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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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At least 775 records · Page 43
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Production of Precursor Materials for the Development of Iron-Based Superconductor (IBS) Wire

The objective of the activities under this Annex is to address the extrinsic Jc limitations uncovered in pioneering work. In order to engineer the defects pinning landscape charged particle irradiations experiments on bulk samples with different doping and chemical additions will be performed at different National facilities (Test Beam Facility at Fermilab; Linac Isotope Producer at Brookhaven National Laboratory; Integrated Biology Laboratory at University of Wisconsin-Madison; Facility for Rare Isotope Beams at Michigan State University). The samples will be produced at TUAT by different synthesis techniques. Magnetization and advanced microscopy measures will be performed at Fermilab. After irradiation, depending on the level of radioactivity, the samples will be tested at Fermilab or where it is possible to measure radioactive materials as University of Wisconsin-Madison. In parallel, the precursor materials produced by TUAT will be used for IBS-wire fabrication at Fermi

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Methodology of the Extraction of Multi-Differential Cross Sections of Charged-Current $\nu_\mu$-Argon Interactions in MicroBooNE Using Wire-Cell $\nu_\mu$CC Selection

Neutrino physics experiments rely on accurate nuclear-interaction models that are in part guided by experimental observations. Multi-differential cross section measurements are particularly valuable for exploring the underlying physics described in these models, making them a significant step forward in the field. This note presents methodology in preparation to unfold neutrino flux-averaged double and triple-differential cross sections of the inclusive muon neutrino charged-current interaction on Argon. This work builds upon the existing framework and methodology presented in recent energy dependent cross section measurements at MicroBooNE using the Wire-Cell tomographic event reconstruction. The signal definition, choice of binning, and handling of estimated detector uncertainties are discussed, and the MicroBooNE simulation model is validated over the multi-dimensional phase space of muon momentum, muon polar angle, and visible hadronic energy.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2021

Measurement of Charged-Current $ν_μ$ and $ν_e$ Interactions Towards a Search for Low-Energy $ν_Ε$ Excess Using Wire-Cell In Microboone

This technote summarizes the existing work in searching for $ν_e$ low-energy excess (eLEE) in MicroBooNE Booster Neutrino Beam (BNB) data stream based on the Wire-Cell event reconstruction paradigm. The charged-current $ν_μ$ and $ν_e$ events are selected from the 5.3e19 POT open data from the BNB beam, 6.37e20 POT far sideband from the BNB beam data, and 2.10e20 POT data from Neutrinos at the Main Injector (NuMI) beam. The charged-current $ν_e$ selection results from the BNB data that are sensitive to the eLEE search are not included. Various comparisons between data and Monte Carlo predictions are performed to validate the overall model and demonstrate the power of the analysis techniques. Physics sensitivities in terms of the exclusion and the discovery potential are presented.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2022

Measurement of Neutral-Current $\pi^0$ Cross Section in MicroBooNE using Wire-Cell Reconstruction

This note presents the extraction of flux-averaged total and differential neutral-current $π^0$ cross section measurements, based on the Wiener-SVD unfolding method, using the MicroBooNE Liquid Argon Time Projection Chamber (LArTPC) and the Wire-Cell reconstruction paradigm. This measurement is critical for single-photon searches as neutral-current pion production represents one of the largest sources of background. We report the results for an exposure corresponding to 5.327 × 10 19 protons-on-target (POT).

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2021

Measurement of charged-current $\nu_{\mu}$ and $\nu_e$ interactions with wire-cell in MicroBooNE towards a search for low-energy $\nu_e$ excess

This technote summarizes the existing work in searching for $\nu_e$ low-energy excess (eLEE) in MicroBooNE Booster Neutrino Beam (BNB) data stream based on the Wire-Cell event reconstruction paradigm. The charged-current $\nu_{\mu}$ and $\nu_e$ events are selected from the 5.3e19 POT data from the BNB beam and 2.06e20 POT data from Neutrinos at the Main Injector (NuMI) beam. The charged-current $\nu_e$ selection results from the BNB data that are sensitive to the eLEE search are not included. Various comparisons between data and Monte Carlo predictions are performed to validate the overall model and demonstrate the power of the analysis techniques.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2022

Progress Towards an Investigation of the MiniBooNE Low Energy Excess Using Neutral-Current Delta-Like Single Photons in MicroBooNE with Wire-Cell 3D Reconstruction Algorithms

This note presents progress towards a Neutral-Current (NC) Delta-like single photon search in MicroBooNE using Wire-Cell 3D reconstruction and pattern recognition algorithms. This analysis will help address the question of the MiniBooNE Low Energy Excess (LEE) [1]. The selections are similar to the previously published Pandora-based single photon selections [2] in many ways, but here we use independent reconstruction and selection tools and examine a larger phase space (including charged pions and multiple protons). In the future, we will significantly reduce systematic uncertainties via the use of constraining sideband observations in order to statistically test specific models of the MiniBooNE LEE.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2022

Progress towards an investigation of the MiniBooNE Low Energy Excess using neutral-current Delta-like single photons in MicroBooNE with Wire-Cell 3D reconstruction algorithms

This note presents progress towards a Neutral-Current (NC) Delta-like single photon search in MicroBooNE using Wire-Cell 3D reconstruction and pattern recognition algorithms. This analysis will help address the question of the MiniBooNE Low Energy Excess (LEE). The selections are similar to the previously published Pandora-based single photon selections in many ways, but here we use independent reconstruction and selection tools and examine a larger phase space (including charged pions and multiple protons). In the future, we will significantly reduce systematic uncertainties via the use of constraining sideband observations in order to statistically test specific models of the MiniBooNE LEE.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2023

Multipole-based Cable Braid Magnetic Penetration Model for Conducting Wires

In this report, we investigate the effects of conductor losses in a multipole-based cable braid magnetic penetration model. Our multipole model uses a mesh of the actual cable geometry, which enables us to model more complicated structures. After summarizing the first principles model formulation, we consider a one-dimensional array of wires, for which an analytical solution is known in the lossless case. We extend this solution to the lossy case by using a complex-valued radius. We also model this structure analytically using a conformal-mapping solution. We then compare both the self-impedance and the transfer impedance results from our first principles cable braid electromagnetic penetration model to those obtained using the analytical solutions. An analysis for various frequencies (and skin depths) usually encountered in cable modeling is reported. These results are found in good agreement up to a radius to half spacing ratio of about 0.7, demonstrating a robustness needed for many commercial and non-commercial cables.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Re-assembly and test of COMB dipole magnet with STAR® wires

Fermilab is developing the Conductor on Molded Barrel (COMB) magnet technology that works well with round REBCO conductors. COMB-STAR-1 magnet based on STAR wire by AMPeers was fabricated and tested in liquid nitrogen in 2023. The magnet demonstrated >90 Ic retention in the coils (before/after winding). Even though the magnet was not originally designed for operation at lower than 77 K temperatures, it was decided to test it in liquid helium to: - check the instrumentation and the DAQ system; - check the ability to detect resistive transitions or quenches and to protect the magnet; - gather the information on possible magnet design chances and upgrades of the test facility for future testing of HTS magnets. The magnet was re-assembled with a larger iron yoke and the axial supports and tested in liquid helium in 2024 at Fermilab s Vertical Magnet Test Facility (VMTF). It was the first HTS magnet test at that facility ever.

Kashikhin, Vadim↗
DOE OSTI2025

Wire Arc Additive Manufacturing of Lightweight High Pressure Die Casting Tooling

Oak Ridge National Laboratory (ORNL) and Mercury Marine partnered to develop and test methods for additively manufactured tooling for aluminum die casting applications under CRADA agreement NFE-20-08193. Tooling is the largest capital expense for high production casting projects. The lead time for tooling is often measured in months with a typical project taking 9-12 months to realize Production Part Approval Process (PPAP) ready die cast samples. This project demonstrated the technical viability of rapidly produced steel components for high pressure die casting tooling via Wire Arc Additive Manufacturing (WAAM). A 410 stainless steel tool was redesigned and optimized with conformal cooling channels and additively manufactured. The finished tool was tested and used to produce over 4000 parts, which well surpassed expectations. A secondary objective was to evaluate the durability of multi-material additively manufactured (AM) components with conformal cooling. A large multi-material tool (H13 and 410SSNiMo) was manufactured using the same methods showing potential reductions in used material and cost. However, the H13 section sustained material cracking. Further analysis showed that the potential cause was the CTE mismatch of the two materials at higher temperatures. It is also suggested that the material mix can be used if the steel processing temperature does not exceed 600 ̊C.This project has shown high potential for using the WAAM technology for creating AM parts for aluminum dies casting. However, the multi-material approach requires extended study and tests.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Wire Arc Additive Manufacturing of Lightweight High Pressure Die Casting Tooling

Oak Ridge National Laboratory (ORNL) and Mercury Marine partnered to develop and test methods for additively manufactured tooling for aluminum die casting applications under CRADA agreement NFE- 20-08193. Tooling is the largest capital expense for high production casting projects. The lead time for tooling is often measured in months with a typical project taking 9-12 months to realize Production Part Approval Process (PPAP) ready die cast samples. This project demonstrated the technical viability of rapidly produced steel components for high pressure die casting tooling via Wire Arc Additive Manufacturing (WAAM). A 410 stainless steel tool was redesigned and optimized with conformal cooling channels and additively manufactured. The finished tool was tested and used to produce over 4000 parts, which well surpassed expectations. A secondary objective was to evaluate the durability of multi-material additively manufactured (AM) components with conformal cooling. A large multi-material tool (H13 and 410SSNiMo) was manufactured using the same methods showing potential reductions in used material and cost. However, the H13 section sustained material cracking. Further analysis showed that the potential cause was the CTE mismatch of the two materials at higher temperatures. It is also suggested that the material mix can be used if the steel processing temperature does not exceed 600 ˚C. This project has shown high potential for using the WAAM technology for creating AM parts for aluminum dies casting. However, the multi-material approach requires extended study and tests.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Feature Based Qualification of 17-4PH Stainless Steel to Evaluate Location-Specific Variability in Wire Arc Additive Manufacturing

Qualifying large-scale metal additive manufacturing (M-AM) technologies such as wire arc additive manufacturing (WAAM) can be challenging. This is especially significant in precipitation hardened martensitic stainless steels like SS 17-4PH, where thermal histories induce location-specific microstructural variability and property anisotropy. The Department of Defense (DOD) and the United States Army Combat Capabilities Development Command Ground Vehicle Systems Center (GVSC) Ground Vehicle Materials Engineering (GVME) aim to build robust and qualified large-scale M-AM workflows that could reduce the time and cost through quick and informed evaluation, testing, and development of feedstock, processes, and parts. The report presents the findings from the collaborative efforts between Oak Ridge National Laboratory (ORNL) and the U.S. Army GVSC GVME. The aim of this project was to develop a geometric feature-based qualification framework for WAAM of SS 17-4PH components. This report outlines selection methodology of representative build geometries, optimization of WAAM process parameters, in-situ monitoring, microstructure-property evaluation, thermal simulations, as well as data visualization techniques incorporated in this project. The results from this project demonstrate a clear understanding of thermal history dependent phase evolution and consequent location-specific property variations in WAAM of SS 17-4PH. These results in conjunction with the data-driven methodologies used in this project are expected to reduce qualification timelines, improve predictability, and accelerate the development of reliable feature-based qualification strategies for part production via large-scale M-AM technologies.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Preliminary Activation Wire Analysis for the POKER Experiment Flattop Irradiation

Activation foils, or in this case wires, are commonly deployed to critical experiments at the Na tional Criticality Experiments Research Center (NCERC) to provide additional neutron diagnostics and provide additional energy-dependent responses to tie back to neutronic and/or multi-physics simulations.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2025

Role of Computational Parameters on Predicting Self-Consistent Residual Stress and Distortion during Wire Arc Additive Manufacturing

Production of three-dimensional metallic parts through integration of an articulated robot and gas metal arc welding, also known as wire arc additive manufacturing (WAAM), can produce large-scale components with moderate geometrical complexity. This technology is particularly appealing due to its high deposition rates, scalability, and cost-effective feedstock compared to other AM processes. Despite its advantages, WAAM adoption is hindered by challenges in ensuring geometric conformity without extensive distortion, defect-free structures, and consistent mechanical properties. Finite element analysis (FEA) is often used to address the challenge of geometrical conformity. As the size of parts increases, the best practices for mesh size and temporal resolution known in the literature become computationally unviable. This research examined the effects of mesh and time-step resolutions during transient FEA of a large-scale (248 layers) metallic part. The impact of computational parameters on the thermal history, displacement, and residual stress distributions were evaluated. The results showed that predicted distortion was consistent across resolutions, while time-step length significantly affected predicted thermal history, and mesh size influenced residual stress distributions. To investigate this relationship further, directionally biased meshes were considered and analyzed. The results indicated that increasing mesh resolution perpendicular to the welding path yielded stress predictions that aligned closely with higher-resolution models while offering substantial computational savings. In conclusion, the significances of this research are related to verification and validation of WAAM models for widespread industrial adoption and pragmatic guidelines for optimizing computation parameters for balancing computational efficiency and predictive accuracy of residual stress and distortion.

Solsbee, Brandon [Univ. of Tennessee, Knoxville, T↗
DOE OSTI2023

Achieving High Strength and Creep Resistance in Inconel 740H Superalloy through Wire-Arc Additive Manufacturing and Thermodynamic-Guided Heat Treatment

Inconel 740H superalloy is commonly used in advanced ultra-supercritical power plants since it possesses excellent strength and creep resistance. This study investigates the microstructure and mechanical properties of Inconel 740H superalloy fabricated using wire-arc additive manufacturing. The as-printed microstructure consisted of columnar γ grains with the Laves phase and (Nb, Ti)C carbides as secondary phases. The anisotropy in grain structure increased from the bottom to the top regions, while the hardness was highest in the middle portion of the build. To guide the post-heat treatment design, thermodynamic and kinetic simulations were employed to predict the temperature and time. Complete recrystallization with the Laves phase dissolution occurred throughout the build after homogenization at 1200 °C for 2 h. The peak hardness was achieved after aging at 760 °C for 12 h with the M 23 C 6 carbides decorating the grain boundaries and γ’ precipitates in the grain interior. The yield strength (655 MPa) and ductility (29.5%) in the post-heat treated condition exceeded the design targets (620 MPa, 20%). Stress rupture tests at 750 °C showed that the high-temperature performance was at par with the wrought counterparts. The fracture mode after rupture was identified to be intergranular with the presence of grain boundary cavities along with grain boundary sliding.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Determination of Location-Specific Solidification Cracking Susceptibility for a Mixed Dissimilar Alloy Processed by Wire-Arc Additive Manufacturing

Solidification cracking is a major obstacle when joining dissimilar alloys using additive manufacturing. In this work, location-specific solidification cracking susceptibility has been investigated using an integrated computational materials engineering (ICME) approach for a graded alloy formed by mixing P91 steel and Inconel 740H superalloy. An alloy mixture of 26 wt.% P91 and 74 wt.% Inconel 740H, with high configurational and total entropy, was fabricated using wire arc additive manufacturing. Microstructure characterization revealed intergranular solidification cracks in the FCC matrix, which increased in length along with the enrichment of Nb (~27 to 56 wt.%) and Cu (~87 wt.%) in the middle and top regions. DICTRA simulations to model location-specific solidification cracking susceptibility showed that the top region with the highest cooling rate (270 K/s) has the highest solidification cracking susceptibility in comparison with the middle and bottom regions. This is in good agreement with the experimentally observed varying crack length. From Scheil simulations, it was deduced that enrichment of Nb and Cu affected the solidification range as high as ~77%, in comparison with the matrix composition. The overall solidification cracking susceptibility and freezing range was highest for the 26 wt.% P91 alloy amongst the mixed compositions between P91 steel and 740H superalloy, proving that solidification characteristics play a major role in alloy design for additive manufacturing.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2023

Corrosion Resistance of 309L Stainless Steel Claddings on Carbon Steel Produced with Wire-Fed Directed Energy Deposition

Additive manufacturing (AM) tools are capable of applying overlay austenitic stainless steel (SS) claddings to carbon steel components. The benefits of this approach over arc welding include a smaller heat-affected zone, residual stress reduction, and material savings. In particular, wire-directed energy deposition is a suitable technique because of its low material cost and high rate of production compared to other AM methods. However, metallurgical variations in composition, phase fraction, and microsegregation can potentially influence the corrosion behavior of such claddings. In this work, 309L SS is clad on carbon steel substrates and electrochemical methods are used to measure their general and pitting corrosion resistance in simulated marine environments (3.5 wt% NaCl solutions). Two-layer claddings are fabricated with four laser powers to understand the effects of bulk chemical composition, austenite/δ-ferrite phase fractions, and individual phase compositions on corrosion behavior. The two-layer claddings are compared to a single-layer cladding, wrought 304 SS, and the carbon steel substrate for a comprehensive assessment of corrosion performance. The two-layer claddings are remarkably resistant to general corrosion in the 3.5 wt% NaCl environment because of their high Cr content (21.6 wt% to 23.3 wt% Cr). The single-layer cladding exhibits localized corrosion at unmixed Fe-rich peninsulas that originate at the dissimilar metal boundary and protrude into the first cladding layer. All two-layer claddings possess higher pitting corrosion resistance than wrought 304 SS, demonstrating their effectiveness as a corrosion-resistant barrier. Here, the pitting corrosion resistance is superior for claddings made with lower laser powers, due to low dilution and greater δ-ferrite contents.

36 MATERIALS SCIENCE↗