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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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66 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

On the Computation of the Beam Position in the Arcs of the Hadron Storage Ring

To compensate for the velocity differences of the hadrons and electrons in the Electron-Ion Collider, the hadron beam will be operated in a large range of the radial displacement (±20 mm in the 64 mm wide vacuum chamber). Machine protection and beam optics measurement require high-accuracy calculations of the beam position from the signal induced on the pickup electrodes. For the HSR, we need at least the fifth-order polynomial fit, which provides 70 microns r.m.s. error in the 40 by 20 mm region of interest as shown in Fig. 1. The calculations are made using a MATLAB script solving the 2D electrostatic problem.

43 PARTICLE ACCELERATORS↗
DOE OSTI2026

Additive Manufacturing of Cryogenic Austenitic Steel JK2LB via Wire-Fed Directed Energy Deposition (DED) for Fusion Energy Applications

This study explores the feasibility of fabricating cryogenic austenitic steel JK2LB via both laser-based directed energy deposition (laser-DED) and arc-based directed energy deposition (arc-DED) additive manufacturing processes for potential application in fusion reactors. JK2LB, a low-nickel, high-manganese stainless steel developed for ITER, offers excellent cryogenic toughness, radiation resistance, and decay-to-clearance characteristics. Although JK2LB was originally designed to endure cyclic stresses at cryogenic temperatures in tokamaks, its low-temperature mechanical integrity and radiation tolerance also make it a promising candidate for structural components, such as the coil case/support structure in nonplanar high-temperature superconducting magnet assemblies in stellarators. Directed energy deposition (DED) additive manufacturing was selected for this study due to its capability to fabricate large structures with complex geometries. Here, to address the long lead time and high cost associated with acquiring conventional JK2LB solid wire, JK2LB powder-cored wire was developed as the feedstock material. Testing blocks were then fabricated using both wire-fed laser-DED and arc-DED processes. Microstructural and compositional analyses revealed that both DED approaches yield fully austenitic phase and columnar grain structures. Mechanical testing at room temperature revealed that both DED routes achieved yield strength and elongation comparable to those of conventionally processed JK2LB via vacuum melting, electroslag remelting, extrusion, and drawing, though ultimate tensile strength was reduced due to Mn loss and large columnar grains. As a study mainly focusing on the additive manufacturing process, this work demonstrates the potential of additive manufacturing for fusion energy applications and provides a basis for optimization and future cryogenic mechanical evaluation.

Cryogenic steel↗
DOE OSTI2024

Thermal simulation of the EIC HSR interconnect module - RF fingers

The Electron Ion Collider (EIC) Hadron Storage Ring (HSR) will reuse most of the existing superconducting magnets from the RHIC storage ring. However, the existing beam vacuum chamber and stripline BPMs will not be compatible with the planned EIC hadron bunches that will have a 3x higher intensity and be 10x shorter, and some operational scenarios with large radial offsets of the beam in the vacuum chamber. To address these challenges, a copper coated beam screen will be implemented, the existing RHIC stripline BPMs will be shielded and an interconnect module design, including new BPM will be installed adjacent to the existing BPMs. A thermal analysis of the new arc BPM interconnect housing has been conducted to assess the heating caused by beam induced resistive wall heating and electron cloud heating. An analysis of the BPM module has been made and reported separately. This report will focus on the other side of the interconnect module, containing the RF fingers.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Electron Cloud Simulations for the Electron-Ion Collider in Brookhaven National Laboratory

For high-intensity circular accelerators and storage rings, if the secondary electron emission yield (SEY) of the vacuum chamber surfaces is high, an EC (Electron Cloud) could build up with the passage of the circulating beam. The presence of EC can strongly affect the beam quality, such as transverse instabilities, transverse emittance growth, and beam loss. Furthermore, the heat load from EC can exceed the available cryogenic capability. For the RHIC superconducting (SC) arc magnets, to be used for the hadron storage ring of the Electron-Ion Collider (EIC), the dynamic heat load budget is 0.5 W/m to the 4.5 K stainless steel beam pipe. This can limit the maximum beam bunches or intensity of the EIC, hence diminishing the luminosity provided by the EIC. The EC has affected the beam instability and significantly contributed to cryogenic heat load in the Large Hadron Collider (LHC). Positron storage rings for which ECs have been a critical factor in the design and performance include KEKB in Japan and EC buildup remains one of the concerns for future high-intensity accelerators design. EC considerations have driven the SuperKEKB collider design and the positron damping ring for the proposed International Linear Collider (ILC). The LHC luminosity upgrade is contingent on reducing the bunch spacing to 25 ns; at this bunch spacing, severe EC buildup has been observed. The success of the upgrade is likely contingent on limiting EC buildup. To study the EC heat load, we did some EC simulations with PyECLOUD code for the dipole, quadrupole, sextupole magnets, and the warm (drift) section of the EIC hadron storage ring. PyECLOUD is an EC simulation code developed by CERN. The code has been validated and used to study EC in the LHC, SPS, and PS. To eliminate EC buildup, the sources of electrons must be minimized. First, we will reduce the production of electrons due to residual gas ionization by specifying the maximum gas density, which requires a vacuum chamber with low electron-stimulated desorption (ESD) yields and a sufficient (preferably distributed) pumping speed. Second, we should reduce the secondary electrons with a lower secondary electron yield (SEY) material.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Electron cloud thresholds at the arcs of the Electron-Ion Collider hadron storage ring

The Electron-Ion Collider is designed to provide high-luminosity collisions. For the highest lu minosity scenario, the hadron storage ring will host a 275 GeV beam consisting of 1160 bunches with 6.9e10 protons per bunch. Previous work has found that some sections of the hadron storage ring will experience electron cloud buildup if their vacuum chamber does not show a sufficiently low secondary electron emission value. This technical note reviews the electron cloud growth thresholds for the updated screen profile and lattice.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Thermo-Mechanical Distortion of Tungsten-Coated Steel During High Heat Flux Testing Using Plasma Arc Lamps

An experimental setup and a test section were designed and fabricated for high heat flux testing (HHFT) of neutron-irradiated specimens using water-wall plasma arc lamps. Because of the radiological considerations and limitations of reactor irradiation, the size of the test articles was limited to disks less than 10 mm in diameter. The specimen was clamped onto an actively cooled block, and clamping allowed the insertion of several thermocouples on the back surface of the specimen through a copper (Cu) block. Five vacuum plasma sprayed tungsten (W)–coated F82H steel specimens were subjected to HHFT. Surface profilometry measurements, which were conducted after HHFT, revealed central bowing of the top W surface. This type of residual distortion occurred for all of the specimens, and the larger the specimens were, the larger was the distortion.In an attempt to understand specimen distortion and address the science questions related to the testing of subsize specimens during HHFT, a simplified thermo-mechanical model was developed. By using a measured temperature in the Cu as an isothermal boundary condition, the model eliminated the need for coupling cooling fluid flow models with stress models, greatly simplifying the analysis. The main variable in the proposed model is hC, i.e., the thermal contact conductance between the F82H and the Cu washer. Inelastic properties, including hardening properties, were considered for F82H steel and Cu. Numerical simulation results demonstrated a buildup of residual deformation during HHFT and a very complex state of stress and deformation during typical heat flux (HF) cycling. Additionally, hoop stress evolution during a high heat flux cycle reveals that F82H at an interface with W would be mainly in compression during HF application and experienced a transition to a tension state during cooldown. Also, specimen distortion evolves during each HF cycle, as the specimen bows downward during HF application and upward during the cooldown period between HF cycles. The final specimen distortion, i.e., upward bowing of the specimen center, was qualitatively predicted for hC values of 4000 to 5000 W/(m 2 ·K). This hC range of values, for which bulging is obtained, is at the lower spectrum of the range of values for hC, consistent with the low thermal contact conductance expected from the unpolished F82H surface.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Pyrolysis Vacuum-Assisted Plasma Ionization Ion Mobility–Mass Spectrometry for Insoluble Polymer Analysis

Wire-based metal additive manufacturing utilizes the ability of additive manufacturing to fabricate complex geometries with high deposition rates (above 7 kg/h), thus finding applications in the fabrication of large-scale components, such as stamping dies. Traditionally, the workhorse materials for stamping dies have been martensitic steels. However, the complex thermal gyrations induced during additive manufacturing can cause the evolution of an inhomogeneous microstructure, which leads to a significant scatter in the mechanical properties, especially the toughness. Therefore, to understand these phenomena, arc-based additive AISI 410 samples were fabricated using robotic gas metal arc welding (GMAW) and were subjected to a detailed characterization campaign. The results show significant scatter in the tensile properties as well as Charpy V-notch impact toughness data, which was then correlated to the microstructural heterogeneity and delta (δ) ferrite formation. Post-processing (austenitizing and tempering) treatments were developed and an ~70% reduction in the scatter of tensile data and a four-times improvement in the toughness were obtained. The changes in mechanical properties were rationalized based on the microstructure evolution during additive manufacturing. Based on these, an outline to tailor the composition of “printable” steels for tooling with isotropic and uniform mechanical properties is presented and discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Constraints on Metastable Helium in the Atmospheres of WASP-69b and WASP-52b with Ultranarrowband Photometry

Infrared observations of metastable 2{sup 3}S helium absorption with ground- and space-based spectroscopy are rapidly maturing, as this species is a unique probe of exoplanet atmospheres. Specifically, the transit depth in the triplet feature (with vacuum wavelengths near 1083.3 nm) can be used to constrain the temperature and mass-loss rate of an exoplanet’s upper atmosphere. Here, we present a new photometric technique to measure metastable 2{sup 3}S helium absorption using an ultranarrowband filter (FWHM 0.635 nm) coupled to a beam-shaping diffuser installed in the Wide-field Infrared Camera on the 200 inch Hale Telescope at Palomar Observatory. We use telluric OH lines and a helium arc lamp to characterize refractive effects through the filter and to confirm our understanding of the filter transmission profile. We benchmark our new technique by observing a transit of WASP-69b and detect an excess absorption of 0.498% ± 0.045% (11.1σ), consistent with previous measurements after considering our bandpass. We then use this method to study the inflated gas giant WASP-52b and place a 95th percentile upper limit on excess absorption in our helium bandpass of 0.47%. Using an atmospheric escape model, we constrain the mass-loss rate for WASP-69b to be 5.25{sub −0.46}{sup +0.65}×10{sup −4} M{sub J} Gyr{sup −1} (3.32{sub −0.56}{sup +0.67}×10{sup −3} M{sub J} Gyr{sup −1}) at 7000 K (12,000 K). Additionally, we set an upper limit on the mass-loss rate of WASP-52b at these temperatures of 2.1×10{sup −4} M{sub J} Gyr{sup −1} (2.1×10{sup −3} M{sub J} Gyr{sup −1}). These results show that ultranarrowband photometry can reliably quantify absorption in the metastable helium feature.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2024

Fabrication and Testing of DOE Standard Canister Closure Leak Test Assembly

DOE manages over 300 types of SNF, most of which are located at the INL site. “Road-ready dry storage” is a management concept where SNF is packaged into dry, sealed canisters, which are then placed in on-site storage in anticipation of later removal. The Idaho Cleanup Project and INL are collaborating on the Road-Ready Capability Demonstration Project, which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE SNF for road-ready dry storage. In support of establishing a large-scale road-ready dry storage program at the INL site, the demonstration will package a select amount of DOE-managed SNF into DOE Standard Canisters. The closure process for the DOE Standard Canisters will include fuel and basket loading, welding, inspection, leak testing, and if needed, repair. As a follow-up to previous discussion on the design of the DOE Closure Leak Test Assembly, this report describes recent fabrication and testing efforts performed at INL. DOE Standard Canisters are sealed by two sequential gas tungsten arc welds. Both are performed by remotely operated and semi-autonomous welding systems. The first weld is a circumferential pipe weld that completes assembly of the canister body and lid assembly. The second and final closure weld connects the vent plug to the vent port with an identical butt joint to the circumferential pipe weld. After the second weld is performed on the vent port, these welds are helium leak tested using an inside-out technique. In addition to the commercially available vacuum and leak detector systems, the DOE Standard Canister Closure Leak Test Assembly was designed for both remote and manual operation. This report describes fabrication and performance testing associated with the inside-out technique. INL staff designed and tested systems to accomplish these tasks. Hardware fabrication occurred at INL facilities. Forthcoming work includes design optimization, integration to existing systems, and implementation to packaging demonstration operations.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Design and Study of Inductively Coupled Plasma Chamber Components Using the SupRISE Test Device at DIII-D

The DIII-D National Fusion Facility aims to increase the auxiliary heating power for the tokamak by upgrading the Neutral Beam Injection (NBI) system. In collaboration with North Carolina State University, the conventional ‘arc and filament’ NBI ion sources will be converted to inductively coupled plasma (ICP) sources which utilize radio frequency (RF) coupling to maximize reliability for high power operation. In support of this initiative, a full scale test device (SupRISE, Superior Radiofrequency Ion Source Experiment) is currently under construction at the DIII-D Facility. In preparation for the construction of a full scale prototype that can be installed on the DIII-D NBI system, experiments on SupRISE will be conducted to determine the optimal RF frequency for high power coupling, Faraday shield slit configuration, and ICP chamber length. SupRISE is comprised of an approximately 30 x 70 cm quartz dielectric vessel with an internal Faraday shield enclosed in a secondary vacuum chamber to ensure structural stability of the dielectric. Actively cooled front and back plates are designed to reduce the thermal stresses on the plasma facing components and mate with the existing accelerator used by the NBI system at DIII-D. 50 kW of RF power will be coupled to the plasma through the quartz over a variable frequency range of 4-8 MHz to sustain a plasma density of ∼ 10 18 m −3 for a 10 s ON, 210 s OFF duty cycle. Various modelling efforts have been employed to simulate the thermal and stress profiles over the primary components of the SupRISE device as well as the inductance behavior of the RF antenna. These simulation results and the final design for SupRISE will be presented. An additional reduced-scale predecessor ICP source (called RISE) has been used to develop a predictive match model that will be applied to frequency optimization studies on SupRISE. Furthermore, the outcomes of this research and complementary efforts at North Carolina State University are essential for the incorporation of ICP NBI positive ion sources at the DIII-D facility.

DIII-D↗
DOE OSTI2023

Structural Tolerance of Zirconium Diboride under Electron Irradiation through in-situ Convergent Beam Electron Diffraction and Energy-dispersive X-ray Spectroscopy

Zirconium diboride (ZrB 2 ) is a ultra-high temperature ceramic with high melting temperature (>3000 K), super strength and hardness, good thermal conductivity, and excellent resistance to plasma erosion and chemical erosion, being widely applied in hypersonic flight, arc-electrodes, refractory materials, and plasma-facing materials in fusion reactors. Therefore, the structural stability of the material is essential for the applications. Up to now, the material was investigated under neutron irradiation and high-energy ion irradiations. It was reported that the neutron irradiation caused swelling and catastrophic cracking. High-energy ions (30 keV He + ) changed the surface morphology and caused the bright blue and brown colors on ZrB 2 surfaces between 920 K and 1120 K. The electron irradiation tolerance of the material has not been reported yet. Here we used convergent beam electron diffraction (CBED) and energy-dispersive X-ray spectroscopy (EDS) to investigate structural tolerances of ZrB 2 crystals under high-energy electrons at room temperature under vacuum. Finally, the investigation would benefit the understanding of its structural tolerance at microscales.

42 ENGINEERING↗
DOE OSTI2020

Modular In-Chamber Electron Beam Welding – Process Planning: Welding, Cladding, Inspection, and Manufacturing

Electron beam welding (EBW) is commonly employed by industry today to join relatively thin section components. Industrial sectors which utilize the technology include; automotive, aircraft, aerospace, defense, medical, oil & gas, etc. The ability to produce single pass, thick section (up to 6 inches, 150mm) welds has also been available for more than 40 years; however, the technology has not been deployed for civil nuclear manufacturing and fabrication such as reactor pressure vessels, steam generators, or pressurizers. Instead, thick section joining is performed much in the same manner it has been for decades using submerged arc or gas tungsten arc welding processes. Recent research performed under U.S. Department of Energy (DOE) project DE-NE0008629 has demonstrated that the overall welding time to produce one major reactor pressure vessel (RPV) girth weld can be reduced from weeks to less than 90 minutes, while maintaining exceptional quality and inspection characteristics. The subject project (DE-NE0008846) investigates a modular in-chamber (MIC) EBW approach which allows various RPV sections to be joined within a “modular” chamber. The MIC-EBW approach utilizes individual modules that can be stacked and de-stacked to various heights to enable production girth welds to be performed at a given elevation. This report describes the various processing methodology necessary to complete major girth weldments for the NuScale Power small modular reactor including welding development, manufacturing, production sequence, inspection, and cladding.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗