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DOE OSTI2023

A Novel Design for Improving the Control on the Stainless-Steel Vessel Welding Process for Superconducting Magnets

Stainless steel vessels see widespread use in superconducting magnets for particle accelerator applications. Their function varies in different magnet designs: they always provide the necessary liquid helium containment, but in some cases are also used to provide azimuthal prestress and can also be welded to the magnet end plate to provide additional longitudinal stiffness. A magnet designed with the bladder and key technology does not rely on the structural role of the vessel. They are structurally supported using azimuthally prestressed aluminum shells, and the longitudinal constraint by rods. In this case, the magnet designer would generally like to minimize the interaction between the magnet and the stainless-steel vessel and to minimize the coil stress variation due to the vessel. The stress state in the vessel and in the coil is a function of the circumferential interference, defined as the vessel azimuthal length minus the magnet circumference. The vessel and the magnet azimuthal length machining tolerances are relatively large resulting in significant stress variations in the superconducting coils. In this paper we introduce an interference control shim, which can significantly limit the stress variation of the coils for a given variation of the interference. The effectiveness of the interference-control shim is evaluated numerically on the MQXF, the low-β quadrupole for the High Luminosity LHC.

43 PARTICLE ACCELERATORS↗

DOE OSTI2022

A Quench Detection and Monitoring System for Superconducting Magnets at Fermilab

A quench detection system was developed for protecting and monitoring the superconducting solenoids for the Muon-to-Electron Conversion Experiment (Mu2e) at Fermilab. The quench system was designed for a high level of dependability and long-term continuous operation. It is based on three tiers: Tier-I, FPGA-based Digital Quench Detection (DQD); Tier-II, Analog Quench Detection (AQD); and Tier-3, the quench controls and data management system. The Tier-I and Tier-II are completely independent and fully redundant systems. The Tier-3 system is based on National Instruments (NI) C-RIO and provides the user interface for quench controls and data management. It is independent from Tiers I & II. The DQD provides both quench detection and quench characterization (monitoring) capability. Both DQD and AQD have built-in high voltage isolation and user programmable gains and attenuations. The DQD and AQD also includes user configured current dependent thresholding and validation times. A 1 st article of the three-tier system was fully implemented on the new Fermilab magnet test stand for the HL-LHC Accelerator Up-grade Project (AUP). It successfully provided quench protection and monitoring (QPM) for a cold superconducting bus test in November 2020. The Mu2e quench detection design has since been implemented for production testing of the AUP magnets. A detailed description of the system along with results from the AUP superconducting bus test will be presented.

monitoring↗

DOE OSTI2026

Operation of a Modular 3D-Pixelated Liquid Argon Time-Projection Chamber in a Neutrino Beam

The 2x2 Demonstrator, a prototype for the Deep Underground Neutrino Experiment (DUNE) liquid argon (LAr) Near Detector, was exposed to the Neutrinos from the Main Injector (NuMI) neutrino beam at Fermi National Accelerator Laboratory (Fermilab). This detector is a prototype of a new modular design for a liquid argon time-projection chamber (LArTPC), comprising a two-by-two array of four modules, each further segmented into two optically isolated LArTPCs. The 2x2 Demonstrator features a number of pioneering technologies, including a low-profile resistive field shell to establish drift fields, native 3D ionization pixelated imaging, and a high-coverage dielectric light readout system. The 2.4-tonne active mass detector is flanked upstream and downstream by supplemental solid-scintillator tracking planes, repurposed from the MINERvA experiment, which track ionizing particles exiting the argon volume. The antineutrino beam data collected by the detector over a 4.5 day period in 2024 include over 30,000 neutrino interactions in the LAr active volume—the first neutrino interactions reported by a DUNE detector prototype. During its physics-quality run, the 2x2 Demonstrator operated at a nominal drift field of 500 V/cm and maintained good LAr purity, with a stable electron lifetime of approximately 1.25 ms. This paper describes the detector and supporting systems, summarizes the installation and commissioning, and presents the initial validation of collected NuMI beam and off-beam self-triggers. In addition, it highlights observed interactions in the detector volume, including candidate muon antineutrino events.

47 OTHER INSTRUMENTATION↗

DOE OSTI2026

Revolutionizing thermal Management in Next-Generation AI data centers: Challenges and breakthrough innovations

Data centers (DCs) serve as critical infrastructure for powering the growth and evolution of AI. Next-generation AI DCs present unique challenges in thermal management driven by unprecedented computational demands. This paper provides a comprehensive summary of key stakeholder perspectives on technology gaps, infrastructure requirements, test bed needs, emerging opportunities, and preliminary solutions related to thermal management for AI DCs. It establishes six strategic pillars of thermal management for next generation AI DC: reliability, deployability, efficiency, resilience, measurability, and valorization. The discussion spans a range of critical topics, including advanced cooling technologies, thermal strategies for emerging modular and edge DCs, system-level optimization and control frameworks, infrastructure planning and grid integration designs, benchmarking approaches, and pathways for waste heat recovery and reuse. The proposed research, development, and demonstration efforts are aimed at accelerating the deployment of AI DCs while ensuring energy efficiency, reliability, safety, and regulatory compliance.

Wang, Pengtao [ORNL] (ORCID:0000000214713429)↗

DOE OSTI2026

Computational design of materials for nuclear reactors

Computational design for fission reactor materials is ready to accelerate the development and qualification of nuclear materials. This review is primarily aimed at computational materials scientists that seek to apply ICME to the development of fission reactor materials. We summarize reactor materials and technology, discuss reactor material development and qualification today, show how ICME is being applied to the unique requirements of reactor materials, and provide a future vision.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

RESONANT MATCHING SECTION FOR CEBAF ENERGY UPGRADE

Thomas Jefferson National Accelerator Facility (Jeffer- son Lab) currently studies the feasibility of upgrading its energy to 22 GeV. It considers addition of six more linac passes. The highest energy passes will share two new arcs designed using the Fixed-Field Alternating Gradient (FFA) technology. The FFA arcs are built using permanent combined-function magnets. They will be connected to the linacs through transition sections that will match the optics of all six passes to the linacs. With the high number of con- straints and the limited space available, we are investigating a parametric resonance technique to match the optics quasi- independently at each energy. A resonance is excited at each individual energy to selectively control its optics. The reso- nant dipole and quadrupole kick harmonics are imposed for all energies simultaneously using Panofsky corrector mag- nets placed throughout the FFA arcs. This paper presents the current progress on that transition section design

Deitrick, K.↗

DOE OSTI2025

Science of Scale-Up: Accelerating chemical manufacturing technology development workshop report

The Science of Scale-Up: Accelerating chemical manufacturing technology development workshop report outlines key insights and actionable recommendations for accelerating the scale-up of disruptive chemical manufacturing technologies. Convened in October 2024, the workshop brought together approximately fifty experts from academia, industry, national laboratories, and government agencies to address the barriers and solutions for maturing technologies from proof-of-concept to commercialization. The report identifies seven critical themes for enabling faster scale-up. These themes were explored through general discussions and breakout sessions focused on three specific chemical manufacturing technologies—electrochemical, thermochemical, and biological conversion processes. The findings emphasize the importance of interdisciplinary collaboration, robust funding mechanisms, and shared resources to overcome technical barriers and accelerate technology deployment. The report also highlights technology-specific challenges and opportunities, including the need for advanced materials, scalable manufacturing processes, and integrated testing environments. For electrochemical manufacturing processes, durability and material optimization are key priorities, while thermochemical processes require novel reactor designs and better supply chain integration. Biological conversion processes face hurdles in strain engineering, reactor design, and process integration. Across all technologies, the workshop emphasized the importance of leveraging computational tools, standardized protocols, and collaborative networks to address knowledge gaps and technical barriers. By acting on these insights, stakeholders can reduce the timeline for scaling up critical chemical manufacturing technologies, ensuring their timely impact on manufacturing competitiveness, and environmental sustainability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2006

Extending NASA Research Results to Benefit Society: Rapid Prototyping for Coastal Applications

The mission of the NASA Applied Sciences Program is to expand and accelerate the use of NASA research results to benefit society in 12 application areas of national priority. ONe of the program's major challenges is to perform a quick, efficient, and detailed review (i.e., prototyping) of the large number of combinations of NASA observations and results from Earth system models that may be used by a wide range of decision support tools. A Rapid Prototyping Capacity (RPC) is being developed to accelerate the use of NASA research results. Here, we present the conceptual framework of the Rapid Prototyping Capacity within the context of quickly assessing the efficacy of NASA research results and technologies to support the Coastal Management application. An initial RPC project designed to quickly evaluate the utility of moderate-resolution MODIS products for calibrating/validating coastal sediment transport models is also presented.

Glorioso, Mark V.↗

NASA NTRS2007

Smart Payload Development for High Data Rate Instrument Systems

This slide presentation reviews the development of smart payloads instruments systems with high data rates. On-board computation has become a bottleneck for advanced science instrument and engineering capabilities. In order to improve the computation capability on board, smart payloads have been proposed. A smart payload is a Localized instrument, that can offload the flight processor of extensive computing cycles, simplify the interfaces, and minimize the dependency of the instrument on the flight system. This has been proposed for the Mars mission, Mars Atmospheric Trace Molecule Spectroscopy (MATMOS). The design of this system is discussed; the features of the Virtex-4, are discussed, and the technical approach is reviewed. The proposed Hybrid Field Programmable Gate Array (FPGA) technology has been shown to deliver breakthrough performance by tightly coupling hardware and software. Smart Payload designs for instruments such as MATMOS can meet science data return requirements with more competitive use of available on-board resources and can provide algorithm acceleration in hardware leading to implementation of better (more advanced) algorithms in on-board systems for improved science data return

Virtex-4↗

NASA NTRS2014

Spinoff 2013

Topics covered include: Innovative Software Tools Measure Behavioral Alertness; Miniaturized, Portable Sensors Monitor Metabolic Health; Patient Simulators Train Emergency Caregivers; Solar Refrigerators Store Life-Saving Vaccines; Monitors Enable Medication Management in Patients' Homes; Handheld Diagnostic Device Delivers Quick Medical Readings; Experiments Result in Safer, Spin-Resistant Aircraft; Interfaces Visualize Data for Airline Safety, Efficiency; Data Mining Tools Make Flights Safer, More Efficient; NASA Standards Inform Comfortable Car Seats; Heat Shield Paves the Way for Commercial Space; Air Systems Provide Life Support to Miners; Coatings Preserve Metal, Stone, Tile, and Concrete; Robots Spur Software That Lends a Hand; Cloud-Based Data Sharing Connects Emergency Managers; Catalytic Converters Maintain Air Quality in Mines; NASA-Enhanced Water Bottles Filter Water on the Go; Brainwave Monitoring Software Improves Distracted Minds; Thermal Materials Protect Priceless, Personal Keepsakes; Home Air Purifiers Eradicate Harmful Pathogens; Thermal Materials Drive Professional Apparel Line; Radiant Barriers Save Energy in Buildings; Open Source Initiative Powers Real-Time Data Streams; Shuttle Engine Designs Revolutionize Solar Power; Procedure-Authoring Tool Improves Safety on Oil Rigs; Satellite Data Aid Monitoring of Nation's Forests; Mars Technologies Spawn Durable Wind Turbines; Programs Visualize Earth and Space for Interactive Education; Processor Units Reduce Satellite Construction Costs; Software Accelerates Computing Time for Complex Math; Simulation Tools Prevent Signal Interference on Spacecraft; Software Simplifies the Sharing of Numerical Models; Virtual Machine Language Controls Remote Devices; Micro-Accelerometers Monitor Equipment Health; Reactors Save Energy, Costs for Hydrogen Production; Cameras Monitor Spacecraft Integrity to Prevent Failures; Testing Devices Garner Data on Insulation Performance; Smart Sensors Gather Information for Machine Diagnostics; Oxygen Sensors Monitor Bioreactors and Ensure Health and Safety; Vision Algorithms Catch Defects in Screen Displays; and Deformable Mirrors Capture Exoplanet Data, Reflect Lasers.

Source record↗

DOE OSTI2023

Demonstration of Niobium Tin in 218 MHz Low-beta Quarter Wave Accelerator Cavity

A 218 MHz quarter wave niobium cavity has been fabricated for the purpose of demonstrating Nb3Sn technology on a low-beta accelerator cavity. Niobiumtin has been established as a promising next generation SRF material, but development has focused primarily in high-beta elliptical cell cavities. This material has a significantly higher TC than niobium, allowing for design of higher frequency quarter wave cavities (that are subsequently smaller) as well as for significantly lowered cooling requirements (possibly leading to cryocooler based designs). The fabrication, initial cold testing, and Nb3Sn coating are discussed as well as test plans and details of future applications.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

A Design and Fabrication Options Trade Study for Metallic Fuel without Internal Sodium Bonding

Nuclear fuels using alloys of uranium, or metallic fuels, have many beneficial properties. The classical metallic fuel design uses a loose fitting cylindrical “slug” of fuel placed inside stainless-steel cladding tubes where the gap is filled with sodium. This sodium bond is liquid at operating temperature and conducts heat from the slug to the cladding, especially in early life before fuel swells into contact with the cladding. Despite the benefits of sodium bonding, there is a desire to develop metallic fuel technologies without it chiefly to reduce chemical reaction hazards in spent fuel storage from sodium fast reactors operating on once-through fuel cycles. Elimination of the sodium bond may also help unlock potential benefits for fuel fabrication, reactor neutronics, and compatibility with other types of reactors. Creating a sodium-free metallic fuel revolves around the problem of manufacturing fuel slug geometries which are in close contact with the cladding at beginning of life to facilitate heat transport while alleviating fuel-cladding chemical interactions (FCCI) at this interface and providing enough free volume to accommodate fuel swelling. Accelerating development and qualification of this fuel system will require careful selection of design and manufacturing options. To this end, a design trade-off study was performed to evaluate candidate options. Several design and manufacturing options were assessed, weighted, scored, and ranked with respect to fabrication, normal reactor operation, off-normal scenarios, and back-end considerations. This effort was performed both for “baseline” needs, which represented a once-through fuel cycle at temperatures and burnups known to be viable for sodium-bonded metallic fuel, and for “enhanced” needs to represent opportunities for closed fuel cycles and/or more aggressive temperatures/burnups. The outcomes of this study prioritized a baseline technology using U-Zr alloy with additives to mitigate FCCI, produced in annular slug geometry by continuous casting, clad in austenitic stainless-steel alloy, and followed by a final step to swage the cladding down to close the gap. This study prioritized an enhanced fuel technology using U-Mo alloy, also produced by continuous casting into an annular geometry, followed by coating/plating with an FCCI barrier on the slug, again with a final step to swage the cladding diameter down using oxide dispersion strengthened steel. It was noted that development of the enhanced fuel technology would entail more risk, thus U-Zr alloy was put forth as a backup to U-Mo if challenges are encountered with FCCI barriers, and advanced ferritic/martensitic steels are put forth as a backup to oxide dispersion strengthened steels if swaging and welding are found unworkable.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Through the lens of bioenergy crops: advances, bottlenecks, and promises of plant engineering

Advances in engineering of bioenergy crops were driven over the past years by adapting technological breakthroughs and accelerating conventional applications but also exposed intriguing challenges. New tools revealed rich interconnectivity in the exponentially growing and dynamic 'big' omics data' of metabolomes, transcriptomes, and genomes at previously inaccessible magnitude (global, cross-species, meta-) and resolution (single cell). Insights enabled fresh hypotheses and stimulated disciplines such as functional genomics with discovery of broad regulatory networks and their determinants, that is, DNA parts, including promoters, regulatory elements, and transcription factors. Their rational design, assembly into increasingly complex blueprints, and installation into diverse chassis is an existing frontier that may benefit from emerging technologies to address bottlenecks. Interweaving nature-inspired to fully synthetic parts has already allowed building of fine-tuned regulatory circuits, or new-to-nature metabolic routes insulated from the biological context of the chassis species. Similarly, developments and the evolving need for unifying principles in plant transformation and species-agnostic technologies highlight future opportunities for engineering the next generation of bioenergy plants.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2022

2021 Prototype Design Development Awardee: Accelerate Wind, Inc.

In the United States, rooftop photovoltaic systems can be installed on most commercial buildings. However, even if all available rooftop space is used, solar energy cannot satisfy the building's total energy demand. With many building owners trying to move toward net-zero-carbon-emission energy generation, these customers often have no way to achieve this goal on-site. Rooftop wind energy technology could be an option, but most rooftop wind turbines are not economically viable because they do not produce meaningful amounts of energy and are not likely to pay for themselves within their lifetime. Some rooftop wind turbine companies have attempted to exploit the fact that wind naturally speeds up at the edge of a roof; but, so far, these solutions have also struggled to produce significant energy because only a small portion of that wind can be captured so close to the edge of the roof.

CIP↗

NASA NTRS2018

Dynamic Power Convertor Development for Radioisotope Power Systems at NASA GRC

The Thermal Energy Conversion Branch at NASA Glenn Research Center (GRC) is supporting the development of high-efficiency power convertors in support of Radioisotope Power System (RPS) development. Significant progress was made towards such a system that utilized Stirling conversion machines during the 2001 to 2015 timeframe. Flight development of the Advanced Stirling Radioisotope Generator (ASRG) was cancelled in 2013 by the Department of Energy (DOE) and NASA Headquarters primarily due to budget constraints, and the Advanced Stirling Convertor (ASC) technology contract was subsequently concluded in 2015. A new chapter of technology development has recently been initiated by the NASA RPS Program. This new effort is considering all dynamic power convertor options, such as Stirling and Brayton cycles. Four convertor development contracts supporting this effort were awarded in 2017. The awarded contracts include two free-piston Stirling, one thermoacoustic Stirling, and one turbo-Brayton designs. The technology development contracts each consist of up to three phases: Design, Fabricate, and Test. As of May 2018, all contracts have completed the Design Phase, and each underwent a design review with an independent review board. Two of the contracts have been awarded the Phase 2 option for fabrication. Convertors manifesting from these development efforts will then undergo independent validation and verification at NASA facilities, which will consist of convertor performance and RPS viability demonstrations. Example tests include launch vibration simulation, performance mapping over the environmental temperature range, and static acceleration exposure. In parallel with this renewed development effort, NASA GRC is still demonstrating free-piston Stirling convertor technology using assets from previous projects. The Stirling Research Laboratory (SRL) is still operating 10 convertors from previous development projects. Four of which are flexure-bearing based, and the other six are gas-bearing based. One of the flexure-bearing convertors has accumulated over 110,000 hours of operation, and holds the current maintenance-free heat-engine run-time record. Another flexure-bearing convertor was recently manually shutdown after 105,620 hours of operation, then disassembled and inspected. This inspection produced a wealth of information about the effects of this amount of runtime on the technology's components. One of the engineering unit flexure-bearing convertors recently underwent launch simulation vibration test, a static acceleration exposure up to 20 g, and was then placed on extended operation. Amongst the gas-bearing convertors, the longest running unit has accumulated over 70,000 hours of operation. Four high-fidelity gas-bearing convertors from the ASRG project are still operating continuously, for which the longest runtime has reached 26,000 hours.

Oriti, Salvatore↗

DOE OSTI2020

Characterization of NbTi busbar for HL LHC Interaction Region Quadrupoles

The US Accelerator Upgrade for the HiLumi-LHC (US-HL-LHC AUP) project and CERN are designing and fabricating superconducting quadrupole magnets for the interaction regions of the High Luminosity Large Hadron Collider (HLLHC). The triplet is made of three optical elements: Q1, Q2, and Q3. The Nb3Sn quadrupole magnets operate in superfluid He at 1.9 K with a nominal field gradient of 132.6 T/m. The three inner triplet elements are connected together with superconducting buses. The design and fabrication of the through and local buses is carried out at Applied Physics and Superconducting Technology Division (APS-TD) at Fermilab (FNAL). This paper reports the characterization of the bus-bar thermoelectric properties. The bus was tested with a short Nb3Sn magnet (MQXFS1e) in the vertical test facility of the APS-TD at FNAL. The test demonstrated that the bus design is adequate since no spontaneous quench took place up to 17.87 kA current value. Quench propagation velocities were investigated over a range of currents that is typical for accelerator superconducting magnets. Temperature margins were found above that required for the Hi- Lumi triplet bus. The design guarantees the protection of the bus at operational current value according to the quench detection voltage threshold (100 mV) established for the Hi-Lumi LHC interaction region.

43 PARTICLE ACCELERATORS↗

NASA NTRS2018

Vision 2040: A Roadmap for Integrated, Multiscale Modeling and Simulation of Materials and Systems

Over the last few decades, advances in high-performance computing, new materials characterization methods, and, more recently, an emphasis on integrated computational materials engineering (ICME) and additive manufacturing have been a catalyst for multiscale modeling and simulation-based design of materials and structures in the aerospace industry. While these advances have driven significant progress in the development of aerospace components and systems, that progress has been limited by persistent technology and infrastructure challenges that must be overcome to realize the full potential of integrated materials and systems design and simulation modeling throughout the supply chain. As a result, NASA's Transformational Tools and Technology (TTT) Project sponsored a study (performed by a diverse team led by Pratt & Whitney) to define the potential 25-year future state required for integrated multiscale modeling of materials and systems (e.g., load-bearing structures) to accelerate the pace and reduce the expense of innovation in future aerospace and aeronautical systems. This report describes the findings of this 2040 Vision study (e.g., the 2040 vision state; the required interdependent core technical work areas, Key Element (KE); identified gaps and actions to close those gaps; and major recommendations) which constitutes a community consensus document as it is a result of over 450 professionals input obtain via: 1) four society workshops (AIAA, NAFEMS, and two TMS), 2) community-wide survey, and 3) the establishment of 9 expert panels (one per KE) consisting on average of 10 non-team members from academia, government and industry to review, update content, and prioritize gaps and actions. The study envisions the development of a cyber-physical-social ecosystem comprised of experimentally verified and validated computational models, tools, and techniques, along with the associated digital tapestry, that impacts the entire supply chain to enable cost-effective, rapid, and revolutionary design of fit-for-purpose materials, components, and systems. Although the vision focused on aeronautics and space applications, it is believed that other engineering communities (e.g., automotive, biomedical, etc.) can benefit as well from the proposed framework with only minor modifications. Finally, it is TTT's hope and desire that this vision provides the strategic guidance to both public and private research and development decision makers to make the proposed 2040 vision state a reality and thereby provide a significant advancement in the United States global competitiveness.

multi-scale modeling↗

DOE OSTI2025

Rapid Bayesian High Entropy Alloy Designs Fabricated via Wire Arc Additive Manufacturing

Purpose: This project seeks to demonstrate a new high-throughput (rapid) alloy design technique applied to creating new high entropy alloys (HEAs) for extreme environments. High entropy alloys shift the design paradigm from being focused on a single principal element (e.g. nickel-based alloys) to target alloys that include high atomic fractions (X >10%) of multiple elements. These HEA materials can exhibit sluggish diffusion and enhanced corrosion resistance, ideal for potential applications in advanced ultra supercritical (A-USC) steam cycles for power generation. Scope: The addition of multiple elements in high atomic fractions creates an enormous design space that cannot easily be investigated by traditional material design strategies such as designed of experiments (DOE). This project utilizes a Bayesian machine learning algorithm that has been modified to work with calculation of phase diagrams (CALPHAD) software. This Bayesian algorithm reduces manual inputs and increase the likelihood of achieving an optimal solution. Compositional inputs to this algorithm will be assessed using existing material property models for high temperature strength and corrosion resistance. The target for alloy performance will be a 15% (~100 ⁰C) increase in allowable service temperature beyond heat-resistant stainless steels while maintaining or improving alloy cost and corrosion resistance. Haynes 230 was selected as a baseline, which is 57 wt% Ni with 22 wt% Cr 14 wt% W, and 2 wt% Mo as solid solution strengtheners. In addition to rapid design via Bayesian machine learning, the alloys were rapidly fabricated using a multi-wire arc additive manufacturing (mWAAM) technique which allows for precise control of alloy composition and assessing of alloy design “windows” to study composition effects. Build speeds for wire-arc additive processes are among the highest for additive technologies enabling rapid and reliable sample fabrication when compared to conventional methods such as arc button melting. The mWAAM samples will be rapidly characterized via instrumented indentation for room temperature modulus and strength and for elevated temperature strength via hot hardness tests. After being screened with hardness testing, potential alloys will be further evaluated with conventional microscopy techniques including scanning electron microscopy (SEM) and transmission electron microscopy (TEM) to assess agreement with modeling results. The most promising compositions will also be evaluated by printing full sized tensile specimens for mechanical behavior tests at elevated temperatures. Results: Bayesian machine learning of a single performance function was initially used to optimize five performance metrics: 1) single phase stability, 2) yield strength, 3) creep resistance (low diffusion coefficient), 4) freezing range (weldability), and 5) material cost. The single performance function was suboptimal as assumptions had to be made about the results while formulating the optimization. A goal-oriented Bayesian optimization strategy (Hanaoka, 2021) was implemented with CALPHAD for use with the five metrics above. This multi-objective Bayesian optimization (MOBO) enabled the design of NiCrCoFe alloys with V and W additions. A base composition of NiCoCr was selected as Ni provides a stable FCC matrix, Cr aids corrosion/oxidation resistance, and Co is a solid-solutions strengthener that also improves creep by increasing the activation energy. Fe helps reduce diffusion coefficients and cost. Finally, V and W were selected for their reasonable solubility and high atomic misfit to aid in solid solution strengthening. Cracking of the mWAAM specimens was an early issue, and the Easton solidification cracking model (Easton et al., 2014a) was selected for addition to the MOBO function. High performing alloys fabricated by mWAAM included Ni 28 Cr 25 Co 26 Fe 15 V 8 and Ni 62 Cr 18 Co 1 Fe 3 W 15 . It was observed that even after adapting the mWAAM process for W, the W did not fully dissolve. To fully evaluate the Ni 62 Cr 18 Co 1 Fe 3 W 15 composition, a cored wire (80-20 NiCr sheath/powder core) was manufactured and printed via WAAM, and HIP’ing was utilized to homogenize and densify the printed alloy. The V and W alloys produced met metrics 1 (solid solution), 4 (solidification cracking), and 5 (cost). However, an unmodeled mechanism of thermal stress cracking was identified in the WAAM produced materials, perhaps exacerbated by the lack of grain boundary strengthening elements (B, C). Conclusions & Recommendations: A high-throughput (rapid) alloy design technique was applied to designing and manufacturing new high entropy alloys (HEAs) for extreme environments utilizing MOBO and mWAAM. The developed process was rapid and effective in addressing the mechanisms included in the model. The lack of grain boundary strengthening element additions (e.g., B, C) was a simplification that likely produced thermal stress cracking that turned into a large part of the investigation. Additions on the order of 0.005 wt% B and 0.05 wt% C likely would have minimized thermal stress grain boundary cracking. Overall, the high throughput design strategy is promising for rapid design of metrics-driven alloys for advanced ultra supercritical (A-USC) steam cycles for power generation. The MOBO and mWAAM process could be commercialized to accelerate metrics-driven alloy design. In addition, the cored-wire process utilized for scale-up is a promising high-volume process for WAAM alloy development and scale-up.

36 MATERIALS SCIENCE↗