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Thermal Barrier Coatings Overview: Design, Manufacturing, and Applications in High-Temperature Industries
Today’s competitive world economy is creating an indispensable demand for increased efficiency of engineering components that operate in harsh environments (i.e., very high-temperature, corrosive, or neutron irradiation environments), for applications in the energy, automotive, aerospace, electronics, and power industries. Increased research is being done on thermal barrier coatings (TBCs) for protecting such components, since the versatility of manufacturing techniques and the scale of deployment result in increased life, economics, performance, and durability. This review focuses on the advances that led to using TBCs for component life extension and, more recently, as an integral part of advanced component design for high-temperature and other types of harsh environments, such as those found in nuclear-related applications. Furthermore, factors that led to state-of-the-art advanced coating-fabrication techniques [e.g., electron-beam physical vapor deposition (EB-PVD), plasma spray deposition, and electrophoretically deposited TBCs, as well as functionally graded material (FGM) manufacturing] have also been emphasized in current coating R&D. This review explores the current state of TBCs, i.e., the latest advances regarding their fabrication and performance, associated challenges, and recommendations for their future use in aerospace, nuclear, high-temperature, or otherwise harsh environments.
Tuning the electronic structure of Ag-Pd alloys to enhance performance for alkaline oxygen reduction
Alloying is a powerful tool that can improve the electrocatalytic performance and viability of diverse electrochemical renewable energy technologies. Herein, we enhance the activity of Pd-based electrocatalysts via Ag-Pd alloying while simultaneously lowering precious metal content in a broad-range compositional study focusing on highly comparable Ag-Pd thin films synthesized systematically via electron-beam physical vapor co-deposition. Cyclic voltammetry in 0.1 M KOH shows enhancements across a wide range of alloys; even slight alloying with Ag (e.g. Ag 0.1 Pd 0.9 ) leads to intrinsic activity enhancements up to 5-fold at 0.9 V vs. RHE compared to pure Pd. Based on density functional theory and x-ray absorption, we hypothesize that these enhancements arise mainly from ligand effects that optimize adsorbate–metal binding energies with enhanced Ag-Pd hybridization. This work shows the versatility of coupled experimental-theoretical methods in designing materials with specific and tunable properties and aids the development of highly active electrocatalysts with decreased precious-metal content.
High-energy X-ray phase analysis of CMAS-infiltrated 7YSZ thermal barrier coatings: Effect of time and temperature
Calcium–magnesium–alumino-silicate (CMAS) particulates enter the aero-engine in a sandy environment, melt and infiltrate into 7 wt% yttria-stabilized zirconia (7YSZ) thermal barrier coatings (TBCs), reducing their lifetime. This leads to chemical degradation in 7YSZ accompanied by tetragonal to monoclinic phase transformation upon cooling. In this work, electron-beam physical vapor deposition coatings were infiltrated with a synthetic CMAS. Here, synchrotron X-ray diffraction measurements show that CMAS infiltration at 1250 °C has about 43% higher monoclinic phase volume fraction (PVF) at the coating surface compared to 1225 °C and remains consistently higher throughout the coating depth. Additionally, the increase in annealing time from 1 to 10 h results in a 31% higher monoclinic phase at the surface. Scanning electron microscopy revealed the presence of globular monoclinic phases corresponding spatially with the above findings. These results resolve the impact of time and temperature on CMAS infiltration kinetics which is important for mitigation.
Validating pyORBIT for Modeling Beam Dynamics in the IOTA Ring
The Integrable Optics Test Accelerator (IOTA) ring is a new Fermilab facility dedicated to beam physics experiments, currently operating with 150 MeV electrons. Space charge effects are expected to be significant when it operates with 2.5 MeV protons. In this contribution, we present results of a suite of validation tests of PyORBIT, a PICstyle space charge code. Single particle dynamics of quasiintegrable optics using an octupole string in IOTA is compared with MADX, and shown to be in good agreement. Requirements for the convergence of space charge computations are systematically established and when possible, tests involving space charge are compared with theoretical predictions.
Status of the IOTA proton injector
The IOTA Proton Injector (IPI), currently under installation at the Fermilab Accelerator Science and Technology facility (FAST), is a machine capable of delivering 20\,mA pulses of protons at 2.5\,MeV to the Integrable Optics Test Accelerator (IOTA) ring. First beam in the IPI beamline is anticipated in the first half of~2024, when it will operate alongside the existing electron injector beamline to facilitate further beam physics research and continued development of novel accelerator technologies at the IOTA ring. This report details the expected operational profile, known challenges, and the current state of installation.
On the Electromagnetic Field of a Focusing Charged Particle Beam and Its Two-Dimensional Approximation
The analytical expressions for the electromagnetic potential generated from a focusing charged particle beam are indispensable in various beam physics problems. In this article, we review the theory in detail and point out the necessary assumptions made in the derivation.
Commissioning of the IOTA Proton Injector
The IOTA Proton Injector (IPI) at the Fermilab Accelerator Science and Technology facility (FAST) is a machine capable of delivering up to 14 mA pulses of protons at 2.5 MeV to the Integrable Optics Test Accelerator (IOTA) ring. Its construction was completed in the fall of 2025, followed by a successful commissioning run scheduled to conclude at the end of May 2026. It operates alongside the existing electron injector beamline to facilitate further beam physics research and continued development of novel accelerator technologies at the IOTA ring. This report details the current operational profile, known challenges, and future plans for the proton program development at FAST.
Design of Ionization Profile Monitors at the Integrable Optics Test Accelerator Facility at Fermilab
The Integrable Optics Test Accelerator (IOTA) at Fermilab is transitioning from an electron beam facility to a proton beam facility for studies in nonlinear accelerator optics and space-charge dominated proton beams. This project involves the commissioning and fabrication of Ionization Profile Monitors (IPMs) to enable beam profile measurements at IOTA. In general, IPMs work on principle of residual gas ionization by the beam to generate beam profile. This work focuses on a mechanical design that leverages a controlled injection of noble gases, primarily Argon, as the ultra-high vacuum of the IOTA ring provides insufficient residual gas for ionization. Efforts to understand vacuum integration to ensure compatibility with the storage ring environment, the integration of real-time data acquisition systems and the commissioning of the IPMs will be discussed. This project provides a versatile diagnostic tool, supporting IOTA’s role as a testbed for larger-scale accelerator facilities and contributing to the broader understanding of beam physics in high-intensity, high-space-charge regimes.
3D Toroidal Field Multipoles for Curved Accelerator Magnets
Curved magnets producing continuously rotating field multipoles along the length of the bend can provide strong and continuous transverse focusing, making them of interest for accelerator systems such as compact ion beam gantries and synchrotron light sources. Evaluating the utility of such rotating multipole systems requires an accurate description of field behavior for beam physics calculations. This paper presents a helical scalar potential solution in 3D toroidal harmonics relevant to boundary conditions on the surface of a torus. The resulting fields are evaluated for a curved helical quadrupole channel to illustrate field rotation and the effect of magnet curvature.
Status of the IOTA Proton Injector
The IOTA Proton Injector (IPI), currently under installation at the Fermilab Accelerator Science and Technology facility (FAST), is a machine capable of delivering 20 mA pulses of protons at 2.5 MeV to the Integrable Optics Test Accelerator (IOTA) ring. First beam in the IPI beamline is anticipated in the first half of 2024, when it will operate alongside the existing electron injector beamline to facilitate further beam physics research and continued development of novel accelerator technologies at the IOTA ring. This report details the expected operational profile, known challenges, and the current state of installation.
Strategies in Education, Outreach, and Inclusion to Enhance the US Workforce in Accelerator Science and Engineering
We summarize the community-based consensus for improvements concerning education, public outreach, and inclusion in Accelerator Science and Engineering that will enhance the workforce in the USA. The improvements identified reflect the product of discussions held within the 2021-2022 Snowmass community planning process by topical group AF1: Beam Physics and Accelerator Education within the Accelerator Frontier. Although the Snowmass process centers on high-energy physics, this document outlines required improvements for the entire U.S. accelerator science and engineering enterprise because education of those entering and in the field, outreach to the public, and inclusion are inextricably linked.
The QCD phase diagram and Beam Energy Scan physics: A theory overview
Herein we review recent theoretical developments relevant to heavy-ion experiments carried out within the Beam Energy Scan program at the Relativistic Heavy Ion Collider. Our main focus is on the description of the dynamics of systems created in heavy-ion collisions and establishing the necessary connection between the experimental observables and the QCD phase diagram.
Physics of beam-driven ion cyclotron emission in the large plasma device
Abstract Ion cyclotron emission (ICE) is widely observed from spatially localised minority energetic ion populations in toroidal magnetically confined fusion (MCF) plasmas, both tokamaks and stellarators. Its spectral structure is typically regular with narrow suprathermal peaks, whose frequency separation matches a local energetic ion cyclotron frequency. Here we report the first computational (fully nonlinear self-consistent kinetic particle-in-cell code) and analytical (linear magnetoacoustic cyclotron instability (MCI)) studies of ICE observations from cylindrical plasmas contained in the Large Plasma Device (LAPD). Because LAPD is cylindrical, the plasma physics giving rise to the observed ICE spectrum necessarily excludes toroidal effects. Our approach, previously successful for toroidal plasma ICE, assumes slab geometry and hence is well adapted to LAPD. ICE from LAPD is strongly electrostatic, as distinct from electromagnetic, and is driven by 15 keV beam ions for which the ratio of perpendicular speed to the local Alfven speed, v ⊥ / v A , is 0.15, lower than in MCF plasmas from which beam-driven ICE has previously been observed. Our results are in good agreement with these observations. There is congruence between simulated ICE spectra, obtained in the saturated nonlinear regime of our computations, and observed ICE spectra; the underlying physics is essentially the same as in toroidal plasmas; and there is alignment with linear analytical theory where appropriate. The present work establishes a mapping from the cylindrical LAPD ICE observations to toroidal MCF ICE observations. The LAPD spectra are instances of beam-driven MCI-type ICE in its sub-Alfvenic, predominantly electrostatic manifestation, which has precedents in MCF stretching back to the 1990s. An interesting corollary is that, for many purposes, ICE in toroidal MCF plasmas ‘might as well’ be occurring in a cylinder.
Physics Opportunities at a Beam Dump Facility at PIP-II and Beyond
The accelerator complex at Fermilab is currently undergoing improvements which will increase the available beam power to the complex and is known as Proton Improvement Plan-II (PIP-II). The PIP-II Linac is slated for operation near the end of this decade and will be the main proton driver for Fermilab experiments moving forward and provide the beam to LBNF/DUNE. However, the DUNE physics program requires only ~1% of the available protons provided by PIP-II. The Accelerator Complex Enhancement, or ACE, will provide further up grades in the 2030s in the form of increased power to LBNF along with a replacement for the Fermilab Booster which could also include an accumulator ring. A workshop was recently held at Fermilab in order to explore the physics possible when PIP-II is coupled with a fixed target or beam dump. The beam dump scenario pro vides an exciting opportunity to search for dark sector physics across detector threshold energy scales with examples being accelerator-produced dark matter, active-to-sterile neutrino oscillations, millicharged parti cles, and axion-like particles, which can be produced in the proton collisions with a fixed target. Additionally, experiments located at a PIP-II facility that is coupled to an accumulator ring would also be able to study coherent elastic neutrino-nucleus scattering, or CEvNS. In this talk, I will summarize the physics possible at a PIP-II beam dump facility and sensitivities to different dark sector physics and other beyond the Standard Model searches with detector concepts spanning from an eV-scale to MeV-scale detection threshold.
The new physics case for beam-dump experiments with accelerated muon beams
As the field examines a future muon collider as a possible successor to the LHC, we must consider how to fully utilize not only the high-energy particle collisions, but also any lower-energy staging facilities necessary in the R&D process. An economical and efficient possibility is to use the accelerated muon beam from either the full experiment or from cooling and acceleration tests in beam-dump experiments. Beam-dump experiments are complementary to the main collider as they achieve sensitivity to very small couplings with minimal instrumentation. We demonstrate the utility of muon beam-dump experiments for new physics searches at energies from 10 GeV to 5 TeV. We find that, even at low energies like those accessible at staging or demonstrator facilities, it is possible to probe new regions of parameter space for a variety of generic BSM models, including muonphilic, leptophilic, L μ − L τ , and dark photon scenarios. Such experiments could therefore provide opportunities for discovery of new physics well before the completion of the full multi-TeV collider.
Linearization of an Electron Beam’s Longitudinal Phase Space Using a Hollow-Channel Plasma
The removal of undesired beam nonlinear energy chirp (time-energy correlation) or linearization of the beam longitudinal phase space (LPS) is crucial for high-brightness linac-based scientific applications, such as x-ray free-electron lasers. In this paper, we propose that a low-density hollow channel plasma can be used as a near-ideal passive linearizer to significantly linearize the beam LPS and, at the same time, preserve the beam emittance. Physically, the passage of the beam through the hollow plasma channel excites a strong quasicosinoidal longitudinal wakefield that acts to mitigate the beam nonlinear energy chirp by superimposing a reverse chirp on the beam. The theoretical analyses and large-scale three-dimensional start-to-end simulations confirm that the beam longitudinal phase space can be almost completely linearized without noticeable beam emittance growth. In conclusion, application of such a near-ideal linearizer may significantly improve the performance of numerous accelerator-based applications.
Sunbeam: Near-sun statites as beam platforms for beam-driven rockets
Here, we outline a method of beamed power for propulsion that utilizes relativistic electron beams. The physics of charged particle beam propagation in the space plasma environment is discussed and the long-range (> 100 AU) advantage of relativistic electron beams is emphasized. A preliminary statite-based beam emitter for powering probes to 0.1c is proposed and the challenges in beamed-power uses are explored.