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DOE OSTI2025

Microstructure-sensitive mechanical behavior of an additively manufactured psuedoelastic shape memory alloy

The additive manufacturing of shape memory alloys into complex geometries enables fabrication of advanced functional systems across a variety of fields and domains. This work presents results focused on the mechanical behavior of additively manufactured shape memory pseudoelastic NiTi. The deformation induced solid state phase transformation from austenite to martensite allows this system to accommodate large recoverable strains. This deformation behavior is fundamentally driven by crystal-scale transformation physics. Laser powder bed fusion processing reveals that the resulting microstructure, both grain morphology and crystallographic texture, is strongly dependent on the manufacturing processing history. Exhaustive mechanical testing demonstrates that these microstructural factors strongly impact both tensile and cyclic stress–strain behavior. Cyclic dissipative behavior, however, is similar across all tested microstructures following an initial transient period. Remarkably, analysis of spatial strain fields during tensile loading reveals two distinctly different localization “modes”. The first is initiation of localized deformation bands which continuously propagate through the tensile bar during loading. In the second mode localization is observed but lacks propagation; instead additional localization cites nucleate during subsequent loading. The latter phenomena is suspected to be driven by grain-scale deformation physics as the localized band morphologies coincide with grain morphologies. These phenomena strongly impact the resulting aggregate stress–strain behavior. Hence, manufacturers and designers of psuedoelastic functional components must at the very least consider the potential variability in properties when considering additive manufacturing processing. More ideally the process–structure–property relations can be used to further tailor and optimize final functional performance.

Additive manufacturing↗

NASA NTRS2020

Technology Advancements for Channel Wall Nozzle Manufacturing In Liquid Rocket Engines

A regeneratively-cooled or dump-cooled nozzle is a critical component for expansion of hot gases to enable high temperature and performance in liquid rocket engines systems. Regeneratively-cooled channel wall nozzles are a design solution used across the propulsion industry as a simplified method to fabricate the nozzle structure with internal coolant passages. The scale and complexity of the channel wall nozzle (CWN) design can be challenging to fabricate which results in extended lead times and higher costs. Some of these challenges include: 1) Unique and high temperature materials, 2) Tight tolerances on large parts during manufacturing and assembly to contain high pressure propellants, 3) Thin-walled features to maintain adequate wall temperatures, and 4) Unique manufacturing process operations and complex tooling. The United States (U.S.) National Aeronautics and Space Administration (NASA) and U.S. specialty manufacturing vendors are maturing modern fabrication techniques to reduce complexity and decrease costs associated with channel wall nozzle manufacturing technology. Additive Manufacturing (AM) is one of the key technology advancements under evaluation for channel wall nozzles. Much of additive manufacturing for propulsion components has focused on laser powder bed fusion (L-PBF), but the scale is not yet feasible for application to large scale nozzles. NASA is evolving directed energy deposition (DED) techniques for nozzles including arc-based deposition, blown powder deposition, and Laser Wire Direct Closeout (LWDC). There are different approaches being considered for fabrication of the nozzle, and each of these DED processes offer unique process steps for rapid fabrication. The arc-based and blown powder deposition techniques are used for the forming of the CWN liner. A variety of materials are being demonstrated including Inconel 625, Haynes 230, JBK-75, and NASA HR-1. The blown powder DED process is also being demonstrated for forming an integral channel nozzle in a single operation in similar materials. The LWDC process is a method for closing out the channels within the liner and forming the structural jacket using a localized laser wire deposition technique. Identical materials mentioned above have been used for this process in addition to bimetallic closeout (C-18150–SS347, and C-18150–Inconel 625). NASA has completed process development, material characterization, and hot-fire testing on a variety of these channel wall nozzle fabrication technique. This publication presents an overview of the various channel wall nozzle manufacturing processes and materials under evaluation including results from the hot-fire testing. Future development and technology focus areas is also discussed relative to channel wall nozzle manufacturing.

Additive manufacturing↗

DOE OSTI2024

Formation of a spherical plasma liner for plasma-jet-driven magneto-inertial fusion

Plasma-jet-driven magneto-inertial fusion is an alternative approach to controlled nuclear fusion, which aims to utilize a line-replaceable dense plasma liner as a repetitive spherical compression driver. In this experiment, first measurements of the formation of a spherical argon plasma liner formed from 36 discrete pulsed plasma jets are obtained on the Plasma Liner Experiment. Properties including liner uniformity and morphology, plasma density, temperature, and ram pressure are assessed as a function of time throughout the implosion process and indicate an apparent transition from initial kinetic inter-jet interpenetration to collisional regime near stagnation times, in accordance with theoretical expectation. A lack of primary shock structures between adjacent jets during flight implies that arbitrarily smooth liners may be formed by way of corresponding improvements in jet parameters and control. The measurements facilitate the benchmarking of computational models and understanding the scaling of plasma liners toward fusion-relevant energy density.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRSDate not supplied

Process Development and Hot-fire Testing of Additively Manufactured NASA HR-1 for Liquid Rocket Engine Applications

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. Optimized materials in the extreme high pressure and hydrogen environment for liquid rocket engines remains a key challenge. NASA has advanced an enabling material called NASA HR-1 (Hydrogen Resistant -1) as a solution using AM techniques. NASA HR-1 is a high-strength Fe-Ni superalloy designed to resist high pressure, hydrogen environment embrittlement, oxidation, and corrosion. NASA HR-1 meets materials requirements for liquid rocket engine components, including good hydrogen resistance, high conductivity, good low cycle fatigue performance, and high elongation and strength for components in high heat flux environments. Material properties and process characterization have been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full-scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

DED↗

NASA NTRSDate not supplied

Process Development and Hot-fire Testing of Additively Manufactured NASA HR-1 for Liquid Rocket Engine Applications

Additive Manufacturing↗

DOE OSTI2024

Hybrid direct drive with a two-sided ultraviolet laser

This paper presents a “hybrid” approach to direct drive inertial confinement fusion that can exploit a high-energy gas laser with two opposed beams. The target and driver are asymmetric, much like experiments performed on the National Ignition Facility, but have been designed to benefit from scale and their particular compatibility with a fusion power plant. The imploded masses (and areal densities) are increased by a factor of 12 (3) and provide a path to high-gain implosions that robustly ignite. The design also mitigates common concerns such as laser imprint and cross-beam energy transfer. We discuss the rationales for a hybrid target, the methods used to control implosion symmetry, and the implication(s) for inertial fusion energy.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Detachment scalings derived from 1D scrape-off-layer simulations

Fusion power plants will require detachment to mitigate sputtering and keep divertor heat fluxes at tolerable levels. Controlling detachment on these devices may require the use of real-time scrape-off-layer modeling to complement the limited set of available diagnostics. In this work, we use the configurable Hermes-3 edge modeling framework to perform time-dependent, fixed-fraction-impurity 1D detachment simulations. Although currently far from real-time, these simulations are used to investigate time-dependent effects and the minimum physics set required for control-relevant modeling. We show that these simulations reproduce the expected rollover of the target ion flux — a typical characteristic of detachment onset. We also perform scans of the input heat flux and impurity concentration and show that the steady-state results closely match the scalings predicted by the 0D time-independent Lengyel–Goedheer model. This allows us to indirectly compare to SOLPS simulations, which find a similar scaling but a lower value for the impurity concentration required for detachment for given upstream conditions. We use this result to suggest a series of improvements for the Hermes simulations, and finally show simulations demonstrating the impact of time-dependence.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

A dynamic volumetric heat source model for laser additive manufacturing

Melt pool scale models of laser powder bed fusion (LPBF) offer insights into the process-structure-property relationships in additive manufacturing (AM). These models often neglect physical phenomena such as vapor cavity formation and fluid mechanics to reduce computational demands. Instead, volumetric heat source models are used to represent the effects that these phenomena have on the predicted melt pool dimensions. Generally, the dimensions and effective absorption of the volumetric heat source are calibrated to reproduce melt pool dimensions observed in metallographic cross sections taken from single-track experiments on bare plate. However, the transient nature of LPBF often deviates the melt pool dimensions from the assumed steady-state conditions of single-track experiments, motivating the need for a volumetric heat source model that more generally considers the dynamic relationship between melt pool shape and laser-material interactions. Here, we introduce a two-parameter volumetric heat source model that integrates several existing models into a generalized mathematical expression, providing independent control over the radial heat distribution via the parameter k and the volumetric shape of the heat source via the parameter m. This parameterization enables the calibration of melt pool shape predictions through simultaneous adjustment of these parameters, while keeping the radial heat source dimensions consistent with the experimental spot size (D4σ) and constraining the heat source depth and absorption to physically derived expressions for cavities. Consequently, the proposed volumetric heat source model adapts to changes in the local melt pool conditions due to scanning strategy and part geometry by dynamically adjusting the heat source depth and absorption. We demonstrate the capabilities of the proposed model through comparisons with a collection of experiments from the Additive Manufacturing Benchmark (AMBench).

36 MATERIALS SCIENCE↗

NASA NTRS1988

Strategy for D/He-3 fusion development

It is concluded that Deuterium/Helium-3 fusion faces a more difficult physics development path but an easier technology development path than does Deuterium/Tritium. Early D/He-3 tests in next generation D/T fusion experiments might provide a valuable D/He-3 proof-of-principle at modest cost. At least one high leverage alternate concept should be vigorously pursued. Space applications of D/He-3 fusion are critically important to large scale development.

Santarius, John F.↗

NASA NTRS1995

The Weathering of Antarctic Meteorites: Climatic Controls on Weathering Rates and Implications for Meteorite Accumulation

Weathering of meteorites includes a variety of chemical and mineralogical changes, including conversion of metal to iron oxides, or rust. Other changes include the devitrification of glass, especially in fusion crust. On a longer time scale, major minerals such as olivine, pyroxene, and feldspar are partially or wholly converted to various phyllosilicates. The degree of weathering of meteorite finds is often noted using a qualitative system based on visual inspection of hand specimens. Several quantitative weathering classification systems have been proposed or are currently under development. Wlotzka has proposed a classification system based on mineralogical changes observed in polished sections and Mossbauer properties of meteorite powders have also been used. In the current paper, we discuss induced thermoluminescence (TL) as an indicator of degree of weathering of individual meteorites. The quantitative measures of weathering, including induced TL, suffer from one major flaw, namely that their results only apply to small portions of the meteorite.

Benoit, P. H.↗

NASA NTRS2020

Efficient production of a high-performance dispersion strengthened, multi-principal element alloy

Additive manufacturing currently facilitates new avenues for materials discovery that have not been fully explored. In this study we reveal how additive manufacturing can be leveraged to produce dispersion strengthened (DS), multi-principal element alloys (MPEA) without the use of traditional mechanical alloying or chemical reactions. This new processing technique employed resonant acoustic mixing to coat an equiatomic NiCoCr powder with nano-scale yttrium oxides. Then, through laser powder bed fusion (L-PBF), the coated powder was successfully consolidated into 99.9% dense parts. Microstructural analysis confirmed the successful incorporation and dispersion of nano-scale oxides throughout the build volume. Furthermore, high temperature mechanical testing of the DS alloys showed significant improvements in strength and ductility over the baseline NiCoCr. As a result, this recently discovered processing route opens a new alloy design and production path that is synergistic between additive manufacturing and dispersion strengthening, possibly enabling a new generation of high-performance alloys.

T.M. Smith↗

DOE OSTI2024

Universal function for heavy-ion fusion cross sections

A universal function for heavy-ion fusion cross sections, Y = $\sqrt{π}$ Xerfc (- X ) + exp(- X 2 ) is proposed. By scaling both the cross section σ(E) and the energy E, heavy-ion fusion cross section data are found to follow closely a universal function over the whole energy range. The scaling is developed from either a simple, empirical single-Gaussian barrier distribution model for the representation d 2 (σE)/dE 2 , or the modified Siwek-Wilczynski model. The cross section expressions of these models are analytical, and can be easily used for all heavy-ion fusion excitation functions. Thus a bench marking of heavy-ion fusion excitation functions has been achieved. Finally, a general discussion regarding the universal function is given.

low & intermediate energy heavy-ion reactions↗

DOE OSTI2025

Software For Advanced Large-scale Analysis Of Magnetic Confinement For Numerical Design, Engineering & Research (salamander)

As magnetic confinement fusion energy gains traction internationally to enable abundant energy production, designing components for fusion systems is a pressing challenge. During the planned lifetime of a fusion device, components evolve in extreme environments and must withstand large, repeated thermal loads and bombardment by 14 MeV neutrons, plasma ions, and neutral particles (deuterium, tritium, and helium), corrosive conditions, etc. All these physical processes take place simultaneously, interact in intricate ways, and impose important constraints that can affect performance. Experimental data is rare and costly to obtain, making design particularly challenging. Predictive computational frameworks must be an integral part of an accelerated and cost-effective design process by modeling fusion system performance in simulated environments. To better understand component degradation and operational impacts on their performance, the Software for Advanced Large-scale Analysis of MAgnetic confinement for Numerical Design, Engineering & Research (SALAMANDER) is designed as an open-source, fully integrated, multiphysics, multiscale, NQA-1 compliant framework facilitating 3D, high-fidelity fusion system modeling. To that end, SALAMANDER is a MOOSE-based framework, and therefore leverages MOOSE upstream libraries such as PETSc and libMesh to deliver sophisticated finite element, finite volume, and nonlinear solver technology for fusion energy simulations. SALAMANDER couples MOOSE physics module capabilities—such as thermal hydraulics, heat conduction, Navier-Stokes, and thermomechanics—with tritium transport via TMAP8, neutronics via Cardinal, and nascent particle-in-cell capabilities. Direct simulation Monte Carlo methods will be used to address neutral transport near the walls. By coupling all these physics in an integrated application, SALAMANDER will enable high-fidelity modeling of irradiation levels and plasma exposure conditions of plasma facing components and their impact on heat and tritium distributions, as well as the resulting mechanical constraints experienced by the plasma facing components and performance of blanket systems. Furthermore, SALAMANDER will be particularly suited for engineering studies thanks to the stochastic tool module readily available in MOOSE, allowing for extended uncertainty quantification and risk analysis studies. It is also able to use computer-aided design (CAD) meshes to model complex geometries, which is indispensable for fusion systems. SALAMANDER therefore supports design, safety, engineering, and research projects for magnetic confinement fusion systems

Simon, Pierre-Clement [Idaho National Laboratory (↗

DOE OSTI2024

Searching for heavy neutral leptons at a future muon collider

As the planning stages for a high energy muon collider enter a more concrete era, an important question arises as to what new physics could be uncovered. A TeV-scale muon collider is also a vector boson fusion (VBF) factory with a very clean background, and as such it is a promising environment to look for new physics that couples to the electroweak (EW) sector. In this paper, we explore the ability of a future TeV-scale muon collider to search for Majorana and Dirac heavy neutral leptons (HNLs) produced via EW bosons. Employing a model-independent, conservative approach, we present an estimation of the production and decay rate of HNLs over a mass range between 200 GeV and 9.5 TeV in two benchmark collider proposals with s = 3 , 10 TeV, as well as an estimation of the dominant Standard Model (SM) background. We find that exclusion limits for the mixing between the HNLs and SM neutrinos can be as low as O ( 10 − 6 ) . Additionally, we demonstrate that a TeV-scale muon collider allows for the ability to discriminate between Majorana and Dirac type HNLs for a large range of mixing values. Published by the American Physical Society 2024

Kwok, Tsz Hong↗

NASA NTRS1988

Lunar Helium-3 and Fusion Power

The NASA Office of Exploration sponsored the NASA Lunar Helium-3 and Fusion Power Workshop. The meeting was held to understand the potential of using He-3 from the moon for terrestrial fusion power production. It provided an overview, two parallel working sessions, a review of sessions, and discussions. The lunar mining session concluded that mining, beneficiation, separation, and return of He-3 from the moon would be possible but that a large scale operation and improved technology is required. The fusion power session concluded that: (1) that He-3 offers significant, possibly compelling, advantages over fusion of tritium, principally increased reactor life, reduced radioactive wastes, and high efficiency conversion, (2) that detailed assessment of the potential of the D/He-3 fuel cycle requires more information, and (3) D/He-3 fusion may be best for commercial purposes, although D/T fusion is more near term.

Source record↗

DOE OSTI2024

Inferring fusion nuclear burnwidths with low gain photomultiplier impulse response functions

When an inertial confinement fusion implosion is compressed, it maintains thermonuclear density and temperatures for a very short time scale, about 100 ps. The Gamma Reaction History diagnostic measures the time evolution of the fusion burn, but its temporal resolution is limited by the use of a photomultiplier tube (PMT) to amplify the photon signal. Multichannel plate-based PMTs have a fast (~120 ps) full-width at half-max impulse response function (IRF), but the time scale is similar to the incoming physics signal. An analysis routine is used to remove the effect of the PMT IRF and infer the incident fusion burnwidth. With the National Ignition Facility achieving ignition and creating much brighter signals, the PMTs are run at gains three orders of magnitude lower than nominal operation. Calibration at these settings shows the PMT IRFs get ~15% wider. Taking the gain-dependent IRF can affect the inferred nuclear burnwidths by up to ~15%.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Milestone in predicting core plasma turbulence: successful multi-channel validation of the gyrokinetic code GENE

On the basis of several recent breakthroughs in fusion research, many activities have been launched around the world to develop fusion power plants on the fastest possible time scale. In this context, high-fidelity simulations of the plasma behavior on large supercomputers provide one of the main pathways to accelerating progress by guiding crucial design decisions. When it comes to determining the energy confinement time of a magnetic confinement fusion device, which is a key quantity of interest, gyrokinetic turbulence simulations are considered the approach of choice – but the question, whether they are really able to reliably predict the plasma behavior is still open. The present study addresses this important issue by means of careful comparisons between state-of-the-art gyrokinetic turbulence simulations with the GENE code and experimental observations in the ASDEX Upgrade tokamak for an unprecedented number of simultaneous plasma observables.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRSDate not supplied

Fusion of Hyperspectral Sounder Products Via Spectral Fingerprinting Methodology

Satellite based measurements of top-of-atmosphere (TOA) spectral radiances in the infrared (IR) region have been in existence for almost two decades and are expected to be continued in the following decades. The data from multiple hyper-spectral IR sounders can therefore be combined to build a long-term data record to further global scale climate trend research. Challenges associated with the fusion of data from different sensors come from the stability and consistency requirement on the climate record. The direct radiance observations from different sounders need to be homogenized by reconciling the differences in calibration, spectral response function (SRF), and spatial-temporal sampling. When geophysical variables derived from radiances measured by different sounders are combined to form long-term climate records, the impacts of any inconsistencies between overlapping measurements on the retrieval must be carefully assessed in order to estimate the uncertainty of the corresponding climate anomalies/trends derived. This paper presents a novel climate fingerprinting methodology and establishes a rigorously-defined inverse relationship that allows us to efficiently evaluate the change in essential climate variables from the change in spectral radiances measured in prescribed spatial and temporal averaging scales. The inverse spectral fingerprinting relationship is constructed based on a unified spectral kernel scheme, providing a direct means for quantifying the potential discontinuity in the derived climate anomalies due to inconsistencies between overlapping measurements. We show in this paper a sample application of using the spectral fingerprinting scheme to derive long-term, global-scale surface temperatures from the Climate Hyperspectral Infrared Radiance Product (CHIRP) and quantify the inter-satellite biases.

Wan Wu↗