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DOE OSTI2022

In-process monitoring and prediction of droplet quality in droplet-on-demand liquid metal jetting additive manufacturing using machine learning

Abstract In droplet-on-demand liquid metal jetting (DoD-LMJ) additive manufacturing, complex physical interactions govern the droplet characteristics, such as size, velocity, and shape. These droplet characteristics, in turn, determine the functional quality of the printed parts. Hence, to ensure repeatable and reliable part quality it is necessary to monitor and control the droplet characteristics. Existing approaches for in-situ monitoring of droplet behavior in DoD-LMJ rely on high-speed imaging sensors. The resulting high volume of droplet images acquired is computationally demanding to analyze and hinders real-time control of the process. To overcome this challenge, the objective of this work is to use time series data acquired from an in-process millimeter-wave sensor for predicting the size, velocity, and shape characteristics of droplets in DoD-LMJ process. As opposed to high-speed imaging, this sensor produces data-efficient time series signatures that allows rapid, real-time process monitoring. We devise machine learning models that use the millimeter-wave sensor data to predict the droplet characteristics. Specifically, we developed multilayer perceptron-based non-linear autoregressive models to predict the size and velocity of droplets. Likewise, a supervised machine learning model was trained to classify the droplet shape using the frequency spectrum information contained in the millimeter-wave sensor signatures. High-speed imaging data served as ground truth for model training and validation. These models captured the droplet characteristics with a statistical fidelity exceeding 90%, and vastly outperformed conventional statistical modeling approaches. Thus, this work achieves a practically viable sensing approach for real-time quality monitoring of the DoD-LMJ process, in lieu of the existing data-intensive image-based techniques.

Gaikwad, Aniruddha (ORCID:0000000285642621)↗

DOE OSTI2023

Experimental, numerical and analytical evaluation of j × B -thrust for fast-liquid-metal-flow divertor systems of nuclear fusion devices

Abstract Divertor systems of fusion devices are exposed to intense heat loads from plasmas, which degrade solid plasma-facing components. Fast liquid metal (LM) flow divertors may be more advantageous for this purpose but have risk of piling due to intense magnetohydrodynamic (MHD) drag. However, severe deceleration of the flow could be countered with the injection of currents that are transverse to external magnetic fields, allowing to thrust the flow with j × B (Lorentz) forces. Given that the injection of currents as an approach to propel LM-divertor flows has remained experimentally understudied, this article focuses on the evaluation of j × B -thrust and finding its drawbacks. j × B -thrust was experimentally tested with free-surface-LM flows, a vertical magnetic field and an externally applied current. Experiments were reviewed with a theoretical model, showing agreement in the trends of theory and experiments. Full 3D-MHD-free-surface-flow simulations were also performed with FreeMHD and confirmed the sensitivity to unstable flow behavior in LM systems when applying external currents. Furthermore, excessive power requirements are expected for the implementation of j × B -thrust at the reactor scale, making these systems inefficient for commercial devices. This paper evidences that the simple operation of a LM-flow divertor with j × B -thrust, without any of the instabilities caused from reactor plasmas or parasitic currents, already presents intrinsic challenges.

Magnetohydrodynamics↗

DOE OSTI2022

Modeling of Transport Processes in Liquid-Metal Fusion Blankets: Past, Present, and Future

The successful development of robust breeding blanket systems will strongly rely on computational tools for predicting the complex behavior of the electrically conducting liquid-metal (LM) breeder flowing in the complex-shaped blanket ducts in the presence of a strong plasma-confining magnetic field, volumetric heating, and tritium generation. Associated transport processes involve magnetohydrodynamic (MHD) flows, heat transfer, corrosion, and tritium transport. This paper is an overview of past and present efforts in the development, application, and verification and validation (V&V) of such computational tools. As a result of the ongoing campaign on V&V of computer codes for LM blankets, the international fusion community has identified several candidates that promise to become real blanket design and analysis tools in the near future. Among them are HIMAG, MHD-UCAS, COMSOL Multiphysics, ANSYS FLUENT, ANSYS CFX, and OpenFOAM. The progress, over the last decade, in the application of such codes in blanket studies is tremendous. This is illustrated with two examples for a dual-coolant lead-lithium (DCLL) blanket: (1) integrated computer modeling for the recently designed DCLL blanket in the United States and (2) application of the code MHD-UCAS to the analysis of PbLi flows and heat transfer in a generic DCLL blanket prototype at high Hartmann (Ha ~ 10 4 ) and Grashof numbers (Gr ~ 10 12 ). Here, this paper also presents an approach to the development of a new integrated computational tool called the virtual dual-coolant lead-lithium (VDCLL) blanket, which elaborates the existing U.S. MHD code HIMAG.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

In Situ Alloying Enabled by Active Liquid Metal Filler for Self‐Healing Composite Polymer Electrolytes

Abstract Solid inorganics, known for kinetically inhibiting polymer crystallization and enhancing ionic conductivity, have attracted significant attention in solid polymer electrolytes. However, current composite polymer electrolytes (CPEs) are still facing challenges in Li metal batteries, falling short of inhibiting severe dendritic growth and resulting in very limited cycling life. This study introduces Ga 62.5 In 21.5 Sn 16 (Galinstan) liquid metal (LM) as an active liquid alternative to conventional passive solid fillers, aiming at realizing self‐healing protection against dendrite problems. Compared to solid inorganics, for example silica, LM droplets could more significantly reduce polymer crystallinity and enhance Li‐ion conductivity due to their liquid nature, especially at temperatures below the polymer melting point. More importantly, LMs are unraveled as dynamic chemical traps, which are capable of blocking and consuming lithium dendrites upon contact via in situ alloying during battery operation and further inhibiting dendritic growth due to the lower deposition energy barrier of the formed Li‐LM alloy. As a proof of concept, by strategically designing an asymmetric CPE with the active LM filling, a solid‐state Li/LiFePO 4 battery achieves promising full‐cell functionality with notable rate performance and stable cycle life. This active filler‐mediated self‐healing approach could bring new insights into the battery design in versatile solid‐state systems.

Wu, Kai↗

DOE OSTI2025

Compatibility of Zircaloy-4 in eutectic PbSn and PbBiSn liquid metals

Here, a novel nuclear fuel concept has been proposed, consisting of UO₂ particles suspended in a liquid metal alloy. To evaluate its feasibility, the compatibility of Zircaloy-4 cladding with candidate eutectic PbSn and PbBiSn alloys—as well as with pure Pb, Bi, and Sn—was investigated through 1000-hour exposures at 400 °C and 600 °C. Severe degradation of the Zircaloy-4 specimens was observed in eutectic PbSn at 600 °C, whereas oxidation and oxygen diffusion were evident after exposure at 400 °C. At 600 °C, the formation of Zr₃Fe precipitates at the oxide–alloy interface was identified in specimens exposed to Pb and PbBiSn. Thermodynamic analysis suggested that the observed intermetallic formation resulted from the destabilization of Laves phases due to oxygen ingress at elevated temperatures.

Bismuth↗

DOE OSTI2025

Microreactor-liquid metal battery system in energy markets: An evaluation of potential costs, technology, and policy impacts

Microreactors represent an emerging innovation in the nuclear industry; yet have been overshadowed by their high capital costs. With the Inflation Reduction Act of 2022 (IRA), new opportunities have emerged to improve the economics of microreactor systems. This work examines liquid metal batteries (LMB) as a value-adding technology as part of microreactor-LMB systems within three U.S. electricity markets: ERCOT, PJM, and MISO. Our investigation considers key uncertainties: the cost of microreactors, the performance of LMBs, and the eligible tax credit levels. To this end, we use a dispatch optimization to trace not only the changes in system economics but also to provide a granular picture of energy delivery within the systems. We find that even with favorable costs for microreactors, significant regional variations in the project sizing and returns exist across the markets. Our heuristic method identifies their non-electric application potentials beyond electricity and technical requirements to maximize returns. The results suggest that 12–39 % of reactor heat could be cost-effectively diverted to produce more valuable by-products in U.S. markets. Including the impacts of tax credits, we establish the outcomes of each provision with varying rates. Coupling an LMB to a microreactor consistently improves the net present value of a microreactor compared to its standalone operation. In conclusion, for reasonable assumed conditions, we quantify a heterogeneous impact of round-trip efficiency (RTE) and extended LMB service life across the three markets—a one-year extension in LMB service life is roughly equivalent to a 2.11 % improvement in RTE for ERCOT, 1.16 % for PJM, and 1.04 % for MISO.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Techno-Economic Analysis of a Nuclear Reactor System coupled with a Liquid Metal Battery

There is a need for nuclear reactor systems to become more dynamic as defossilization and renewable energy sources continue to reshape the energy grid. One option to meet these changing demands is to pair the reactor with an energy storage system. This work details a technoeconomic analysis and sensitivity analysis of a high temperature gas cooled microreactor, supercritical carbon dioxide power cycle, and liquid metal battery. Dynamic modeling has shown that these three systems compliment each other to provide load following and black-start capabilities to the grid. Current cost estimates for installing the systems yield a competitive levelized cost of electricity and levelized cost of storage, indicating that such a combined system may be economically viable as technological advances lead to them being technically feasible.

25 ENERGY STORAGE↗

DOE OSTI2024

Modelling and analysis of nuclear reactor system coupled with a liquid metal battery

Traditionally, nuclear power plants in the U.S. provide baseload power to the power grid because they have less flexibility for ramping their output power than natural gas peaking plants. However, achieving climate goals to reduce the consumption of fossil‐based natural gas places pressure on nuclear power plants and other power generators to ramp up their power output to balance grid generation with demand. This paper presents the modelling and performance analysis of a nuclear reactor system (NRS) coupled to a liquid‐metal battery (LMB) to improve its dynamic response and enable its black start capability. The NRS and LMB thermal behaviour are modelled in Dymola, while the electrical dynamics of the LMB and power grid are modelled in RTDS‐RSCAD. Both simulation platforms are coupled and share their thermal and electrical data using a Transmission Control Protocol/Internet Protocol (TCP/IP) communication protocol. The dynamic performance of the NRS‐LMB integration is tested on the IEEE 9 bus, which demonstrates its ability to respond and provide frequency and voltage regulation. The black start capability of the NRS‐LMB is also evaluated by simulating a grid outage and using the LMB to supply the auxiliary loads required to bring the NRS back online as soon as possible. The results show that coupling an NRS to an LMB improves the system dynamic performance and enables it to black start after being disconnected from the grid for several days.

25 ENERGY STORAGE↗

DOE OSTI2024

Liquid metal walls

Here, the plasma performance of fusion devices depends strongly on the chosen wall materials. Solid plasma-facing components (PFCs) are predominantly used in present devices, and are the most investigated candidates for fusion designs. High-Z materials such as tungsten (W) are the leading solid PFC material candidates. To date, a material choice that scales to steady-state reactor conditions has not been identified. Moreover, if plasma transient events such as edge-localized modes and disruptions cannot be altogether avoided or sufficiently mitigated, the projected peak heat and particle loads far exceed the power exhaust capabilities of solids. Liquid metal (LM) PFCs represent an intrinsic self-healing boundary that are both resilient to surface damage from transients, and that could handle high steady-state heat and particle fluxes. Flowing LM PFCs can be designed to remove “slag,” the buildup of material erosion due to plasma-material interactions, including charge exchange sputtering in the main chamber. Further, LM offer the prospect to manage hydrogenic species otherwise retained in the PFCs, which is important from a safety and inventory standpoint. The two most promising LMs are lithium (Li) and tin (Sn), although Sn–Li eutectics may be considered. While Sn offers a higher temperature window with low vapor pressure and low hydrogen retention, Li offers the prospect of enhanced energy confinement and higher acceptable core contamination limits, and this section focuses on Li PFCs. An LM PFC development research program developed LM PFC concepts for a nuclear fusion device via engineering design calculations, single-effect experiments, and staged prototypical experiments. A self-consistent design window was identified with liquid Li flow speeds ~5–10 m/s; plasma contamination was negligible for predicted Li evolution rates. While these preconceptual designs hold promise, there is substantial R&D needed to advance the technical readiness levels of LM PFCs for application to fusion power plants.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Comparison of Mg-based liquid metal ion sources for scalable focused-ion-implantation doping of GaN

We compare the suitability of various magnesium-based liquid metal alloy ion sources (LMAISs) for scalable focused-ion-beam (FIB) implantation doping of GaN. We consider GaMg, MgSO 4 $\bullet$7H 2 O, MgZn, AlMg, and AuMgSi alloys. Although issues of oxidation (GaMg), decomposition (MgSO 4 $\bullet$7H 2 O), and excessive vapor pressure (MgZn and AlMg) were encountered, the AuMgSi alloy LMAIS operating in a Wien-filtered FIB column emits all Mg isotopes in singly and doubly charged ionization states. We discuss the operating conditions to achieve <20 nm spot size Mg FIB implantation and present Mg depth profile data from time-of-flight secondary ion mass spectrometry. We also provide insight into implantation damage and recovery based on cathodoluminescence spectroscopy before and after rapid thermal processing. Prospects for incorporating the Mg LMAIS into high-power electronic device fabrication are also discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Real-space atomic dynamics in metallic liquids investigated by inelastic neutron scattering

Understanding the dynamics of liquids at the atomic level remains a major challenge. Even though viscosity is one of the most fundamental properties of liquids, its atomistic origin is not fully elucidated. Through inelastic neutron scattering experiment on levitated metallic liquid droplets, the time-dependent pair correlation function, the Van Hove function, was determined for Z⁢r 50 ⁢C⁢u 50 and Z⁢r 80 ⁢P⁢t 20 liquids at various temperatures. The time for change in local atomic connectivity, τ LC , which is the timescale of atomic bond cutting and forming, is estimated based on the exponential decay of the nearest neighbor peak of the Van Hove function. At high temperatures above the crossover temperature T A , τ LC is equal to the Maxwell relaxation time, τ M =η/G ∞ , where η is the macroscopic shear viscosity and G ∞ is the high-frequency shear modulus. Below T A the ratio of τ M /τ LC increases with decreasing temperature, indicating increased atomic cooperativity as predicted by molecular dynamics simulation.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2026

Tin–Lead Liquid Metal Alloy Source for Focused Ion Beams

Focused Ion Beam (FIB) systems are increasingly utilized in nanotechnology for nanostructuring, surface modification, doping, and rapid prototyping. Recently, their potential for quantum applications has been explored, leveraging FIB’s direct-write capabilities for in situ single ion implantation, which is crucial for fabricating single photon emitters. Color centers in diamond can function as qubits and are of particular interest due to their capacity to store and transmit quantum information. While Group-IV color centers exhibit high brightness, they require low temperatures to retain coherence. However, lead-vacancy in diamond (PbV) operates at the higher end (4 K) of this temperature spectrum due to larger ground-state splitting, making them particularly interesting. In this context, our study presents results for lead (Pb)-containing alloys with eutectic points below 600 °C and results on using tantalum (Ta) and titanium (Ti) as emitter materials for a Pb liquid metal alloy ion source. We show that a standard FIB system is able to resolve the different Pb isotopes and achieve nanoscale spot sizes, as required for quantum information science applications.

color center↗

DOE OSTI2026

Considerations and Mitigations for Liquid Metal Target Campaigns in the Material Plasma Exposure eXperiment

This document reports a detailed initial risk assessment associated with the exposure of liquid metal (LM) targets to plasma flux in the Material Plasma Exposure eXperiment (MPEX) at ORNL. This document, while preliminary, does give a comprehensive mitigation plan to the risks along with justification and recommendations before potentially proceeding to LM exposures. At the date of issuance of this report, the MPEX Project has completed Final Design, and the MPEX device is in the Fabrication stage. Remaining project stages include Commissioning of the device with plasma and transitioning to routine Operations for research. As will be described in this document, since the MPEX device is currently being fabricated and the existing design does not include sufficient engineering provisions for most LM targets, no LM exposures will be conducted in MPEX until further assessment can be conducted and the necessary engineering changes incorporated (during MPEX Operations.)

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Geostrophic to magnetically-damped turbulence in liquid metal rotating magnetoconvection

Understanding planetary core convection dynamics requires the study of convective flows in which the Coriolis and Lorentz forces attain a leading-order, so-called magnetostrophic balance. Experimental investigations of rotating magnetoconvection (RMC) in the magnetostrophic regime are therefore essential to broadly characterize the properties of local-scale planetary core flow. Toward this end, we present here the first thermovelocimetric measurements of magnetostrophic, liquid metal convection, which are made using liquid gallium as the working fluid, at moderate rotation rates (Ekman numbers 10 -4 ≤ Ek ≤ 10 -5 ) and in the presence of dynamically strong magnetic fields (Elsasser number Λ = 1). Complementary rotating convection (RC) experiments are performed at the same rotation rates to serve as reference cases. Our RMC velocity measurements adequately follow a geostrophic turbulent scaling for cases in which local-scale convective inertial forces exceed the Lorentz forces in the fluid bulk. In cases where Lorentz forces exceed local-scale inertia (local or convective interaction parameter N ℓ or N C ≳ 3), the root-mean-square RMC velocities are magnetically damped, yielding values below the geostrophic turbulent RC scaling prediction. An enhancement in heat transfer is observed, which we attribute to the increased coherence of vertically aligned magnetostrophic convective flow. Finally, our results and comparisons to dynamo simulations suggest that the system is in the strong-field regime, where convection-scale flows are magnetically damped with N C ≳ 3).

Convective turbulence↗

DOE OSTI2022

Development of a Subchannel Capability for Liquid-Metal Fast Reactors in Pronghorn

This report details the development and demonstration of an entirely new capability in Pronghorn, namely the ability to model liquid-metal fast reactor (LMFR) flow conditions on the engineering scale. We developed two modeling approaches for LMFR that can be used separately or be combined into a hybrid simulation: (1) a modern subchannel capability called Pronghorn-Subchannel for square and hexagonal lattices, and (2) a porous flow capability for LMFR geometries. The report emphasizes the novel aspects of the developed subchannel capability and the interoperability of the subchannel capability, porous flow capability, and multiphysics tools within the multiphysics object oriented simulation environment (MOOSE). Here we demonstrate the ability to: (1) Accurately model subchannel flow in hexagonal lattices; (2) Couple the subchannel flow model to multidimensional finite-element method (FEM) or finite-volume method (FVM) heat conduction models; (3) Model LMFRs using Pronghorn’s porous media FVM approach; (4) Couple porous flow FVM and subchannel models in a single simulation; (5) Explicitly model inter-wrapper flows along with conjugate heat transfer from the intra-element flow; and (6) Demonstrate the numerical robustness of the subchannel algorithm by simulating intra-element flow recirculation in a high-buoyancy, low-flow fuel element.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

FY24 – FY25 Efforts to Revive the ANS-54.8 Liquid Metal Fire Protection in LMR Plants Standard

The current multi-year effort seeks to utilize national laboratory support from Argonne to expedite revival of the ANS-54.8 standard titled “Liquid Metal Fire Protection in LMR Plants.” To achieve that objective, the following tasks were identified: Task 1 involves working directly with ANS to revive the ANS-54.8 Working Group. This was to be accomplished by completing necessary paperwork, submitting that paperwork to ANS for approval, enlisting potential working group members from industry, the NRC, national laboratories, and universities, and organizing and leading Working Group activities. The overall purpose of the Working Group is to develop an updated draft of ANS-54.8 for review and approval by ANS consensus committees, the ANS Standards Board, and certification from ANSI. Task 2 focuses on leveraging historical information and expertise at Argonne related to sodium fire protection systems and strategies. For more than a decade, Argonne has worked on both international and domestic projects related to sodium fire protection system development and evaluation. The goal of this task is to utilize that experience to help inform the ANS-54.8 Working Group on important considerations that may be addressed in an updated draft of ANS-54.8. Task 3 focuses on leveraging Argonne experience in the development of and use of analysis methods and tools for the simulation of sodium fire scenarios and evaluation of the effectiveness of sodium fire protection systems and strategies. For more than a decade, Argonne has recovered, modified, and utilized several historical sodium fire analysis software tools. The goal of this task is to utilize that experience to help inform the ANS-54.8 Working Group of best practices for sodium fire progression analysis that may be addressed in an updated draft of ANS-54.8.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Toward full simulations for a liquid metal blanket: part 2. Computations of MHD flows with volumetric heating for a PbLi blanket prototype at Ha ~10 4 and Gr ~10 12

On the pathway toward full simulations for a liquid metal (LM) blanket, this part 2 extends a previous study of purely magnetohydrodynamic (MHD) flows in a DCLL blanket in reference Chen et al (2020 Nucl. Fusion 60 076003) to more general conditions when the MHD flow is coupled with heat transfer. The simulated prototypic blanket module includes all components of a real LM blanket system, such as supply ducts, inlet and outlet manifolds, multiple poloidal ducts and a U-turn zone. Volumetric heating generated by fusion neutrons is added to simulate thermal effects in the flowing lead–lithium (PbLi) breeder. The MHD flow equations and the energy equation are solved with a DNS-type finite-volume code ‘MHD-UCAS’ on a very fine mesh of 470 × 10 6 cells. The applied magnetic field is 5 T (Hartmann number Ha ~ 10 4 ), the PbLi velocity in the poloidal ducts is 10 cm s –1 (Reynolds number Re ~10 5 ), whereas the maximum volumetric heating is 30 MW m –3 (Grashof number Gr ~ 10 12 ). Four cases have been simulated, including forced- and mixed-convection flows, and either an electrically conducting or insulating blanket structure. Various comparisons are made between the four computed cases and also against the purely MHD flows computed earlier in reference Chen et al (2020 Nucl. Fusion 60 076003) with regards to the (1) MHD pressure drop, (2) flow balancing, (3) temperature field, (4) flows in particular blanket components, and (5) 3D and turbulent flow effects. The strongest buoyancy effects were found in the poloidal ducts. In the electrically non-conducting blanket, the buoyancy forces lead to significant modifications of the flow structure, such as formation of reverse flows, whereas their effect on the MHD pressure drop is relatively small. In the electrically conducting blanket case, the buoyancy effects on the flow and MHD pressure drop are almost negligible.

Physics↗

DOE OSTI2020

Calculation of electron-ion temperature equilibration rates and friction coefficients in plasmas and liquid metals using quantum molecular dynamics

In this work, we discuss a method to calculate with quantum molecular dynamics simulations the rate of energy exchanges between electrons and ions in two-temperature plasmas, liquid metals, and hot solids. Promising results from this method were recently reported for various materials and physical conditions. Like other ab initio calculations, the approach offers a very useful comparison with the experimental measurements and permits an extension into conditions not covered by the experiments. The energy relaxation rate is related to the friction coefficients felt by individual ions due to their nonadiabatic interactions with electrons. Each coefficient satisfies a Kubo relation given by the time integral of the autocorrelation function of the interaction force between an ion and the electrons. These Kubo relations are evaluated using the output of quantum molecular dynamics calculations in which electrons are treated in the framework of finite-temperature density functional theory. The calculation presents difficulties that are unlike those encountered with the Kubo formulas for the electrical and thermal conductivities. In particular, the widely used Kubo-Greenwood approximation is inapplicable here. Indeed, the friction coefficients and the energy relaxation rate diverge in this approximation since it does not properly account for the electronic screening of electron-ion interactions. The inclusion of screening effects considerably complicates the calculations. We discuss the physically motivated approximations we applied to deal with these complications in order to investigate a widest range of materials and physical conditions. Unlike the standard method used for the electronic conductivities, the Kubo formulas are evaluated directly in the time domain and not in the energy domain, which spares one from needing to introduce an extraneous undetermined numerical parameter to account for the discrete character of the numerical density of states. We highlight interesting properties of the energy relaxation rate not shared by other electronic properties, in particular its self-averaging character. We then present a detailed parametric and convergence study with the numerical parameters, including the system size, the number of bands and k-points, and the physical approximations for the dielectric function and the exchange-correlation energy.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗