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At least 1,009 records · Page 56

Abstract for CRADA among NETL, Ohio University, and MetalKraft Technologies, LLC

The electrical grid faces challenges for meeting accelerated electricity demand arising from the electrification of building and transportation sectors. According to the DOE Grid Development Office, 70% of transmission lines are approaching the end of their lifecycle. The aging grid and insufficient transmission capacity necessitate the development of new technologies to improve overall grid performance. The conventional conductors used for electrical transmission lines suffer from substantial energy losses, high costs and low durability. These inefficiencies result in higher operational costs, increased energy waste, and difficulties in managing power flow. Improving the grid will require metals and composites with higher electrical conductivity and strength than the materials currently used. This CRADA will develop technologies to improve the grid by fabricating carbon metal composites with improved electrical, structural, and mechanical properties in comparison to metals that do not contain carbon additives. The composites will be made by incorporating carbon materials (graphite, graphene) into aluminum, copper, and other metals. The work will focus primarily on improving material properties that enhance the performance of these materials in electrical conductor applications.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Helium recovery system at IB3A

The growing demand for sustainable cryogenic operations at Fermilab has underscored the need to improve helium management, particularly at the Industrial Building 3A (IB3A) test facility. IB3A characterizes and tests superconductors, cables, and coils for projects such as the HL-LHC AUP and Mu2e, yet currently relies on 500 L Dewars whose boil-off is vented to atmosphere, wasting a critical, non-renewable resource and increasing the cost of testing. A project is therefore under way to link IB3A to an existing purification and liquefaction station in a neighboring building through a dedicated pipeline. Captured helium will be transferred, purified, reliquefied, and returned for reuse, cutting losses and operating costs. This paper details the first two project phases: "Design and Engineering" and "Procurement and Installation." The design phase finalizes pipeline specifications, establishes flow-control requirements, and resolves integration challenges with existing cryogenic infrastructure. The procurement and installation phase covers material sourcing, pipeline construction, and deployment of control and monitoring systems to assure reliable, efficient operation. Key technical hurdles-route optimization, pressure drop mitigation, and interface compatibility-are discussed alongside implemented solutions. Implementing the pipeline and upgrading IB3A will dramatically reduce helium consumption and therefore testing cost, strengthening Fermilab's capacity to support frontier science far into the future.

Porwisiak, D. [Fermilab; Wroclaw Tech. U.]↗

System and method for rapid, high throughput, high pressure synthesis of materials from a liquid precursor

The present disclosure relates to a system and method for synthesis of condensed, nano-carbon materials to create nanoparticles. In one embodiment the system may have a source of liquid precursor, a flow control element and a shock wave generating subsystem. The flow control element is in communication with the source of the liquid precursor and creates a jet of liquid precursor. The shock wave generating subsystem drives a shock wave through at least a substantial portion of a thickness of the jet of liquid precursor to sufficiently compress the jet of liquid precursor, and to increase a pressure and a temperature of the jet of liquid precursor, to create solid state nanoparticles.

Armstrong, Mike↗

3D printable feedstock inks for signal control or computation

A 3D printable feedstock ink is disclosed for use in a 3D printing process where the ink is flowed through a printing nozzle. The ink may be made up of a non-conductive flowable material and a plurality of chiplets contained in the non-conductive flowable material in random orientations. The chiplets may form a plurality of percolating chiplet networks within the non-conductive flowable material as ones of the chiplets contact one another. Each one of the chiplets has a predetermined circuit characteristic which is responsive to a predetermined electrical signal, and which becomes electrically conductive when the predetermined electrical signal is applied to the ink, to thus form at least one conductive signal path through the ink.

Murialdo, Maxwell↗

System and operation for thermochemical renewable energy storage

Systems and methods for energy storage and energy recovery are provided. An electrical-to-electrical energy storage system includes a thermochemical energy storage device, a blower, a compressor, a turbine, and an electrical generator. The TCES device includes a vessel, a porous bed, and a heater. The porous bed is disposed within an interior volume of the vessel. The porous bed comprises a reactive material. The reactive material is configured to release oxygen upon being heated to a reduction temperature, and generate heat when exposed to oxygen. The heater is in thermal contact with the reactive material. The blower is configured to remove oxygen from the interior volume. The compressor is configured to flow oxygen into the interior volume. The turbine is configured to receive a heated, oxygen-depleted gas from the interior volume. The generator is configured to be powered by the turbine to generate electricity.

Klausner, James F.↗

Thermochemical renewable energy storage

Systems and methods for energy storage and energy recovery are provided. An electrical-to-electrical energy storage system includes a thermochemical energy storage device, a blower, a compressor, a turbine, and an electrical generator. The TCES device includes a vessel, a porous bed, and a heater. The porous bed is disposed within an interior volume of the vessel. The porous bed comprises a reactive material. The reactive material is configured to release oxygen upon being heated to a reduction temperature, and generate heat when exposed to oxygen. The heater is in thermal contact with the reactive material. The blower is configured to remove oxygen from the interior volume. The compressor is configured to flow oxygen into the interior volume. The turbine is configured to receive a heated, oxygen-depleted gas from the interior volume. The generator is configured to be powered by the turbine to generate electricity.

Klausner, James F.↗

Experimental and Computational Study of Weld Drop-Through Hydraulic Effects in Multi-Layer Concentric Pipes Servicing Cryogenic Liquid Hydrogen

The Cryogenic Moderator System (CMS) at the Oak Ridge National Laboratory (ORNL)-Spallation Neutron Source (SNS) supplies liquid hydrogen, through vacuum insulated transfer lines to the moderators. The welding process used to make the transfer lines produces weld drop-through, which can constrict the flow of hydrogen and/or cause thermal bridges between adjacent layers. To ensure proper operation of the CMS it is therefore necessary to conduct a flow test to verify the pressure drop caused by the welds. Measurements in as-built piping sections intended to provide liquid hydrogen service to the SNS-CMS system were performed to test the effect of weld penetrations into the fluid flow area focusing on pressure drop effects. The reference test sections were designed using prototypical piping dimensions, materials and expected penetration welds. A numerical study using Computational Fluid Dynamics (CFD) tools in the transfer lines provided a conversion factor from the pressure drop measured in the lines with water to the expected pressure drop using liquid cryogenic hydrogen. The results show evidence of a maximum pressure drop modification in water of 78 KPa in the tested parts, which scales to liquid hydrogen as PHydrogen = 5.2 KPa. The maximum measured equivalent blockage area percentage was found in the as-built TDM transfer line spool 2 with a value of 31%. The measured values obtained in the as-built transfer lines provided accurate values to estimate the expected total pressure drop in the CMS system providing operational limits for the current recirculatory capacity. The effect of the weld drop-through in hydrogen evacuation capacity scenarios was better evaluated as a result of this study.

Dominguez-Ontiveros, Elvis [ORNL] (ORCID:000000018↗

Optimization of the electron transport layer in quantum dot light-emitting devices

Quantum dot light-emitting devices have emerged as an important technology for display applications. Their emission is a result of recombination between positive and negative charge carriers that are transported through the hole and electron conductive layers, respectively. The selection of electron or hole transport materials in these devices not only demands the alignment of energy levels between the layers but also balances the flow of electrons and holes toward the recombination sites. In this work, we examine a method for device optimization through control of the charge carrier kinetics. We employ impedance spectroscopy to examine the mobility of charge carriers through each of the layers. The derived mobility values provide a path to estimate the transition time of each charge carrier toward the emitting layer. We suggest that an optimal device structure can be obtained when the transition times of both charge carriers toward the active layer are similar. Finally, we examine our hypothesis by focusing on thickness optimization of the electron transport layer.

36 MATERIALS SCIENCE↗

Molecular-gas-dynamics simulations of turbulent Couette flow over a mean-free-path-scale permeable substrate

Here we report flow statistics and visualizations from molecular-gas-dynamics simulations using the direct simulation Monte Carlo (DSMC) method for turbulent Couette flow in a minimal domain where the lower wall is replaced by an idealized permeable fibrous substrate representative of thermal-protection-system materials for which the Knudsen number is O(10 -1 ). Comparisons are made with smooth-wall DSMC simulations and smooth-wall direct numerical simulations (DNS) of the Navier-Stokes equations for the same conditions. Roughness, permeability, and noncontinuum effects are assessed. In the range of Reynolds numbers considered herein, the scalings of the skin friction on the permeable substrate and of the mean flow within the substrate suggest that they are dominated by viscous effects. While the regenerative cycle characteristic of smooth-wall turbulence remains intact for all cases considered, we observe that the near-wall velocity fluctuations are modulated by the permeable substrate with a wavelength equal to the pore spacing. Additionally, the flow within the substrate shows significant rarefaction effects, resulting in an apparent permeability that is 13% larger than the intrinsic permeability. In contrast, the smooth-wall DSMC and DNS simulations exhibit remarkably good agreement for the statistics examined, despite the Knudsen number based on the viscous length scale being as large as O(10 -1 ). This latter result is at variance with classical estimates for the breakdown of the continuum assumption and calls for further investigations into the interaction of noncontinuum effects and turbulence.

42 ENGINEERING↗

Assessing the coating implications of slurry formulations in NCMA and LFMP blend cathodes for lithium-ion batteries

This paper investigates the implications of slurry formulations and electrode processing on the performance of lithium-ion battery (LIB) cathodes, focusing on Nickel Cobalt Manganese Aluminum (NCMA) and Lithium Ferro Manganese Phosphate (LFMP) blends. Through a comprehensive examination of electrode processing steps, from material selection to coating application, we elucidate the critical role of processing parameters in shaping electrode morphology and electrochemical behavior. Rheological studies reveal the influence of slurry composition on viscosity and flow behavior, highlighting the importance of achieving optimal rheological properties for uniform coating deposition. Electrochemical characterization, including cyclic voltammetry and rate capability tests, unveils the electrochemical behavior of NCMA, LFMP, and their blend, showcasing the synergistic effects of material blending on battery performance. In conclusion, our findings underscore the intricate relationship between slurry formulation, electrode processing, and LIB performance, offering valuable insights for the design and optimization of high-performance electrode materials for next-generation batteries.

25 ENERGY STORAGE↗

Development and Validation of SAM Multi-dimensional Flow Model for Thermal Mixing and Stratification Modeling

Thermal mixing and stratification in large pools or enclosures are very important phenomena that are critical to nuclear reactor safety. Because of the wide ranges of time and length scales associated with such phenomena, accurate modeling and simulation of thermal mixing and stratification remain as the key unresolved, challenging problems for reactor transient analyses. In traditional system analysis codes, simplified zero-dimensional (0-D) models are widely used for their high numerical efficiency, but they generally suffer from very limited prediction accuracies or range of applicability. Like traditional system analysis codes, the current version of the SAM code has implemented such simplified 0-D and one-dimensional mixing models. On the other hand, high-resolution Computational Fluid Dynamics (CFD) tools are often used to model complex thermal mixing and stratification phenomena. They are, however, generally numerically expensive, and they require large amounts of computational resources. It is therefore desirable to implement advanced and efficient thermal mixing and stratification modeling capabilities embedded in a system analysis code. This approach will improve the accuracy of reactor safety analyses when thermal mixing and stratification are involved, and also avoid using the large computational resources needed for high-resolution CFD analysis. Currently, with the support of the U.S. DOE Office of Nuclear Energy’s Nuclear Energy Advanced Modeling and Simulation program, an effort has been launched to develop and implement a multi-dimensional flow model in the system analysis code SAM, and demonstrate its applications to model thermal mixing and stratification phenomena in large enclosures. The main outcomes of this research and development activity are summarized in this report, which presents an attempt to include a built-in advanced multi-dimensional flow model in a system analysis code with the focus on overcoming the simulation challenges of thermal mixing and stratification phenomena. In this report, we start with the introduction of existing SAM code capabilities to simulate thermal mixing and stratification phenomena, which is followed by a short summary of the multi-dimensional model implemented in the SAM code, including both the physical model and the Finite Element Method code implementation. In this study, two options were implemented in the SAM code to model turbulent flows: a relatively simple built-in turbulence model and an interface to accept externally computed turbulent viscosities (e.g., from a high- resolution CFD simulation). Code validation studies on this newly added capability were then carried out to compare SAM simulation results with experimental data from the SUPERCAVNA facility, which was designed to study the complex flow recirculation and thermal stratification phenomena relevant to sodium fast reactor designs. In this study, one transient and two steady-state test cases were used for code validation. Different approaches have been used to model the complex turbulence flow fields in the SUPERCAVNA facility. A highly simplified zero-equation turbulence model was first used, but it was determined that it is too simple to capture the complex turbulence flow fields in these test cases. Subsequently, the code validation continued with the use of turbulent viscosity data from high-resolution STAR-CCM+ CFD simulations to improve the accuracy of the results. Using this approach, the SAM simulation results showed very good agreement with both the SUPERCAVNA experimental data and STAR-CCM+ simulation results. In this report, we demonstrate the development, implementation, and successful validation of a multi-dimensional flow model in the SAM code, which aims to improve the simulation accuracy for complex thermal mixing and stratification phenomena. Lessons have also been learned, including that in cases where the flow fields are not well predicted by the zero-equation model, the iinput of turbulent viscosities from an external source can enhance the overall predictive capabilities needed to accurately capture complex thermal-hydraulic phenomena. Therefore, future research will be needed to further improve the code’s capabilities, such as by developing a more efficient and robust approach to capture the turbulence effects in the SAM code.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Impurity screening behavior of the high-field side scrape-off layer in near-double-null configurations: prospect for mitigating plasma-material interactions on RF actuators and first-wall components

The impurity screening response of the high-field side (HFS) scrape-off layer (SOL) to localized nitrogen injection is investigated on Alcator C-Mod for magnetic equilibria spanning lower-single null, double-null and upper single null configurations under otherwise identical plasma conditions. L-mode, EDA H-mode and I-mode discharges are investigated. HFS impurity screening is found to depend on magnetic flux balance and the direction of B×?B relative to the most active divertor. Impurity ‘plume’ emission patterns indicate that both parallel and perpendicular (E×B) flows in the SOL contribute to the ‘flushing’ of impurities towards the active divertor, thereby affecting the overall impurity screening behavior. Despite the fact that the HFS scrape-off layer is extremely narrow in near-double-null configurations, this SOL is able to screen locally injected nitrogen at least as effectively as the low-field side (LFS) SOL – up to a factor of 10 more effective, depending on specific plasma conditions and whether the magnetic geometry produces parallel flows that work with or against E×B flows. For situations in which the E×B drift of the impurity ions opposes parallel flow toward the primary divertor, HFS impurity screening is found to be least effective. When E×B drifts assist parallel flow toward the primary divertor, HFS impurity screening is found to be very effective. These data support the idea of placing RF actuators and close-fitting wall components on the high-field side of the tokamak. With this configuration, near-double-null magnetic topologies may be used for active control of plasma parameters at the antenna/plasma interface for optimal RF coupling, mitigate the generation of local impurities from plasma-material interactions and, taking advantage of favorable plasma flows and good screening properties of the HFS SOL, further minimize the impact of wall-born impurity sources on the plasma core.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Equations of State in Computational Physics: What, Why, and How

Summary: 1. Equations of state furnish thermodynamic properties of a material. 2. Usually involve P, p (or V), and T, or P, r, and E 3. Necessary ingredient to solve compressible flow problems. 4. Varieties: i. Analytical expressions (ideal gas, Grüneisen) – fast, convenient for verification and test problems ii. Graphs and charts – good for hand calculations iii. Tables and databases – generally most accurate, require interpolation i. Steam tables ii. NIST database iii. SESAME EOS Library 5. Constructed by using semi-empirical models from Statistical Mechanics and fitting to available data

36 MATERIALS SCIENCE↗

Beam Shaping and Oscillation for Metals Additive Manufacturing

Additive Manufacturing (AM) is pivotal for next-generation industrial manufacturing but is hampered by process control challenges leading to unwanted defects and sub-optimal material properties. Our research builds on prior work that utilized beam oscillation techniques to mitigate these issues (Wu et al., 2023). We focus on investigating the influence of beam oscillation frequency on melt pool dynamics, utilizing in-situ synchrotron material characterization from the ESRF (Chen et al., 2026). Preliminary findings indicated that beam oscillation results in unique fluid flow patterns and enhanced melting stability. These findings suggested the possibility of optimized AM process control, including minimized defects and tailored thermal histories. We proposed further research to explore the effects of beam oscillation frequencies comprehensively, using the in-situ characterization capabilities at the ESRF. The goal was to quantify this relationship, offering a pathway to more precise AM process control and optimization. Our research is expected to offer new scientific insights into the fluid mechanics and thermal behaviour in AM, contributing to its broader applicability and commercial viability.

36 MATERIALS SCIENCE↗

What Can Plastic Flow Fields Tell Us About Heat Sources in Deformation Processing?

We characterize primary (shape-change) and secondary (friction) deformation, and associated temperature fields, in metal cutting and forming processes, using in situ imaging and simulation. The experimental configurations enable access to the deformation zones and die contact-interfaces, for measuring deformation, temperature, and frictional drag. Infra-red thermography reveals that the plastic strain-rate field is an excellent proxy for the deformation-induced heat sources. Both spatially confined and diffuse strain-rate fields occur, depending on the initial workpiece deformation state. When the strain rate is confined, as in pre-hardened material, the temperature modeling is much simplified, as the heat source is also now localized. However complex, microstructure-driven deformation modes, like sinuous flow in annealed metals, result in spatially diffuse strain-rate and body heat sources, more challenging to analyze. Furthermore, our unified measurements should be of value for accurately estimating the fraction of plastic dissipation that is converted into heat in large-strain deformation processes.

36 MATERIALS SCIENCE↗

Novel Mechanisms for the Formation of Dislocation Cell Patterns in BCC Metal

In this study, we present the first simulation results of the formation of dislocation cell wall microstructures in tantalum subjected to shock loading. Dislocation patterns and cell wall formation are important to understanding the mechanical properties of the materials in which they spontaneously arise, and yet the processing and self-assembly mechanisms leading to their formation are poorly understood. By employing transmission electron microscopy and discrete dislocation dynamics, we propose a new mechanism involving coplanar dislocations and pseudo-dipole mixed dislocation arrays that is essential to the pattern formation process. Our large-scale 3D DDD simulations demonstrate the self-organization of dislocation networks into cell walls in deformed BCC metal (tantalum) persisting at strain ε = 20%. The simulation analysis captures several crucial aspects of how the dislocation cell pattern affects metal plasticity, as observed in experiments. Although experimental evidence is inconclusive regarding whether cell wall formation takes place at the shock front, after the shock, during release, or when the sample has had enough time to relax post-recovery, our simulations indicate cell wall formation occurs after the shock and before release. The extended Taylor hardening composite model effectively considers the non-uniform dislocation density when cell walls form and accurately describes the corresponding flow stress.

36 MATERIALS SCIENCE↗

Optical transient grating pumped X-ray diffraction microscopy for studying mesoscale structural dynamics

Abstract A fundamental understanding of materials’ structural dynamics, with fine spatial and temporal control, underpins future developments in electronic and quantum materials. Here, we introduce an optical transient grating pump and focused X-ray diffraction probe technique (TGXD) to examine the structural evolution of materials excited by modulated light with a precisely controlled spatial profile. This method adds spatial resolution and direct structural sensitivity to the established utility of a sinusoidal transient-grating excitation. We demonstrate TGXD using two thin-film samples: epitaxial BiFeO 3 , which exhibits a photoinduced strain (structural grating) with an amplitude proportional to the optical fluence, and FeRh, which undergoes a magnetostructural phase transformation. In BiFeO 3 , structural relaxation is location independent, and the strain persists on the order of microseconds, consistent with the optical excitation of long-lived charge carriers. The strain profile of the structural grating in FeRh, in comparison, deviates from the sinusoidal excitation and exhibits both higher-order spatial frequencies and a location-dependent relaxation. The focused X-ray probe provides spatial resolution within the engineered optical excitation profile, resolving the spatiotemporal flow of heat through FeRh locally heated above the phase transition temperature. TGXD successfully characterizes mesoscopic energy transport in functional materials without relying on a specific transport model.

36 MATERIALS SCIENCE↗

Uncoupling Electrokinetic Flow Solutions

The continuum-scale electrokinetic porous-media flow and excess charge redistribution equations are uncoupled using eigenvalue decomposition. The uncoupling results in a pair of independent diffusion equations for “intermediate” potentials subject to modified material properties and boundary conditions. The fluid pressure and electrostatic potential are then found by recombining the solutions to the two intermediate uncoupled problems in a matrix-vector multiplication. Expressions for the material properties or source terms in the intermediate uncoupled problem may require extended precision or careful rewriting to avoid numerical cancellation, but the solutions themselves can typically be computed in double precision. The approach works with analytical or gridded numerical solutions and is illustrated through two examples. The solution for flow to a pumping well is manipulated to predict streaming potential and electroosmosis, and a periodic one-dimensional analytical solution is derived and used to predict electroosmosis and streaming potential in a laboratory flow cell subjected to low frequency alternating current and pressure excitation. The examples illustrate the utility of the eigenvalue decoupling approach, repurposing existing analytical solutions or numerical models and leveraging solutions that are simpler to derive for coupled physics.

58 GEOSCIENCES↗