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NASA NTRS2018

Zero Launch Mass Three Dimensional Print Head

NASA's strategic goal is to put humans on Mars in the 2030s. The NASA Human Spaceflight Architecture Team (HAT) and NASA Mars Design Reference Architecture (DRA) 5.0 has determined that in-situ resource utilization (ISRU) is an essential technology to accomplish this mission. Additive construction technology using in-situ materials from planetary surfaces will reduce launch mass, allow structures to be three dimensionally (3D) printed on demand, and will allow building designs to be transmitted digitally from Earth and printed in space. This will ultimately lead to elimination of reliance on structural materials launched from Earth (zero launch mass of construction consumables). The zero launch mass (ZLM) 3D print head project addressed this need by developing a system that 3D prints using a mixture of in-situ regolith and polymer as feedstock, determining the optimum mixture ratio and regolith particle size distribution, developing software to convert g-code into motion instructions for a FANUC robotic arm, printing test samples, performing materials testing, and printing a reduced scale habitable structure concept. This paper will focus on the ZLM 3D Print Head design, materials selection, software development, and lessons learned from operating the system in the NASA KSC Swamp Works Granular Mechanics & Regolith Operations (GMRO) Laboratory.

Regolith↗

DOE OSTI2025

Greenhouse Gas Emissions and Decarbonization Potential of Global Fired Clay Brick Production

Fired clay bricks (FCBs) are a dominant building material globally due to their low cost and simplicity of production, especially in low- and middle-income countries. With a projected rising housing demand, commensurate growth in brick demand is anticipated, the production of which could result in significant greenhouse gas (GHG) emissions. Robust models are needed to estimate brick demand and emissions to systematically address decarbonization pathways. Few sources report production values; hence, we present two novel proxy models: (i) a consumption prediction model, relying on country-specific clay extraction data, dynamic building stock modeling, and average material intensity use allowing for projections to 2050; and (ii) a GHG emissions model, using literature-based data and production technology-specific inputs. Based on these models, the current global FCB consumption is estimated as 2.18 Gt annually, resulting in approximately 500 million tCO2e (1% of current global GHG emissions). If unaddressed, this fraction could increase to 3.5-5% in 2050 considering a moderate SSP 2-4.5 climate change mitigation scenario. Consequently, we explored three potential decarbonization pathways: (i) improving energy efficiency; (ii) shifting production to best practices; and (iii) replacing half of FCB demand with hollow concrete blocks, resulting in 27%, 49%, and 51% reduction in GHG emissions, respectively.

Olsson, Josefine A↗

DOE OSTI2021

CFD/FEA Co-Simulation Framework for Analysis of the Thermal Barrier Coating Design and Its Impact on the HD Diesel Engine Performance

Thermal barrier coatings (TBCs) have been investigated both experimentally and through simulation for mixing controlled combustion (MCC) concepts as a method for reducing heat transfer losses and increasing cycle efficiency, but it is still a very active research area. Early studies were inconclusive, with different groups discovering obstacles to realizing the theoretical potential. Nuanced papers have shown that coating material properties, thickness, microstructure, and surface morphology/roughness all can impact the efficacy of the thermal barrier coating and must be accounted for. Adding to the complexities, a strong spatial and temporal heat flux inhomogeneity exists for mixing controlled combustion (diesel) imposed onto the surfaces from the impinging flame jets. In support of the United States Department of Energy SuperTruck II program goal to achieve 55% brake thermal efficiency on a heavy-duty diesel engines, this study sought to develop a deeper insight into the inhomogeneous heat flux from mixing controlled combustion on thermal barrier coatings and to infer concrete guidance for designing coatings. To that end, a co-simulation approach was developed that couples high-fidelity computational fluid dynamics (CFD) modeling of in-cylinder processes and combustion, and finite element analysis (FEA) modeling of the thermal barrier-coated and metal engine components to resolve spatial and temporal thermal boundary conditions. The models interface at the surface of the combustion chamber; FEA modeling predicts the spatially resolved surface temperature profile, while CFD develops insights into the effect of the thermal barrier coating on the combustion process and the boundary conditions on the gas side. The paper demonstrates the capability of the framework to estimate cycle impacts of the temperature swing at the surface, as well as identify critical locations on the piston/thermal barrier coating that exhibit the highest charge temperature and highest heat fluxes. In addition, the FEA results include predictions of thermal stresses, thus enabling insight into factors affecting coating durability. An example of the capability of the framework is provided to illustrate its use for investigating novel coatings and provide deeper insights to guide future coating design.

42 ENGINEERING↗

NASA NTRS2010

Development and Implementation of Nationally Recognized Laboratory for Material Characterization in the Microwave and Millimeter Wave Bands

This report provides a progress update for establishing a laboratory for material characterization in the microwave and millimeter wave bands. During the launch of STS-124 a large area of refractory bricks was liberated from the flame trench built for the exhaust of the solid rocket motors (SRM). The inspection of the liberated area revealed many defects, debonds, corrosion and voids that are a cause for concern relating to the health of the entire flame trench wall. A request for assistance was received for the nondestructive evaluation (NDE) of these anomalies behind the refractory bricks, with the primary interest being a health assessment based on the quality of the brick, epoxy and concrete bond.

Hepburn, Frank L.↗

DOE OSTI2020

Sampling and Analysis Plan for Investigation of Undeclared Nuclear Activities - 20104

The nuclear-centered energy policy in South Korea is moving towards a nuclear-free era. It also facilitates an action or progress on the denuclearization of the Korean peninsula. The Nuclear Safety and Security Commission (NSSC) launched a new R and D project which attempts to verify nuclear activities via analyzing environmental samples. Environmental samples possibly contain significant radiological information relevant to past undeclared activities. In order to precisely verify them, it is essential to provide 1) the concrete information of target facilities, 2) appropriate methodologies and procedures, and 3) well-suited instrumentation and equipment corresponding to sample signatures. It is also important to provide scientific reliability or validity in any process such as sample collection, handling, transportation and laboratory analysis. Therefore, the information of nuclear facilities (fuel fabrication plant, graphite moderated reactor, reprocessing plant) in North Korea are reviewed in order to determine parameters for appropriate sampling methods representing a facility's characteristics. Secondly, a sampling procedure for radioactive elements is being developed based on international and domestic standards such as ASTM (American Society for Testing and Materials), KS (Korean industrial Standards), and International Atomic Energy Agency (IAEA) manuals. The procedure contains some specific information including sampling process, sampling tools, amount of sample, sample identification, and other related information. Developing the qualified national guidelines is most important since sampling and analyzing results can be used as evidences of nuclear activities. The guideline developed through this work will clearly define various methodologies such as document verification, sampling procedures, collection methods, sample storage criteria, chain of custody, and transportation conditions. The final objective of this work is to establish the infrastructure and regulatory framework for assessment of nuclear activities, and provide a national guideline for sampling and analysis. This will bring confidence in the results and play a critical role in complete denuclearization progress in South Korea. (authors)

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

NASA NTRS2011

D.R.O.P: The Durable Reconnaissance and Observation Platform

Robots can provide a remote presence in areas that are either inaccessible or too dangerous for humans. However, robots are often limited by their ability to adapt to the terrain or resist environmental factors. The Durable Reconnaissance and Observation Platform (DROP) is a lightweight robot that addresses these challenges with the capability to survive falls from significant heights, carry a useable payload, and traverse a variety of surfaces, including climbing vertical surfaces like wood, stone, and concrete. DROP is manufactured using a combination of rapid prototyping and shape deposition manufacturing. It uses microspine technology to create a new wheel-like design for vertical climbing. To date, DROP has successfully engaged several vertical surfaces, hanging statically without assistance, and traversed horizontal surfaces at approximately 30 cm/s. Unassisted vertical climbing is capable on surfaces up to 85deg at a rate of approximately 25cm*s(sup -1). DROP can also survive falls from up to 3 meters and has the ability to be thrown off of and onto rooftops. Future efforts will focus on improving the microspine wheels, selecting more resilient materials, customizing the controls, and performing more rigorous and quantifiable testing.

Durable Reconnaissance and Observation Platform (D↗

DOE OSTI2020

Influence of mineralogical and chemical compositions on alkali-silica-reaction of Tennessee limestones

The paper aims to identify potential correlations between mineralogical and chemical compositions of AAR reactive dolomitic limestone aggregates from Tennessee and their expansion on ASTM C1293 for quick evaluation of reactivity. The chemical compositions of 26 limestones, namely the silica content (SiO 2 ), showed a strong correlation with the expansion in the concrete prism test. The early and highly expansive limestones are characterized by a high clay/ mica content (>5%). The reactivity of Tennessee limestones is mainly caused by crypto/microcrystalline quartz, chert, and finely disseminated silica in carbonate and clay/mica matrices, and it can be reasonably evaluated using X-ray diffraction and chemical analysis coupled with petrographic examinations.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Tank Waste Characterization: History, Challenges, and Success Stories

The preparation and chemical and radiochemical analysis of Hanford tank waste samples can be performed with standard laboratory equipment and instruments as relatively routine processes that are not particularly challenging. Rather, the main challenges of tank waste characterization are associated with radiological dose and sampling limitations. Accurate, representative and effective sampling techniques are difficult with the waste tanks because they were not designed for routine sampling. There are a finite number of sampling locations for each tank based on riser positioning, depth and the operational functionality of the sampling riser. For example, in one recently emptied SST, there was one riser that was found to have had concrete dumped down it, thereby eliminating that sampling port. Additionally, the waste within the tank; especially true for the saltcake and sludge, is not homogenous. The ability to adequately mix a million-gallon double shell tank (DST) is a concern for data reproducibility. Another real challenge that must be addressed for sampling single shell tanks, is how to dissolve the salt cake waste in a compromised (leaking) SST. These physical constraints mean that uncertainty in the representativeness of samples must be considered when applying analytical results to the bulk contents of the tank. The tank waste is highly radioactive and thus can only be handled initially by facilities that can receive samples into concrete-shielded hot cells with remote operation with an example provided in Figure 1. The shielding protects the worker from the radiological dose while mineral oil windows and remotely operated manipulators enables the samples to be handled. At Hanford, analytical laboratories with these hot cell capabilities are limited to the Pacific Northwest National Laboratory and the main Hanford operations support laboratory, 222-S Laboratory. Because of their highly radioactive nature, samples must be sufficiently diluted to facilitate their analysis outside of a shielded cell. In some cases, this means some accuracy must be compromised to complete the analysis beyond that normally encountered for non-radioactive material.

Waste Characterization, BBI, PHOENIX: Tank Farms: ↗

DOE OSTI2022

Radiation-Induced Changes in Single Crystal Calcite and Dolomite: Mineral Analogues of Light Water Reactor, Nuclear Power Plant Concrete Aggregates

Two analogues of aggregates (calcite and dolomite) found in nuclear power plant (NPP) concrete have been neutron irradiated to fluences up to 2 × 10 20 n/cm 2 at 52 °C and 4 × 10 19 n/cm 2 at 95 °C (E > 0.1 MeV). X-ray diffraction studies showed that these aging conditions affected crystallography of both calcite and dolomite, with both showing a growth in their unit cells compared to that of the unirradiated samples. Only dolomite samples showed a continuous increase of its lattice parameters with the increase in irradiation. In calcites, the lattice growth with irradiation dissipated after a fluence of 5 × 10 18 n/cm 2 . Radiation-induced disordering of the crystal structure was observed in both materials, while a healing effect of irradiation temperature was mainly observed in calcites. Dislocation densities calculated by using XRD data also supported these observations. Insights made into the unit cells of both minerals by using Fourier synthesis showed that the Mg sites are more prone to the neutron irradiation than the Ca sites, resulting in larger radiation effects and higher disruption in the crystal structure of dolomite than that of calcite. Furthermore, other than the polycrystalline characteristics observed by using TEM, these minerals did not show complete amorphization or significant structural decomposition at the studied irradiation fluences.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Feasibility of Algal Biochar, a Byproduct of Biofuel Production, as a Supplemental Cementitious Material

Algal biochar, as the solid residue of biofuel production from algal biomass, is reported to explore disposition options, aiming to lessen the liability or obstacles to biofuel production processes. However, landfills and open combustion lead to adverse environmental impacts. One way to add value to such wastes is to use them as admixtures in cementitious construction materials. This study aims to investigate the feasibility of algae-derived biochar as supplementary cementitious materials (SCM) at different water contents and mixture ratios. Algal biochar-cement composites were prepared with different algal biochar content as well as different water-to-cement (w/c) ratios, and the surface area, morphology, elemental, and mineralogical composition were characterized. To compensate for the high-water absorption of algal biochar, a small concentration of a superplasticizer was used since higher w/c ratios negatively impact strength. The mechanical performance of algal biochar-cement composites is compared with control composites using commercial silica fume as a typical commercial SCM. The findings suggest that algal biochar is a promising candidate to replace commercial SCM, like silica fume, since algal biochar-cement composites can reach comparable compressive strength and Young’s modulus to commercial pozzolan-cement materials with the same w/c ratio, though at later curing times, 33 days. Although the tensile strength of algal biochar-cement composites is statistically similar at 7 days, it is significantly lower at later curing times, and further investigation is required to improve this property. Algal biochar-based cement binders showed comparable embodied carbon to silica fume-based cement binders based on a cradle-to-gate lifecycle analysis. However, the ability of algal biochar to absorb large volumes of CO 2 over short periods of time, as measured in this study, makes this novel SCM an excellent alternative to reduce the embodied carbon of concrete structures cradle-to-grave at 1/10 of the cost. In conclusion, valorization of algae-derived solid waste provides great potential to reduce embodied carbon and brings credit to biofuel production and concrete-based construction.

algae-derived↗

DOE OSTI2023

MARSAME Radiological Release Report for Diamond Drive Widening and Roundabout Construction Projects, Revision 1

Environmental Protection and Compliance, Environmental Stewardship (EPC-ES) has determined that the soil, concrete and asphalt associated with the Diamond Drive Widening/Roundabout Projects (Figure 1) meets the criteria for unrestricted release to the public under Department of Energy (DOE) Order 458.1, Radiation Protection for the Public and the Environment (DOE, 2020). These conclusions are based on the known history of the area combined with soil sample data collected in 2022; the findings are consistent with DOE Order 458.1 and Los Alamos National Laboratory (LANL) Functional Series Document EPC-ES-FSD-004, Environmental Radiation Protection (LANL, 2021). Sampling and data analysis, as described in this report, were sufficient to meet measurement quality objectives (MQOs) under the Multi-Agency Radiation Survey and Assessment of Materials and Equipment (MARSAME) manual (NUREG, 2009) and LANL procedures (LANL, 2020). Final approvals for waste disposition will come from LANL’s Waste Management Program.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Initial Refinement and Optimization of the Image Reconstruction (U-MBIR) Algorithm to Optimize its Performance in Detecting Damage and Flaws

Concrete is a critical component of nuclear power plants; thus, its safety and reliability must be thoroughly examined throughout the life cycle of the structural system. During the life cycle of this infrastructure, monitoring of the concrete for signs of degradation should be performed through nondestructive evaluation (NDE). Ultrasonic measurements have been an industry standard for both surface and subsurface inspections. As such, Oak Ridge National Laboratory (ORNL) is developing advanced image reconstruction algorithms to overcome the limitations of traditional ultrasonic NDE methodologies. The results and discussion presented herein summarize the current state of the ultrasonic model–based iterative reconstruction (U-MBIR) algorithm developed at ORNL.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Persistent compositions of non-stoichiometric compounds with low bulk diffusivity: A theory and application to Nb3Sn superconductors

Non-stoichiometric compounds may develop a composition gradient when they are formed by reactive diffusional processes. This paper reports an interesting phenomenon that in compounds with low bulk diffusivities, which rely mainly on grain boundary diffusion for their growth, the final bulk compositions may be far from equilibrium, with a very low bulk diffusivity leading to fixed (persistent) compositions – one such example is Nb 3 Sn, a superconductor. We investigated the microchemistry at the reactive interface using atom probe tomography to clarify the diffusion reaction mechanism for this low-bulk-diffusivity case and thus propose a theory for what determines the compound composition, using Nb 3 Sn as an example for concreteness. Using certain approximations, we derive an explicit analytical equation that illustrates what factors determine its composition profile. We compare our model with the known facts of Nb 3 Sn and see good agreement. In particular, this model predicts that internal oxidation may lead to higher Sn contents than conventional, non-oxidized Nb 3 Sn. Our measurements show that this is indeed true, and that the internally-oxidized Nb 3 Sn also has higher upper critical fields, achieving up to 28.2 T at 4.2 K. We discuss the general applicability of this model to non-stoichiometric compounds with low bulk diffusivity, and propose it as a tool to help in the design and processing of such materials for compositional control.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Monitoring accelerated alkali-silica reaction in concrete prisms with petrography and electrical conductivity measurements

We report deterioration of concrete due to alkali-silica reaction (ASR) involves a reaction between alkaline ions in the cement pore solution and non-crystalline silica found in many aggregates. Diagnosing and quantifying deterioration due to ASR in concrete currently requires destructive testing for microscopy examinations. In this paper, electrical conductivity is investigated qualitatively as an alternative non-destructive evaluation (NDE) method of ASR in hardened concrete. The study was performed using an unrestrained set of small concrete prism specimens made with highly reactive small aggregates, and kept in an environmental chamber according to ASTM C1293 standard. In a companion study, destructive petrography and damage rating index (DRI) assessment, and pore solution extraction and analysis were performed on the same set of accelerated ASR specimens. The results show that temporal evolution of nondestructive bulk resistivity is linearly correlated with destructive DRI score.

36 MATERIALS SCIENCE↗

NASA NTRS1996

A Concept for the Use and Integration of Super-Conducting Magnets in Structural Systems in General and Maglev Guideway Mega-Structures in Particular

Recent breakthroughs in several different fields now make it possible to incorporate the use of superconducting magnets in structures in ways which enhance the performance of structural members or components of structural systems in general and Maglev guideway mega-structures in particular. The building of structural systems which connect appropriately scaled superconducting magnets with the post-tensioned tensile components of beams, girders, or columns would, if coupled with 'state of the art' structure monitoring, feedback and control systems, and advanced computer software, constitute a distinct new generation of structures that would possess the unique characteristic of being heuristic and demand or live-load responsive. The holistic integration of powerful superconducting magnets in structures so that they do actual structural work, creates a class of 'technologically endowed' structures that, in part - literally substitute superconductive electric power and magnetism for concrete and steel. The research and development engineering, and architectural design issues associated with such 'technologically endowed' structural system can now be conceptualized, designed, computer simulates built and tested. The Maglev guideway mega-structure delineated herein incorporates these concepts, and is designed for operation in the median strip of U.S. Interstate Highway 5 from San Diego to Seattle an Vancouver, and possibly on to Fairbanks, Alaska. This system also fits in the median strip of U.S. Interstate Highway 55 and 95 North-South, and 80 and 10, East-West. As a Western Region 'Peace Dividend' project, it could become a National or Bi-National research, design and build, super turnkey project that would create thousands of jobs by applying superconducting, material science, electronic aerospace and other defense industry technologies to a multi-vehicle, multi-use Maglev guideway megastructure that integrates urban mass transit Lower Speed (0-100 mph), High Speed (100-200 mph), Super Speed (200-400 mph), and Hypersonic evacuated tube (400-10,000 mph) Maglev systems.

Ussery, Wilfred T.↗

DOE OSTI2026

Nanoscale Defects as Probes of Time-Reversal Symmetry Breaking

Nanoscale defects such as nitrogen-vacancy (NV) centers can serve as sensitive and noninvasive probes of electromagnetic fields and fluctuations from materials, which in turn can be used to characterize these systems. Here we specifically discuss how NV centers can probe time-reversal symmetry breaking (TRSB) phenomena in low-dimensional electronic systems. We argue that the difference in relaxation rates Γ$_{±\hat{z}}$ of NV centers starting from 𝑚 = ±1 spin states to the ground state with 𝑚 = 0 directly probes TRSB. The effect arises from the difference in the fluctuation spectrum of left- and right-polarized electromagnetic fields emanating from such materials. In the quantum Hall setting, the NV center experiences (nearly zero) large additional contribution to its relaxation due to the presence of the material when its magnetic dipole (anti)aligns with the external field. More generally, the difference in the relaxation rates is sensitive to the imaginary part of the wave-vector-dependent Hall conductivity. We argue that this can be used to determine the Hall viscosity, which can potentially distinguish candidate fractional quantum Hall states and be used to infer the pairing angular momentum in TRSB superconductors. We compute the average relaxation rate [Γ$_{+\hat{z}}$ + Γ$_{-\hat{z}}$] near thin film superconductors and find that it exhibits a Hebel-Slichter-like enhancement below 𝑇 𝑐 . The difference Γ$_{+\hat{z}}$ −Γ$_{-\hat{z}}$ also inherits this peak but is only nonzero for 𝑇 < 𝑇 𝑐 and only if the superconductivity is chiral. We provide concrete estimates for observing this effect in stacked twisted bismuth strontium calcium copper oxide flakes.

NV centers↗

DOE OSTI2020

Superfluid density of a photo-induced superconducting state

Nonequilibrium conditions offer novel routes to superconductivity that are not available at equilibrium. For example, by engineering nonequilibrium electronic populations, pairing may develop between electrons in different energy bands. A concrete proposal has been made to photo-induce superconductivity in a semiconductor, where pairing occurs between electrons in the conduction and valence bands, even for repulsive interactions. Here, we calculate the superfluid density for such a nonequilibrium paired state, and find it to be positive for repulsive interactions and interband pairing. Further, the positivity of the superfluid density implies the stability of the photo-induced superconducting state as well as the existence of the Meissner effect.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Anyon superconductivity from topological criticality in a Hofstadter–Hubbard model

We argue that the combination of strong repulsive interactions and high magnetic fields can generate electron pairing and superconductivity. Inspired by the large lattice constants of moiré materials, which make large flux per unit cell accessible at laboratory fields, we study the triangular lattice Hofstadter-Hubbard model at one-quarter flux quantum per plaquette, where previous literature has argued that a chiral spin liquid separates a weak-coupling integer quantum Hall phase and a strong-coupling topologically trivial antiferromagnetic insulator at a density of one electron per site. We argue that topological superconductivity emerges upon doping in the vicinity of the integer quantum Hall to chiral spin liquid transition. We employ exact diagonalization and density matrix renormalization group methods to examine this theoretical scenario and find that electronic pairing indeed occurs on both sides of criticality over a remarkably broad range of interaction strengths. On the chiral spin liquid side, our results provide a concrete model realization of the long-hypothesized mechanism of anyon superconductivity. Our study thus establishes a beyond-Bardeen-Cooper-Schrieffer route to electron pairing in a well-controlled limit, relying crucially on the interplay between electron correlations and band topology.

Hubbard model↗