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At least 1,063 records · Page 59
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Epitaxy of Beta-Ga2O3 on Highly-Offcut (Greater than 10 Degrees) Substrates

Beta-Ga2O3 has emerged as a leading candidate for next-generation power electronics, radio frequency (RF) switches, and extreme environment electronics due to a wide band gap (4.6 - 4.9 eV), high dopability (approximately 40 meV activation energy for an isolated silicon donor), and melt growth characteristics resulting in commercially available 4-inch substrates and commercial demonstrations of 6-inch substrates by multiple techniques. The (100) surface of Ga2O3 is highly desirable from a device and epitaxy standpoint - bulk growth of (100) material is more scalable than (010), the surface is nearly lattice-matched to p-type partner NiO, and Al2O3 incorporates at higher concentrations without phase separation. However, the epitaxial growth rate on (100) surfaces is less than 10% of other faces due to weak bonding and favorable desorption. Recent demonstrations have shown growth rate improvements from 0.4 nm/min to 1.5 nm/min by growing on (100) wafers that are offcut 6 degrees in the -c direction.1 These films show step-flow growth from (-201) step-edges and high electron mobility. Despite these exciting results, offcuts greater than 6 degrees have not been explored due to the waste associated with grinding and polishing large offcuts. In this talk we will discuss the molecular beam epitaxy (MBE) growth and properties of Beta-Ga2O3 grown on (100) substrates offcut in the -c direction up to 13.4 degrees. These large offcuts are enabled by edge-fed film-defined growth (EFG) where the offcut is grown into the surface by pulling the crystal through the EFG die with the seed crystal rotated by the desired offcut angle. We will demonstrate that 13.4 degrees offcut substrates still exhibit a terraced (100) surface, and that a >10x increase (4.8 nm/min) in growth rate is achieved. As previously reported on lower offcuts, we observe 100% reversal of substrate twin domains around the (001) direction at the substrate-epilayer interface. We will discuss electrical properties including record-low (by MBE) unintentional doping densities of < 5E15 cm-3.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials using MALAMUTE

The Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy aims to develop and qualify additively manufactured materials for nuclear applications. One key challenge to this is the microstructural variability observed in the additively manufactured products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-throughput experimental and modeling techniques to accelerate qualification. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the additive manufacturing process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture microstructural variability is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning models to develop a digital twin for additive manufacturing that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation. The melting and subsequent solidification that occurs during the additive process is a complex phenomenon that requires multiscale multiphysics analysis. This work package focuses on understanding the role of process variabilities on the unique microstructural characteristics of additively manufactured materials. Microstructural features at the subgrain level, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. Idaho National Laboratory’s Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for additively manufactured materials in an efficient, reliable, and cost-effective way. This work focuses on capturing the microstructural variabilities at the subgrain level that are often missing in the part-scale models. In fiscal year 2025, we significantly advanced upon our work in the last fiscal year, in terms of the predictive capabilities of the physics-based and ML models, by adding the capabilities to capture subgrain-level micro-segregation during solidification using phase-field model and to predict the time-dependent dynamics of the AM process through the MOGPAR model. The alloy solidification model in MOOSE incorporates the thermodynamic properties and free energy relevant to 316 stainless steel. The model demonstrates the Cr and Ni segregation that occurs during solidification, including that the rate of solidification. The microstructural evolution model is connected to the process conditions via the surrogate model developed in this work. This enables predictions of the final microstructure in conjunctions with the manufacturing process. This work supports AMMT's rapid qualification goals by laying the foundation for an efficient and cost-effective model establishing the PSPP correlation for AM. The generated microstructures and predicted micro-segregation can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work helps to identify the key microstructural features at the subgrain level that are significant in property and performance predictions of additively manufactured components. This work will also provide inputs to the large-scale process variability models to reevaluate and validate assumptions and simplifications made in the part-scale models. Furthermore, through active learning this work can help identify the data need from both modeling and experimental sides for development of a robust digital twin for additive manufacturing and accelerate the AMMT's qualification efforts.

36 - MATERIALS SCIENCE↗
DOE OSTI2023

An Assessment of the Laminar Hypersonic Double-Cone Experiments in the LENS-XX Tunnel

This is an investigation on two experimental datasets of laminar hypersonic flows, over a double-cone geometry, acquired in Calspan—University at Buffalo Research Center’s Large Energy National Shock (LENS)-XX expansion tunnel. These datasets have yet to be modeled accurately. A previous paper suggested that this could partly be due to mis-specified inlet conditions. The authors of this paper solved a Bayesian inverse problem to infer the inlet conditions of the LENS-XX test section and found that in one case they lay outside the uncertainty bounds specified in the experimental dataset. However, the inference was performed using approximate surrogate models. Here in this paper, the experimental datasets are revisited and inversions for the tunnel test-section inlet conditions are performed with a Navier–Stokes simulator. The inversion is deterministic and can provide uncertainty bounds on the inlet conditions under a Gaussian assumption. It was found that deterministic inversion yields inlet conditions that do not agree with what was stated in the experiments. An a posteriori method is also presented to check the validity of the Gaussian assumption for the posterior distribution. This paper contributes to ongoing work on the assessment of datasets from challenging experiments conducted in extreme environments, where the experimental apparatus is pushed to the margins of its design and performance envelopes.

42 ENGINEERING↗
DOE OSTI2016

Assembly, Test and Launch Operations for a Nuclear-enabled NASA Mission: Considerations that are Specific to Use of a Nuclear Payload

For more than five decades, Radioisotope Power Systems (RPS) have played a critical role in the exploration of space, enabling missions of scientific discovery to destinations across the solar system by providing electrical power to explore remote, challenging and extreme environments. In particular, RPS enable deep space missions where increased heliocentric distances reduce the ability of solar power to adequately meet spacecraft and instruments power requirements. Some previous notable missions that were enabled by RPS include Nimbus III, the Apollo Surface Experiments, the Pioneers 10 and 11, the Viking Mars Landers, Galileo, Ulysses, Cassini, New Horizons and Curiosity. The current operating set of missions that are enabled by RPS are Voyagers 1 and 2, Cassini, New Horizons, and Curiosity. The Multi-Mission Radioisotope Thermal Generator (MMRTG) is the current RPS used for missions. An enhanced version of this generator outfitted with higher efficiency thermoelectrics is under development for potential use in the future. Other previously deployed power systems include the Multi-hundred Watt Radisotope Thermo-electric Generator (MHW RTG) and the General Purpose Heat Source Radisotope Thermo-electric Generator (GPHS RTG). The common thread for all of these power systems is that they are fueled with Pu-238. The use of this unique isotope involves additional planning activities and requires specific actions when the devices are delivered to Kennedy Space Center (KSC), launch site, and incorporated into the assembly, test and launch operations (ATLO) process to ensure mission success, met safety and security challenges. It has been forecasted that the use of a nuclear reactor system is on the horizon. This system could be used for either specifically powering S/C propulsion system or for surface power use once the mission arrived at its destina-tion. Since a nuclear-fission-based system has never been handled or integrated into a spacecraft at KSC, this nuclear reactor system would potentially require further challenges that must be accounted for in the ATLO process. This paper will explain ATLO considerations for the recent RTG-enabled launches that have occurred and planned in the near future (Mars 2020 NASA mission). It will also describe where further challenges that need to be met for the placement of a nuclear reactor (either for propulsion or transportation for surface power use) onto a space mission. Specifically, the following topics will be addressed: • Approach for nuclear safety planning for nuclear material use and its transportation to launch site • Planning for security posture for nuclear materials at launch site • Preparation for transportation of the nuclear power system from the fueling/testing location to the launch site • Preparation of documentation and procedures for nuclear material use at launch site • Planning for coordination between power system and space mission groups • Planning for appropriate staffing and scheduling of operations

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2018

Radioisotope Power Systems: Considerations for use of Dynamic versus Static Conversion Technologies for NASA Missions

For more than five decades, Radioisotope Power Systems (RPS) have played a critical role in the exploration of space, enabling missions of scientific discovery to destinations across the solar system by providing electrical power to explore remote, challenging and extreme environments. In particular, RPS enable deep space missions where increased heliocentric distances reduce the ability of solar power to adequately meet spacecraft and instruments power requirements. Some previous notable missions that were enabled by RPS include Nimbus III, the Apollo Sur-face Experiments, the Pioneers 10 and 11, the Viking Mars Landers, Galileo, Ulysses, Cassini, New Horizons and Curiosity. The current operating set of missions that are enabled by RPS are Voyagers 1 and 2, Cassini, New Hori-zons, and Curiosity. The Multi-Mission Radioisotope Thermal Generator (MMRTG) is the current RPS used for mis-sions. An enhanced version of this generator outfitted with higher efficiency thermoelectrics is under development for potential use in the future. There are also current development efforts underway by NASA to explore dynamic power conversion systems such as Brayton and Stirling. This paper will compare and contrast the pros and cons of a generalized dynamic system with the current state-of-the-art thermoelectric static conversion system. The reason for this paper is to calmly analyze the pros and cons so that all the pertinent factors are placed under the same examination light with equal brightness. As with any purchase made the “newness” of certain items sometimes overrides a needed desire to fully vet all characteristics of the merchandise so that the best choice is made. The following areas will be specifically examined and discussed as they may impact the choice of radioisotope power system for a specific mission: • Projected power output to weight ratio (We/kg) • Amount of Pu-238 required per a fixed power output • Excess heat available to be rejected or used • Fueling operations during assembly by the Department of Energy (DOE) • Planetary protection protocol during fueling and testing of RPS • Transportation operations from DOE assembly site to Kennedy Space Center (KSC) • Remote operations at KSC prior to launch during Assembly Test and Launch Operations (ATLO) phase o Timing of the placement of the RPS onto spacecraft/rover o Off-normal operations at KSC

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2012

Genetic manipulation of Methanosarcina spp.

The discovery of the third domain of life, the Archaea, is one of the most exciting findings of the last century. These remarkable prokaryotes are well known for their adaptations to extreme environments; however, Archaea have also conquered moderate environments. Many of the archaeal biochemical processes, such as methane production, are unique in nature and therefore of great scientific interest. Although formerly restricted to biochemical and physiological studies, sophisticated systems for genetic manipulation have been developed during the last two decades for methanogenic archaea, halophilic archaea and thermophilic, sulfur-metabolizing archaea. The availability of these tools has allowed for more complete studies of archaeal physiology and metabolism and most importantly provides the basis for the investigation of gene expression, regulation and function. In this review we provide an overview of methods for genetic manipulation of Methanosarcina spp., a group of methanogenic archaea that are key players in the global carbon cycle and which can be found in a variety of anaerobic environments.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2014

Phylogeny and phylogeography of functional genes shared among seven terrestrial subsurface metagenomes reveal N-cycling and microbial evolutionary relationships

Comparative studies on community phylogenetics and phylogeography of microorganisms living in extreme environments are rare. Terrestrial subsurface habitats are valuable for studying microbial biogeographical patterns due to their isolation and the restricted dispersal mechanisms. Since the taxonomic identity of a microorganism does not always correspond well with its functional role in a particular community, the use of taxonomic assignments or patterns may give limited inference on how microbial functions are affected by historical, geographical and environmental factors. With seven metagenomic libraries generated from fracture water samples collected from five South African mines, this study was carried out to (1) screen for ubiquitous functions or pathways of biogeochemical cycling of CH 4 , S, and N; (2) to characterize the biodiversity represented by the common functional genes; (3) to investigate the subsurface biogeography as revealed by this subset of genes; and (4) to explore the possibility of using metagenomic data for evolutionary study. The ubiquitous functional genes are NarV, NPD, PAPS reductase, NifH, NifD, NifK, NifE, and NifN genes. Although these eight common functional genes were taxonomically and phylogenetically diverse and distinct from each other, the dissimilarity between samples did not correlate strongly with geographical or environmental parameters or residence time of the water. Por genes homologous to those of Thermodesulfovibrio yellowstonii detected in all metagenomes were deep lineages of Nitrospirae, suggesting that subsurface habitats have preserved ancestral genetic signatures that inform the study of the origin and evolution of prokaryotes.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Unconventional genetic code systems in archaea

Archaea constitute the third domain of life, distinct from bacteria and eukaryotes given their ability to tolerate extreme environments. To survive these harsh conditions, certain archaeal lineages possess unique genetic code systems to encode either selenocysteine or pyrrolysine, rare amino acids not found in all organisms. Furthermore, archaea utilize alternate tRNA-dependent pathways to biosynthesize and incorporate members of the 20 canonical amino acids. Recent discoveries of new archaeal species have revealed the co-occurrence of these genetic code systems within a single lineage. This review discusses the diverse genetic code systems of archaea, while detailing the associated biochemical elements and molecular mechanisms.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Insights into the physiological and genomic characterization of three bacterial isolates from a highly alkaline, terrestrial serpentinizing system

The terrestrial serpentinite-hosted ecosystem known as “The Cedars” is home to a diverse microbial community persisting under highly alkaline (pH ~ 12) and reducing (Eh < -550 mV) conditions. This extreme environment presents particular difficulties for microbial life, and efforts to isolate microorganisms from The Cedars over the past decade have remained challenging. Herein, we report the initial physiological assessment and/or full genomic characterization of three isolates: Paenibacillus sp. Cedars (‘Paeni-Cedars’), Alishewanella sp. BS5-314 (‘Ali-BS5-314’), and Anaerobacillus sp. CMMVII (‘Anaero-CMMVII’). Paeni-Cedars is a Gram-positive, rod-shaped, mesophilic facultative anaerobe that grows between pH 7–10 (minimum pH tested was 7), temperatures 20–40°C, and 0–3% NaCl concentration. The addition of 10–20 mM CaCl 2 enhanced growth, and iron reduction was observed in the following order, 2-line ferrihydrite > magnetite > serpentinite ~ chromite ~ hematite. Genome analysis identified genes for flavin-mediated iron reduction and synthesis of a bacillibactin-like, catechol-type siderophore. Ali-BS5-314 is a Gram-negative, rod-shaped, mesophilic, facultative anaerobic alkaliphile that grows between pH 10–12 and temperatures 10–40°C, with limited growth observed 1–5% NaCl. Nitrate is used as a terminal electron acceptor under anaerobic conditions, which was corroborated by genome analysis. The Ali-BS5-314 genome also includes genes for benzoate-like compound metabolism. Anaero-CMMVII remained difficult to cultivate for physiological studies; however, growth was observed between pH 9–12, with the addition of 0.01–1% yeast extract. Anaero-CMMVII is a probable oxygen-tolerant anaerobic alkaliphile with hydrogenotrophic respiration coupled with nitrate reduction, as determined by genome analysis. Based on single-copy genes, ANI, AAI and dDDH analyses, Paeni-Cedars and Ali-BS5-314 are related to other species (P. glucanolyticus and A. aestuarii, respectively), and Anaero-CMMVII represents a new species. The characterization of these three isolates demonstrate the range of ecophysiological adaptations and metabolisms present in serpentinite-hosted ecosystems, including mineral reduction, alkaliphily, and siderophore production.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2019

Making BREAD: Biomimetic Strategies for Artificial Intelligence Now and in the Future

The Artificial Intelligence (AI) revolution foretold of during the 1960s is well underway in the second decade of the twenty first century. Its period of phenomenal growth likely lies ahead. AI-operated machines and technologies will extend the reach of Homo sapiens far beyond the biological constraints imposed by evolution: outwards further into deep space, as well as inwards into the nano-world of DNA sequences and relevant medical applications. And yet, we believe, there are crucial lessons that biology can offer that will enable a prosperous future for AI. For machines in general, and for AI's especially, operating over extended periods or in extreme environments will require energy usage orders of magnitudes more efficient than exists today. In many operational environments, energy sources will be constrained. The AI's design and function may be dependent upon the type of energy source, as well as its availability and accessibility. Any plans for AI devices operating in a challenging environment must begin with the question of how they are powered, where fuel is located, how energy is stored and made available to the machine, and how long the machine can operate on specific energy units. While one of the key advantages of AI use is to reduce the dimensionality of a complex problem, the fact remains that some energy is required for functionality. Hence, the materials and technologies that provide the needed energy represent a critical challenge toward future use scenarios of AI and should be integrated into their design. Here we look to the brain and other aspects of biology as inspiration for Biomimetic Research for Energy-efficient AI Designs (BREAD).

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Redox and Thiols in Archaea

Low molecular weight (LMW) thiols have many functions in bacteria and eukarya, ranging from redox homeostasis to acting as cofactors in numerous reactions, including detoxification of xenobiotic compounds. The LMW thiol, glutathione (GSH), is found in eukaryotes and many species of bacteria. Analogues of GSH include the structurally different LMW thiols: bacillithiol, mycothiol, ergothioneine, and coenzyme A. Many advances have been made in understanding the diverse and multiple functions of GSH and GSH analogues in bacteria but much less is known about distribution and functions of GSH and its analogues in archaea, which constitute the third domain of life, occupying many niches, including those in extreme environments. Archaea are able to use many energy sources and have many unique metabolic reactions and as a result are major contributors to geochemical cycles. As LMW thiols are major players in cells, this review explores the distribution of thiols and their biochemistry in archaea.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

Single Mode Air-Clad Single Crystal Sapphire Optical Fiber

The observation of single mode propagation in an air-clad single crystal sapphire optical fiber at wavelengths at and above 783 nm is presented for the first time. A high-temperature wet acid etching method was used to reduce the diameter of a 10 cm length of commercially-sourced sapphire fiber from 125 micrometers to 6.5 micrometers, and far-field imaging provided modal information at intervals as the fiber diameter decreased. Modal volume was shown to decrease with decreasing diameter, and single mode behavior was observed at the minimum diameter achieved. While weakly-guiding approximations are generally inaccurate for low modal volume optical fiber with high core-cladding refractive index disparity, consistency between these approximations and experimental results was observed when the effective numerical aperture was measured and substituted for the theoretical numerical aperture in weakly-guiding approximation calculations. With the demonstration of very low modal volume in sapphire at fiber diameters much larger than anticipated by legacy calculations, the resolution of sapphire fiber distributed sensors may be increased and other sensing schemes requiring very low modal volume, such as fiber Bragg gratings, may be realized in extreme environment applications.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Elevated-Temperature Tribo-Corrosion Response of Eutectic High-Entropy Alloy

The combination of elevated temperature and tribo-corrosion leads to the accelerated degradation of structural components used in many extreme environments. Recently developed high-entropy alloys (HEAs) with multiple principal elements have the potential for superior degradation resistance compared with presently used structural alloys. Here, we demonstrate the microstructural stability, pitting resistance, and superior tribo-corrosion degradation resistance of the AlCoCrFeNi 2.1 eutectic HEA in comparison with duplex stainless steel 2205 in deionized water (controlled low-ionic-strength electrolyte) at 25 °C, 50 °C and 100 °C. The AlCoCrFeNi 2.1 HEA showed excellent microstructural stability and tribo-corrosion resistance at all three temperatures, an order-of-magnitude lower wear rate, and a lower coefficient of friction compared with duplex 2205 steel. The lowest wear volume loss and wear rate for both AlCoCrFeNi 2.1 and duplex steel were recorded at 50 °C, which was attributed to temperature-assisted passivation and formation of a comparatively stable tribological surface condition. These results suggest superior performance of eutectic HEAs in tribo-corrosion applications compared with currently used dual-phase steels and motivate future evaluation in ion-containing industrial water chemistries.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Shed Light in the DaRk LineagES of the Fungal Tree of Life—STRES

The polyphyletic group of black fungi within the Ascomycota (Arthoniomycetes, Dothideomycetes, and Eurotiomycetes) is ubiquitous in natural and anthropogenic habitats. Partly because of their dark, melanin-based pigmentation, black fungi are resistant to stresses including UV- and ionizing-radiation, heat and desiccation, toxic metals, and organic pollutants. Consequently, they are amongst the most stunning extremophiles and poly-extreme-tolerant organisms on Earth. Even though ca. 60 black fungal genomes have been sequenced to date, [mostly in the family Herpotrichiellaceae (Eurotiomycetes)], the class Dothideomycetes that hosts the largest majority of extremophiles has only been sparsely sampled. By sequencing up to 92 species that will become reference genomes, the “Shed light in The daRk lineagES of the fungal tree of life” (STRES) project will cover a broad collection of black fungal diversity spread throughout the Fungal Tree of Life. Interestingly, the STRES project will focus on mostly unsampled genera that display different ecologies and life-styles (e.g., ant- and lichen-associated fungi, rock-inhabiting fungi, etc.). With a resequencing strategy of 10- to 15-fold depth coverage of up to ~550 strains, numerous new reference genomes will be established. To identify metabolites and functional processes, these new genomic resources will be enriched with metabolomics analyses coupled with transcriptomics experiments on selected species under various stress conditions (salinity, dryness, UV radiation, oligotrophy). The data acquired will serve as a reference and foundation for establishing an encyclopedic database for fungal metagenomics as well as the biology, evolution, and ecology of the fungi in extreme environments.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

Experimental and Computational Studies on Superhard Material Rhenium Diboride under Ultrahigh Pressures

An emerging class of superhard materials for extreme environment applications are compounds formed by heavy transition metals with light elements. In this work, ultrahigh pressure experiments on transition metal rhenium diboride (ReB 2 ) were carried out in a diamond anvil cell under isothermal and non-hydrostatic compression. Two independent high-pressure experiments were carried out on ReB 2 for the first time up to a pressure of 241 GPa (volume compression V/V 0 = 0.731 ± 0.004), with platinum as an internal pressure standard in X-ray diffraction studies. The hexagonal phase of ReB 2 was stable under highest pressure, and the anisotropy between the a-axis and c-axis compression increases with pressure to 241 GPa. The measured equation of state (EOS) above the yield stress of ReB 2 is well represented by the bulk modulus K 0 = 364 GPa and its first pressure derivative K 0 ´ = 3.53. Corresponding density-functional-theory (DFT) simulations of the EOS and elastic constants agreed well with the experimental data. DFT results indicated that ReB 2 becomes more ductile with enhanced tendency towards metallic bonding under compression. The DFT results also showed strong crystal anisotropy up to the maximum pressure under study. The pressure-enhanced electron density distribution along the Re and B bond direction renders the material highly incompressible along the c-axis. Our study helps to establish the fundamental basis for anisotropic compression of ReB 2 under ultrahigh pressures

36 MATERIALS SCIENCE↗
DOE OSTI2024

Theoretical Prediction of Thermal Expansion Anisotropy for Y 2 Si 2 O 7 Environmental Barrier Coatings Using a Deep Neural Network Potential and Comparison to Experiment

Environmental barrier coatings (EBCs) are an enabling technology for silicon carbide (SiC)-based ceramic matrix composites (CMCs) in extreme environments such as gas turbine engines. However, the development of new coating systems is hindered by the large design space and difficulty in predicting the properties for these materials. Density Functional Theory (DFT) has successfully been used to model and predict some thermodynamic and thermo-mechanical properties of high-temperature ceramics for EBCs, although these calculations are challenging due to their high computational costs. In this work, we use machine learning to train a deep neural network potential (DNP) for Y 2 Si 2 O 7 , which is then applied to calculate the thermodynamic and thermo-mechanical properties at near-DFT accuracy much faster and using less computational resources than DFT. We use this DNP to predict the phonon-based thermodynamic properties of Y 2 Si 2 O 7 with good agreement to DFT and experiments. We also utilize the DNP to calculate the anisotropic, lattice direction-dependent coefficients of thermal expansion (CTEs) for Y 2 Si 2 O 7 . Molecular dynamics trajectories using the DNP correctly demonstrate the accurate prediction of the anisotropy of the CTE in good agreement with the diffraction experiments. In the future, this DNP could be applied to accelerate additional property calculations for Y 2 Si 2 O 7 compared to DFT or experiments.

36 MATERIALS SCIENCE↗
DOE OSTI2024

LPBF Processability of NiTiHf Alloys: Systematic Modeling and Single-Track Studies

Research into the processability of NiTiHf high-temperature shape memory alloys (HTSMAs) via laser powder bed fusion (LPBF) is limited; nevertheless, these alloys show promise for applications in extreme environments. This study aims to address this limitation by investigating the printability of four NiTiHf alloys with varying Hf content (1, 2, 15, and 20 at. %) to assess their suitability for LPBF applications. Solidification cracking is one of the main limiting factors in LPBF processes, which occurs during the final stage of solidification. To investigate the effect of alloy composition on printability, this study focuses on this defect via a combination of computational modeling and experimental validation. To this end, solidification cracking susceptibility is calculated as Kou’s index and Scheil–Gulliver model, implemented in Thermo-Calc/2022a software. An innovative powder-free experimental method through laser remelting was conducted on bare NiTiHf ingots to validate the parameter impacts of the LPBF process. The result is the processability window with no cracking likelihood under diverse LPBF conditions, including laser power and scan speed. This comprehensive investigation enhances our understanding of the processability challenges and opportunities for NiTiHf HTSMAs in advanced engineering applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Microstructural Transitions during Powder Metallurgical Processing of Solute Stabilized Nanostructured Tungsten Alloys

Exploiting grain boundary engineering in the design of alloys for extreme environments provides a promising pathway for enhancing performance relative to coarse-grained counterparts. Due to its attractive properties as a plasma facing material for fusion devices, tungsten presents an opportunity to exploit this approach in addressing the significant materials challenges imposed by the fusion environment. Here, we employ a ternary alloy design approach for stabilizing W against recrystallization and grain growth while simultaneously enhancing its manufacturability through powder metallurgical processing. Mechanical alloying and grain refinement in W-10 at.% Ti-(10,20) at.% Cr alloys are accomplished through high-energy ball milling with transitions in the microstructure mapped as a function of milling time. We demonstrate the multi-modal nature of the resulting nanocrystalline grain structure and its stability up to 1300 °C with the coarser grain size population correlated to transitions in crystallographic texture that result from the preferred slip systems in BCC W. Field-assisted sintering is employed to consolidate the alloy powders into bulk samples, which, due to the deliberately designed compositional features, are shown to retain ultrafine grain structures despite the presence of minor carbides formed during sintering due to carbon impurities in the ball-milled powders.

36 MATERIALS SCIENCE↗