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At least 775 records · Page 43
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Universal method for the optimization of HDC coating uniformity on non-planar, non-stationary substrates for inertial confinement fusion targets

The thickness uniformity of chemical vapor deposited (CVD) diamond coatings on non-planar, non-stationary substrates depends on both the intrinsic instantaneous coating thickness distribution (ICTD) of the coating conditions used and, if applicable, on the frequency of substrate reorientation. While important for many CVD diamond applications, the relative impact of the ICTD and substrate reorientation on the coating thickness uniformity has not been studied. In this work, we systematically investigate the effect of these factors for microwave-plasma chemical vapor deposition (MPCVD) of diamond (referred to as high density carbon (HDC) in the inertial confinement fusion (ICF) community) coatings on spherical, rolling substrates. This coating technique is used to fabricate capsules for ICF experiments, which require extreme coating uniformity with <0.3 % thickness variation (so-called Mode 1 or M1) to ensure symmetric compression of imploding targets. To extract the otherwise unobservable reorientation timescale (Δt), Monte Carlo simulations were performed using experimental ICTD data as input. This combined approach confirms scaling relationships between the substrate reorientation timescale as well as coating thickness and coating uniformity, as expected from a 3D random walk. Simulations confirm that M1 is Rayleigh-distributed and scales as (Δt) 1/2 , consistent with the randomization of two angles that determine orientation of a sphere. We also demonstrate that, under the conditions studied, Δt is the dominant factor in determining thickness uniformity while the intrinsic ICTD has minimal impact. Finally, experiments show that Δt can be affected by total batch size under constant agitation conditions due to space constraints that limit the capsule reorientation kinetics. In conclusion, this study highlights the utility of a combined experiment-simulation approach as a general methodology for understanding and improving coating uniformity on non-planar, non-stationary substrates.

Capsule↗
DOE OSTI2021

The effect of rigid electron rotation on the Grad–Shafranov equilibria of a class of FRC devices

Rigid electron rotation of a Rotamak-FRC produces a pressure flux function that is more peaked than the Solov'ev flux function. This paper explores the implications of this peaked pressure flux function, including the isothermal case, which appear when the temperature profile is broader than the density profile, creating both benefits and challenges to a Rotamak-FRC based fusion reactor. In this regime, the density distribution becomes very peaked, enhancing the fusion power. The separatrix has a tendency to become oblate, which can be mitigated by flux conserving current loops. Plasma extends outside the separatrix, notably in the open field line region. Furthermore, this model does not apply to very kinetic FRCs or FRCs in which there are significant ion flows, but it may have some applicability to their outer layers.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Nested Pebble Bed Blanket (NesPeB)

Recent advances in magnetic confinement fusion technology have attracted billions of dollars of investments in startups from venture capitals and corporations, resulting in the development of devices aiming to demonstrate net energy gain in a self-heated burning plasma, such as SPARC (under construction) and others. However, future fusion power plants must operate in regimes that will require technologies far beyond current experience. According to a National Academies of Science, Engineering, and Medicine report, to have nuclear fusion power plants contributing in a timely manner to the planned reduction of atmospheric carbon dioxide, a pilot plant should be built by 2035, and it should demonstrate fusion power production and the performance of the tritium fuel system (requiring a high enough tritium breeding) by 2040. A recognized key technology gap by [26] is the fusion first wall and blanket since no current blanket concept is considered satisfactory or has been built and proven. The first wall and blanket in magnetic fusion reactors form a vital and complex system, as it must satisfy different functions such as power extraction, tritium breeding, plasma containment, radiation shielding, and safety. The list of design requirements is even longer: high enough tritium production for fusion self-sufficiency, low material activation, decay heat and shutdown dose rates, high thermal efficiency, high-capacity factor, high magnets-divertor-vacuum vessel-first wall life, low corrosion, low cost, and intrinsically safe (requiring minimal licensing). Despite fifty-plus years of research, the first wall and blanket concepts proposed suffer from fundamental technical problems and immaturity (TRL=2-3) that jeopardize the timely delivery of a commercial fusion power plant. A fusion first-wall blanket has never been built nor tested, and a "winning", practical functioning design requires enough engineering margins (high enough tritium breeding considering the uncertainty, etc.), manufacturing simplicity, ease of continuous operation, maintenance, and low cost. A new, groundbreaking blanket concept called "Nested Pebble Bed Blanket" (NesPeB) was developed at ORNL under the successful ARPA-E GAMOW FERMI project (patent application allowed by the USPTO). The NesPeB blanket concept addresses current blanket concepts' shortcomings and technical immaturity, paving the way for accelerated delivery of fusion power plants. NesPeB is based on nested pebbles, which are binary-sized lithium-ceramic pebbles enclosed in "Beryllide" perforated and coated spherical shells, which are also binary-sized, stacked on top of each other, forming a "bed" and cooled by Nitrogen gas also "sweeping" the Helium and Tritium generated by the neutron irradiation of Lithium; the vacuum vessel plasma facing material is Molybdenum-96 and -97 with the first wall cooled by Helium while the divertor armor is made of Tungsten. The simulations of the NesPeB blanket using Fusion Reactors Models Integrator (FERMI) are encouraging as they estimate a tritium breeding ratio (TBR) greater than 1.2 using natural Lithium, acceptable pressure drop, and excellent heat transfer properties. Furthermore, the NesPeB blanket is not limited by magneto-hydro-dynamics (MHD) effects, is designed for online refueling, relies on existing tritium extraction technologies, has a simple construction, and limits the corrosion and chemical reactivity problems. NesPeB has the potential to be transformational and disruptive since it can solve all the main, challenging technical problems of fusion device blankets and accelerate a pilot plant delivery for 10 or more years.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

The Princeton Field-Reversed Configuration for Compact Nuclear Fusion Power Plants

The Princeton Field-Reversed Configuration (PFRC) nuclear fusion reactor concept is an innovative approach to fusion power generation prioritizing low neutron production and small size. Here, a combination of analytical modeling and numerical simulation shows that the novel heating approach generates an FRC with closed field lines. Simulation data from a single-particle Hamiltonian code predicts ms-scale plasma heating in reactor-scale conditions while PIC codes predict formation of warm FRC plasmas from initial mirror fields. The PFRC-1 and PFRC-2 experiments have heated electrons to energies well in excess of 100 eV and plasma durations to 300 ms, more than 10 4 times longer than the predicted tilt instability growth time. From these data, we have created a development plan and anticipated performance metrics for a fusion reactor based on the PFRC concept. The resulting 1–10 MW PFRC reactors would be suitable for diverse applications, from submarines to urban environments to space propulsion. PFRC is a steady-state, driven magnetic confinement device. Plasma, inside a cylindrical array of coils, is confined and heated by external RF antennae. PFRC would be ultra-low radiation due to both its fuel and small size. The choice of advanced fuels, deuterium and helium-3 (D– 3 He), may be enabled by the high-β FRC configuration. The small size of the reactor would enable rapid exhaust of the dangerous tritium ash. Low radiation would make the reactor safer to operate and, in combination with simple geometry and small size, dramatically lowers development and maintenance costs. This review paper gives an introduction to the physics of the PFRC and a summary of the PFRC-2 experiment results to date. It then discusses the future program plan and how PFRC reactors would be commercialized.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Gamma-based nuclear fusion measurements at inertial confinement fusion facilities

Experiments performed on an inertial confinement fusion (ICF) platform offer a unique opportunity to study nuclear reactions, including reaction branches that are useful for diagnostic applications in ICF experiments as well as several that are relevant to nuclear astrophysics. In contrast to beam-accelerator experiments, experiments performed on an ICF platform occur over a short time scale and produce a plasma environment with physical parameters that are directly relevant to big bang and/or stellar nucleosynthesis. Several reactions of interest, such as D(T,γ) 5 He, H(D,γ) 3 He, H(T,γ) 4 He, and T( 3 He,γ) 6 Li produce high-energy gamma rays. S factors or branching ratios for these four reactions have recently been studied using various temporally-resolved Cherenkov detectors at the Omega laser facility. This work describes these detectors as well as the current standard technique for performing these measurements. Recent results for reactions D(T,γ) 5 He, H(D,γ) 3 He, H(T,γ) 4 He, and T( 3 He,γ) 6 Li are reviewed and compared to accelerator-based measurements. Limitations associated with implosion experiments and use of the current standard gamma detectors are discussed. A basic design for a gamma spectrometer for use at ICF facilities is briefly outlined.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Corrosion of 304 stainless steel in static liquid lithium under high vacuum

To study the compatibility especially the corrosion characteristic of structural material stainless steel (SS) with liquid lithium (Li) is an important factor for the simultaneous application of liquid Li and SS as a blanket material or potential plasma facing material (PFM) in future fusion devices. Here, the corrosion behaviors of 304SS exposed to liquid Li at 700 K for 1320 hr under high vacuum were investigated. After exposure to liquid Li, 304SS produces non-uniform corrosion which includes corrosion products and grain boundary corrosion. Compared with the corrosion behaviors at 600 K and 640 K, temperature plays an important role in the corrosion behaviors of 304SS in static liquid Li. The weight loss, corrosion depth and corrosion products of 304SS specimens increase with the corrosion temperature. In general, the compatibility between 304SS and static liquid Li is relatively good under the experimental conditions. And besides, it is unexpectedly found that the compatibility of copper with Li is not good.

304SS↗
DOE OSTI2021

Absolute ion density measurements in the afterglow of a radiofrequency atmospheric pressure plasma jet

Atmospheric pressure plasma jets (APPJs) can enable large fluxes of reactive species impinging on treated substrates in many applications. The relative importance of ionic versus neutral reactive species fluxes produced by APPJs is to date mainly deduced from modeling due to the challenge of measuring absolute ion densities/fluxes. In this study, a calibration was performed to determine the absolute densities of cold ions in the afterglow region of an RF-driven atmospheric pressure plasma jet (APPJ) in Ar + 1% O 2 by molecular beam mass spectrometry. Here, positive ion densities were found to be about 3-4 orders of magnitudes lower than the densities of the dominant reactive neutral species (O, O 2 (a 1 Δ g ), O 3 ) in the afterglow region of the APPJ at a distance larger than 2 mm from the visible plasma plume. The results illustrate the ability of molecular beam mass spectrometry to enable a quantitative evaluation of both neutral and ionic species in many applications using APPJs.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Thermal effects mediating the flow induced by laser-induced optical breakdown

Here, a short focused laser pulse can generate a hot plasma, which expands then contracts and can eject a hot jet, the speed and direction of which is sensitive to the details of the plasma kernel. The coupling of thermal and chemical nonequilibrium plasma mechanisms with this hydrodynamic development is assessed with detailed simulations of a two-temperature, three-species plasma model. Time scales for electron recombination, thermal relaxation, and diffusion are compared to that of the plasma expansion to anticipate conditions in which these mechanisms might affect the vorticity generation that leads to the ultimate flow pattern. The effect of these mechanisms are analyzed through comparison with corresponding inert-gas and equilibrium models. Thermal-nonequilibrium effects are found to be weak due to rapid relaxation of the heavy-particle and electronic temperatures. In contrast, chemical equilibration occurs at a rate comparable to the expansion and thereby enhance both it and subsequent hydrodynamic mechanisms as the energy stored in ion formation during the preceding breakdown is released by electron recombination. Thermal conduction, enhanced by high-temperature free electrons, weakens the ejection.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Critical instability at moving keyhole tip generates porosity in laser melting

Laser powder bed fusion is a dominant metal 3D printing technology. However, porosity defects remain a challenge for fatigue-sensitive applications. Some porosity is associated with deep and narrow vapor depressions called keyholes, which occur under high-power, low–scan speed laser melting conditions. High-speed x-ray imaging enables operando observation of the detailed formation process of pores in Ti-6Al-4V caused by a critical instability at the keyhole tip. We found that the boundary of the keyhole porosity regime in power-velocity space is sharp and smooth, varying only slightly between the bare plate and powder bed. The critical keyhole instability generates acoustic waves in the melt pool that provide additional yet vital driving force for the pores near the keyhole tip to move away from the keyhole and become trapped as defects.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

7th World Congress on Integrated Computational Materials Engineering (ICME 2023) (Final Technical Report)

Integrated Computational Materials Engineering (ICME) has received international attention due to its potential to shorten product development time, while lowering cost and improving design and manufacturing outcomes. ICME is an approach to designing materials solutions for specific applications that use computer modeling programs to predict the behavior of materials and integrate this information into the overall materials, processing, and manufacturing design cycle. The 7th World Congress on Integrated Computational Materials Engineering (ICME 2023) was held in Orlando, Florida from May 21–25, 2023 with the goal to convene stakeholders from across all areas of modeling and simulation, experimental specialization, and design, as well as from across academia, government, and industry, to address ICME tools and techniques and their integration, as well as to examine their application in engineering. This atmosphere facilitated rich interactions between the experimentalists, modelers, and computational and design, from academia, government, and industry, to discuss ICME tools and techniques and their application in engineering.

36 MATERIALS SCIENCE↗
NASA NTRS2017

Real-Time Radar-Based Tracking and State Estimation of Multiple Non-Conformant Aircraft

In this study, a novel solution for automated tracking of multiple unknown aircraft is proposed. Many current methods use transponders to self-report state information and augment track identification. While conformant aircraft typically report transponder information to alert surrounding aircraft of its state, vehicles may exist in the airspace that are non-compliant and need to be accurately tracked using alternative methods. In this study, a multi-agent tracking solution is presented that solely utilizes primary surveillance radar data to estimate aircraft state information. Main research challenges include state estimation, track management, data association, and establishing persistent track validity. In an effort to realize these challenges, techniques such as Maximum a Posteriori estimation, Kalman filtering, degree of membership data association, and Nearest Neighbor Spanning Tree clustering are implemented for this application.

RADAR tracking↗
DOE OSTI2020

Integrated linker-regulation and ring-fusion engineering for efficient additive-free non-fullerene organic solar cells

The rational molecular design and structural modification of quasi-two-dimensional fused perylene diimide (quasi-2D FPDI) acceptors have received growing attention for application in non-fullerene organic solar cells (NF-OSCs). Herein, we designed and synthesized two pairs of FPDI acceptors, one in the form of FPDI–π-bridge–FPDI with the π-bridge being either an axisymmetric thiophene (T) or a centrosymmetric thienothiophene (TT) unit, and the other being the corresponding ring-fusion counterpart. Additionally, four small molecule acceptors, namely T-FPDI, TT-FPDI, FT-FPDI and FTT-FPDI, were paired with a common PTB7-Th polymeric electron donor as active materials for a comparative study of the effects of linkers and ring fusion on their photovoltaic performances. The T-FPDI-based NF-OSC exhibited a decent power conversion efficiency (PCE) of 5.50%, while a higher PCE of 7.17% with a simultaneous enhancement in the open circuit voltage ( V oc ), the short-circuit current density ( J sc ) and the fill factor (FF) was achieved for the TT-FPDI-based solar cells. The solar cells based on the ring-fused FT-FPDI and FTT-FPDI acceptors displayed PCEs of 6.75% and 7.66%, respectively, both higher than those of the corresponding non-fused counterparts. Notably, the trade-off between the J sc and V oc , commonly observed in fullerene OSCs, is alleviated in these systems. It is also worth noting that the NF-OSCs based on these FPDI acceptors do not need any solvent additives. Overall, this successful molecular engineering based on novel quasi-2D FPDI building blocks may inspire the development of emergent electron acceptors for high performance additive-free NF-OSCs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Divertorlets concept for low-recycling fusion reactor divertor: experimental, analytical and numerical verification

The 'divertorlets' concept is a potential non-evaporative liquid metal solution for heat removal at low recycling regime. A toroidal divertorlets prototype was built and tested in LMX-U at Princeton Plasma Physics Laboratory to evaluate the performance of this configuration. Here, details of the design, experimental results, comparison with analytical theory and MHD numerical simulations of toroidal divertorlets are covered. Experiments, analytical model and simulations showed agreement and allowed the projection of operation properties at higher magnetic flux densities (reactor-like operation), proving the concept to be a compelling solution for divertor applications.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Concept of Operations of Next-Generation Traffic Control Utilizing Infrastructure-Based Cooperative Perception: Preprint

This paper puts forth a system architecture for an infrastructure-based cooperative perception (CP) fusion engine, to provide a complete state-space digital representation, with measurable accuracy, to support a wide-range of applications. The architecture includes the inputs, functional flow, data standardization recommendations, outputs and supported applications. The CP engine addresses critical needs with respect to accelerating the benefits of automation through intelligent roadway infrastructure (IRI), that complements and accelerates connected and automated vehicle (CAV) technology. that the CP acquires and fuses information from sensors (radar, LiDAR, and cameras), and CAVs to intelligently perceive roadway traffic states of all moving objects, create a complete three-dimensional digital representation of that state-space, and communicate it to downstream application such as intelligent signal control, safety and energy applications, and cooperate driving applications for CAVs as examples. The IRI approach, as opposed to a vehicle centric approach, is found to be more scalable in that it can deployed to the roughly 300,000 signalized intersections more readily than the over 300 million vehicles in the US, and accrues early-stage benefits equitable to all roadway users addressing safety, equity, fuel efficiency, and GHG reduction.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Understanding Formation of Irradiation-Induced Defects through 4D-STEM, Electron Tomography, and WBDF-STEM

A major challenge in advancing nuclear materials for next-generation fission and proposed fusion reactors is to comprehensively understand the formation of irradiation-induced defects. Here it is essential to correlate the evolution of irradiation-induced defects and the degradation of mechanical properties, as they collectively dictate the material's lifespan and ensure nuclear safety. Scanning transmission electron microscopy (STEM) based techniques have emerged as indispensable tools for irradiation-induced defect characterization, offering high spatial resolution imaging and chemical analysis, such as electron energy loss spectroscopy (EELS) and energy dispersive X-ray spectroscopy (EDXS). These techniques have been effectively used to obtain an atomic-scale view of the defect structure. Recent advances in electron microscopy, particularly in 4D-STEM, offer detailed insight into microstructural evolution by capturing full 2D diffraction patterns at every pixel position. Using high-speed direct electron detectors, this technology generates a four-dimensional dataset, overcoming the limitations of traditional STEM imaging.

36 MATERIALS SCIENCE↗
NASA NTRS1998

Friction Stir Welding of Large Scale Cryogenic Tanks for Aerospace Applications

The Marshall Space Flight Center (MSFC) has established a facility for the joining of large-scale aluminum cryogenic propellant tanks using the friction stir welding process. Longitudinal welds, approximately five meters in length, have been made by retrofitting an existing vertical fusion weld system, designed to fabricate tank barrel sections ranging from two to ten meters in diameter. The structural design requirements of the tooling, clamping and travel system will be described in this presentation along with process controls and real-time data acquisition developed for this application. The approach to retrofitting other large welding tools at MSFC with the friction stir welding process will also be discussed.

Russell, Carolyn↗
DOE OSTI2020

Process optimization of complex geometries using feed forward control for laser powder bed fusion additive manufacturing

Additive manufacturing (AM) enables the fabrication of complex designs that are difficult to create by other means. Metal parts manufactured by laser powder bed fusion (LPBF) can incorporate intricate design features and demonstrate desirable mechanical properties. However, printing a part that is qualified for its intended application often involves reprinting and discarding many parts to eliminate defects, improve dimensional accuracy, and increase repeatability. The process of iteratively converging on the appropriate build parameters increases the time and cost of creating functional LPBF manufactured parts. This work describes a fast, scalable method for part-scale process optimization of arbitrary geometries. Additionally, the computational approach uses feature extraction to identify scan vectors in need of parameter adaptation and applies results from simulation-based feed forward control models. This method provides a framework to quickly optimize complex parts through the targeted application of models with a range of fidelity and by automating the transfer of optimization strategies to new part designs. The computational approach and algorithmic framework are described, a software package is implemented, the method is applied to parts with complex features, and parts are printed on a customized open architecture LPBF machine.

3D printing↗