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DOE OSTI2020

Inverse-Designed Photonics for Semiconductor Foundries

Silicon photonics is becoming a leading technology in photonics, displacing traditional fiber optic transceivers and enabling new applications. Further improving the density and performance of silicon photonics, however, has been challenging due to the large size and limited performance of traditional semianalytically designed components. Automated optimization of photonic devices using inverse design is a promising path forward but has, until now, faced difficulties in producing designs that can be fabricated reliably at scale. In this paper we experimentally demonstrate four inverse-designed devices made successfully in a commercial silicon photonics foundry: a spatial mode multiplexer, wavelength demultiplexer, 50–50 directional coupler, and 3-way power splitter. These devices are efficient, robust to fabrication variability, and compact, with footprints only a few micrometers across. They pave the way forward for the widespread practical use of inverse design.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Inter-ligand cross-links determine secondary building unit formation in oligoMOFs

OligoMOFs are a class of metal–organic frameworks (MOFs) that feature ligands covalently cross-linked into oligomers as intrinsic structural components. A recent study has demonstrated that the size and flexibility of the tether moieties can result in the formation of oligoMOFs with different isomeric structures via geometrical distortions in the secondary building unit (SBU). In this work, it is demonstrated that tethered dimeric ligands with slightly different carbon chain lengths can direct the formation of oligoMOFs with SBUs of different structure and nuclearity. Specifically, inter-ligand cross links are used as a sensitive probe of the phase landscape of MOFs with the composition [Zn 2 (R-bdc) 2 (bpy)] (bdc = 1,4-benzenedicarboxylate, bpy = 4,4′-bipyridine), showing that a hexyl tether results in a framework structure identical to MOF-508, based on dinuclear {Zn 2 } “paddlewheel” SBUs, while heptyl and octyl tethers result in a “honeycomb-like” framework structure based on an infinite rod-like Zn 2+ SBU bridged by carboxylate ligands. Furthermore, these results are the first examples of tether length influencing SBU chemistry in MOFs and help understand the interplay between the MOF lattice and the geometric constraints imposed by inter-ligand cross-links in oligoMOFs.

MOFs↗

DOE OSTI2024

Divertor heat load estimates on NSTX and DIII-D using new and open-source 2D inversion analysis code

A thermography inversion algorithm has been developed in the open-source Python-based computer code, HYPERION, to calculate the heat flux incident on plasma-facing components (PFCs) in axisymmetric tokamaks. The chosen mesh size at the surface significantly affects the calculated transient heat flux results. The calculated transient heat flux will exceed the real value when the mesh size tends to zero but will underestimate the real value when the mesh size is large. A criterion for determining the appropriate mesh size for the transient heat flux calculation will be discussed. The numerical scheme for HYPERION uses a 2D fully implicit finite-difference approach, allowing temperature-dependent thermal properties of PFC materials. The inversion algorithm is benchmarked against established heat flux calculation codes, TACO and THEODOR, based on thermography data from NSTX and DIII-D respectively. The primary benefits of HYPERION compared to TACO and THEODOR are that it is open-source and it allows for the optimization of mesh thickness along the substrate. The algorithm also accounts for the thermal properties of thin surface layers that characteristically form on PFCs due to plasma-material interactions. The agreement between HYPERION and THEODOR is excellent, as the percent difference between the codes is ~5% on average in the case of the DIII-D data for moderate to high heat flux. Verification tests with TACO show slightly higher average percent differences of 8% and 12%. In using HYPERION to study filaments in heat flux, the initial results indicate that small ELMs filaments significantly broaden the divertor heat flux, and decrease divertor peak flux. Compared to the inter-ELM, the small ELM filaments decrease the divertor peak surface temperature. With intermittent divertor filaments, the divertor heat flux width is comparable with that found in L-mode.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Tuning Stoichiometry to Promote Formation of Binary Colloidal Superlattices

The self-assembly of binary nanoparticle superlattices from colloidal mixtures is a promising method for the fabrication of complex colloidal cocrystal structures. However, binary mixtures often form amorphous or metastable phases instead of the thermodynamically stable phase. Here we show that in binary mixtures of differently sized spherical particles, an excess of the smaller component can promote—and, in some cases, may be necessary for—the self-assembly of a binary cocrystal. Using computer simulations, we identify two mechanisms responsible for this phenomenon. First, excess small particles act like plasticizers and enable systems to reach a greater supersaturation before kinetic arrest occurs. Second, they can disfavor competing structures that may interfere with the growth of the target structure. We find the phase behavior of simulated mixtures of nearly hard spheres closely matches published experimental results. We demonstrate the generality of our findings for mixtures of particles of arbitrary shape by presenting a binary mixture of hard shapes that only self-assembles with an excess of the smaller component.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Laminated Permanent Magnets Enable Compact Magnetic Components in Current Source Converters

Magnetic components play a key role in determining the size, cost, efficiency of a power converter. They are more significant in current source converters, where the dc-link energy is stored in an inductor/transformer. In such cases, the magnetics have a predominantly DC flux, superimposed by an AC flux at switching frequency. Previously, permanent magnets have been proposed to offset the DC flux and thereby reduce the size, cost, and losses of the inductors/transformers. This paper starts by analyzing the issue of eddy currents when using such standard permanent magnets, especially in medium frequency applications, making them practically unusable. Alternatively, the paper proposes the use of laminated permanent magnets to reduce these eddy currents and thereby realize the benefits of offsetting the DC flux to reduce the size, cost, and loss of inductors/transformers. Using a soft-switching solid-state transformer as an example, experimental results are presented to show the impact of eddy currents in standard permanent magnets when used with a medium frequency transformer. Here, experimental results showing the benefits of using laminated magnets in reducing the eddy currents are presented.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2022

Environmentally Sound One-Step Solar Silicon From Natural Quartzite

This project aimed to demonstrate a new molten salt electrodeposition process to go straight from low-cost silica at $200/tonne ($40¢/kg Si basis) to polysilicon in a single step using less than 30 kWh/kg. This would eliminate the carbothermic reduction step and all direct greenhouse emissions, along with 90% of the energy. It would also eliminate the chemical hazards of chlorosilane handling which have resulted in multiple fatalities in the polysilicon industry – in Japan, the US and China. This project had the following major accomplishments: Stakeholder engagement indicated that the solar silicon market is very sensitive to price, provided quality is sufficient. The most important measure of silicon quality is not purity but carrier lifetime, as many impurities can reduce performance at concentrations too small to measure; Experiments set a baseline of current efficiency which is too low for commercial application (~3%), with electronic current ruled out as a mechanism for reduced current efficiency; A scale-up plant narrative narrative described a potential plant and formed the basis for the TEA components; TEA showed that current efficiency, large cell size, and zirconia membrane lifetime are key factors which determine capital and operating costs for the process.

14 SOLAR ENERGY↗

DOE OSTI2026

Powder metallurgy hot isostatic pressing - workshop report

The findings of the powder metallurgy (PM) hot isostatic pressing (HIP) workshop confirmed that the accelerated adoption of this technology requires the following action items: 1. By 2035, the HIP infrastructure must be scaled to sizes larger than 4 .0 meters for manufacturing components relevant to energy and defense industries at large. 2. The community must develop cost-effective and agile standards, qualifications, and certification pathways for these HIP parts. 3. At the same time, domestic powder production should be expanded to a wide range of metallic alloys, including Cr-Mo steels, stainless steels, and titanium- and nickel-based superalloys, as well as to emerging alloy classes in the refractory space. 4. The above initiatives can be enhanced by implementing digital modeling and controls, including AI-driven simulations, in situ monitoring, and digital twins.

36 MATERIALS SCIENCE↗

NASA NTRS1972

Advanced technology for Space Shuttle Auxiliary Propellant Valves.

Propellant shutoff valves required for the operation of the pulse modulated gaseous hydrogen/gaseous oxygen rocket engines for the Space Shuttle Auxiliary Propulsion System are specified to operate for one million cycles over a ten-year period with zero maintenance, very fast response, very low leakage, and over a wide temperature range. Based on an analytical leakage and wear model, sealing configurations were conceived, sized, and developed. Two prototype valves featuring different components were designed, built, and evaluated for 100,000 cycles. Design concepts and test results are presented.

Wichmann, H.↗

NASA NTRS1976

Single stage, low noise, advanced technology fan. Volume 1: Aerodynamic design

The aerodynamic design for a half-scale fan vehicle, which would have application on an advanced transport aircraft, is described. The single stage advanced technology fan was designed to a pressure ratio of 1.8 at a tip speed of 503 m/sec 11,650 ft/sec). The fan and booster components are designed in a scale model flow size convenient for testing with existing facility and vehicle hardware. The design corrected flow per unit annulus area at the fan face is 215 kg/sec sq m (44.0 lb m/sec sq ft) with a hub-tip ratio of 0.38 at the leading edge of the fan rotor. This results in an inlet corrected airflow of 117.9 kg/sec (259.9 lb m/sec) for the selected rotor tip diameter if 90.37 cm (35.58 in.). The variable geometry inlet is designed utilizing a combination of high throat Mach number and acoustic treatment in the inlet diffuser for noise suppression (hybrid inlet). A variable fan exhaust nozzle was assumed in conjunction with the variable inlet throat area to limit the required area change of the inlet throat at approach and hence limit the overall diffusion and inlet length. The fan exit duct design was primarily influenced by acoustic requirements, including length of suppressor wall treatment; length, thickness and position on a duct splitter for additional suppressor treatment; and duct surface Mach numbers.

Sullivan, T. J.↗

NASA NTRS1982

Compositional trends in Apollo 16 soils

Data on the bulk chemical composition of the soils collected at and under the surface of the Apollo 16 landing site are synthesized and reviewed, with emphasis placed on the way in which the compositional trends within the soils relate to the site geology. Two distinct compositional mixing trends are discerned. One involves addition to this surface Cayley component of a material such as that ejected by North Ray Crater. The other is thought to be a segment of a mixing line between the average melt fraction of the local Cayley component and pure or nearly pure anorthosite. Grain size fractions of Apollo 16 soils exhibit a general trend of higher concentrations of large ion lithophile (LIL) elements associated with plagioclase in the finest fraction compared with the coarse fractions. The suite of pristine nonmare rocks (as currently recognized) is found to be insufficient to model the Apollo 16 soils.

Korotev, R. L.↗

NASA NTRS1982

Solar-powered airplane design for long-endurance, high-altitude flight

This paper describes the performance analysis and design of a solar-powered airplane for long-endurance, unmanned, high-altitude cruise flight utilizing electric propulsion and solar energy collection/storage devices. For a fixed calendar date and geocentric latitude, the daily energy balance, airplane sizing, and airplane aerodynamics relations combine to determine airplane size and geometry to meet mission requirements. Vehicle component weight loadings, aerodynamic parameters, and current and projected values of power train component characteristics form the basis of the solution. For a specified mission, a candidate airplane design is presented to demonstrate the feasibility of solar-powered long endurance flight. Parametric data are presented to illustrate the airplane's mission flexibility.

Youngblood, J. W.↗

NASA NTRS1983

X-ray and microwave observations of active regions

Coordinated high-resolution (1-3 arcsec) observations of two active solar regions (H 421 and H 419) on November 16, 1979, are reported: soft-X-ray filtergrams from a sounding rocket flight, VLA total-intensity and circular-polarization microwave (6-cm) radio maps, KPNO full-disk photospheric magnetograms, and BBSO H-alpha data. The images were converted to 4.8-arcsec/mm-scale transparencies and coaligned on the basis of sunspot positions for comparison. The two active regions are characterized in detail, and intensity, size, and polarization data for the brightest microwave components (BMC) are listed. It is found that 19 of the 32 BMC are farther than 5 arcsec from any sunspot, and that X-ray-emitting structures only rarely correspond to sunspots, or BMC. About one third of the BMC are located at the feet or legs of coronal loops smaller than about 50,000 km. The limitations implied by these obervations for proposed thermal-bremsstrahlung, thermal-gyro-resonance, and nonthermal microwave-emission mechanisms are discussed.

Webb, D. F.↗

NASA NTRS1987

A diffuse radar scattering model from Martian surface rocks

Remote sensing of Mars has been done with a variety of instrumentation at various wavelengths. Many of these data sets can be reconciled with a surface model of bonded fines (or duricrust) which varies widely across the surface and a surface rock distribution which varies less so. A surface rock distribution map from -60 to +60 deg latitude has been generated by Christensen. Our objective is to model the diffuse component of radar reflection based on this surface distribution of rocks. The diffuse, rather than specular, scattering is modeled because the diffuse component arises due to scattering from rocks with sizes on the order of the wavelength of the radar beam. Scattering for radio waves of 12.5 cm is then indicative of the meter scale and smaller structure of the surface. The specular term is indicative of large scale surface undulations and should not be causally related to other surface physical properties. A simplified model of diffuse scattering is described along with two rock distribution models. The results of applying the models to a planet of uniform fractional rock coverage with values ranging from 5 to 20% are discussed.

Calvin, W. M.↗

NASA NTRS1987

The thermal control challenge of the Mars observer spacecraft

The thermal control subsystem for the Mars Observer spacecraft has been synthesized from hardware currently in use on earth-orbiting satellites. Heat input to the spacecraft from environmental and internal sources varies widely throughout the mission, and system requirements, such as accommodation of payload instrument fields-of-view and minimization of weight and power, limit the sizes and locations of thermal control elements. Subsystem components are primarily passive, although heaters and louvers provide augmented control where required. Spacecraft-level finite difference thermal models have shown that all component temperature requirements are met with margin.

Braun, C. E.↗

NASA NTRS1988

Impact damage in composite laminates

Damage tolerance requirements have become an important consideration in the design and fabrication of composite structural components for modern aircraft. The ability of a component to contain a flaw of a given size without serious loss of its structural integrity is of prime concern. Composite laminates are particularly susceptible to damage caused by transverse impact loading. The ongoing program described is aimed at developing experimental and analytical methods that can be used to assess damage tolerance capabilities in composite structures subjected to impulsive loading. Some significant results of this work and the methodology used to obtain them are outlined.

Grady, Joseph E.↗

NASA NTRS1988

Overview of SDCM - The Spacecraft Design and Cost Model

The Spacecraft Design and Cost Model (SDCM) is a computer-aided design and analysis tool for synthesizing spacecraft configurations, integrating their subsystems, and generating information concerning on-orbit servicing and costs. SDCM uses a bottom-up method in which the cost and performance parameters for subsystem components are first calculated; the model then sums the contributions from individual components in order to obtain an estimate of sizes and costs for each candidate configuration within a selected spacecraft system. An optimum spacraft configuration can then be selected.

Ferebee, Melvin J.↗

NASA NTRS1989

System level design analyses for the Space Station Environmental Control and Life Support System

The development and verification of a computer model for the design and analysis of the current Space Station ECLSS configuration are discussed. The model is used to resolve system-level design issues, such as sizing accumulators and assessing flow control techniques. Actual component verification efforts are outlined, and technical aspects of each component model are identified. The results obtained to date and plans for future analytical efforts are summarized.

Bacskay, A. S.↗

NASA NTRS1991

Analysis of two-equation turbulence models for recirculating flows

The two-equation kappa-epsilon model is used to analyze turbulent separated flow past a backward-facing step. It is shown that if the model constraints are modified to be consistent with the accepted energy decay rate for isotropic turbulence, the dominant features of the flow field, namely the size of the separation bubble and the streamwise component of the mean velocity, can be accurately predicted. In addition, except in the vicinity of the step, very good predictions for the turbulent shear stress, the wall pressure, and the wall shear stress are obtained. The model is also shown to provide good predictions for the turbulence intensity in the region downstream of the reattachment point. Estimated long time growth rates for the turbulent kinetic energy and dissipation rate of homogeneous shear flow are utilized to develop an optimal set of constants for the two equation kappa-epsilon model. The physical implications of the model performance are also discussed.

Thangam, S.↗