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DOE OSTI2022

Laser 3D printing of highly compacted protonic ceramic electrolyzer stack

Solid oxide electrolysis cells (SOECs) for H 2 production is a core technology for H2@scale. However, its conventional manufacturing methods adapted from the manufacture of solid oxide fuel cells (SOFC) need high cost, especially for small-volume production. The emerging laser 3D printing (L3DP) technology with computer-aided 3D printing and computer-controlled laser processing can fulfill layer-by-layer digital shaping and rapid in-situ consolidating feedstock into complicated geometries. L3DP, a promising additive manufacturing (AM) technology, has achieved significant success in manufacturing plastic and metal parts, which is currently attracting considerable attention for the cost-effective, rapid, and flexible manufacturing of heterogeneous multilayered ceramic devices (e.g., SOECs, SOFCs, and solid-state batteries). It is believed that the L3DP can integrate the advantages of selective consolidation of heterogeneous layers, accurate control of layer microstructures, high processing heat efficiency, high processing speed, high stack compactness, high stack design flexibility, and low stack sealing area for cost-effective, rapid, and flexible manufacturing of SOECs to meet DOE’s electrolyzer target.

08 HYDROGEN↗

DOE OSTI2022

Developing an Ultra-Compact, Topology-Optimized Heat Exchanger using Additive Manufacturing

Traditional heat exchanger designs have relied on a plate-fin architecture, assembled in a crossflow configuration. These HX designs are limited in their maximum allowable temperature and, therefore, efficiency. More advanced designs, such as those containing counter-flow, microtube cores, can yield higher efficiencies, but generally require complex headers. The design of such headers is usually determined based on user experience rather than on rigorous design tools, which can lead to lossy architectures; conventional headers can generate up to 50% of the total pressure loss through the HX. Furthermore, the consequences of manufacturing techniques are rarely considered during the design phase. Our team has developed an ultra-compact, topology-optimized heat exchanger capable of operating in environments with temperatures and pressures up to 800°C (1472°F) and 250 bar (3626 psi), respectively. Throughout the program, the team leveraged extensive additive manufacturing research and experience in supercritical carbon dioxide (sCO 2 ) power generation experience to develop and commercialize the technology. The final power density numbers for the subscale and full-scale heat exchangers are >15 kW/kg and >50 kW/L, which includes the core and the headers. The team has involved the RTX business units, notably Collins Aerospace, in discussions for commercializing the technology.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2024

Heteroatom-Modified and Compacted Zeolite-Templated Carbons for Gas Storage

Methane, the primary component of natural gas, is an energy-rich fuel by weight but exhibits lower energy density by volume than diesel and gasoline; efforts to increase its “volumetric” energy density have been focused on the design and synthesis of a porous scaffold that can bind the methane favorably. Novel approaches typically invoke the highly designable class of materials known as metal-organic frameworks (MOFs) owing to the relative difficulty of controlling carbon structure and composition precisely, without the use of a metal-based node. In this project, we instead explore the concept of carbon templating to achieve a porous scaffold with atomistically thin walls separated at a distance of ~1.2 nm, ideal for the formation of precisely two layers of methane per pore. This bottom-up templating approach permits the use of any small molecular precursor to build up the carbon scaffold, begging the question: which other elements (besides carbon) can be used to tune the surface for optimal methane binding without compromising the structure of the overall material? Boron and nitrogen were both explored and nitrogen was identified as the ideal agent for increasing methane binding to the optimal strength for use at near room temperature. Densification of the resulting materials by mechanical compaction was then explored to produce free-standing pellets with the highest methane “delivery” capacities of any known material. Here we define the amount “delivered” as the amount stored minus the amount remaining in the tank at 73 psi, the lowest useful pressure for vehicular transportation applications. The key features of the resulting methane storage system are rapid discharging and refueling speeds, extremely long cycle life (infinite cycle life for high-purity methane), a near-constant heat of refueling (making the heat generated upon refueling easier to manage), and a low maximum pressure of operation (<1500 psi), enabling the use of all-metal Type I cylinders and significantly reducing the costs of conversion of existing vehicles to cleaner burning, abundantly available natural gas). The technical effectiveness of this approach was further improved by exploring several cost-reduction strategies and investigating the reliability of such storage systems in the presence of “real” natural gas mixtures which contain a mixture of gaseous species.

03 NATURAL GAS↗

DOE OSTI2023

A Conceptual Design of the Reactor Cavity Cooling System for the Horizontal Compact High Temperature Gas Reactor (HC-HTGR)

Horizontal Compact High Temperature Gas Reactor (HC-HTGR) is being designed by a multi-disciplinary team of nuclear, mechanical, and structural engineers under the support of a DOE-NE Advanced Reactor Demonstration Program’s Advanced Reactor Concepts-20 (ARC-20) award. The objective of this ARC-20 project is to deliver a conceptual design for the proposed HC-HTGR in 3 years and support its commercialization as a safe, low-cost HTGR. Argonne National Laboratory (Argonne) is responsible for the design and analysis of the reactor cavity cooling system (RCCS) as a safety system for passive decay heat removal of the reactor concept. This report documents the design study to derive a conceptual design study of the RCCS for the HC-HTGR. It includes the identification of the functions and requirements of the HC-HTGR RCCS, design analyses including high-level design consideration and the calculations for optimizing design space of the system with supporting component-level analysis to inform the material selection and performance of the water panel, the description of the conceptual design of the HC-HTGR RCCS derived based on the analyses results, and performance evaluation of the conceptual RCCS for the HC-HTGR. A detailed concept of the RCCS has been identified and high-level system requirements has been developed for the HC-HTGR. Design space focusing on the natural circulation loop portion of the RCCS has been investigated to optimize the system performance. The initial baseline dimensions were firstly derived based on the scoping calculations. A component level design analysis was conducted for the water panel to inform the material selection and to assess its conduction performance. A preliminary system-level performance analysis was performed for the 1/8th of the compartment of the initial baseline design of the RCCS using RELAP5-3D. To improve the system thermal performance, the RCCS design has been updated by exploring various design options by design parametric analyses. Based on the results, the conceptual design of the RCCS for the HC-HTGR has been derived, which satisfies the target performance of ~1 MWt at the elevated vessel wall temperature conditions. Transient simulations were conducted for the conceptual RCCS design for the HC-HTGR under various operation modes and heat load conditions using RELAP5-3D. The system dynamics in different operating states was investigated and the system performance under transients of interest was evaluated. The results demonstrated the overall system feasibility that the RCCS design maintains structures temperatures lower than maximum allowable temperature with sufficient system inventory without any active heat removal in the design process with certain transients addressed. The HC-HTGR RCCS will have additional design updates of subsystems or optimization of the system components during the preliminary and final design phases. Since the entire plant has not been integrated yet, this delivered conceptual design is subject to changes for integration, that require additional conceptual design activities and Quality and Assurance implementation (Q&A). The performance assessment of the RCCS for the HC-HTGR will be then revisited and optimized to finalize the system design, and the RCCS integrated primary system analysis will be utilized to simulate selective accident scenarios of interest where efforts are currently undergoing in the project.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

High-density SSiC 3D-printed Lattices for Compact HTHP Aero-engine Recuperators

The proposed project utilizes advanced ceramic-based 3D-printing technology to develop light, low-cost, ultra-compact, high-temperature high-pressure (HTHP) heat exchangers (HX) for the harsh oxidizing environment of aircraft gas-turbine engines. Typical 3D printing technologies (powder bed or lithographic techniques) cannot produce large high-density, monolithic ceramic material with intricate internal features and channels required for high-temperature, high-pressure recuperators. Furthermore, typical 3D printing technologies are not yet economical for large high-density components. A high-density material is required for hermeticity, high-temperature strength, and oxidation, corrosion, and wear resistance. The team has invented an extrusion-based additive manufacturing technology (referred to as robocasting) and developed processing techniques to tailor composition and rheological mix properties for rapid 3D printing of high-density alumina and SiC parts. The goal of the proposed project is to use robocasting technology to demonstrate commercializable high-density 3D-printed ceramic HX modules with high durability and quality, thereby reducing the risk of thermo-mechanical failure under extreme environments. In addition, the proposed project improves the quality of the ceramic 3D-printing process over a large printed area and HTHP operating conditions. Ceramic 3D printing technology also provides a means to create advanced topologies that are unobtainable with conventional manufacturing.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Demonstration of low-density, high-performance operation of sustained spheromaks and favorable scalability toward compact, low-cost fusion power plants (Final Scientific/Technical Report)

This project worked to advance the technical viability of a novel method for efficiently sustaining stable, high-performance spheromak plasma configurations to serve as the basis of compact, low-cost fusion power plants. In particular, our group worked to improve the method of Steady Inductive Helicity Injection (SIHI) with Imposed-Dynamo Current Drive (IDCD) for spheromak plasma sustainment. Prior to this project demonstrations of this plasma sustainment technology have achieved plasma performance consistent with entry milestone 3 of the BETHE FOA. Research and development (R&D) activities for this project were focused on increasing plasma performance toward a level consistent with exit milestone 4. To do this the PI and his group worked to increase the performance of sustained spheromaks produced in an existing experimental prototype (HIT-SIU) while improving confidence in projections to and design of future, higher performance devices through three primary R&D activities: 1) Improved control over the density of plasma in the device throughout a discharge to provide a pathway for demonstration of spheromaks Ohmically heating to the Mercier beta limit via: a. Fueling the device directly with plasma through the installation of pre-ionized source on the injectors b. Optimization of electrical current waveforms in the driver circuits to enable low-density plasma formation with a lower fueling rate 2) Computational demonstration of a validated, realistic injector circuit coupled to a dynamic plasma model capable of use as a design tool for SIHI drivers and associated circuits for new experimental design points on the pathway to commercial reactors. The improvements in plasma performance achieved during research activity 1), and the computational projections performed in research activity 2) increased the technological readiness level (TRL) of this fusion energy concept toward a level sufficient to attract early-stage private investment and/or other forms of follow-on investment to pursue required R&D activities required for the eventual fusion power plants based on this novel technical approach.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Primary System Thermal Fluids Analysis Model Development for the Compact High Temperature Gas Reactor (HC-HTGR) (Final Report)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

UHT-CAMANCHE: Ultra-High Temperature Ceramic Additively Manufactured Compact Heat Exchangers

The conceptual basis for this project is the convergence of advanced ultra-high temperature ceramic materials and additive manufacturing technologies to produce compact ceramic heat exchangers with complex internal flow path geometries. Task areas were broadly divided into materials and manufacturing development, heat exchanger design, component testing, and techno-economic analysis. Technical challenges included the design and commissioning of new test facilities, improving feature resolution and deposition rate of ceramic additive manufacturing techniques, establishing process-structure-property relationships in additively manufactured ultra-high temperature ceramics, and assessing high temperature materials compatibility in CO 2 environments. The primary candidate material evaluated in this work is a composite comprising zirconium diboride (ZrB2) with 30 vol. % silicon carbide (SiC) which was selected based on its desirable combination of high temperature mechanical properties, high thermal and electrical conductivities, and oxidation resistance. High solids loaded ZrB2-SiC pastes suitable for extrusion-based additive manufacturing were developed for the first time as part of this work. Materials compatibility studies indicate this material oxidizes in CO 2 to form a protective borosilicate scale which transforms to pure silica above 1000°C. Parts made by additive manufacturing displayed enlarged grain sizes produced by pressureless sintering as compared to hot-press sintering. Increases in microstructural coarseness have outsized effect on oxidation performance up to 1400°C due to incomplete oxidation of coarse large diameter SiC particles resulting in lower amounts of silica that apparently inhibit protective scale formation. Additive manufacturing as a forming technique did not appear to significantly affect thermal conductivity, hardness, or elastic modulus, though flexural strength was reduced by half or more as compared to traditionally hot-pressed materials. This effect was attributed to the presence of strength-limiting flaws (ca. 40 microns in size) originating from extrudate inhomogeneities that could potentially be eliminated with further process improvements. Attempts to attain economies of scale for production of multi-kilowatt scale heat exchangers by ceramic additive manufacturing proved difficult. Lack of automation and a modest extrusion rate while retaining fine feature resolution made the overall process labor intensive and limited experimental throughput. A number of full-scale components were taken through post-process heat treatments including drying, binder burnout, and sintering; however, none survived without significant flaws or cracks. Therefore, no operational data from a newly installed heat exchanger test loop were able to be obtained during the performance period. Continued research and development is recommended to improve economic feasibility of ceramic additive manufacturing by standardizing the use of advanced sensors, artificial intelligence, and automation tools to reduce associated labor costs and accelerate production rates. The materials and manufacturing techniques demonstrated in this work are likely to find applications in defense and energy applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

High power density compact drive integrated motor for electric transportation

This project, initially part of OPEN 2018, and subsequently the ASCEND effort, targeted demonstration of significant enhancements in internal permanent magnet (IPM) motor torque and power density for current and future ground and air electric transportation applications. These were achieved through: (1) embedded two-phase system thermal management, (2) coupled, multi-scale electrical-electromagnetic-thermal-mechanical co-design and optimization, (3) size and weight reduction of motor and drive electronics through elimination of redundant cooling and coupling hardware, and (4) higher efficiency operation of SiC wide bandgap power electronics packaging through high temperature operation (200 oC). The proposed approach utilizes a single dielectric coolant for closed loop two-phase thermal management, and a combined heat rejection unit for the IPM and drive. Wick assisted liquid delivery for evaporative thermal management is utilized for the motor, and the drive electronics utilize the same coolant in flow boiling within the cold plate structures. Through the use of three-dimensional packaging for SiC, and novel drive topologies with reduced switching losses, significant increases in power density and compactness were targeted.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

Compact Coaxial HOM Damper for SRF Cavities

SRF technology enable particle accelerators operate with greater average beam currents and higher duty cycles. In these regimes parasitic excitation of the cavity HOM spectrum become the limiting factor due to extra RF losses and instabilities appearing in the beam. We discuss the limitations of HOMs for large accelerator projects as the Fermilab MI upgrade and the proposed future circular and linear colliders EIC and ILC. A new compact HOM damper concept is suggested providing required HOM suppression. The idea is based on an oversized coaxial line with radial sections, which is directly connected to the axial region of the SRF cavity. Such radially sectioned coaxial works as a filter for the operating mode, while being transparent for the HOMs. Implementations of this design for the accelerator and crab cavities developed for the MI and EIC machines, respectively, are discussed.

Lunin, A. [Fermilab]↗

DOE OSTI2026

A Compact Monolithic Electro-Optic Package for Quantum Microwave-to-Optical Transduction

We present a novel quantum transduction package that integrates a macroscopic electro-optic crystal into a compact, monolithic assembly designed for superconducting quantum processors. The device provides an efficient and scalable interface between microwave and optical domains while preserving cryogenic compatibility. We performed full-wave and quantum dynamical simulations to assess the performance of the hybrid system, focusing on the interaction between a transmon-based microwave cavity and the crystal’s and cavity low-frequency microwave mode. The transmon operates both as an ancilla for the QPU and as a nonlinear element enabling four-wave mixing between cavity and electro-optic crystal microwave fields. Our results indicate that this architecture can coherently mediate quantum information transfer from the cavity to the electro-optic mode, offering a promising platform for on-chip quantum transduction within superconducting quantum networks.

Reineri, Alessandro [Fermilab] (ORCID:000000016175↗

DOE OSTI2026

A Compact Monolithic Electro-Optic Package for Quantum Microwave-to-Optical Transduction

Reineri, Alessandro [Fermilab] (ORCID:000000016175↗

DOE OSTI2024

Optimization of Triply Periodic Minimal Surface Heat Exchanger to Achieve Compactness, High Efficiency, and Low-Pressure Drop

With advancements in additive manufacturing (AM) techniques, high-quality triply periodic minimal surface (TPMS) structures can now be produced. TPMS walled heat exchangers (HX) hold significant potential for industrial applications and are receiving increasing attention. This paper explores the impact of various TPMS design variables on flow and thermal performance to optimize TPMS heat exchangers for compactness, high efficiency, and low pressure drop. The design variables examined include the type of TPMS lattice, unit cell size, wall thickness, aspect ratio, TPMS orientation, and equivalent thickness. The study reveals that the flow and heat transfer performance of TPMS structures are significantly affected by these design variables. For the Gyroid, Diamond, and SplitP lattices, performance is nearly identical when the surface-to-volume ratio is kept constant. The average velocity of the fluid in the TPMS HX should be 0.3 m/s. The corresponding Re is between 300~800. Thin wall thickness, small equivalent thickness, and flat lattice configurations can significantly reduce pressure drop while maintaining the overall heat transfer coefficient. Additionally, the angle between the flow direction and TPMS orientation can increase pressure drop. Three aluminum heat exchangers were successfully printed using an AM machine, and testing results are comparable with theoretical prediction.

42 ENGINEERING↗

DOE OSTI2026

A Compact Cryogenic Environment for In Situ Neutron Diffraction Under Mechanical Loading

Understanding the deformation mechanisms of materials at cryogenic temperatures is crucial for cryogenic engineering applications. In situ neutron diffraction is a powerful technique for probing such mechanisms under cryogenic conditions. In this study, we present the development of a compact cryogenic environment (CCE) designed to facil-itate in situ neutron diffraction experiments under mechanical loading at tempera-tures as low as 77 K. The CCE features a polystyrene foam cryogenic chamber, alumi-num blocks serving as neutron-transparent cold sinks, a liquid nitrogen dosing system for cryogen delivery, a nitrogen gas flow control system for thermal management, a process controller for temperature control, and a pair of thermally isolated grip adapt-ers for mechanical testing. The CCE achieves reliable temperature control with mini-mal neutron attenuation. Utilizing this setup, we conducted three in situ neutron dif-fraction tensile tests on a 316L stainless steel at 77 , 173 , and 298 K, respectively. The results highlight the pronounced effects of cryogenic temperatures on the material's deformation mechanisms, underscoring both the significance of cryogenic deformation studies and the effectiveness of the CCE.

Yu, Dunji [ORNL] (ORCID:0000000189467851)↗

DOE OSTI2021

Deep Learning with Quantized Neural Networks for Gravitational-wave Forecasting of Eccentric Compact Binary Coalescence

We present the first application of deep learning forecasting for binary neutron stars, neutron star–black hole systems, and binary black hole mergers that span an eccentricity range e ≤ 0.9. In this work, we train neural networks that describe these astrophysical populations, and then test their performance by injecting simulated eccentric signals in advanced Laser Interferometer Gravitational-Wave Observatory (LIGO) noise available at the Gravitational Wave Open Science Center to (1) quantify how fast neural networks identify these signals before the binary components merge; (2) quantify how accurately neural networks estimate the time to merger once gravitational waves are identified; and (3) estimate the time-dependent sky localization of these events from early detection to merger. Our findings show that deep learning can identify eccentric signals from a few seconds (for binary black holes) up to tens of seconds (for binary neutron stars) prior to merger. A quantized version of our neural networks achieves 4× reduction in model size, and up to 2.5× inference speedup. These novel algorithms may be used to facilitate time-sensitive multimessenger astrophysics observations of compact binaries in dense stellar environments.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2022

The Compact Structures of Massive z ~ 0.7 Post-starburst Galaxies in the ${\bf{SQuIGG}}\vec{{\boldsymbol{L}}}{\bf{E}}$ Sample

We present structural measurements of 145 spectroscopically selected intermediate-redshift (z ~ 0.7), massive (M $\star$ ~ 10 11 M ⊙ ) post-starburst galaxies from the ${\bf{SQuIGG}}\vec{{\boldsymbol{L}}}{\bf{E}}$ sample measured using wide-depth Hyper Suprime-Cam i-band imaging. This deep imaging allows us to probe the sizes and structures of these galaxies, which we compare to a control sample of star-forming and quiescent galaxies drawn from the LEGA-C Survey. We find that post-starburst galaxies systematically lie ~0.1 dex below the quiescent mass–size (half-light radius) relation, with a scatter of ~0.2 dex. This finding is bolstered by nonparametric measures, such as the Gini coefficient and the concentration, which also reveal these galaxies to have more compact light profiles than both quiescent and star-forming populations at similar mass and redshift. The sizes of post-starburst galaxies show either negative or no correlation with the time since quenching, such that more recently quenched galaxies are larger or similarly sized. This empirical finding disfavors the formation of post-starburst galaxies via a purely central burst of star formation that simultaneously shrinks the galaxy and shuts off star formation. We show that the central densities of post-starburst and quiescent galaxies at this epoch are very similar, in contrast with their effective radii. The structural properties of z ~ 0.7 post-starburst galaxies match those of quiescent galaxies that formed in the early universe, suggesting that rapid quenching in the present epoch is driven by a similar mechanism to the one at high redshift.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2022

MaNGA 8313-1901: Gas Accretion Observed in a Blue Compact Dwarf Galaxy?

Gas accretion is an important process in the evolution of galaxies, but it has limited direct observational evidences. In this paper, we report the detection of a possible ongoing gas accretion event in a blue compact dwarf (BCD) galaxy, MaNGA 8313-1901, observed by the Mapping Nearby Galaxies and Apache Point Observatory (MaNGA) program. This galaxy has a distinct off-centered blue clump to the northeast (the NE clump) that shows low metallicity and enhanced star formation. The kinematics of the gas in the NE clump also seems to be detached from the host BCD galaxy. Together with the metallicity drop of the NE clump, it suggests that the NE clump likely has an external origin, such as gas accretion or galaxy interaction, rather than an internal origin, such as an H II complex in the disk. After removing the underlying host component, we find that the spectrum of the "pure" clump can match very well with a modeled spectrum containing a stellar population of the young stars (≤7 Myr) only. This may imply that the galaxy is experiencing an accretion of cold gas, instead of a merger event involving galaxies with significant preexisting old stars. We also find signs of another clump (the SW clump) at the southwest corner of the host galaxy, and the two clumps may share the same origin of gas accretion.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2023

New Covariant Density Functionals of Nuclear Matter for Compact Star Simulations

We generate three families of extended covariant density functionals of nuclear matter that have varying slope of symmetry energy and skewness at nuclear saturation density, but otherwise share the same basic parameters (symmetry energy, compressibility, saturation parameters, etc.) with the standard DDME2, DD2, and MPE functionals. Tables of the parameters of these new density functionals are given, which can be straightforwardly used in DDME2, DD2, and MPE parameterization-based codes. Furthermore, we provide tables of a large number of equations of state (81 for each family) that can be used in astrophysical simulations to assess the impact of variations of the not-well-known slope of symmetry energy and skewness of nuclear systems on the astrophysics of compact objects. We also provide tables of computed integral parameters (mass, radius, and tidal deformability) that can be used, e.g., for modeling gravitational waveforms. Finally, for the extended DDME2-based parameterization, we implement a first-order phase transition to quark matter to obtain a family of equations of state that accommodates a phase transition to quark matter. Analogous tables of the equations of state and integral parameters are provided for this case as well.

79 ASTRONOMY AND ASTROPHYSICS↗