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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

A Domestic Program for Liquid Metal PFC Research in Fusion

While high-Z solid plasma-facing components (PFCs) are the leading candidates for reactors, it is unclear that they can survive the intense plasma material interaction (PMI). Liquid metals (LM) PFCs offer potential solutions since they are not susceptible to the same type of damage, and can be “self-healing”. Following the Fusion Energy System Study on Liquid Metal Plasma Facing Components study that recently was completed by Kessel et al. (Fusion Sci Technnol 75:886, 2019) a domestic LM PFC design program has been initiated to develop reactor-relevant LM PFC concepts. This program seeks to evaluate LM PFC concepts for a Fusion Nuclear Science Facility (FNSF) or a Compact Pilot Plant via engineering design calculations, modeling of PMI and PFC components and laboratory experiments. The latter involves experiments in dedicated test stands and confinement devices and seeks to identify and answer open questions in LM PFC design. The new national LM PFC program is first investigating lithium as the plasma facing material for a flowing divertor PFC concept. Several flow speeds will be evaluated, ranging from ~ cm/s to m/s. The surface temperature will initially be held below the strongly evaporative limit in the first design; higher temperatures with strong evaporation will be considered in future concepts. Other topics of interest include: understanding of the hydrogen and helium interaction with the liquid lithium; single effect experiments on wetting, compatibility and embrittlement; and prototypical experiments for control and characterization of flowing LM. A path to plasma and future tokamak exposure of these concepts will be developed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Enhanced liquid metal wetting on oxide surfaces via patterned particles

Liquid metals typically do not intrinsically wet oxide surfaces due to chemical dissimilarity, preventing the formation of well-bonded interfaces in many applications. This paper investigates how the wetting and spreading of liquid silver (Ag) droplets on oxide surfaces can be enhanced via patterned nickel (Ni) particles using multiscale modeling. First, a force field (FF) for an Ag/yttria-stabilized-zirconia system was developed by fitting the interfacial binding energy to density-functional theory (DFT) calculations. Then, molecular dynamics (MD) simulations using these FF parameters revealed that the good wetting of Ag on Ni caused Ag droplets to be attracted to the Ni particles, promoting spreading. Thus, the optimal hexagonal Ni pattern was shown to enhance the wetting area by 224% compared to a bare oxide surface. Second, an analytical model predicting the maximum possible enhancement in wetting area as a function of the intrinsic wetting angle, size of the Ag droplet, and size of the Ni particles was derived and validated with MD simulations, to generalize this method to other substrates. Here, both the analytical model and MD results suggested that the ability of Ni patterns to enhance the Ag wetting area becomes more significant as the wettability of substrate becomes worse.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Magnetohydrodynamics in free surface liquid metal flow relevant to plasma-facing components

Abstract While flowing Liquid Metal (LM) Plasma-Facing Components (PFCs) represent a potentially transformative technology to enable long-pulse operation with high-power exhaust for fusion reactors, Magnetohydrodynamic (MHD) drag in the conducting LM will reduce the flow speed. Experiments have been completed in the linear open-channel LMX-U device [Hvasta et al 2018 Nucl. Fusion 58 01602] for validation of MHD drag calculations with either insulating or conducting walls, with codes similar to those used to design flowing LM PFCs for a Fusion Nuclear Science Facility [Kessel et al 2019 Fusion Sci. Technol . 75 886]. We observe that the average channel flow speed decreased with the use of conducting walls and the strength of the applied transverse magnetic field. The MHD drag from the retarding Lorentz force resulted in an increase of the LM depth in the channel that ‘piled up’ near the inlet, but not the outlet. As reproduced by OpenFOAM and ANSYS CFX calculations, the magnitude and characteristics of the pileup in the flow direction increased with the applied traverse magnetic field by up to 120%, as compared to the case without an applied magnetic field, corresponding to an average velocity reduction of ∼45%. Particle tracking measurements confirmed a predicted shear in the flow speed, with the surface velocity increasing by 300%, despite the 45% drop in the average bulk speed. The MHD effect makes the bulk flow laminarized but keeps surface waves aligned along the magnetic field lines due to the anisotropy of MHD drag. The 3D fringe field and high surface velocity generate ripples around the outlet region. It was also confirmed that the MHD drag strongly depends on the conductivity of the channel walls, magnetic field, and volumetric flow rate, in agreement with the simulations and a developed analytical model. These validated models are now available to begin to determine the conditions under which the ideal LM channel design of a constant flow speed and fluid depth could be attained.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Millimeter-wave electromagnetic monitoring for liquid metal droplet-on-demand printing

As new printing approaches emerge, in situ diagnostics to monitor the print quality in real-time become essential for long-term monitoring and feedback control. In this article, we present a millimeter-wave electromagnetic monitoring approach for liquid metal droplet-on-demand printing to support the high-speed and real-time evaluation of droplet ejection. An open-ended rectangular waveguide is placed perpendicular to a jetted droplet stream and operated at a continuous-wave frequency of 40 GHz. Liquid metal droplets with diameters as low as 1.2 mm are characterized, and droplet jetting events on the order of 500 μm are detected at ejection rates up to 80 Hz. The measured results demonstrate that trends at the macro-level (large-scale print variation and anomalies at the nozzle tip) as well as micro-level (droplet size, position, and dynamics) can be detected using this technique.

42 ENGINEERING↗
DOE OSTI2020

In-situ monitoring for liquid metal jetting using a millimeter-wave impedance diagnostic

Abstract This article presents a millimeter-wave diagnostic for the in-situ monitoring of liquid metal jetting additive manufacturing systems. The diagnostic leverages a T-junction waveguide device to monitor impedance changes due to jetted metal droplets in real time. An analytical formulation for the time-domain T-junction operation is presented and supported with a quasi-static full-wave electromagnetic simulation model. The approach is evaluated experimentally with metallic spheres of known diameters ranging from 0.79 to 3.18 mm. It is then demonstrated in a custom drop-on-demand liquid metal jetting system where effective droplet diameters ranging from 0.8 to 1.6 mm are detected. Experimental results demonstrate that this approach can provide information about droplet size, timing, and motion by monitoring a single parameter, the reflection coefficient amplitude at the input port. These results show the promise of the impedance diagnostic as a reliable in-situ characterization method for metal droplets in an advanced manufacturing system.

42 ENGINEERING↗
DOE OSTI2025

Conductive Liquid Metal Vitrimer Composites for Reconfigurable and Recyclable Flexible Electronics

Liquid metal (LM) elastomer composites exhibit excellent functionality for stretchable electronics and wearables, but limited recycling and reuse pathways constrain their sustainable use. Here, to address these challenges amid growing concerns over electronic waste, a conductive LM–vitrimer composite is presented that enables recyclable and reconfigurable electronics. This soft and stretchable composite features uniformly distributed LM inclusions that enhance thermal conductivity by 6.53× and enable the formation of conductive traces with electrical self-healing, while the vitrimer provides structural restoration. The dynamic covalent bonds of the vitrimer matrix are leveraged for both reprocessing the composite and chemically recovering 94% of the LM. This liquid-state filler slightly reduces the vitrimer's stiffness to 2.63 MPa (≈20% lower), while maintaining its high stretchability (>135% strain) and thermal stability. It is further examined how ultrasonicated LM inclusions interact with the vitrimer matrix and demonstrate the composite's self-healing and recyclability through two distinct approaches: 1) thermomechanical reprocessing, which restores fragmented composites under heat and compression for circuit reconfiguration; and 2) chemical recycling, which recovers the embedded LM for reuse in fabricating new composites and redesigned circuitry. With the integration of recyclability and diverse functional capabilities, LM–vitrimer composites emerge as a promising material platform for sustainable, flexible electronics.

Han, Youngshang [Univ. of Washington, Seattle, WA ↗
DOE OSTI2025

Thermovelocimetric characterization of liquid metal convection in a rotating slender cylinder

Rotating turbulent convection occurs ubiquitously in natural convective systems encompassing planetary cores, oceans and atmospheres, as well as in many industrial applications. While the global heat and mass transfer of water-like rotating Rayleigh–Bénard convection is well-documented, the dynamics in low-Prandtl-number liquid metals remain less understood. In this study, we experimentally investigate rotating Rayleigh-Bénard convection in liquid gallium (Prandtl number Pr ≈ 0.027) within a slender cylinder (diameter-to-height aspect ratio Γ = D/H =1/2) using novel thermovelocimetric diagnostic techniques that integrate simultaneous multi-point thermometry and ultrasonic Doppler velocity measurements. Our results reveal the formation of a stable, global-scale azimuthal wavenumber m = 2 quadrupolar vortex at low supercriticality. We propose that enhanced wall modes facilitated by the slender cylinder geometry interact with the bulk flow to create these large-scale axialized vortices. Furthermore, our findings imply a distinct scaling behavior for the wall-mode precession frequency in liquid metals, extending previous results obtained for moderate-Pr fluids. In conclusion, this provides new insights into wall-bulk coupling mechanisms of low-Pr rotating convective turbulence.

Magnetohydrodynamics↗
DOE OSTI2022

Self-Sensing, Stretchable, Active Circuit Arrays: Liquid Metal Paste as a Combination Interconnect and Strain Sensor

Stretchable electrical interconnects and substrate materials are increasingly used to create flexible and con-formable electronic systems for soft robotics, smart textiles, and wearable devices. Wires fabricated using composite or liquid conductive inks encapsulated in silicone enable high strain and are mechanically robust. The resistance of these inter-connects increases with strain, which can present challenges for power delivery and signaling among electronic components. However, this effect can be used directly to estimate strain within a stretchable circuit without the need for additional sensor components. In this work, we present an approach for fabricating fully-stretchable, multi-layer active circuit arrays in silicone using liquid metal paste interconnects, in which power and data wires are re-purposed as strain sensors to estimate substrate deformation. As a proof-of-principle, we demonstrate a 3×3 active circuit array that self-senses relative voltage supply at each node to estimate deformation and consumes less than 10 mA per node. Each node is digitally addressable and performs both analog measurement and digital conversion. All interconnects are fabricated using liquid metal paste, and power, data, and sensing are performed over a shared, four-wire interface in this multi-layer stretchable printed circuit board.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2022

Polymer-Stabilized Liquid Metal Nanoparticles as a Scalable Current Collector Engineering Approach Enabling Lithium Metal Anodes

Dendrites and dead lithium formation over prolonged cycling have long been challenges that hinder the safe implementation of metallic Li anodes. In this study, we employ polymer-stabilized liquid metal nanoparticles (LM-P NPs) of eutectic gallium indium (EGaIn) to create uniform Li nucleation sites enabling homogeneous lithium electrodeposition. Block copolymers of poly(ethylene oxide) and poly(acrylic acid) (PEO-b-PAA) were grafted onto the EGaIn surface, forming stabilized, well-dispersed NPs. Using a scalable spray coating approach, LM-P NPs were fabricated on copper current collectors, providing lithiophilic PEO sites and interactive carboxyl groups to guide Li deposition. The Li-EGaIn alloying process greatly reduced the Li + diffusion barrier, enabling fast Li transport through the coating layer, resulting in decreased nucleation overpotential. Therefore, about five times lower Li nucleation overpotential was obtained on the LM-P modified Cu with an optimal composition of the polymers than the bare Cu substrates. DFT computations was used to reveal the binding properties between the LM-P layer and Li. Due to the regulated Li plating/stripping process, as-obtained 30 μm Li anodes paired with LiNi 0.8 Co 0.1 Mn 0.1 O 2 (NCM8 11 ) with a negative/positive electrode capacity (N/P) ratio ~ 10 exhibited stable cycling performance at 0.5C for over 250 cycles, with an average Coulombic efficiency of 99.55%. Ultrathin Li (1 μm) anodes with an N/P ratio ~ 0.6 were also demonstrated in Li|LiFePO 4 cells, which examined the stabilization of Li by LM-P NPs and monitored practical loadings of Li anodes that are close to anode-free systems.

25 ENERGY STORAGE↗
DOE OSTI2025

Investigation of a gallium alloy liquid metal mirror for application in inertial fusion energy systems

The final optic in future inertial fusion energy plants must maintain high performance and survivability under gigashot laser irradiation while exposed to fusion byproducts. Although no practical solution has been demonstrated, a self-healing final turning mirror based on a grazing-incidence liquid metal mirror has been theoretically explored. This work investigates the suitability of a gallium alloy. The experimental system simulates key conditions, including vacuum exposure and 10-Hz, 355-nm, and 6-ns laser pulses. Experiments address reflectivity, damage, and response as a function of pressure. Results highlight the potential of liquid metal gallium alloys for robust final optics in laser-based fusion power plants and inform non-traditional optics for intense laser systems.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Electrically Reconfigurable Liquid Metal Nanophotonic Platform for Color Display and Imaging

Dynamically tunable optical materials and device architectures are essential for future photonic technologies, yet conventional solid metals lack the intrinsic tunability required for advanced functionalities. Gallium-based liquid metals (LMs) present an appealing alternative thanks to their distinctive mechanical and optical properties; however, their practical integration in tunable photonic elements remains largely unexplored. Here, in this study, an electrochemically controlled nanophotonic platform is demonstrated that integrates a dynamically reconfigurable LM ground plane with gold nanoantenna arrays within a microfluidic system, enabling precise and reversible modulation of optical resonances across the visible to mid-infrared spectral ranges. By employing moderate operational voltages (1.5–3.0 V), real-time tuning of high-resolution structural color patterns is achieved through nanoscale control of the interfacial gap between the LM and Au nanoantennas. This innovative platform facilitates electrically programmable, high-contrast color patterns suitable for dynamic optical displays, secure anti-counterfeiting labels, and imaging applications. Additionally, this platform enables tunable mid-infrared spectral responses, which may be utilized for chemical and biological sensing applications. This versatile integrated LM-based nanophotonic platform opens new paths toward multifunctional, actively tunable/reconfigurable photonic device and system technologies.

Imaging↗
DOE OSTI2025

Numerical investigation of two-dimensional buoyancy-driven eddies in liquid metal magnetohydrodynamic flows in breeding blankets *

Abstract Lead–lithium flows are key features in the design of tokamak breeding blanket concepts such as the dual-coolant lead–lithium (DCLL). Since they flow under magnetic fields, they are affected by magnetohydrodynamic (MHD) effects. The neutron flux originating in the tokamak plasma heats the breeding blanket channels in a non-uniform manner, inducing buoyancy forces in the liquid metal. Buoyancy may become a source of quasi-two-dimensional (Q2D) turbulence, and the appearance of eddies may affect the transport of heat and tritium across the blanket. Blankets characterized by high-speed liquid metal flows (such as DCLL) will need ceramic insulating walls to reduce the MHD-related pressure drop in the channels. In our simulations, we have used the Q2D model proposed by Sommeria and Moreau (SM82) which is especially suitable for modeling electrically insulating channel flows. On top of that, we have modelled buoyancy forces in the momentum equation using the Oberbeck–Boussinesq approximation. In this work, we include a validation of the implemented Q2D model in buoyancy-driven cases and identify a thermohydraulic configuration that promotes the generation of eddies and the accumulation of tritium. We also show the results provided by our post-processing tool based on the bi-dimensional fast Fourier transform for eddy detection and characterization. We complete our investigation by performing an initial assessment of how eddies can accumulate tritium in the breeding blanket. We conclude by discussing the relevance of preventing accumulation of tritium within the blanket and suggest a possible solution.

Suarez, Daniel (ORCID:0000000251740100)↗
DOE OSTI2023

Overview of Liquid-Metal PFC R&D at the University of Illinois Urbana-Champaign

The design and implementation of future flowing liquid-lithium plasma-facing components (LLPFCs) will be dependent on several factors. Of course, one of the most important is the need to be able to deal with high heat fluxes incident on the surface of the LLPFCs, but there are also several other important liquid-metal behaviors that have been identified for their critical impact on the feasibility of a LLPFC. One of these is the ability to constantly wet 100% of the plasma-facing component area and the best way to achieve that. Another key point is knowing and understanding the erosion and corrosion of the surfaces subject to a flowing liquid-lithium system and the ability for hydrogen and helium uptake by the system. The Center for Plasma Material Interactions (CPMI) has been tasked with looking at these various issues. The Mock-up Entry module for EAST device was used to investigate wetting and erosion effects and to design a suitable distribution and collection system with a liquid-lithium loop. The vapor shielding effects of lithium on the surface were also modeled and studied. A model coupling CRANE, an open-source global reaction network solver, and Zapdos, a plasma transport solver, is being developed to better understand the dynamics of the vapor cloud. Experiments on the Magnum-PSI at the Dutch Institute for Fundamental Energy Research have been carried out to study the vapor shielding effect and obtain experimental benchmarks to verify the model. Also, initial experiments using the Hybrid Illinois Device for Research and Applications have been performed to understand the pumping effects of lithium on helium. Experiments with a drop of liquid lithium (~100 mg) into a helium plasma have shown the ability of lithium to take out the cold recycling helium gas as well as hydrogen and oxygen impurity gases. The improvement in plasma performance was significant, and further understanding of this effect will have impacts on how future LLPFCs will be designed. Further investigation into the exact mechanism for helium pumping by lithium needs to be performed in the future. Finally, this paper presents a summary of the results obtained at the CPMI.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Role of generic scale invariance in a Mott transition from a U(1) spin-liquid insulator to a Landau Fermi-liquid metal

Highlights: • We look at the role played by generic scale invariance (GSI) in the phase transition between a U(1) spin liquid and a Fermi liquid. • We identify dangerously irrelevant operators in the renormalization group transformation, involved with the GSI. • We highlight novel mean-field dynamics of this Mott quantum criticality, resulting from the GSI. We investigate the role of generic scale invariance in a Mott transition from a U(1) spin-liquid insulator to a Landau Fermi-liquid metal, where there exist massless degrees of freedom in addition to quantum critical fluctuations. Here, the Mott quantum criticality is described by critical charge fluctuations, and additional gapless excitations are U(1) gauge-field fluctuations coupled to a spinon Fermi surface in the spin-liquid state, which turn out to play a central role in the Mott transition. An interesting feature of this problem is that the scaling dimension of effective leading local interactions between critical charge fluctuations differs from that of the coupling constant between U(1) gauge fields and matter-field fluctuations in the presence of a Fermi surface. As a result, there appear dangerously irrelevant operators, which can cause conceptual difficulty in the implementation of renormalization group (RG) transformations. Indeed, we find that the curvature term along the angular direction of the spinon Fermi surface is dangerously irrelevant at this spin-liquid Mott quantum criticality, responsible for divergence of the self-energy correction term in U(1) gauge-field fluctuations. Performing the RG analysis in the one-loop level based on the dimensional regularization method, we reveal that such extremely overdamped dynamics of U(1) gauge-field fluctuations, which originates from the emergent one-dimensional dynamics of spinons, does not cause any renormalization effects to the effective dynamics of both critical charge fluctuations and spinon excitations. However, it turns out that the coupling between U(1) gauge-field fluctuations and both matter-field excitations still persists at this Mott transition, which results in novel mean-field dynamics to explain the nature of the spin-liquid Mott quantum criticality. We discuss physical implications of effective one-dimensional spin dynamics and extremely overdamped gauge dynamics at the Mott quantum criticality.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Stretchable and wearable polymeric heaters and strain sensors fabricated using liquid metals

Wearable electronic devices (WEDs) are receiving significant attention because of the increasing interest in soft robotics, electronic skin, and wearable sensors. Liquid metals (LMs) are compelling for WEDs owing to their metallic conductivity, fluidic nature, and low toxicity. For this study, we fabricated stretchable and soft WEDs using LM (eutectic gallium-indium alloy) wires (LMWs) patterned via force wetting through custom-made stencils on an elastic substrate. LMWs can generate thermal energy via Joule heating upon current application and deliver it to the substrate, resulting in wearable polymeric heaters. The LM mixed with carbonyl iron particles (CIPs) can also be patterned while preserving fluidic behavior. The degree of thermal energy generated through the LMWs can be manipulated as a function of the CIP concentration in the LM and geometrical factors of the electrode patterns, i.e., width and length. An elastic film patterned with LMWs attached to the human body exhibits changes in the effective electrical resistance depending on applied strain, demonstrating potential as a wearable strain sensor. This LM utilized WED that can generate thermal energy upon current application through the LMWs and detect the bodily motion has significant potential for application in wearable thermotherapy, electronic skin, and soft sensors.

47 OTHER INSTRUMENTATION↗
DOE OSTI2026

Complexity in the medium-range order of gallium as a polyvalent liquid metal

Simplicity in chemical composition does not always translate into simplicity in the structures and dynamics of liquids and solids. Some elementary liquid metals, such as gallium, show unusual behaviors in thermodynamic and transport properties as a result of their complex atomic structure and dynamics. Here, in this work, we study the real-space atomic correlation function of liquid gallium by neutron scattering. In the pair-distribution function, there exist two kinds of medium-range order (MRO), characterized by oscillations beyond the first nearest neighbors. On the other hand, the first neighbor shell shows only one kind of bond. The two types of MRO are strongly overlapping in space and fluctuating in time. We propose that they are the basis for anomalous behavior of liquid gallium. This view challenges the current view that liquid gallium consists of fluctuating metallic and insulating domains. These findings shed light on the interpretation of similar microscopic anomalies observed in other semimetallic liquids.

Hua, Chengyun [Oak Ridge National Laboratory (ORNL↗