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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Condensers and electronic assemblies

Provided is a condenser for use in an electronic assembly. The condenser includes a first vertical wall extending in a vertical direction, the first vertical wall defining a first plurality of vertical condensation channels within the first vertical wall, a second vertical wall extending in the vertical direction, the second vertical wall defining a second plurality of vertical condensation channels within the second vertical wall, and a first plurality of fins extending in the vertical direction, each of the first plurality of fins connected to the first vertical wall, the second vertical wall or both the first vertical wall and the second vertical wall.

Cousineau, Emily↗
DOE OSTI2024

Coated boron layers by boronization and a real-time boron coating using impurity powder dropper in LHD

In Large Helical Device (LHD), diborane (B 2 H 6 ) is used as a standard boron source for boronization, which is assisted by helium glow discharges. In 2019, a new Impurity Powder Dropper (IPD) system has been installed and is under evaluation as a real-time wall conditioning technique. In LHD), which is a large size heliotron device, an additional helium (He) glow discharge cleaning (GDC) after boronization has been operated for a reduction of hydrogen recycling from coated boron layers, and this operational time of 3 h was determined by spectroscopic data during glow discharges. A flat hydrogen profile is obtained on the top surface of coated boron on the specimen exposed to boronization, the result suggests a reduction of hydrogen at the top surface by He-GDC. Trapped oxygen in coated boron was obtained by boronization, and the coated boron, which has boron-oxide, on the first wall by B-IPD was also shown. Finally, considering the difference in coating areas between B 2 H 6 boronization and B-IPD operation, it would be most effective to use the IPD and B 2 H 6 boronization coating together for optimized wall conditioning.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Impact of Resonant Magnetic Perturbations on the Toroidal Location of the Runaway Electron Final Loss Strike Point

It is demonstrated that the peak toroidal impact phase of the post-disruption runaway electrons (REs) can be varied shot-to-shot by means of applied static non-axisymmetric (3D) magnetic fields, or resonant magnetic perturbations (RMPs). In the experiments, high-current (500 kA), purged RE plateaus (i.e. low impurity post-disruption plasmas with current carried completely by REs) were terminated on the DIII-D tokamak center post (CP). The global toroidal impact peak of the REs appears to be dominantly set by the toroidal phase of a wall-locked tearing mode, typically (m/n) = (2/1), but sometimes (m/n) = (3/2). In the absence of external RMP, the locked mode reliably locks close to a preferred toroidal phase Φ ≃ 75◦ probably set by intrinsic error fields. With applied RMP, the locked mode and RE impact phase is pushed to a new location. When the tearing mode is (m/n) = (2/1), the phase is well controlled and tracks the applied RMP phase, but in the case of an (m/n) = (3/2) tearing mode, the new phase location is not well controlled. These results could have application in ITER and other fusion power plant (FPP) - sized tokamaks as a method for spreading disruption first wall damage from REs

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Glow Discharge Boronization and Real-Time Boronization Using an Impurity Powder Dropper in LHD

In the Large Helical Device (LHD), boronization is utilized for wall conditioning, employing two distinct methods: glow discharge using diborane gas and the injection of boron powder into the plasma via an impurity powder dropper (IPD). Glow discharge boronization is conducted after maintenance when the vacuum vessel is exposed to air and just before the start of an experimental campaign. In contrast, real-time boronization using the IPD is performed during discharges. The distribution of boron on plasma-facing components was assessed through long-term material probes in the case of glow discharge and through numerical simulations for the IPD method. Results indicated non-uniform boron distributions in both cases. The impact of these boronization techniques on impurity levels and the lifetime of their effects were also examined. Both methods effectively reduced oxygen and iron in the plasma, with the iron impurities originating from the first wall. For glow discharge boronization, the reduction in oxygen levels persisted until the end of the experimental campaign, whereas the reduction in iron levels only lasted a few days. In the case of boron injection during long pulse discharges exceeding 200 s, the suppression of oxygen and iron was observed. The effect on iron quickly diminished within several seconds after the injection ended, whereas the effect on oxygen lasted more than 100 s. The difference in the lifetimes of the boronization effects is further discussed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Feasibility of fusion plasma burn control via real-time, sub-divertor neutral gas isotopic and compositional analysis

The ability to provide fusion burn control without requiring physical access through the first wall and fuel breeding blankets, would be vital for any future, magnetically confined fusion power reactor. A multi-sensor, fusion fuel cycle exhaust, neutral gas analysis system on JET, capable of delivering real time data, and accessing only the sub-divertor region, provides an excellent example of such capability. Optimized for and operated during the deuterium–tritium experimental campaigns 2 and 3 (DTE2, DTE3), it is proving valuable for planning to explore fusion reactor burn control in ITER with a comparable diagnostic system called the Diagnostic Residual Gas Analyzer (DRGA). This paper aims to show feasibility of developing model-based controllers for ITER and next generation, reactor-relevant devices, by building both on the empirical experience in JET-DTE2, and on the already emerging experience on developing such models specifically for ITER. The paper begins with a specific use-case from JET-DTE2, pertaining to the observed sensitivity of the fusion neutron yield on the concentration of isotopic helium-3 ( 3 He), with data from one of the high-performance DT shots exhibited with emphasis on the 3 He measurement via the sub-divertor. Then, a first model is developed and then explored with simulations that aim to discover how well the controllers in the model react to either insufficient levels of 3 He or excessive levels of 3 He. The simulations then explore potential impact from a delay in the measurement (or the response) that would be comparable to the ∼1 s, conductance limited response for the ITER DRGA system, currently in its final design. The simulations show that control is feasible, and that its effectiveness is not significantly impacted by such delay.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Investigating the role of edge neutrals in exciting tearing mode activity and achieving flat temperature profiles in LTX-β

Abstract We present observations, numerical simulations, and analysis from experiments in the Lithium Tokamak Experiment-Beta (LTX- β ) in which the electron temperature profile ( T e ( r )) shifts from flat to peaked and a tearing mode is also destabilized when the average density ( n e ave ) exceeds ∼10 19 m −3 . Flat T e ( r ) is obtained routinely in LTX- β , with a lithium coated, low-recycling first wall, once the external fueling is stopped and density decays [Boyle et al 2023 Nucl. Fusion 63 056020]. In the present experiment, flat T e profiles can be sustained while maintaining constant n e ave below a line averaged density threshold ( n e ave th ) of ∼10 19 m −3 . Above n e ave th , T e ( r ) shifts from flat to peaked and a tearing mode is destabilized. Due to low recycling, the achieved n e ave can be controlled precisely by external fueling and hence, a certain threshold of the edge neutral inventory from the external fueling is experimentally manifested through n e ave th . The goal of the present work is to investigate the role of edge neutrals in determining T e ( r ) and MHD stability in the unique low-recycling regime of LTX- β . Our hypothesis is that the peaking of T e ( r ) beyond n e ave th is due ultimately to the edge cooling by the cold neutrals beyond a critical fueling flux. At lower fueling flux, flat T e ( r ) results in broader pressure profile and lower resistivity, which in turn stabilizes the tearing mode. This hypothesis is supported by edge neutral density estimation by DEGAS 2 code. Mode analysis by singular value decomposition confirms the tearing mode structure to be m / n = 2/1 ( m and n being the poloidal and toroidal mode numbers). Linear tearing stability analysis with M3D-C1 predicts that plasmas with n e ave > 10 19 are highly susceptible to a n = 1 tearing mode. ORBIT simulations, however, confirmed that the tearing modes do not contribute to the loss of fast ions from neutral beam injection. This study shows for the first time that the neutral inventory at the edge could be one of the deciding factors for the achievability of the unique operation regime of flat T e ( r ) and the excitation of tearing activity that could be disruptive for the plasmas.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Optimising Foil Selection for Neutron Activation Systems

Abstract Neutron spectrum unfolding using activation foils is currently the primary technique planned for measuring the neutron energy spectrum at the first wall of power-generating fusion reactors. Room for improvement in the effectiveness of current foil selection was identified, and a program produced to select foils procedurally in order to maximise the accuracy of the unfolding procedure. Using Kullback–Leibler Divergence to quantify the accuracy, the spectrum unfolded by the procedurally selected set of foils is found to be more accurate than the spectrum unfolded by a set of foils used in the literature.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Nanoscale lattice strains in self-ion implanted tungsten

Developing a comprehensive understanding of the modification of material properties by neutron irradiation is important for the design of future fission and fusion power reactors. Self-ion implantation is commonly used to mimic neutron irradiation damage, however an interesting question concerns the effect of ion energy on the resulting damage structures. The reduction in the thickness of the implanted layer as the implantation energy is reduced results in the significant quandary: Does one attempt to match the primary knock-on atom energy produced during neutron irradiation or implant at a much higher energy, such that a thicker damage layer is produced? In this work, we address this question by measuring the full strain tensor for two ion implantation energies, 2 MeV and 20 MeV in self-ion implanted tungsten, a critical material for the first wall and divertor of fusion reactors. A comparison of 2 MeV and 20 MeV implanted samples is shown to result in similar lattice swelling. Multi-reflection Bragg coherent diffractive imaging (MBCDI) shows that implantation induced strain is in fact heterogeneous at the nanoscale, suggesting that there is a non-uniform distribution of defects, an observation that is not fully captured by micro-beam Laue diffraction. At the surface, MBCDI and high-resolution electron back-scattered diffraction (HR-EBSD) strain measurements agree quite well in terms of this clustering/non-uniformity of the strain distribution. However, MBCDI reveals that the heterogeneity at greater depths in the sample is much larger than at the surface. This combination of techniques provides a powerful method for detailed investigation of the microstructural damage caused by ion bombardment, and more generally of strain related phenomena in micro-volumes that are inaccessible via any other technique.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Be Surface Structures on W(110) and W(211): A DFT Study

Beryllium and Tungsten are promising candidates for use as plasma facing materials (PFMs) in upcoming fusion reactors. Many complex and competing phenomena however complicate the understanding and development of materials that operate in the harsh conditions of the reactor. In particular, redeposition of Be onto the W divertor must be considered due to the expected erosion of the Be first wall under exposure to the plasma. It is known that a build up of Be on W allows for the formation of BeW alloys which can harm the longevity and performance of the fusion divertor. In an effort to understand the interaction of Be with W surfaces, a study of Be structures on W(110) and W(211) as a function of Be coverage has been carried out using Density Functional Theory. We have found that both W surfaces develop monolayers of Be characterized by a densely packed hexagonal structure. Below this monolayer coverage, Be structures are found to have two motifs of coverage, a densely packed hexagonal pattern punctuated by areas of low-density coverage. The structures found here produce work function values and trends in good agreement with experimental measurements.

36 MATERIALS SCIENCE↗
DOE OSTI2021

The development of a Sustained High Power Density (SHPD) facility

A Sustained High Power Density (SHPD) facility is being planned within the U.S. as a non DT device which can be a bridge to a Compact Fusion Pilot Plant (CFPP) DT operated facility with the future capacity to produce a levelised cost of electricity at a rate competitive with current power generating systems. To accomplish this a review of ITER cost data and recent next step physics/engineering studies that promoted technology development, physics enhancements and innovated configuration improvements that increase operating availability have been injected into a proposed PPPL SHPD design. Much of the physics and engineering design basis for this effort centers on a series of ST studies carried out in recent years attempting to maximize the low aspect ratio (AR) ST performance within realistic engineering constraints of this compact fusion device. One issue found in the low AR design is the lack of volt-seconds generated by a small central solenoid that resides in the available space left after sizing the TF structure to support the high current density/HTS TF coil. Although not required in a larger pilot plant device, a solenoid wrapped around the plasma side of the SC TF coil was considered for the small low aspect ratio SHPD device. Adding a solenoid to the plasma side of the TF imposes a major change to the device configuration – a change which has been found to have cost and assembly issues when compared with an OH solenoid located at the machine center. Finally, the inclusion of a liquid metal first wall divertor system, the integration of local pairs of outboard DCLL blanket segments and a summary of physics performance conditions will be presented.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Design and engineering challenges of a multi-energy hard x-ray camera for long-pulse profile measurements at WEST tokamak

The WEST tokamak has recently been prepared for long pulse operation with a water-cooled full first wall. Heating is provided by radiofrequency systems, including Lower Hybrid Current Drive (LHCD). The Princeton Plasma Physics Laboratory has developed a multi-energy hard x-ray camera for profile measurements at WEST. The camera is based on a new generation of 2D pixel array detectors that allow the energy threshold to be independently set for each pixel. The diagnostic will provide spatial, temporal and energy resolved measurements of the hard x-ray emission from the full plasma cross-section, investigating several physical quantities such as the electron temperature from continuum emission, the fast electron tail density produced by radiofrequency current drive and runaway electrons, as well as characteristic tungsten x-rays due to beam-target emission at the edge. Overall, this work describes the engineering challenges that the WEST long pulse scenario poses for this diagnostic and how the design addresses and solves them. Vacuum, thermal stress and heat transfer calculations are presented and discussed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Steady state thermo-mechanics and material property definition framework for analyzing DCLL blanket in the fusion nuclear science facility

In this work, a thermo-mechanics model that relies on creating the material property definition framework (MPDF) and multiphysics coupling of the heat transfer and the solid mechanics modules is developed to determine the structural integrity of the recently designed dual cooled lead lithium (DCLL) inboard blanket (IB) for the Fusion Nuclear Science Facility under steady state loads. The MPDF is called to supply fusion relevant neutron irradiation and temperature induced changes in material properties during multiphysics finite element runs, and PbLi temperature profiles are used to approximate Magnetohydrodynamics effect and the nuclear volumetric heating on the PbLi. Neutron irradiation and temperature induced reduction of the yield and ultimate strengths of F82H steel at the first wall (FW) are quantified for one year. A blanket in an assembly with gaps between blanket sectors and another blanket in an assembly with no gaps between blanket sectors, both exposed to radiation damage that lasted for one year are analyzed. Analysis using the elastic ITER structural design criteria for in-vessel components (ITER SDC-IC) design rules and a linear isotropic-hardening-type elastoplastic material model are used where most appropriate. The IB blanket with gaps between blanket sectors will withstand the steady state combined thermal and coolant loads for one year operational period but will fail if no gaps are allowed between blanket sectors. It is recommended that a gap of about 7.62 mm should be provided between IB blanket sectors during assembly which would close up during service, stop neutron streaming, reduce stresses and reduce bending of the FW into the scrape-off layer.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Neutron irradiation & thermomechanical experiment (NITE) - design

For the reliable long-term operation of fusion power plants, it is crucial to understand and predict the lifetime of materials in use. These materials include all structural and functional materials utilized at the first wall, blanket, magnets, and shielding. The key challenge is, that the harsh environment including high heat fluxes, high thermal stress and stress cycling, neutron irradiation, and sputtering on such materials should not be viewed separately. Currently, the synergistic loads cannot be evaluated experimentally because of the lack of adequate facilities. The purpose of that work is to design a synergetic Neutron Irradiation and Thermomechanical Experiment (NITE) for fusion materials. This design will leverage the existing Advanced-Test-Reactor (ATR), a fission reactor at the Idaho National Laboratory. We also acknowledge that with existing fission reactors the exact fusion condition cannot be created, and the limitations are critically discussed. The combination of neutron irradiation with a high heat flux is the focus. This is realized with an irradiation capsule design that includes a TRISO fueled region inside the capsule to enable a steady-state heat flux on one side of the specimen. In conclusion, the experimental design modeling showed that steady-state heat fluxes of 2.4 MW/m 2 with a thermal gradient of above 250°C can be achieved in a 5 mm thick specimen.

70 - PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Predicting roughness effects in additively manufactured coolant channels with helical enhancements

Additive manufacturing (AM) is a promising technique for fabrication of complex geometries such as those expected to be utilized in the blanket, first wall, and divertor. In the case of cooling, metallic AM may be exploited to embed geometric enhancements (ribs, rifling, etc.) to improve cooling performance. However, due to the roughness of these unfinished internal AM surfaces, prediction of thermal hydraulic performance in such channels is difficult. In this work, we consider a methodology for predicting pressure drop and heat transfer in AM channels containing helical enhancements (e.g. helical ribs, twisted tapes) that allows the incorporation of roughness data through conventional pipe flow correlations. This methodology is tested using experimental friction factor and heat transfer coefficient data from high-pressure helium coolant flow measurements in AM stainless steel tubes fabricated by laser powder bed fusion. Both a featureless AM tube and one containing helical ribs were considered alongside a conventionally manufactured smooth tube. The AM surface roughness is obtained by profilometry and used to predict an equivalent sand-grain roughness, with this equivalent roughness confirmed through AM featureless tube measurements. Under the proposed methodology, this roughness information is incorporated into predictions of friction factor and Nusselt number for the rifled tube. Furthermore, these predictions agree well with experimental data across a large range of Reynolds numbers, encouraging the use of this methodology for thermal hydraulic analysis of similar systems and design of future coolant channel geometries.

Additive manufacturing↗
DOE OSTI2026

Systematic analysis of melt pool dynamics in laser processing of mixed powder feedstocks

Functionally graded materials (FGMs) fabricated via additive manufacturing of blended powders offer the potential to spatially tailor properties for new technologies, such as fusion first-wall systems, turbine blades, and spacecraft. However, processing these materials is difficult due to the multiplicity of processing parameters to optimize, all of which must be changed as substrate material, powder feedstock compositions, and melt pool dynamics evolve. Here, this work systematically evaluates the qualitative and quantitative effects of these variables on the melt pool size, shape, composition, and particle distribution in an exemplar Ti-Ta system, and connects the experimental results to Marangoni flow behavior and phenomena observed in other systems. Increasing laser power linearly increases melt pool size and layer thickness, driving engineering considerations such as part/geometrical tolerances. Decreasing laser velocity changes the melt pool shape from lenticular to convex and reduces chemical homogeneity due to extreme thermal and compositional gradients between the melt pool center and boundaries. Thermophysical property differences between the powder feedstock and substrate material, as well as the directionality of the gradient, affect dilution and melt pool dynamics, which in turn affect the melt pool boundary characteristics, shape, and uniformity. Mixed powder feedstocks of intermediate compositions do not behave according to linear interpolations between single-material endpoints, instead building taller and wider melt pools. As such, it is recommended to quantify process maps for at least one intermediate composition in the FGM or multi-material system of interest to ensure optimized processing parameters, predictable melt pool sizes and shapes, and compositional and spatial precision.

Dissimilar↗
DOE OSTI2021

Deuterium retention in MeV ion-irradiated beryllium

Beryllium, as the material of choice for the ITER first wall, will be subject to high energy neutrons during the operation of the fusion device. Such irradiation will create displacement damage in the crystal lattice, which is known to influence hydrogen isotope retention, e.g. in iron and tungsten. Here in our study, we irradiated beryllium samples with high-energy oxygen ions up to various dpa levels (0.01 dpa, 0.1 dpa, and 1 dpa) and subsequently exposed the samples to deuterium plasma at 370 K and 573 K. The amount of retained deuterium was measured by thermal desorption spectroscopy and nuclear reaction analysis and was found to decrease by about 18% in the samples damaged up to 0.1 dpa compared to the undamaged ones. Further damaging up to 1 dpa did not show any additional effects on deuterium retention. Transmission electron microscopy was used to check for the existence of bubbles after plasma exposure.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Directed energy deposition of functionally graded V-4Cr-4Ti to Fe-9Cr transition for fusion power systems

This study proposes a graded structure via additive manufacturing for divertor and first wall blanket applications in fusion reactors. Materials were selected based on thermodynamic calculations to operate from 1100 °C at the plasma-facing level to 550 °C at the structural steel level. Conventional joining methods often lead to failures due to discrete reaction layers with significant mechanical property differences. Using laser beam-directed energy deposition (LB-DED), this study demonstrates the fabrication of a VCrTi-Gr91 steel functionally graded component through a novel process parameter optimization framework. A systematic approach included powder characterization, single-track depositions, and construction of printability maps. Near full-density specimens of each interlayer were additively manufactured, and a transition from V-based alloys to reduced activation ferritic martensitic steels was achieved. Computational material selection of interlayer alloys and thermodynamic/diffusion kinetics simulations prevented most interface incompatibilities. A brittle intermetallic formed at one interface, causing cracking, which was not predicted by current thermodynamic models. Transition alloy design approach was updated with a more recent database and a mitigation strategy has been proposed to eliminate the formation of deleterious intermetallic phases. Ultimately, LB-DED has proven effective for producing multi-material graded systems for fusion applications, with the demonstrated process parameter optimization framework applicable to various materials.

Additive manufacturing↗
DOE OSTI2021

Modeling and experimental validation of a W f /W-fabrication by chemical vapor deposition and infiltration

Tungsten (W) has a unique combination of excellent thermal properties, low sputter yield, low hydrogen retention, and acceptable activation. Therefore, W is presently the main candidate for the first wall material in future fusion devices. However, its intrinsic brittleness and its further embrittlement during operation bears the risk of a sudden and catastrophic component failure. As a countermeasure, tungsten fiber-reinforced tungsten (W f /W) with extrinsic toughening is being developed. A possible synthesis route is chemical vapor deposition (CVD) using heated W fabrics as substrate. The challenge is that the growing CVD-W can isolate domains from precursor access leading to strength-reducing pores. To deepen the process understanding and to optimize the CVD parameters, models were developed with COMSOL Multiphysics and validated experimentally. W deposition rate equations as function of the temperature and the partial pressures of the precursors H 2 and WF 6 were experimentally validated in previous work. In the present article, these equations are applied to obtain partial pressures within the CVD reactor. The results are taken as input for transient simulations in the microscale, in which W coatings, growing onto multiple adjacent W fibers, were simulated via mesh deformation and remeshing. The surface-to-surface contact of the W coatings and the corresponding potential pore formation were simulated by implementing sophisticated deposition rate stop conditions. Within the measuring uncertainties of ≃ ±1%, the models are validated successfully by experimental comparison regarding the deposition rate, pore structure, and relative densities ranging from 0.6 to 0.9.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗