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At least 757 records · Page 42

All sources NASA NTRS DOE OSTI

DOE OSTI2025

Numerical framework for integrated additive manufacturing-compression molding (AM-CM) of thermoplastic composites

Additive manufacturing-compression molding (AM-CM) has emerged as a transformative technology in advanced composite manufacturing. Additive manufacturing (AM) offers high design flexibility and the ability to produce complex geometries with precisely aligned fibers in the preferred orientation. Compression molding (CM) enhances composite materials by providing excellent dimensional stability, reduced porosity, high production rates, and a smooth surface finish. Despite these advantages, extensive integrated analysis is required to optimize processing conditions for improved fiber orientation distribution (FOD) and porosity control. Here, this study develops a comprehensive numerical model to simulate the AM-CM manufacturing process. The model isolates the effects of both the AM and CM phases while also capturing their integration. Additionally, it accounts for heat transfer, temperature-dependent viscosity, and fiber orientation in the extruded fiber-filled polymer, accurately representing material behavior during processing. This approach enables the analysis of interactions between deposited beads of complex strand shapes and their interface regions after full compression. Moreover, the model predicts key parameters such as polymer flowability, fiber orientation, and temperature evolution in AM-CM parts. By optimizing processing conditions, it facilitates a controlled and predictable microstructure.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Combined Effects of Fe(III)-Bearing Clay Minerals and Organic Ligands on U(VI) Bioreduction and U(IV) Speciation

Reduction of U(VI) to U(IV) drastically reduces its solubility and has been proposed as a method for remediation of uranium contamination. However, much is still unknown about the kinetics, mechanisms, and products of U(VI) bioreduction in complex systems. In this work, U(VI) bioreduction experiments were conducted with Shewanella putrefaciens strain CN32 in the presence of clay minerals and two organic ligands: citrate and EDTA. In reactors with U and Fe(III)-clay minerals, the rate of U(VI) bioreduction was enhanced due to the presence of ligands, likely because soluble Fe 3+ - and Fe 2+ -ligand complexes served as electron shuttles. In the presence of citrate, bioreduced U(IV) formed a soluble U(IV)-citrate complex in experiments with either Fe-rich or Fe-poor clay mineral. In the presence of EDTA, U(IV) occurred as a soluble U(IV)-EDTA complex in Fe-poor montmorillonite experiments. However, U(IV) remained associated with the solid phase in Fe-rich nontronite experiments through the formation of a ternary U(IV)-EDTA-surface complex, as suggested by the EXAFS analysis. Our study indicates that organic ligands and Fe(III)-bearing clays can significantly affect the microbial reduction of U(VI) and the stability of the resulting U(IV) phase.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Deterministic multi-phonon entanglement between two mechanical resonators on separate substrates

Mechanical systems have emerged as a compelling platform for applications in quantum information, leveraging advances in the control of phonons, the quanta of mechanical vibrations. Experiments have demonstrated the control and measurement of phonon states in mechanical resonators, and while dual-resonator entanglement has been demonstrated, more complex entangled states remain a challenge. Here, we demonstrate rapid multi-phonon entanglement generation and subsequent tomographic analysis, using a scalable platform comprising two surface acoustic wave resonators on separate substrates, each connected to a superconducting qubit. We synthesize a mechanical Bell state with a fidelity of $\mathcal{F}$ = 0.872 ± 0.002, and a multi-phonon entangled N = 2 N00N state with a fidelity of $\mathcal{F}$ = 0.748 ± 0.008. The compact, modular, and scalable platform we demonstrate will enable further advances in the quantum control of complex mechanical systems.

74 ATOMIC AND MOLECULAR PHYSICS↗

DOE OSTI2020

Chapter 12: Photoelectron Spectroscopy Methods in Solar Cell Research

Photoelectron spectroscopy (PES), also referred to as photoemission spectroscopy, is a direct experimental method for assessing the chemical and electronic properties of materials. The technique is becoming increasingly important in the research of photovoltaic (PV) devices--where, more specifically, X-ray photoelectron spectroscopy (XPS) is used primarily to measure the chemical properties such as composition and contamination of solar cell materials, whereas ultraviolet photoelectron spectroscopy (UPS) reveals key electronic properties such as work function and electronic energy-level positions. PES is a surface-sensitive technique ideally suited for the analysis of thin films and interfaces, either completed ones or during their formation process. Because the new generation of PV devices comprise a multitude of complex interfaces--each of which plays a critical role for performance and functionality--PES analysis of functional cell components has gained even more relevance.

photoelectron spectroscopy↗

DOE OSTI2021

A digital holography ex situ measurement characterization of plasma-exposed surface erosion from an electrothermal arc source

Digital holography has been proposed to fulfill a need for an imaging diagnostic capable of in situ monitoring of surface erosion caused by plasma–material interaction in nuclear fusion devices. A digital holography diagnostic for 3D surface erosion measurement has been developed at Oak Ridge National Laboratory with the goal of deployment on a plasma device. A proof-of-concept in situ demonstration is planned which would involve measurement of plasma erosion on targets exposed to an electrothermal arc source. This work presents the results of an ex situ characterization of the capability and limitations of holographic imaging of targets exposed to the arc source. Targets were designed to provide a fiducial for comparison of deformed and unaffected areas. The results indicated that the average net erosion was ~150 nm/plasma exposure, which is expected to be within the diagnostic’s measurement capacity. Surface roughness averages determined by holographic image analysis showed good agreement with measurements taken with a profilometer. Finally, the limit of the holography diagnostic’s x–y spatial resolution was characterized by comparison with scanning electron microscope imaging.

47 OTHER INSTRUMENTATION↗

DOE OSTI2026

Computational Thermal Hydraulics of a High-Performance Low-Enriched-Uranium Annular Target for HFIR Irradiation

Molybdenum-99 has historically been generated via isolation from fissioned highly enriched uranium (HEU) targets. Here, this isotope is in high demand due to its daily use across the world in radiopharmaceutical medical procedures. The primary objective of this work was to design and analyze an experimental target assembly containing one low-enriched-uranium (LEU) annular target for irradiation at the High Flux Isotope Reactor (HFIR). Efforts included incorporating spatially dependent energy sources from neutron and gamma interactions, quantifying thermal contact conductance at material interfaces, performing grid-independent studies, comparing turbulence models, and simulating various steady-state and transient scenarios relevant for irradiation qualification and eventual insertion. These models provide velocity, pressure, and temperature distributions in both space and time. Such results enable the selection of an appropriate irradiation location, fission rate density, and flow-limiting orifice size and demonstrate compliance with HFIR safety requirements such that insertion into the reactor can be approved. This analysis shows that across all scenarios, wetted surface temperatures remain below the coolant saturation temperature with no net vapor formation in the coolant. In every scenario, all components stay below 30% of the aluminum 6061 melting temperature. Computational fluid dynamics and system-level models predict peak target temperatures that agree within 4%, though the predicted axial location of the peak differs by about 10% of the heated length due to differences in flow development length. These results de-risk the irradiation of LEU (annular targets) and strengthen a domestic, HEU-independent 99 Mo supply by providing important fuel performance data to form the foundation for a robust licensing basis.

Molybdenum-99↗

DOE OSTI2021

Thermal Stability Testing of LANA.75

Savannah River Site has used the metal hydride LaNi 4.25 Al 0.75 (LANA.75) in the Tritium Facilities for over two decades. LANA.75 beds store significant quantities of tritium but have a limited service life due to the radiolytic decay of tritium to 3He within the metal matrix. It has been shown that the isotherm performance of a tritium-aged LANA.75 sample can be restored by heating under vacuum. Additional investigation is needed to ensure there are no unexpected changes to the hydride before this technique is employed in full-scale beds in the Tritium Facilities. In addition, it is necessary to verify the regenerable behavior and thermal stability of LANA.75 on a small scale prior to it being implemented on a large scale. In this work, a non-tritiated bench-scale LANA.75 sample was held at 750°C under vacuum for 200 h to simulate exposure to multiple restoration evolutions. Hydride isotherm performance, chemical composition, crystallinity, and morphology are compared between the pre-restorative and post-restorative testing samples. No significant changes were observed in composition or crystallinity. Comparison of pre-anneal and post-anneal isotherms showed that performance improved rather than deteriorated during the evolution. Scanning electron microscopy analysis showed small growths on the particle surface after exposure to regeneration conditions. Additional testing will be required to determine the cause of these growths.

08 HYDROGEN↗

DOE OSTI2020

In situ laser reflectivity to monitor and control the nucleation and growth of atomically thin 2D materials*

The growth of atomically thin two-dimensional (2D) layered and other quantum materials is typically performed without in situ monitoring or control. Here, a simple laser reflectivity approach is demonstrated to provide in situ control over sub-monolayer thickness and growth kinetics during pulsed laser deposition (PLD) of MoSe 2 layers. First, the general technique is presented with emphasis on designing the maximum sensitivity of the optical contrast through consideration of Fresnel's equations with proper choice of layer thickness, substrate, and laser monitoring wavelength, incidence angle, and laser polarization. Then the 632.8 nm optical reflectivity of MoSe 2 layers on SiO 2 /Si substrates was predicted and compared with in situ monitoring of MoSe 2 growth by PLD under actual growth conditions using a probe HeNe laser beam. The measurements showed high sensitivity and excellent agreement with MoSe 2 surface coverages calculated from atomic resolution STEM analysis of 2D layers deposited in arrested growth experiments. Finally, growth kinetics revealed by these measurements showed sigmoidal nucleation and growth stages in the formation of the 2D MoSe 2 layers that are described by a simple model, indicating the promise of the laser reflectivity technique for in situ monitoring and control of 2D materials deposition.

2D materials↗

DOE OSTI2026

Charge correlations and magnetoelastic coupling in intercalated transition metal dichalcogenides

The large van der Waals gap in transition metal dichalcogenides (TMDs) offers an avenue to tune the ground state of 2D materials through the intercalation of magnetic atoms. Here, we investigate the charge correlations in Fe 1/3 ⁢TaS 2 , Co 1/3 ⁢TaS 2 , and Fe 0.35 ⁢NbS 2 by combining angle-resolved photoemission spectroscopy (ARPES), x-ray scattering, magnetometry, and density functional theory (DFT). We find that, while short-range charge fluctuations develop in Ta-based compounds, Fe 0.35 ⁢NbS 2 exhibits long-range charge order which is strongly coupled with magnetic order and tunable by external magnetic field. Our electronic structure analysis reveals that intercalation reconstructs the Fermi surface via charge transfer and band renormalization, yet does not generate the nesting conditions compatible with the observed ordering vectors. Complementary phonon calculations further exclude a conventional electron-phonon origin of charge order. Together, these results establish magnetoelastic coupling as the dominant mechanism behind charge ordering in Fe 0.35 ⁢NbS 2 and highlight the contrasting role of Nb and Ta hosts in stabilizing correlated ground states in intercalated TMDs.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Measurement of the depth of maximum of air-shower profiles with energies between 10 18.5 and 10 20 eV using the surface detector of the Pierre Auger Observatory and deep learning

We report an investigation of the mass composition of cosmic rays with energies from 3 to 100 EeV ( 1 EeV = 10 18 eV ) using the distributions of the depth of shower maximum X max . The analysis relies on ∼ 50 , 000 events recorded by the surface detector of the Pierre Auger Observatory and a deep-learning-based reconstruction algorithm. Above energies of 5 EeV, the dataset offers a 10-fold increase in statistics with respect to fluorescence measurements at the Observatory. After cross-calibration using the fluorescence detector, this enables the first measurement of the evolution of the mean and the standard deviation of the X max distributions up to 100 EeV. Our findings are threefold: (i) The evolution of the mean logarithmic mass toward a heavier composition with increasing energy can be confirmed and is extended to 100 EeV. (ii) The evolution of the fluctuations of X max toward a heavier and purer composition with increasing energy can be confirmed with high statistics. We report a rather heavy composition and small fluctuations in X max at the highest energies. (iii) We find indications for a characteristic structure beyond a constant change in the mean logarithmic mass, featuring three breaks that are observed in proximity to the ankle, instep, and suppression features in the energy spectrum. Published by the American Physical Society 2025

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

Experimental and computational studies of load ratio effect on fatigue crack growth rates in Alloy 709 at elevated temperatures

Abstract Experimental testing and finite element simulations of fatigue crack growth were performed in austenitic 20Cr‐25Ni (Alloy 709) steel at different load ratios and elevated temperatures. The experimental tests were performed using compact tension specimens, and crack growth rates were measured at stress intensity factors ranging between 5 and 35 MPa√m. Fractographic analysis using scanning electron microscopy indicated crack surface roughness and secondary cracking depending on testing temperature and load ratio. Finite element simulations of fatigue crack growth were performed to compute plasticity‐induced crack opening loads and predict crack growth rates. Predictions of fatigue crack growth rates using finite element simulations were performed using the computed crack‐tip opening loads, and they are shown to match well the experimental measurements.

Engineering↗

DOE OSTI2025

Pan-Pacific low-frequency modes of sea level and climate variability

Tide gauges provide a long observational record that can inform the nature of satellite-era basin-scale sea level trends. However, common signals must be extracted from geographically sparse records. Here, by applying low-frequency component analysis (LFCA) to tide gauge records and surface climate reconstructions, we isolate three coherent modes of Pacific Ocean variability that we ascribe to: a secular, greenhouse gas–driven climate change (LFC1); a nonlinear mode of variability with a reversal around 1980, potentially linked to aerosols (LFC2); and the Interdecadal Pacific Oscillation (LFC3). Although sea level trend patterns reflect the superimposed contribution of all modes, satellite-era trends are dominated by an increasing phase of LFC2: They are thus potentially unrepresentative of both longer-term historical patterns and those expected in the future.

Science & Technology - Other Topics↗

DOE OSTI2023

SURFACE ROUGHNESS REDUCTION AND PERFORMANCE OF Nb3Sn FILM FOR SRF APPLICATIONS

Nb3Sn offers better RF performance (Q and Eacc) than Nb at any given temperature because of its superior superconducting properties. The potential deployment of Nb3Sn-coated SRF cavities at 4 K, delivering similar performance to that of Nb cavities at 2 K, will be a transformational technology to enable new classes of SRF accelerator applications. A clean and smooth surface can enhance the performance of the Nb3Sn-coated cavity, typically, the attainable acceleration gradient. The reduction of surface roughness is often linked with a correlative reduction in average coating thickness and grain size. A new approach to enhance the nucleation centers using the pre-deposition of Sn on Nb is introduced for surface roughness reduction. Besides Sn supply's careful tuning, the temperature profiles were varied to engineer the coating surface with reduced roughness as low as ~40 nm in 20 µm × 20 µm AFM scans, one-third that of the typical coating. Electropolishing of coated sample shows surface a clear surface smoothening. A few sets of coating parameters were used to coat 1.3 GHz sin-gle-cell cavities to understand the effects of roughness variation on the RF performance. This presentation discusses ways to reduce surface roughness with results from a systematic analysis of the samples and Nb3Sn-coated single-cell cavities.

Pudasaini, Uttar↗

DOE OSTI2021

Highly Ordered Hierarchical Anodes for Extreme Fast Charging Batteries (Final Report)

The goal of this project is to enable extreme fast charging (XFC) of Li-ion batteries, which was accomplished through a combination of 1) rational design and manufacturing of hierarchically structured anode architectures; 2) blending graphite/hard carbon into a bulk hybrid anode; 3) engineering artificial solid-electrolyte interphase (SEI) coatings with reduced interphase impedance; 4) computational modeling of coupled transport, kinetic, and electrochemical phenomena; and 5) improved fundamental understanding of lithium plating through operando analysis. This work integrated structural, compositional, and surface modification of graphite anodes, multi-physics modeling of ion transport, electrochemical activity, and heat transfer, advanced strategies to detect Li plating, and semi-automated roll-to-roll cell assembly. The unique facilities at the University of Michigan (UM) and Sandia National Laboratories (SNL) were leveraged to manufacture, prototype, and characterize commercially relevant >2Ah and >180 Wh/kg cells with a target of <20% capacity fade over 500 XFC cycles.

25 ENERGY STORAGE↗

DOE OSTI2021

SR19021 Tritium Aging of Regenerated LANA.75 (Final Project Report)

The Savannah River Tritium Enterprise (SRTE) has used the metal hydride LaNi 4.25 Al 0.75 (LANA.75) in the Tritium Facilities for over two decades. LANA.75 beds store significant quantities of tritium but have a limited service life due to the radiolytic decay of tritium to He-3 within the metal matrix. It has been shown that heating tritium-aged LANA.75 under vacuum can reverse tritium aging effects, eliminating the heel of trapped hydrogen, and restoring the reversible capacity. Additional investigation is needed to ensure there are no unexpected changes to the hydride before this restoration technique is employed in full scale beds in the Tritium Facilities. This project was to be comprised of three distinct scopes: obtain tritium aging data on the sample regenerated in 2018, regenerate a tritium-aged sample at 600 °C, and perform thermal stability testing on a non-tritiated sample. Isotherms were collected on the previously regenerated sample after approximately two years of tritium aging. Isotherms were collected at 80, 100, and 120 °C. As expected, there was a decrease in the plateau pressure, an increase in plateau slope, and a portion of the “heel” of tritium trapped in the metal had been reestablished. Unexpectedly, it appeared that the plateau had shortened at the higher tritium to metal ratios as well. This is typically seen in older samples. The second scope, to regenerate a second tritium-aged LANA.75 sample, was not completed. A Task Technical and Quality Assurance Plan was written and approved, a high temperature test cell was fabricated, several pre-job briefs were held, and the hydride sample was passivated with air. Despite these successes, the hydride sample was not recovered from the legacy test cell. The third scope was to perform thermal stability testing on a “cold” LANA.75 sample. A non-tritiated sample of LANA.75 was held at 750 °C under vacuum for 200 hours to simulate exposure to multiple regeneration evolutions. Hydride isotherm performance, chemical composition, crystallinity, particle size, and morphology are compared between the pre- and post-regeneration samples. No significant changes were observed in composition, crystallinity, or particle size. Comparison of before and after isotherms showed that performance improved rather than deteriorated during the evolution. Scanning Electron Microscopy (SEM) analysis showed small growths on the particle surface after exposure to regeneration conditions. Additional testing will be required to determine the cause of these growths.

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2022

Capturing Carbonation: Understanding Kinetic Complexities through a New Era of Electron Microscopy

Cryogenic plasma focused ion beam (PFIB) electron microscopy analysis is applied to visualizing ex situ (surface industrial) and in situ (subsurface geologic) carbonation products, to advance understanding of carbonation kinetics. Ex situ carbonation is investigated using NIST fly ash standard #2689 exposed to aqueous sodium bicarbonate solutions for brief periods of time. In situ carbonation pathways are investigated using volcanic flood basalt samples from Schaef et al. (2010) exposed to aqueous CO 2 solutions by them. The fly ash reaction products at room temperature show small amounts of incipient carbonation, with calcite apparently forming via surface nucleation. Reaction products at 75° C show beginning stages of an iron carbonate phase, e.g., siderite or ankerite, common phases in subsurface carbon sequestration environments. This may suggest an alternative to calcite in carbonation low calcium-bearing fly ashes. Flood basalt carbonation reactions show distinct zonation with high calcium and calcium-magnesium bearing zones alternating with high iron-bearing zones. The calcium-magnesium zones are notable with occurrence of localized pore space. Oscillatory zoning in carbonate minerals is distinctly associated with far-from-equilibrium conditions where local chemical environments fluctuate via a coupling of reaction with transport. The high porosity zones may reflect a precursor phase (e.g., aragonite) with higher molar volume that then “ripens” to the high-Mg calcite phase-plus-porosity. These observations reveal that carbonation can proceed with evolving local chemical environments, formation and disappearance of metastable phases, and evolving reactive surface areas. Together this work shows that future application of cryo-PFIB in carbonation studies would provide advanced understanding of kinetic mechanisms for optimizing industrial-scale and commercial-scale applications.

36 MATERIALS SCIENCE↗

DOE OSTI2023

SURFACE ROUGHNESS REDUCTION AND PERFORMANCE OF Nb3Sn FILM FOR SRF APPLICATIONS

Pudasaini, Uttar↗

DOE OSTI2023

Machine Learning Enabled Sensor Fusion for In-Situ Defect Detection in Laser Powder Bed Fusion

Laser Powder Bed Fusion (L-PBF) Additive Manufacturing (AM) is among the metal 3D printing technologies most broadly adopted by the manufacturing industry. The current industry qualification paradigm for critical-application L-PBF parts relies heavily on expensive non-destructive inspection techniques such as X-Ray Computed Tomography (XCT), which significantly limits the use-cases of L-PBF. In situ monitoring of the process promises a less expensive alternative to ex situ testing, but existing sensor technologies and data analysis techniques struggle to detect sub-surface flaws (e.g., porosity and cracking) on production-scale L-PBF printers. RTX Technologies Research Center (RTRC) has licensed ORNL’s Peregrine software package – a printer- and camera-agnostic data analytics tool designed specifically for detecting process anomalies using in situ data collected during powder bed printing. The goal of this project was to feed temporally rich, multi-modal sensor data, including visible light, integrated near infrared (NIR), and spatially mapped co-axial melt pool thermal emission data into Peregrine to enable detection of subsurface flaws. XCT data was used as ground truth training data to allow Peregrine’s deep learning algorithms to recognize anomalies in these complex data streams in both test artifacts and industrially relevant geometries. Completion of this program has seen the successful implementation of multi-modal, multi-layer sensor data footprints for training of machine learning models in Peregrine. Flaws detected in XCT data have been successfully detected directly from this in situ data footprint, and initial analyses of the in situ probability-of-detection has been conducted, showing performance levels commensurate with traditional non-destructive evaluation (NDE) methods. The in situ monitoring methodology was then applied to an industrially relevant component that was using post-build NDE, highlighting the utility of the proposed method for hard-to-inspect AM components. As a direct result of this program, two journal manuscripts [1], [2] have been published in Additive Manufacturing, with additional manuscripts planned following program completion.

36 MATERIALS SCIENCE↗