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DOE OSTI2024

Modeling of Additively Manufactured Ceramic Heat Exchangers with Semi-Elliptical Cross-Section Flow Channels

An approximate and easily applied analytical model was developed for heat transfer calculations of heat exchangers consisting of multiple rows and columns of heat transfer fluid flow channels with semi-elliptical cross sections. Heat exchangers of this type are being developed by using ceramic material and additive manufacturing for high temperature and pressure-concentrating solar electric power plants. Calculations using the model require only the geometrical dimensions and flow conditions of the heat exchanger. Comparisons of modeling predictions, with both simulation results and experimental data, were conducted to verify the viability of the model. The results showed good agreement where almost all the modeling predictions were within 20% of the simulation results or the experimental data. Finally, the proposed modeling approach is more generally applicable to heat transfer analysis of heat exchangers with similar flow channel configurations to those considered in this study.

Ceramic↗

DOE OSTI2020

Enhancing ZnO nanowire gas sensors using Au/Fe 2 O 3 hybrid nanoparticle decoration

Heterojunctions are an important strategy for designing high performance electrical sensor materials and related devices. Herein, a new type of metal-semiconductor hybrid nanoparticle has been successfully used to remarkably sensitize the surface of ZnO nanowires for detecting NO 2 with high responses over a broad temperature window ranging from room temperature to 600 °C. These hybrid nanoparticles are comprised of iron oxide nanowires with well dispersed single crystalline Au nanoparticles. The hybrid nanoparticle decorated ZnO nanowires have achieved a giant response, as high as 74 500 toward NO 2 gas, about 42 times that of Au decorated ZnO nanowire sensors. This dramatic enhancement may be attributed to the efficient charge transfer across the Au–Fe 2 O 3 Schottky and Fe 2 O 3 –ZnO semiconductor heterojunction interfaces. Due to the incorporation of thermally-stable Fe 2 O 3 nanoparticles as the support of Au nanoparticles, the working temperature of nanowire sensors was successfully extended to higher temperatures, with an increase of 200 °C, from 400 °C to 600 °C. Such a combination of semiconductor heterojunction and semiconductor-metal Schottky contact presents a new strategy for designing high performance electrical sensors with high sensitivity, stability, selectivity, and wide operation temperature window, which are potentially suitable for advanced energy systems such as automotive engines and power plants.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2025

Dispersive Dark Excitons in van der Waals Ferromagnet CrI 3

Spin-flip dark excitons are optical-dipole-forbidden quasiparticles with remarkable potential in optoelectronics, especially when they are realized within cleavable van der Waals materials. Despite this potential, dark excitons have not yet been definitively identified in ferromagnetic van der Waals materials. Here, we report two dark excitons in a model ferromagnetic material CrI 3 using high-resolution resonant inelastic x-ray scattering and show that they feature narrower linewidths compared to the bright excitons previously reported in this material. These excitons are shown to have spin-flip character, to disperse as a function of momentum, and to change through the ferromagnetic transition temperature. Given the versatility of van der Waals materials, these excitons hold promise for new types of magneto-optical functionality.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2023

Mineralogy and petrology of fine‐grained samples recovered from the asteroid (162173) Ryugu

Abstract Samples returned from the carbonaceous asteroid (162173) Ryugu by the Hayabusa2 mission revealed that Ryugu is composed of materials consistent with CI chondrites and some types of space weathering. We report detailed mineralogy of the fine‐grained Ryugu samples allocated to our “Sand” team and report additional space weathering features found on the grains. The dominant mineralogy is composed of a fine‐grained mixture of Mg‐rich saponite and serpentine, magnetite, pyrrhotite, pentlandite, dolomite, and Fe‐bearing magnesite. These grains have mineralogy comparable to that of CI chondrites, showing severe aqueous alteration but lacking ferrihydrite and sulfate. These results are similar to previous works on large Ryugu grains. In addition to the major minerals, we also find many minerals that are rare or have not been reported among CI chondrites. Accessory minerals identified are hydroxyapatite, Mg‐Na phosphate, olivine, low‐Ca pyroxene, Mg‐Al spinel, chromite, manganochromite, eskolaite, ilmenite, cubanite, polydymite, transjordanite, schreibersite, calcite, moissanite, and poorly crystalline phyllosilicate. We also show scanning transmission electron microscope and scanning electron microscope compositional maps and images of some space‐weathered grains and severely heated and melted grains. Although our mineralogical results are consistent with that of millimeter‐sized grains, the fine‐grained fraction is best suited to investigate impact‐induced space weathering.

Geochemistry & Geophysics↗

DOE OSTI2026

Finite deformation implementation of a mixed-mode single-integral type cohesive zone with reorienting surfaces of separation

To model material ductile failure and crack propagation, cohesive zone elements can be embedded along potential fracture paths in a finite element simulation. When damage criteria are met, elements in the mesh decohere, simulating the formation and propagation of a crack. In this paper, we present a novel computational algorithm based on finite deformation theory, essential to modeling crack initiation and growth in solids undergoing large deformations. This new algorithm was formulated within a Lagrangian frame of reference to extend previous cohesive zone algorithms to include modeling crack growth in finite deformation contexts. The local coordinate system, necessary for defining an embedded cohesive zone, is constructed based upon the current configuration and is updated within the nonlinear iteration process, thereby resulting in the convergence of the solution for a growing crack in a large deformation quasi-static setting. The model’s accuracy was demonstrated by comparing finite element model simulation results with the analytic case of a constant surface separation, as shown in the verification examples. The power and efficacy of the algorithm to capture large deformations during crack growth were then demonstrated with a double cantilever beam example case. It indicates that the model can be applied to a variety of physical circumstances for predicting crack initiation and growth with delamination and fracture.

42 ENGINEERING↗

DOE OSTI2023

Topography and canopy cover influence soil organic carbon composition and distribution across a forested hillslope in the discontinuous permafrost zone

This dataset contains data used for the paper "Topography and canopy cover influence soil organic carbon composition and distribution across a forested hillslope in the discontinuous permafrost zone". The Related References field will be updated with a full citation when available. Topography and canopy cover influence ground temperature in warming permafrost landscapes, yet soil temperature heterogeneity introduced by meso-topographic slope positions, microtopographic differences in vegetation cover, and the subsequent impact of contrasting temperature conditions to soil organic carbon (SOC) dynamics are understudied. Buffering of permafrost-affected soils against warming air temperatures in boreal forests can reflect surface soil characteristics (e.g., thickness of organic material) as well as the degree and type of canopy cover (e.g., open cover vs closed cover). Both landscape and soil properties interact to determine meso- and micro-scale heterogeneity of ground warming. We sampled a hillslope catena transect in a discontinuous permafrost zone near Fairbanks, Alaska to test the small-scale (1 to 3 meter) impacts of slope position and cover type on soil organic matter composition. Mineral active layer samples were collected from backslope, low backslope, and footslope positions at depths spanning 19 to 60 cm. We examined soil mineralogical composition, soil moisture, total carbon and nitrogen content, and organic mat thickness in conjunction with an assessment of SOC composition using Fourier-transform ion Cyclotron Resonance Mass Spectrometry (FT-ICR-MS). Soils in the footslope position had a higher relative contribution of lignin-like compounds while backslope soils had more aliphatic and condensed aromatic compounds as determined by FT-ICR-MS. The effect of open versus closed tree canopy cover varied with slope position. On the backslope, we found higher oxidation of molecules under open cover compared with closed cover, indicating an effect of warmer soil temperature on decomposition. Little to no effect of canopy was observed for soils at the footslope position, which we attributed, in part, to the strong impact of soil moisture content in SOC dynamics in the water-gathering footslope position. The thin organic mat under open cover on the backslope position may have contributed to differences in soil temperature and thus SOC oxidation under open and closed canopy. Here, the thinner organic mat did not appear to buffer the underlying soil against warm season air temperatures and thus increased SOC decomposition as indicated by higher oxidation of SOC molecules and a lower contribution of simple molecules under open cover compared with the closed canopy sites. Our findings suggest that the role of canopy cover in SOC dynamics varies as a function of landscape position and soil properties, namely organic mat thickness and soil moisture. Condition-specific heterogeneity of SOC composition under open and closed canopy cover highlights the protective effect of canopy cover for soils on backslope positions. This dataset contains a compressed (.zip) archive of the data and R scripts used for this manuscript. The dataset includes files in .csv format, which can be accessed and processed using MS Excel or R. This archive can also be accessed on GitHub at https://github.com/Erin-Rooney/Y1_fairbanks (DOI: 10.5281/zenodo.8071247).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

High Throughput Genome Releaser

In this study, we present the development of a High Throughput Genome Releaser, an innovative device addressing common challenges in screening PCR. This genome DNA releaser is designed for rapid, cost-effective, and efficient DNA extraction, optimized for subsequent PCR reactions. Our experimentation with various synthetic materials led us to select a particular type of plastic that mirrors the properties of glass cover slides, providing a smooth surface and effective compression capabilities. We engineered a 96-well device equipped with a 96-well plate and a top rod, operable both manually and automatically, which is compatible with widely used liquid-handling robot decks. This compatibility enhances ease of use in high-throughput PCR setups. Additionally, we developed software to support its automatic functions. The genome releaser facilitates the extraction of PCR-amplifiable genomic DNA from 96 samples within minutes, eliminates the need for extraction buffers, and is adaptable to a wide range of microorganisms and cells. This versatility could significantly advance biomanufacturing processes.

42 ENGINEERING↗

DOE OSTI2025

Characterization of MC&A for the Molten Salt Fuel Cycle

Advanced reactor developers are exploring diverse reactor designs, including molten salt reactors (MSRs). These advanced reactors are considered for wider applications and a range of deployment locations, including supporting the integration of renewable energy sources in the grid. There are three main types of MSRs: (1) reactors in which the fuel salt freely circulates within the core; (2) reactors with the fuel salt contained within vented fuel tubes; and (3) reactors that use molten salt solely as a coolant, with the fuel in a separate, solid form. In this document, the term MSR refers specifically to the first two types, which use fuel salt—special nuclear material (enriched uranium, plutonium, and 233 U) in chloride or fluoride form mixed with chloride- or fluoride-based carrier salt in a peritectic mixture—as the primary medium for fission. The composition of fuel salt, both at startup and for makeup or refueling, varies depending on the MSR design and the chosen fuel cycle approach, which can be either once-through or closed. For MSRs, a variety of fuel cycle approaches (e.g., U, U–Pu, U–Pu–TRU, U–Th, U–Pu–Th) are being considered. Fuel in MSRs is much different than traditional solid fuel, including its preparation. The uniqueness warrants investigation into characterizing fuel preparation processes, known as fuel salt synthesis . This effort characterized major fuel preparation and synthesis processes, identifying temperature, equipment, and environmental requirements for uranium-, plutonium-, and thorium-based fuel preparation and synthesis. Because MSR fuel salt synthesis facilities handle special nuclear material in loose, bulk form, a material control and accounting plan will be required for licensing from the US Nuclear Regulatory Commission or under the US Department of Energy authorization. This effort serves as a foundation to investigate material control and accounting approaches for synthesis facilities, including determining measurement points and techniques. Because several MSR developers are planning demonstration facilities in the coming years, this effort will support stakeholders with preparing or reviewing material control and accounting plans for providing assurance that all special nuclear material is accounted for at fuel salt synthesis facilities. This report was produced for Materials Protection, Accounting, and Control Technologies (MPACT) program under the US Department of Energy (DOE), Office of Nuclear Energy, Nuclear Fuel Cycle and Supply Chain.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Review of Graphite Properties Relevant to Micro-Reactor Design

Microreactors are advanced reactors that are designed to be small, scalable, and portable with up to 20 MW power. These reactors could operate independently, or as part of a microgrid, without need of a frequent refueling. Micro-reactors are designed to be deployable to provide electric power in remote locations, therefore providing greater flexibility. Several micro-reactors are under development in the US. These reactors are based on advanced gas-cooled or heat-pipe concepts. While Graphite can be found in various applications, some high-temperature reactors plan to employ Graphite in their core components due to its role as a moderator and its ability to maintain its structural integrity when subjected to elevated temperatures and high neutron fluence. Although there is significant experience with use of Graphite in nuclear applications, there are still unknowns that should be addressed. Graphite properties depend on the graphite type and affected by the fabrication procedures. Material properties are functions of the temperature and irradiation dose. The fundamental properties also affected by the oxidation environment. Therefore, in-depth understanding of graphite properties, including the effect of irradiation, oxidation and other influencing parameters are required to evaluate the design accurately. This draft aims to provide a comprehensive review of material properties for Graphite relevant to micro reactor design. For this work, two distinct grades of graphite were considered, namely IG-110 and Mersen-2114. Physical, thermal, and mechanical properties for these grades were comparatively evaluated. The properties that are discussed in this draft aim to serve as a basis for design and safety analysis.

42 ENGINEERING↗

DOE OSTI2025

Monte Carlo N-Particle Transport Performance of Predicting Digital Radiographic IQI Inspection

The identification of porosity, geometric noncompliance, and other defect types are critical to the qualification of materials and components. X-ray radiographic nondestructive testing is a common industrial inspection method for process quality control and component qualification and certification. Digital radiography provides a quick and efficient alternative when compared to traditional film-based inspection. The quality of radiographic inspection is dependent on equipment specifications, such as the source spot size and detector pixel size, and the specific parameters selected for use for the radiographic technique. To evaluate if an x-ray system and technique is sufficient for a given requirement, a radiographic image quality indicator (IQI) can be used. Radiographic IQIs in hard to machine materials or hard to manufacture defects can be time consuming and expensive to manufacture. This study was conducted to evaluate current Savannah River National Laboratory (SRNL) x-ray imaging systems with a custom tantalum IQI and using Monte Carlo simulations to predict the performance of future systems. The tantalum IQI was tested using a Siefert Isovolt 420 keV x-ray tube with a Perkin Elmer XRD 1611 flat panel with 100-micron pixels. Using the Monte Carlo N-Particle transport software, the radiographic tally was used to simulate the photon flux through an identical tantalum IQI. These simulations provided a benchmark as to the best theoretical identification on a given system using our tantalum IQI. The simulations were refined to match SRNL’s current systems’ noise levels, leading to confidence in their ability to predict the performance of other systems that may be purchased and deployed in the future at the Savannah River Site. Future studies will be conducted to prove this research can be extended to artificially evaluate the ability for systems to identify critical defect sizes through x-ray radiographic inspection, drastically reducing the cost and time burdens of producing high-fidelity radiographic test articles.

digital X-ray radiography↗

DOE OSTI2020

Automated Threat Recognition For Aviation Security Applications

We have developed a framework for automated threat recognition (ATR) of explosive threat materials for both single-energy and dual-energy X-ray CT systems. Under this framework, two different types of ATR have been developed. The first type of ATR employs supervised machine learning with statistical characterization of target materials for threat identification training. The reliance only on statistical characterization information for threat training uniquely enables this style of ATR to adapt quickly to evolving threats. The second type of ATR employs deep learning through convolutional neural networks. Convolutional neural networks are attractive due to their human-like capacity for learning and strong ability to identify trends and patterns. Although this method is more powerful than the first type, it requires large amounts of training data and therefore is less agile. Each ATR performs threat characterization at the voxel neighborhood level. This approach avoids the use of threat shape as a detection criterion, which is prohibited by DHS and TSA guidelines.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

A better understanding of the mechanics of borehole breakout utilizing a finite strain gradient-enhanced micropolar continuum model

Borehole breakout denotes the failure in rock mass subjected to drilling, caused by stress concentrations exceeding the material strength. Depending on the material properties, the preexisting in situ stress state, and the borehole dimensions, different types of borehole breakout, such as spiral-shaped breakout or v-shaped breakout, are distinguished in the literature. In the present work, we address the influence of the material properties on the predicted borehole breakout mode in a comprehensive finite element study. To this end, herein we employ a gradient-enhanced micropolar damage-plasticity model based on the Mohr–Coulomb strength criterion, formulated in the finite strain regime, which is calibrated based on experimental results from plane strain compression tests on Red Wildmoor sandstone. In the numerical study, the influence of the in situ stress state, the material friction angle, plastic dilation, post peak residual strength, and the inherent material length scale parameters are investigated. Thereby, we demonstrate that depending on the material parameters, substantially different failure modes, characterized by strongly localized shear bands or diffuse failure zones, are predicted. It is shown that in particular the brittleness of the material in the post peak regime has a major influence on the predicted breakout type. Moreover, a statistical validation of the results is obtained by considering different random field distributions of the initial material strength.

58 GEOSCIENCES↗

DOE OSTI2021

Review of Dew Point Evaporative Cooling Technology for Air Conditioning Applications

Indirect evaporative cooling has the potential to significantly improve the natural environment. It follows from a significant reduction in electricity consumption in the hot period, and hence lower operating costs for cooling systems. This paper presents the current state of knowledge and research directions on dew point indirect evaporative cooling. It was found that researchers focus on the development of dew point indirect evaporative coolers (DPIEC) by improving its design, geometry, water distribution, and new porous materials implementation. To evaluate the performance of new types of DPIEC, different methods are used by the scientists. Finally, optimized devices are studied in terms of their performance in different systems, like hybrid and desiccant systems, considering different climate conditions. Potential directions of development of evaporative technologies were indicated, such as increasing the coefficient of performance of solid desiccant evaporative cooling systems, developing novel geometry, and efficient water distribution, including development of porous materials.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Characterization of paste microstructure for durability properties of concrete

In this study, paste samples from different cementitious systems were characterized by using X-Ray Micro Computed Tomography (µ-CT) and Fluorescence Microscopy techniques. Quantitative and qualitative aspects of defects from paste samples were investigated to develop indicators of durability related properties of corresponding concrete samples. In the first phase of this study, hour glass shaped 3D printed molds were used to investigate five cementitious combinations consisting of three cement types (Coarse Ground portland cement, Type IL Portland Limestone Cement and Type I/II ordinary portland cement) and fly ash as a supplementary cementitious material. In the second phase, metal molds were used to compare the results of Coarse Ground portland cement with Type I ordinary portland cement, 5% of which was replaced with colloidal nanosilica. Potential correlations between paste and concrete have been presented. This work was supported by US Department of Energy and North Dakota Department of Commerce.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Methods of forming interdigitated back contact solar cells

Methods for forming interdigitated back contact solar cells from III-V materials are provided. According to an aspect of the invention, a method includes depositing a patterned Zn layer to cover first areas of an n-type emitter region, wherein the emitter region comprises a III-V material, and forming a passivated back contact region by counter-doping the first areas of the emitter region by diffusing Zn from the patterned Zn layer into the first areas of the emitter region, such that the first areas of the emitter region become p-type.

14 SOLAR ENERGY↗

DOE OSTI2024

Three-dimensional dispersion in the type-II Dirac semimetals PtTe 2 and PdTe 2 revealed through circular dichroism in angle-resolved photoemission spectroscopy

PtTe 2 and PdTe 2 are among the first transition metal dichalcogenides that were predicted to host type-II Dirac fermions, exotic particles prohibited in free space. These materials are layered and air stable, which makes them top candidates for technological applications that take advantage of their anisotropic magnetotransport properties. Here, in this work, we provide a detailed characterization of the electronic structure of PtTe 2 and PdTe 2 using angle-resolved photoemission spectroscopy (ARPES) and density functional theory calculations, offering an alternative interpretation for one of the Dirac-like dispersions in these materials. Through the use of circularly polarized light, we report a different behavior of such dispersion in PdTe 2 compared to PtTe 2 , that we relate to a symmetry analysis of the dipole matrix element. Such analysis reveals a link between the observed circular dichroism and the different momentum-dependent terms in the dispersion of these two compounds, despite their close similarity in crystal structure. Additionally, our data show a clear difference in the circular dichroic signal for the type-II Dirac cones characteristic of these materials, compared to their topologically protected surface states. Our paper provides a useful reference for the ARPES characterization of other transition metal dichalcogenides with topological properties and illustrates the use of circular dichroism as a guide to identify the topological character and attributes of two otherwise equivalent band dispersions.

angle-resolved photoemission spectroscopy↗

DOE OSTI2021

Creep of MARBN-type 9Cr martensitic steel in gaseous CO 2 environment

Here, with an interest in moving from steam to supercritical CO 2 as the working fluid in advanced energy systems, it is important to study the mechanical response of structural alloys to CO 2 -containing environments. MARBN-type 9Cr martensitic steel was originally developed for application in boilers for supercritical and ultra-supercritical power plants where the steam temperature reaches 650 °C. In this research, a MARBN-type 9Cr martensitic steel designed and manufactured at NETL was creep tested in a gaseous CO 2 environment (i.e., 0.1 MPa at 650 °C), and the results are directly compared to creep tests conducted in air. It was found that environmentally-assisted cracking facilitated by carbide formation beneath the growing oxide accelerated failure in gaseous CO 2 . This work indicates that creep-oxidation interactions in advanced martensitic steels represent an important consideration for materials selection in supercritical CO 2 power cycles. Furthermore, this work confirms that more oxidation-resistant alloys will be required for the highest temperature portions of these systems.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Options, Initial Design Requirements, Estimated Costs, Reactor Commitments, and Potential Uses of a Graphite Leadout Type Experiment Supporting Various Commercial HTR Vendors

Multiple commercial High Temperature Reactor (HTR) vendors and nuclear graphite suppliers would benefit by collaborating on a new irradiation capsule(s) that would include graphite grades not included within the AGC Experiment. This new irradiation capsule(s) would provide data to answer vendor graphite licensing issues. Rather than spending money (and especially) time in designing separate irradiation capsules for each designer, the capsule(s) would be used for multiple graphite and composite designs to maximize efficiency and promote multiple HTR designs. However, the primary motivation for assisting vendors with this new irradiation capsule(s) is lack of availability in the existing Material Test Reactors (MTRs). Cost reduction is a secondary goal. A common, collaborative, capsule design can be achieved for graphite and composites due to the similarity of different grades. Irradiation, disassembly, shipping, and PIE costs would be cost-shared by all users. It is anticipated that interest would extend across all DOE campaigns (micro-Rx, SMR, GCR, MSR, etc.) due to the similar requirements for all graphite grades.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗