial for reducing various dephasings in quantum and precision applications. In this work, we demonstrate Raman sideband cooling (RSC) of CaF molecules in optical tweezers to near their motional ground state, with average motional occupation quantum numbers of n ¯ x = 0.16 ( 12 ) , n ¯ y = 0.17 ( 17 ) (radial directions), and n ¯ z = 0.22 ( 16 ) (axial direction), and a 3-D motional-ground-state probability of 54 ± 18 % of the molecules that survive the RSC. This process paves the way to increase molecular coherence times in optical tweezers for robust quantum computation and simulation applications. Published by the American Physical Society 2024

Physics↗

DOE OSTI2025

Biofilm growth in water-cooling towers as collection platforms for airborne radionuclides

Given its history of nuclear material processing, the Savannah River Site (SRS) was used to evaluate whether biofilms growing in water-cooling towers (WCTs) are effective passive collection platforms for environmental radionuclide surveillance. Uranium and plutonium analyses suggest that WCT-sourced biofilms are efficient, indigenous, constantly running samplers that can be used for environmental monitoring, as their isotopic compositions are distinct from atmospheric fallout and representative of SRS historical activities. Further, the ubiquity of WCTs worldwide and demonstrated ability to detect nuclear material processing and constrain specific activities based on biofilm actinide isotopic compositions make WCT biofilms a promising means to improve monitoring.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

NASA NTRS1998

Liquidus Temperatures and Solidification Behavior in the Copper-Niobium System

The copper-niobium phase diagram has been under active debate; thus, a corroboratory experimental study is needed. In this investigation, the melts of Cu-Nb alloys at compositions ranging from 5 to 86 wt pct Nb were processed in different environments and solidified at relatively low cooling rates of 50 to 75 C/s to determine liquidus temperatures and to study solidification behavior. For all samples processed under very clean conditions, only Nb dendrites in a Cu matrix were observed; while in the presence of oxygen impurities the alloys containing 5 to 35 wt pct Nb exhibited microstructure of Nb-rich spheroids and Nb dendrites in the Cu matrix. The results obtained from clean conditions are in fair agreement with the Cu-Nb phase diagram having an S-shaped, near-horizontal appearance of the liquidus. The formation of Nb- rich droplets at slow cooling rates is discussed in terms of a stable liquid miscibility gap induced by oxygen.

Li, D.↗

DOE OSTI2022

Simulations of nonradiative processes in semiconductor nanocrystals

The description of carrier dynamics in spatially confined semiconductor nanocrystals (NCs), which have enhanced electron–hole and exciton–phonon interactions, is a great challenge for modern computational science. These NCs typically contain thousands of atoms and tens of thousands of valence electrons with discrete spectra at low excitation energies, similar to atoms and molecules, that converge to the continuum bulk limit at higher energies. Computational methods developed for molecules are limited to very small nanoclusters, and methods for bulk systems with periodic boundary conditions are not suitable due to the lack of translational symmetry in NCs. This perspective focuses on our recent efforts in developing a unified atomistic model based on the semiempirical pseudopotential approach, which is parameterized by first-principle calculations and validated against experimental measurements, to describe two of the main nonradiative relaxation processes of quantum confined excitons: exciton cooling and Auger recombination. Here, we focus on the description of both electron–hole and exciton–phonon interactions in our approach and discuss the role of size, shape, and interfacing on the electronic properties and dynamics for II–VI and III–V semiconductor NCs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗