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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 1,081 records · Page 60
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Detecting keyhole porosity and monitoring process signatures in additive manufacturing: an in situ pyrometry and ex situ X-ray radiography correlation

Creation of pores and defects during laser powder bed fusion (LPBF) can lead to poor mechanical properties and thus must be minimized. Post-build inspection is required to ensure the printed parts contain acceptably low defect concentrations. These inspections are time consuming and costly, especially for large or complex parts. As a potential solution, in situ process monitoring can be used to detect the creation of defects, characterize local material behavior and predict expected component properties. However, the precise relationship between pore creation and in situ process monitoring still needs to be understood. In this work, high-speed infrared diode-based pyrometry and high-speed optical imaging signals were used to monitor LPBF printing of 446 stainless steel 316 L single tracks with varying laser power and velocity. Results indicate an increase in pyrometer signal and melt pool dimensions with increasing laser power and decreasing velocity in agreement with previous work. In addition, careful analysis of pyrometer signal reveals a distinct signature of the conduction-to-keyhole mode transition which was confirmed by metallography. Critically, pore defect initiation as characterized by ex situ X-ray radiography was correlated with in situ thermal monitoring signals to derive the probability of defect creation. Our results show that, in principle, a probabilistic prediction of pore formation can be achieved based on in situ high-speed pyrometry monitoring of the LPBF melt pool.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Determining processing behaviour of pure Cu in laser powder bed fusion using direct micro-calorimetry

We report copper is challenging to process by laser powder bed fusion (LPBF) given its high reflectivity at common infrared laser diode wavelengths and high thermal conductivity. Successful deposition of copper in a predictable and repeatable fashion relies on understanding the development of the keyhole melting regime, as well as heating, melting, boiling and vapour formation behaviour when interacting with a laser beam within an LPBF environment. In this study, in situ optical absorptivity measurements are used to clarify the complex physics of the laser material interaction. Absorptivity of laser energy is measured using direct micro-calorimetry and compared to melt pool depth in correlation to processing parameters. The measured absorptivity for a 100 μm layer thickness of powder was found to be approximately four times higher than that of the bare polished discs. It was also shown that high laser power above 500 W and scan speed up to 150 mm/s are appropriate for effective melting of the powder layer, with these parameters overcoming the threshold required to achieve keyhole melting. This is explained by multiple reflections withing the powder particles and the lower thermal conductivity of packed powder in comparison to bare discs. Melt pool formation was found to be highly unstable and an explosive behavior was observed when in the keyhole regime, caused by high fluctuations in absorptivity values. This work demonstrates calorimetry can be used to monitor melting behaviour in a real-time fashion during processing for this challenging to process material, thereby avoiding unnecessary parametric optimisation. In addition, the parametric window for optimum processing revealed here can inform future work.

36 MATERIALS SCIENCE↗
DOE OSTI2022

The corrosion effects of neutron activation of 2LiF-BeF 2 (FLiBe)

The redox effect of activation reactions in molten salts has been previously qualitatively defined but never quantified. Here, we quantify the corrosion effects of neutron activation of FLiBe. Rates of change of activation products are computed for FHR and ARC. The impact of activation reactions on salt chemistry is quantitatively compared to other environmental effects of similar consequences on the salt. The results are applied to a redox control case-study and an irradiation-corrosion experiment. The results are presented in a manner useful to the reactor chemist and designer concerned with corrosion and chemistry control and tritium management in irradiated FLiBe, and design of salt-irradiation experiments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
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

Performance characterization of x-ray crystal spectroscopy highly oriented pyrolytic graphite reflectors based on x-ray diffractometry experiments

The use of Highly Oriented Pyrolytic Graphite (HOPG) reflectors is often proposed in the design of X-ray Crystal Spectroscopy (XCS) diagnostic systems for the next-generation tokamak devices, including the ITER project. Here, this study introduces an experimental study based on the X-Ray Diffractometry (XRD) method to evaluate the performance of HOPG reflectors. The experimental method provides both the angular responses and the reflectivities of the HOPG reflectors. A demonstrative XRD experiment is conducted, and the details of the experiment are introduced. This method enables precise studies on HOPG reflectors, facilitating the design of XCS diagnostic systems for future tokamaks.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Edge-localized mode mitigation enabled by active control of pedestal density gradient with new EAST tokamak divertor

Mitigation of large edge-localized modes (ELMs) has been achieved by actively reducing the pedestal density gradient with the EAST new right-angled lower divertor through changing the strike point position from the vertical target to the horizontal target. A series of dedicated experiments in the 2021–2024 EAST campaigns demonstrate that this ELM control solution is highly reproducible in a broad parameter space of edge safety factor q 95 = 4.7–7.1, heating power P total = 2.3–5 MW, and pedestal collisionality $ν_{e,ped}^{*}$ = 1–6, under both favorable and unfavorable magnetic configurations. Higher plasma density could facilitate the achievement of this ELM control solution. Statistical results indicate that the ELM mitigation effect can be observed at relatively larger Greenwald density fraction of f GW > 0.47. In addition, this ELM mitigation effect can be achieved with both lithium-coated and boronized metal walls. The pedestal density gradient is systematically lower in the horizontal target case than that of the vertical target case when the ELM mitigation effect can be observed. SOLPS-ITER simulation results indicate that the pedestal fueling from divertor recycling is significantly lower in the horizontal target case. This could contribute to the formation of a flattened pedestal density profile with small ELMs.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Development of a data-driven neural network model for electron thermal transport in NSTX

A data-driven electron thermal transport neural network (ETT-NN) model, trained on TRANSP interpretative analysis results of National Spherical Torus Experiment (NSTX), was developed to enable faster and more accurate ETT computation for spherical tokamaks (STs). The model incorporates both convolutional NNs and recurrent NNs, allowing it to simultaneously account for the spatial and temporal non-localities and multi-scale features of turbulent transport, which have been considered only in a limited manner in conventional models. The model was validated through interpretative analysis and predictive simulations using Tokamak Reactor Integrated Automated Suite for Simulation and Computation, demonstrating relatively high accuracy. Additionally, parameter scans were performed on test discharges known to exhibit specific turbulent modes, such as microtearing mode, trapped electron mode, kinetic ballooning mode, and electron temperature gradient mode. The scanning results revealed that the ETT-NN model exhibits the same trends as those observed in conventional gyrokinetic simulations or theories, while also capturing the global nature of turbulent transport, indicating that the data-driven model accurately reflects the underlying physical characteristics. Furthermore, due to the dimensionless nature of the model, we can feasibly expand its applicability by incorporating data from other devices and uncovering the characteristics of ETT in STs in the future.

NSTX↗
DOE OSTI2026

Simulating plasma wave propagation on a superconducting quantum chip

Quantum computers may one day enable the efficient simulation of strongly coupled plasmas that lie beyond the reach of classical computation in regimes where quantum effects are important and the scale separation is large. Here, in this article, we take a first step toward efficient simulation of quantum plasmas by demonstrating linear plasma wave propagation on a superconducting quantum chip. Using high-fidelity and highly expressive device-native gates, combined with an error-mitigation technique, we simulate the scattering of laser pulses from inhomogeneous plasmas. Our approach is made feasible by the identification of a suitable local spin model whose excitations mimic plasma waves, and whose circuit implementation requires a lower gate count than other proposed approaches that would require a future fault-tolerant quantum computer. This work opens avenues to study more complicated phenomena that cannot be simulated efficiently on classical computers, such as nonlinear quantum dynamics when strongly coupled plasmas are driven out of equilibrium.

general physics↗
DOE OSTI2023

Ice Dusty Plasma (Final Report)

The NSF/DOE funding described in this final report was for constructing a substantial upgrade that would enable operation at variable and much lower cryogenic temperatures than was available in a previous experiment that operated from 2013 to 2019. Components for the upgraded experiment were designed and ordered from August to December 2019 and assembly began in early 2020. However, COVID-19 halted all lab work for much of 2020 and then when lab work resumed, numerous restrictions on lab access and in-lab time further impeded progress. Because of these delays, first plasma was obtained in late 2021 and a normal work pace resumed only in mid-2022. A no-cost extension was requested because the COVID-19 delays prevented work from being done at the anticipated rate. Constructing a water-ice experiment was a significant gamble because the parameter regime differs substantially from conventional laboratory plasmas and injecting water vapor into a plasma goes very much against convention as one normally goes to great lengths to avoid water vapor. This experiment opens a new frontier, namely the study of how charged ice grains form, grow, and interact with a plasma environment. The just-completed upgrade was a further gamble because it combines technology never previously used together (cryocoolers, plasma, and ice).

36 MATERIALS SCIENCE↗
DOE OSTI2025

Investigating Fast Scanning Calorimetry and Differential Scanning Calorimetry as Screening Tools for Thermoset Polymer Material Compatibility with Laser-Based Powder Bed Fusion

As additive manufacturing (AM) technology has developed and progressed, a constant topic of research in the area is expanding the library of materials to be used with these techniques. Among AM methods that utilize polymers, laser-based powder bed fusion (PBF-LB) has preferentially used thermoplastic polymers as its starting materials, but the deposition and material joining method employed in PBF-LB may also be compatible with powdered thermoset polymer precursors as feedstocks. To assess the compatibility of candidate thermosetting polymers and PBF-LB, characterization techniques and protocols that link fundamental material behavior to material behavior in the processing environment are needed. Therefore, the objectives of this work are to compare the curing behavior measured with two different calorimetry techniques that can operate in different heating rate regimes, differential scanning calorimetry (DSC) and fast scanning calorimetry (FSC), and to assess the capabilities of these techniques to act as materials screening tools for PBF-LB. A commercial polyester powder coating is used as a model material to evaluate the potential of obtaining complimentary information for material screening through a combination of calorimetry methods, and its non-isothermal curing behavior is measured at heating rates between 5 °C/min and 7500 °C/min. Curing exotherms are observed with both calorimetry techniques, and comparing the enthalpy associated with curing shows that incomplete curing occurs at higher heating rates, with relative conversion values of approximately 30%. The curing data are fit with two isoconversional models, Friedman and Starink, which show a reduced activation energy at higher heating rates as well, signifying a lower barrier to curing at the conditions used in the FSC experiments. Overall, the results of this work indicate that using these two calorimetry techniques as tiered screening tools can provide valuable information about how curing may proceed in PBF-LB and inform materials selection and design activities for additive manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Additive manufacturing process parameter determination for a new Fe-C-Cu alloy

As a potential replacement for stainless steel alloys commonly used to print parts with laser powder bed fusion, a new Cu precipitation strengthened ferrous alloy, with composition Fe-0.2C-6Cu (wt%), was recently developed. This material is Co- and Ni-free, printable, has mechanical properties comparable to that of high strength stainless steels (approximately 1300 MPa UTS), and is cost-advantaged relative to existing low-alloy steels for additive manufacturing of parts with complex shapes. To gain traction for broader application, optimal laser powder bed fusion (LPBF) processing conditions to produce nearly defect-free parts without compromising mechanical strength are needed. Here, an optimal processing window based upon laser speeds that achieve minimal porosity was quantified via comparisons of measured melt pool penetration, scan speeds, printed material density and laser beam energy density on a commercial LPBF unit operating at 350 W, 80 μm hatch spacing, and 50 μm layer thickness based upon optimal parameters for 17-4PH. Furthermore, the window is 300 to 500 mm/s to achieve >99.8 % dense Fe-0.2C-6Cu (wt%) specimens. Other defects such as burning, spatter, and lack of fusion were also avoided in this window. The window was validated with in-situ synchrotron X-ray imaging that enabled visualization of the vapor cavity, melting, and solidification during a single laser track scan on a miniature powder bed sample. In addition, in-situ infrared imaging provided temperature fields, cooling rate and solidification range, and confirmed minimal printing defects and spatter within the processing window.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Microstructure and mechanical properties of friction stir welded Haynes 282

Advanced ultrasupercritical (A-USC) steam plants are designed to operate at high temperatures and pressures due to the necessity for higher operational efficiency. The extreme operating conditions of A-USC requires the deployment of precipitation strengthened Ni-base alloys that exhibit elevated temperature strength and good fabricability. Fusion welding of precipitation strengthened nickel alloys lead to solidification cracking in fusion zone and/or liquation cracking in heat affected zone. Therefore, an alternative non-melting welding technique is a necessity to efficiently join nickel alloys. In the current study, friction stir welding, a solid state joining technique was implemented on a precipitation strengthened nickel-based superalloy, Haynes 282. Detailed microstructural and mechanical properties characterization was carried out. The processed region exhibited wrought, fine-grained microstructure, absence of weld defects such as voids and cracks and absence of elemental segregation. Both hardness and cross-weld tensile tests demonstrated that the weld region was stronger than the base material. And the cross-weld tensile samples failed in the base material. Based on joint efficiency analysis, friction stir welded Haynes 282 outperformed fusion welds.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Marf-mediated mitochondrial fusion is imperative for the development and functioning of indirect flight muscles (IFMs) in drosophila

Highlights: • Mitochondrial fusion is essential during development of Drosophila IFM. • Marf expression is required during early muscle development. • Marf knock down during IFM development affects mitochondrial shape and function. • Marf deficiency alters myofibril size and decreases muscle function. Dynamic changes in mitochondrial shape and size are vital for mitochondrial health and for tissue development and function. Adult Drosophila indirect flight muscles contain densely packed mitochondria. We show here that mitochondrial fusion is critical during early muscle development (in pupa) and that silencing of the outer mitochondrial membrane fusion gene, Marf, in muscles results in smaller mitochondria that are functionally defective. This leads to abnormal muscle development resulting in muscle dysfunction in adult flies. However, post-developmental silencing of Marf has no obvious effects on mitochondrial and muscle phenotype in adult flies, indicating the importance of mitochondrial fusion during early muscle development.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2021

Cryo-electron tomography provides topological insights into mutant huntingtin exon 1 and polyQ aggregates

Huntington disease (HD) is a neurodegenerative trinucleotide repeat disorder caused by an expanded poly-glutamine (polyQ) tract in the mutant huntingtin (mHTT) protein. The formation and topology of filamentous mHTT inclusions in the brain (hallmarks of HD implicated in neurotoxicity) remain elusive. Using cryo-electron tomography and subtomogram averaging, here we show that mHTT exon 1 and polyQ-only aggregates in vitro are structurally heterogenous and filamentous, similar to prior observations with other methods. Yet, we find filaments in both types of aggregates under ~2 nm in width, thinner than previously reported, and regions forming large sheets. In addition, our data show a prevalent subpopulation of filaments exhibiting a lumpy slab morphology in both aggregates, supportive of the polyQ core model. This provides a basis for future cryoET studies of various aggregated mHTT and polyQ constructs to improve their structure-based modeling as well as their identification in cells without fusion tags.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Steady-State Mechanical Analysis for Target Assembly in the Material Plasma Exposure eXperiment Facility

The Material Plasma Exposure eXperiment (MPEX) steady-state linear plasma facility is currently under design at Oak Ridge National Laboratory to expose target specimens to fusion divertor regimes. The neutron-irradiated target is actively cooled and remote handled in the MPEX facility for conducting plasma-material–interaction (PMI) experiments. Here, the steady-state stresses in the target and target assembly system are investigated using two-dimensional (2-D) and three-dimensional (3-D) models to provide expected stresses/strains under the heat loads to which various system components would be exposed during MPEX operation. The calculated temperatures from the 2-D axisymmetric mechanical model were found to be in excellent agreement with those from the full 3-D thermohydraulic model, providing a strong model validation. Numerical simulation results for the steady-state mechanical model indicate nonuniform distributions for the temperature, stress, and deformation within the critical components. For the initial design, the deformation results indicate possible gap openings between contacting surfaces below the plasma-facing materials. To reduce the possibility of interfacial gap opening, the target assembly was slightly changed and evaluated using the 2-D stress model. Numerical simulation results indicate that the interfacial gap openings can be minimized without drastically changing the entire target assembly. The stress-strain conditions for the target will be further used to assess the appropriate operation during MPEX experiments and gain insight into materials science phenomena during PMI.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Bayesian Parameter Estimation of the k-ω Shear Stress Transport Model for Accurate Simulations of Impinging-Jet Heat Transfer

Given the lack of fusion-relevant component test facilities, current estimates of the thermo-fluid performance of plasma-facing components are based for the most part on numerical simulations. A major source of uncertainty in these simulations is the semiempirical turbulence (closure) models for the Reynolds stresses appearing in the governing Reynolds-averaged Navier-Stokes equations, which involve a set of constants that depend upon the flow. The objective of this study is to evaluate Bayesian parameter estimation of turbulence closure constants in ANSYS Fluent to model heat transfer in impinging jets. The Bayesian statistical calibration produces a probability distribution for these constants from experimental data; the maximum a posteriori estimates are then taken to be the calibrated constants, or parameters. The turbulence model constants are calibrated using an experimental study of a submerged jet of air impinging on a flat heated surface at Reynolds numbers Re = O(10 4 ) and impingement distance in jet diameters H/d = 2. Numerical predictions using the calibrated model parameters are then compared with those generated using the default constants. Predictions obtained with model parameters calibrated on datasets of two different sizes are compared to evaluate the effect of the number of calibration samples. Lastly, the extrapolative ability of the calibrated model is examined by predictions at a Re beyond the calibration values.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Enhancing the solubility of SARS-CoV-2 inhibitors to increase future prospects for clinical development

SARS-CoV-2 poses an ongoing threat to human health as variants continue to emerge. Several effective vaccines are available, but a diminishing number of Americans receive the updated vaccines (only 22% received the 2023 update). Public hesitancy towards vaccines and common occurrence of “breakthrough” infections (i.e., infections of vaccinated individuals) highlight the need for alternative methods to reduce viral transmission. SARS-CoV-2 enters cells by fusing its envelope with the target cell membrane in a process mediated by the viral spike protein, S. The S protein operates via a Class I fusion mechanism in which fusion between the viral envelope and host cell membrane is mediated by structural rearrangements of the S trimer. We previously reported lipopeptides derived from the C-terminal heptad repeat (HRC) domain of SARS-CoV-2 S that potently inhibit fusion by SARS-CoV-2, both in vitro and in vivo. These lipopeptides bear an attached cholesterol unit to anchor them in the membrane. Here, to improve prospects for experimental development and future clinical utility, we employed structure-guided design to incorporate charged residues at specific sites in the peptide to enhance aqueous solubility. This effort resulted in two new, potent lipopeptide inhibitors.

36 MATERIALS SCIENCE↗