Additive Manufacturing Developments for Rocket Engines: Applications, Advanced Materials and Large Scale Techniques
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LaserNetUS Collaboration Network—University of Rochester (Final Report)
LaserNetUS Collaborative Network established in 2018 is a network of high-power laser facilities supported by the Department of Energy (DOE) Office of Fusion Energy Sciences (FES) and operating effectively as a user facility. Its mission is to advance and promote intense laser science and applications by providing scientists and students with broad access to unique facilities and enabling technologies, advancing the frontiers of laser-science research, and fostering collaboration among researchers and networks from around the world. Users who submit proposals through an annual call are selected by an external and independent proposal review panel (PRP) not involving personnel from any of the facilities. Besides the Omega Laser Facility at the University of Rochester’s Laboratory for Laser Energetics (UR/LLE), the network during this project period includes high-intensity laser facilities from six other universities and three national laboratories, namely, the Colorado State University (CSU), the University of Michigan (UM), the University of Nebraska at Lincoln (UNL), The Ohio State University (OSU), Université du Québec, the University of Texas at Austin (UT Austin), Lawrence Berkeley National Laboratory (LBNL), SLAC National Accelerator Laboratory (SLAC) and Lawrence Livermore National Laboratory (LLNL), respectively. The network facilities span a wide range in laser pulse energy, pulse duration, repetition rate, and experimental diagnostic equipment enabling innovative research in a variety of exciting areas. Details of the LaserNetUS facilities, organization and committees, events, and accomplishments can be found at the network website (https://lasernetus.org/). A very important role that the LaserNetUS fulfills is the training of students and young scientists who will be key for the future development of laser-plasma science and high-power laser technology itself. The network provides these students not only with access to the most advanced instrumentation and laser facilities, but also the opportunities to interact and collaborate with students from other institutions and with a large group of experienced scientists. As the largest university-based laser users’ facility in the world, the Omega Laser Facility at the UR/LLE has served the high-energy-density physics (HEDP) and inertial fusion science community for nearly 40 years. The multi-beam multi-kJ OMEGA EP Laser System brings unique capabilities to the LaserNetUS network. The combination of high intensity and high energy in short- and long-pulse operation together with solid or gas-jet targets and externally applied magnetic fields provides users a wide domain of experimental conditions. This award provides a total of eight shot days on OMEGA EP for LaserNetUS users. During the award period of performance (June 2019–November 2021), seven teams have fully utilized the eight shot days for their unique science experiments on OMEGA EP with a total of 83 target shots. These experiments involve 13 graduate students, two undergraduate students and six postdoctoral researchers. Results have been widely disseminated at international conferences including LaserNetUS annual meeting (~20 presentations including three invited), and in peer-reviewed journal publications (three published with several manuscripts in preparation).
36 MATERIALS SCIENCE↗
Saturn-ring proton backlighters for the National Ignition Facility
Proton radiography is a well-established technique for measuring electromagnetic fields in high-energy-density plasmas. Fusion reactions producing monoenergetic particles, such as D 3 He, are commonly used as a source, produced by a capsule implosion. Using smaller capsules for radiography applications is advantageous as the source size decreases, but on the National Ignition Facility (NIF), this can introduce complications from increasing blow-by light, since the phase plate focal spot size is much larger than the capsules. In this article, we report a demonstration of backlighter targets where a “Saturn” ring is placed around the capsule to block this light. The nuclear performance of the backlighters is unperturbed by the addition of a ring. We also test a ring with an equatorial cutout, which severely affects the proton emission and is not viable for radiography applications. These results demonstrate the general viability of Saturn ring backlighter targets for use on the NIF.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Comparison of CNN-Based Image Classification Approaches for Implementation of Low-Cost Multispectral Arcing Detection
Camera-based sensing has benefited in recent years from developments in machine learning data processing methods, as well as improved data collection options such as Unmanned Aerial Vehicles (UAV) mounted sensors. However, cost considerations, both for the initial purchase of sensors as well as updates, maintenance, or potential replacement if damaged, can limit adoption of more expensive sensing options for some applications. To evaluate more affordable options with less expensive, more available, and more easily replaceable hardware, we examine the use of machine learning-based image classification with custom datasets, utilizing deep learning based-image classification and the use of ensemble models for sensor fusion. Utilizing the same models for each camera to reduce technical overhead, we showed that for a very representative training dataset, camera-based detection can be successful for detection of electrical arcing. We also use multiple validation datasets, based on conditions expected to be of varying difficulty, to evaluate custom data. These results show that ensemble models of different data sources can mitigate risks from gaps in training data, though the system will be less redundant for those cases unless other precautions are taken. We found that with good quality custom datasets, data fusion models can be utilized without specialization in design to the specific cameras utilized, allowing for less specialized, more accessible equipment to be utilized as multispectral camera components. This approach can provide an alternative to expensive sensing equipment for applications in which lower-cost or more easily replaceable sensing equipment is desirable.
convolutional neural networks↗
NANO.PTML model for read-across prediction of nanosystems in neurosciences. computational model and experimental case of study
Abstract Neurodegenerative diseases involve progressive neuronal death. Traditional treatments often struggle due to solubility, bioavailability, and crossing the Blood-Brain Barrier (BBB). Nanoparticles (NPs) in biomedical field are garnering growing attention as neurodegenerative disease drugs (NDDs) carrier to the central nervous system. Here, we introduced computational and experimental analysis. In the computational study, a specific IFPTML technique was used, which combined Information Fusion (IF) + Perturbation Theory (PT) + Machine Learning (ML) to select the most promising Nanoparticle Neuronal Disease Drug Delivery (N2D3) systems. For the application of IFPTML model in the nanoscience, NANO.PTML is used. IF-process was carried out between 4403 NDDs assays and 260 cytotoxicity NP assays conducting a dataset of 500,000 cases. The optimal IFPTML was the Decision Tree (DT) algorithm which shown satisfactory performance with specificity values of 96.4% and 96.2%, and sensitivity values of 79.3% and 75.7% in the training (375k/75%) and validation (125k/25%) set. Moreover, the DT model obtained Area Under Receiver Operating Characteristic (AUROC) scores of 0.97 and 0.96 in the training and validation series, highlighting its effectiveness in classification tasks. In the experimental part, two samples of NPs (Fe 3 O 4 _A and Fe 3 O 4 _B) were synthesized by thermal decomposition of an iron(III) oleate (FeOl) precursor and structurally characterized by different methods. Additionally, in order to make the as-synthesized hydrophobic NPs (Fe 3 O 4 _A and Fe 3 O 4 _B) soluble in water the amphiphilic CTAB (Cetyl Trimethyl Ammonium Bromide) molecule was employed. Therefore, to conduct a study with a wider range of NP system variants, an experimental illustrative simulation experiment was performed using the IFPTML-DT model. For this, a set of 500,000 prediction dataset was created. The outcome of this experiment highlighted certain NANO.PTML systems as promising candidates for further investigation. The NANO.PTML approach holds potential to accelerate experimental investigations and offer initial insights into various NP and NDDs compounds, serving as an efficient alternative to time-consuming trial-and-error procedures.
60 APPLIED LIFE SCIENCES↗
Activation Analysis for the Inboard Region of FNSF Using SERPENT
This study describes an application of the SERPENT 2 code with the TENDL-2017 nuclear data library and the latest available model features of the Fusion Energy System Studies–Fusion Nuclear Science Facility (FNSF), to evaluate the activation of components after shutdown at 1, 10, and 100 years, assuming a plant lifetime of 8.5 full-power years. The primary parameters evaluated include the specific activity, decay heat, and waste disposal rating (WDR). The specific activity and decay heat are calculated with SERPENT 2 using a 360-deg model of the FNSF, while the WDR is calculated and classified based on the waste disposal limits established by the U.S. Nuclear Regulatory Commission under 10 CFR 61.55 as well as by using the Fetter approach. A python-based script developed for a previous high-level waste classification and analysis study was implemented and adapted to this research to calculate the WDR by comparing nuclide concentrations to the values established in 10 CFR 61.55 to generate a waste classification for each component surveyed. As only three short-lived isotopes have limitations for classifications beyond Class A, of which only 63Ni is present in appreciable quantities, there is a limit to the amount that short-lived isotopes contribute to the most significant waste analyzed here. In most cases, a handful of long-lived isotopes can be problematic, such as 59Ni and 94Nb, for example, which are solely responsible for multiple Class C classifications. The results herein reported heavily depend on the specific materials and mass/volume fractions in the specific model used in this study, which has changed and evolved since the inception of the FNSF concept and past studies. Furthermore, the more significant contributions of this study may be the development of a modeling and simulation toolkit and a strategy to perform these calculations, so to help evaluate and optimize future fusion facilities.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Transport of an intense proton beam from a cone-structured target through plastic foam with unique proton source modeling
Laser-accelerated proton beams are applicable to several research areas within high-energy density science, including warm dense matter generation, proton radiography, and inertial confinement fusion, which all involve transport of the beam through matter. Here, we report on experimental measurements of intense proton beam transport through plastic foam blocks. The intense proton beam was accelerated by the 10 ps, 700 $\textit{J}$ OMEGA EP laser irradiating a curved foil target, and focused by an attached hollow cone. The protons then entered the foam block of density 0.38 g/cm 3 and thickness 0.55 or 1.00 mm. At the rear of the foam block, a Cu layer revealed the cross section of the intense beam via proton- and hot electron-induced Cu-K α emission. Images of x-ray emission show a bright spot on the rear Cu film indicative of a forward-directed beam without major breakup. 2D fluid-PIC simulations of the transport were conducted using a unique multi-injection source model incorporating energy-dependent beam divergence. Along with postprocessed calculations of the Cu – $K_α$ emission profile, simulations showed that protons retain their ballistic transport through the foam and are able to heat the foam up to several keV in temperature. The total experimental emission profile for the 1.0 mm foam agrees qualitatively with the simulated profile, suggesting that the protons indeed retain their beamlike qualities.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
High power gas laser - Applications and future developments
Fast flow can be used to create the population inversion required for lasing action, or can be used to improve laser operation, for example by the removal of waste heat. It is pointed out that at the present time all lasers which are capable of continuous high-average power employ flow as an indispensable aspect of operation. High power laser systems are discussed, taking into account the gasdynamic laser, the HF supersonic diffusion laser, and electric discharge lasers. Aerodynamics and high power lasers are considered, giving attention to flow effects in high-power gas lasers, aerodynamic windows and beam manipulation, and the Venus machine. Applications of high-power laser technology reported are related to laser material working, the employment of the laser in controlled fusion machines, laser isotope separation and photochemistry, and laser power transmission.
Hertzberg, A.↗
Space applications of superconductivity - High field magnets
The paper discusses developments in superconducting magnets and their applications in space technology. Superconducting magnets are characterized by high fields (to 15T and higher) and high current densities combined with low mass and small size. The superconducting materials and coil design are being improved and new high-strength composites are being used for magnet structural components. Such problems as maintaining low cooling temperatures (near 4 K) for long periods of time and degradation of existing high-field superconductors at low strain levels can be remedied by research and engineering. Some of the proposed space applications of superconducting magnets include: cosmic ray analysis with magnetic spectrometers, energy storage and conversion, energy generation by magnetohydrodynamic and thermonuclear fusion techniques, and propulsion. Several operational superconducting magnet systems are detailed.
Fickett, F. R.↗
Heat Treatment Optimization of Laser Powder Bed Fusion Additive Manufacture C103
Laser Powder Bed Fusion (L-PBF) and Laser Powder Directed Energy Deposition (LP-DED) additive manufacture C103 is in development for propulsion applications that operate under extreme environments. The standard post-process heat treatment has called for vacuum stress relief, however, depending on the application or certification requirements hot isostatic press (HIP) may be required. Although C103 density responds well to HIP the associated grain growth results in a reduction in mechanical properties. An investigation was conducted to look at the potential benefit of leveraging HIP followed by rapid cooling to minimize grain growth. A series of heat treatment schedules varying temperature and pressure were conducted followed by microstructural and mechanical characterization.
Additive Manufacturing↗
A Dispersion-Strengthened Low-Density Niobium Alloy and Its Elevated Temperature Mechanical Performance
In response to the elevated-temperature and weight-reduction demands of modern aerospace applications, a novel oxide-dispersion-strengthened low-density niobium alloy (LDNb-ODS) was fabricated using laser powder bed fusion (L-PBF). To overcome powder procurement barriers, L-PBF feedstock was produced by blending commercial Nb521, Ti64, and Cr powder with Y2O3 nanoparticles via resonant acoustic mixing. Following L-PBF and a 1400°C vacuum heat treatment, the alloy achieved a density of 6.73 g/cc and a fine mean grain size of 4.62 µm stabilized by uniform ~30 nm yttria dispersoids. Microstructural analysis revealed a chemically inhomogeneous build with lack-of-fusion defects and a titanium (Ti) shift from a nominal 31.5 wt% in the starting powder blend to 24.8 wt% in the printed part due to preferential Ti loss during printing. Elevated-temperature tensile testing demonstrated that LDNb-ODS maintained a superior specific yield strength of 60-85 MPa/(g/cc) up to 800°C, outperforming nickel-based alloys Ni625, Ni230, and GRX-810. Between 870°C and 950°C, its specific strength surpassed both Ni718 and Ni625. In rapid stress-rupture testing at 1093°C and 20.7 MPa, uncoated LDNb-ODS survived 21.4 hours (a tenfold increase over legacy C-103) while an R512E silicide coating extended rupture life to 84.8 hours, confirming that oxidation accelerates low-stress failure. These findings demonstrate that additive manufacturing of LDNb-ODS provides a viable, lightweight alternative to nickel-based superalloys for high-temperature (>850°C) aerospace components.
Low Density Niobium Alloy↗
FY27 Annual LDRD Call for Proposals - external release
Proposals are now being accepted for the fiscal year 2027 (FY-27) Laboratory Directed Research and Development (LDRD) call, the FY-27 Annual LDRD Call for Proposals. Idaho National Laboratory (INL) has renewed its research and development (R&D) portfolio to align with its strategy, and this call seeks high-quality proposals that address these renewed research priorities. The LDRD Office encourages proposals that offer the potential to achieve breakthroughs in the three science and technology (S&T) strategic initiatives: • Unleashing America’s Energy Abundance: Enabling the Quadrupling of Nuclear Power by 2050; • Securing America’s Future by Developing Domestic Supply Chains for Critical and Strategic Minerals and Materials (CSMM); and • Delivering Critical National Security Technology. Proposals that support INL’s four strategic thrust areas are also encouraged: • Enabling Future Fusion Energy Systems; • Delivering Small Nuclear Reactor Technology for Space Exploration and Defense Missions; • Accelerating Technologies for Hybrid Energy and Nuclear Applications; and • Securing America’s Energy Future Through Artificial Intelligence (AI).
99 - GENERAL AND MISCELLANEOUS↗
Multi-fidelity information fusion with concatenated neural networks
Recently, computational modeling has shifted towards the use of statistical inference, deep learning, and other data-driven modeling frameworks. Although this shift in modeling holds promise in many applications like design optimization and real-time control by lowering the computational burden, training deep learning models needs a huge amount of data. This big data is not always available for scientific problems and leads to poorly generalizable data-driven models. This gap can be furnished by leveraging information from physics-based models. Exploiting prior knowledge about the problem at hand, this study puts forth a physics-guided machine learning (PGML) approach to build more tailored, effective, and efficient surrogate models. For our analysis, without losing its generalizability and modularity, we focus on the development of predictive models for laminar and turbulent boundary layer flows. In particular, we combine the self-similarity solution and power-law velocity profile (low-fidelity models) with the noisy data obtained either from experiments or computational fluid dynamics simulations (high-fidelity models) through a concatenated neural network. We illustrate how the knowledge from these simplified models results in reducing uncertainties associated with deep learning models applied to boundary layer flow prediction problems. The proposed multi-fidelity information fusion framework produces physically consistent models that attempt to achieve better generalization than data-driven models obtained purely based on data. While we demonstrate our framework for a problem relevant to fluid mechanics, its workflow and principles can be adopted for many scientific problems where empirical, analytical, or simplified models are prevalent. In line with grand demands in novel PGML principles, this work builds a bridge between extensive physics-based theories and data-driven modeling paradigms and paves the way for using hybrid physics and machine learning modeling approaches for next-generation digital twin technologies.
42 ENGINEERING↗
Laser powder bed fusion of ODS Fe–Cr–Al (0.3Zr, 0.3Y 2 O 3 ): Unveiling processing-microstructure- mechanical property relationships
Here, this study investigates the fabrication of oxide dispersion strengthened (ODS) Fe-Cr-Al alloys via laser powder bed fusion (LPBF) with strategic additions of 0.3 wt% Zr and 0.3 wt% Y 2 O 3 for enhanced mechanical performance in nuclear applications. Systematic processing parameter optimization yielded three distinct conditions: one low-density product with significant defects and two near-full-density materials with improved consolidation. Comprehensive characterization confirmed single-phase α-ferrite matrix formation with successful incorporation of Y-, Zr-, O-, and C-rich precipitates characteristic of ODS alloys. However, precipitate density remained low (∼10 7 cm −3 ), resulting in sink strength values substantially below optimal levels for radiation resistance. Microhardness values (mid-200s HV) correlated inversely with grain size following the Hall-Petch relationship, indicating grain boundary strengthening as the dominant mechanism rather than precipitation strengthening. The optimized processing conditions achieved excellent mechanical properties with room temperature yield strength of approximately 500 MPa and 30 % elongation, demonstrating superior strength-ductility synergy compared to other additively manufactured ODS materials and performance consistent with literature values for LPBF-processed ODS-FeCrAl alloys. This investigation reveals both the potential and limitations of LPBF processing for ODS Fe-Cr-Al alloys. While successful defect-free fabrication was achieved, results highlight the critical need for systematic optimization of processing parameters and post-processing heat treatments to enhance precipitate density for effective dispersion strengthening and radiation resistance while maintaining additive manufacturing advantages.
Additive manufacturing↗
Particle transport in Markov stochastic mixtures with spatial gradients
Markov geometries are a prototype class of stochastic media that are widely used to model complex disordered systems. In a series of recent works, we have shown that spatially homogeneous (but possibly non-isotropic) Poisson tessellations can be conveniently used in order to generate three-dimensional realizations of Markov media and thus characterize the features of particle transport e.g. in fragmented fuel elements following severe nuclear accidents or Rayleigh-Taylor turbulent mixing for inertial confinement fusion. In this paper we show that Poisson tessellations can be extended to take into account the presence of spatial gradients, which commonly occur in real-world applications due to material stratification. For this purpose, we will provide an explicit construction of spatially-non-homogeneous Poisson tessellations, fully characterize their statistical properties, and finally illustrate the behaviour of particle transport in such random media. (authors)
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Endowing low fatigue for elastocaloric effect by refined hierarchical microcomposite in additive manufactured NiTiCuCo alloy
Abstract NiTiCu-based shape memory alloys have been considered as ideal materials for solid-state refrigeration due to their superb cycling stability for elastocaloric effect. However, the embrittlement and deterioration caused by secondary phase and coarse grains restrict their applications, and it is still challenging since the geometric components are required. Here, bulk NiTiCuCo parts with excellent forming quality were fabricated by laser powder bed fusion (LPBF) technique. The as-fabricated alloy exhibits refined three-phases hierarchical microcomposite formed based on the rapid cooling mode of LPBF, composed of intricate dendritic Ti 2 Ni–NiTi composite and nano Ti 2 Cu embedded inside the NiTi-matrix. This configuration endows far superior elastocaloric stability compared to the as-cast counterpart. The low fatigue stems from the strong elastic coupling between the interphases with reversible martensite transformation, revealed byin-situsynchrotron high-energy x-ray diffraction. The fabrication of NiTiCuCo alloy via LPBF fills the bill of complex geometric structures for elastocaloric NiTiCu alloys. The understanding of interphase micro-coupling could provide the guide for designing LPBF fabricated shape memory-based composites, enabling their applications for special demands on other functionalities.
Engineering↗
Machine learning-based real-time kinetic profile reconstruction in DIII-D
Abstract Kinetic equilibrium reconstruction plays a vital role in the physical analysis of plasma stability and control in fusion tokamaks. However, the traditional approach is subjective and prone to human biases. To address this, the consistent automatic kinetic equilibrium reconstruction (CAKE) method was introduced, providing objective results. Nonetheless, its offline nature limits its application in real-time plasma control systems (PCSs). To address this limitation, we present RTCAKENN, a machine learning model that approximates 7 CAKE-level output profiles, namely pressure, inverse q , toroidal current density, electron temperature and density, carbon ion impurity temperature and rotation profiles, using real-time available inputs. The deep neural network consists of an encoder layer, where the scalars and interdependent inputs such as plasma boundary coordinates and motional Stark effect data are encoded using multi-layer perceptrons (MLPs), while profile inputs are encoded by 1D convolutional layers. The encoded data is passed through a MLP for latent feature extraction, before being decoded in the decoding layers, which consist of upsampling and convolutional layers. RTCAKENN has been implemented in the DIII-D PCS and our model achieves accuracy comparable to CAKE and surpasses existing real-time alternatives. Through clever dropout training, RTCAKENN exhibits robustness and can operate even in the absence of Thomson scattering data or charge exchange recombination data. It executes in under 8 ms in the real-time environment, enabling future application in real-time control and analysis.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗