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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Evolution of titanium particle combustion in potassium perchlorate and air

Understanding titanium particle combustion processes is critical not only for characterizing existing pyrotechnic systems but also for creating new igniter designs. In order to characterize titanium particle combustion processes, morphologies, and temperatures, simultaneous spatially-resolved electric field holography and imaging pyrometry techniques were used to capture post-ignition data at up to 7 kHz. Due to the phase and thermal distortions present in the combustion cloud, traditional digital in-line holography techniques fail to capture accurate data. Here in this work, electric field holography techniques are used in order to cancel distortions and capture the three-dimensional spatial locations and diameters of the particles. In order to estimate the projected surface temperatures of the titanium particles, an imaging pyrometry method that ratios emission at 750 and 850 nm is utilized. Using these diagnostics, joint statistics are collected for particle size, morphology, velocity, and temperature. Results show that, early in the combustion process, the titanium particles are primarily oxidized by potassium perchlorate inside the igniter cup, resulting in projected surface temperatures near 3000 K. Later in the process, the particles interact with ambient air, resulting in lower surface temperatures around 2400 K and the formation of flame zones. These results are consistent with adiabatic flame temperature predictions as well as particle morphology observations of a titanium core with a TiO 2 surface. Late stage particle expansion, star fragmentation, and molten droplet breakup events are also observed using the time-resolved morphology and temperature diagnostics. These results illustrate the different stages of titanium particle combustion in pyrotechnic environments, which can be used to inform improvements in next-generation igniters.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Hyperspectral Detection of the Fluorescence Shift between Chirality-Sorted Empty and Water-Filled Single-Wall Carbon Nanotube Enantiomers

Single-wall carbon nanotubes (SWCNTs) have extraordinary electronic and optical properties that depend strongly on their exact chiral structure and their interaction with their inner and outer environment. The fluorescence (PL) of semiconducting SWCNTs, for instance, will shift depending on the molecules with which the SWCNT’s hollow core is filled. These interaction-induced shifts are challenging to resolve on the ensemble level in samples containing a mixture of different filling contents due to the relatively large inhomogeneous line width of the ensemble SWCNT PL compared to the size of these shifts. To circumvent this inhomogeneous broadening, single-tube spectroscopy and hyperspectral imaging are often applied, which until now required time-consuming statistical studies. Here, we present hyperspectral PL microscopy combined with automated SWCNT segmenting based on either principal component analysis or a convolutional neural network, capable of both spatially and spectrally resolving the PL along the length of many individual SWCNTs at the same time and automatically fitting peak positions and line widths of individual SWCNTs. The methodology is demonstrated by accurately determining the emission shifts and line widths of thousands of left- and right-handed empty and water-filled SWCNTs coated with a chiral surfactant, resulting in four statistical distributions which cannot be resolved in ensemble spectroscopy of unsorted samples. The results demonstrate a robust method to quickly probe ensemble properties with single-enantiomer spectral resolution. Moreover, it promises to be an absolute quantitative method to characterize the relative abundances of SWCNTs with different handedness or filling content in macroscopic samples, simply by counting individual species.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Electrochemical Amyloid β Immunosensor Based on Ti 3 C 2 T x MXene Nanosheets

Alzheimer’s disease (AD) is the most common neurodegenerative disease and a major health-care problem. More than 55 million people in the world, including 6.7 million Americans, are living with AD. As AD is characterized by production and deposition of β-amyloid peptide (Aβ) in the brain, Aβ is considered as a potential biomarker for diagnosing and monitoring the progression of AD. Nanomaterials-based electrochemical immunosensor is one of the most promising methods for early diagnosis and therapeutic of AD, due to its highly selective, sensitive, and label-free advantages. The graphene-like two-dimensional (2D) MXene nanosheets have shown large surface area, good conductivity, biocompatibility, high ion transport, and low diffusion barrier, attracting attention in recent years to use it as the nanomaterial substrate for biosensor fabrication. In this paper, we presented a Ti 3 C 2 T x MXene nanosheets-based electrochemical immunosensor to detect trace Aβ for early diagnosis of AD.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Surface Roughness Effects from Additive Manufacturing in High Efficiency Gas Turbine Combustion Systems

In the past, clean combustion systems were characterized by high system development costs due to growing complexity and escalating manufacturing costs from conventional manufacturing processes. As a result, high efficiency concepts are difficult to design and more difficult to be cost-effectively manufactured. In recent years, with the introduction of additive manufacturing (AM) technologies, the rapid prototyping and mass production processes of clean combustion systems are promising to be significantly simplified with significant reduction in terms of engine manufacturing cost and engine energy cost. Compared with conventional manufacturing built parts, the AM process enabled a simpler design to be adopted for the nozzle, reducing the number of required braze and weld joints from twenty-five to just five. The resulting nozzle was 25% lighter and five times more durable and contributed to a 15% reduction in fuel burn in comparison with the previous model produced. Applying these improvements to a fleet of 5,000 turbofan engines at 150 kN thrust would result in fuel cost savings of $ \$ $6B annually (at $ \$ $5/gallon Jet-A fuel price, 700 gallon/hour fuel consumption rate, and 2,300 operational hours per year), and reduce CO2 emissions by more than 25 million tons per year. These advances support core Department of Energy (DOE) missions in energy efficiency, improving productivity, and environmental sustainability. Maximizing the benefit of these new capabilities will require high prediction capability of high speed turbulent flow with wall modeled Large Eddy Simulation (LES). GE Aviation maintains that advanced simulation technology and supercomputing is required in order to provide the appropriate boundary conditions to realize the maximum potential of AM and Ceramic Matrix Composite to reduce cooling flow, a first order penalty on the Brayton cycle. The algorithm developed using the ANSYS/Fluent software would provide the foundation for entirely new avenues of research and development with potential multi-billion dollar impact to the US economy, and significant reduction in carbon based emissions across the aerospace and power generation industries. The formulation of this iWLES (integral wall model for LES) is generic and allows to capture the changes in flow dynamics that have a significant impact on the wall bounded flow characteristics, such as swirler effective area, bulk swirl number, local pressure distribution, exit velocity profile, and turbulence kinetic energy profile. A periodic channel flow with rough flat plate is simulated using LES (Wall-Adapting Local Eddy-viscosity) model to verify the implementation of iWLES in the Fluent User Defined Function (UDF). As the flow fields are highly sensitive due to surface roughness of the wall bounded flows in the combustion systems, there is significant potential to conduct further LES studies focusing on the turbulence boundary layer interaction. Accurately capturing near wall physics will elucidate the impact of rough surfaces on combustor flow and aero-thermal interactions.

42 ENGINEERING↗
DOE OSTI2023

Surface Roughness Effects from Additive Manufacturing in High Efficiency Gas Turbine Combustion Systems

In the past, clean combustion systems were characterized by high system development costs due to growing complexity and escalating manufacturing costs from conventional manufacturing processes. As a result, high efficiency concepts are difficult to design and more difficult to be cost-effectively manufactured. In recent years, with the introduction of additive manufacturing (AM) technologies, the rapid prototyping and mass production processes of clean combustion systems are promising to be significantly simplified with significant reduction in terms of engine manufacturing cost and engine energy cost. Compared with conventional manufacturing built parts, the AM process enabled a simpler design to be adopted for the nozzle, reducing the number of required braze and weld joints from twenty-five to just five. The resulting nozzle was 25% lighter and five times more durable and contributed to a 15% reduction in fuel burn in comparison with the previous model produced. Applying these improvements to a fleet of 5,000 turbofan engines at 150 kN thrust would result in fuel cost savings of $6B annually (at $5/gallon Jet-A fuel price, 700 gallon/hour fuel consumption rate, and 2,300 operational hours per year),and reduce CO2 emissions by more than 25 million tons per year. These advances support core Department of Energy (DOE)missions in energy efficiency, improving productivity, and environmental sustainability. Maximizing the benefit of these new capabilities will require high prediction capability of high speed turbulent flow with wall modeled Large Eddy Simulation (LES). GE Aviation maintains that advanced simulation technology and supercomputing is required in order to provide the appropriate boundary conditions to realize the maximum potential of AM and Ceramic Matrix Composite to reduce cooling flow, a first order penalty on the Brayton cycle. The algorithm developed using the ANSYS/Fluent software would provide the foundation for entirely new avenues of research and development with potential multi-billion dollar impact to the US economy, and significant reduction in carbon based emissions across the aerospace and power generation industries. The formulation of this iWLES (integral wall model for LES) is generic and allows to capture the changes in flow dynamics that have a significant impact on the wall bounded flow characteristics, such as swirler effective area, bulk swirl number, local pressure distribution, exit velocity profile, and turbulence kinetic energy profile. A periodic channel flow with rough flat plate is simulated using LES (Wall-Adapting Local Eddy-viscosity) model to verify the implementation of iWLES in the Fluent User Defined Function (UDF). As the flow fields are highly sensitive due to surface roughness of the wall bounded flows in the combustion systems, there is significant potential to conduct further LES studies focusing on the turbulence boundary layer interaction. Accurately capturing near wall physics will elucidate the impact of rough surfaces on combustor flow and aero-thermal interactions.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2026

A procedure for rule extraction from a Self-Organising plasma disruption predictor for JET

In a previous paper, a Self-Organizing Map had proven to be able to identify the regions of the plasma operative space characterizing the pre-disruptive phase at JET without relying on any a priori information. One of the strengths of this disruption predictor lies in its inherent self-organization capability. The Self-Organizing Map discovers non-trivial relationships and captures the complicated interplay of device diagnostics on the internal plasma states directly from the experimental data. Moreover, the provided model allows the visualization of high-dimensional plasma parameters and facilitates easy interrogation of the model to understand the reasons behind its correlations. In this paper, an additional step is taken towards the interpretability of models for predicting disruptions by training a Decision Tree to classify the plasma states according to the interpretation provided by the Self-Organizing Map (stable or at high risk of disruptions). The Decision tree provides a set of rules which describe the transition of the plasma towards the pre-disruptive phase as visualized in the Self-Organizing Map. The obtained rules for the database explored in the study identify four regions in the map, two of which are at risk of disruption. These regions correspond to partitions of a 3D space based on the peaking factors of the core and divertor radiation, as well as the Locked Mode. The agreement between the Self-Organizing Map answers and the rules supplied by the Decision Tree is confirmed by the comparison of the performance exhibited by the two models in the prediction of disruptions.

Setzu, Samuele [Univ. of Cagliari, Monserrato, Cag↗
DOE OSTI2020

Microstructural characterization of cold-worked 316 stainless steel flux thimble tubes irradiated up to 100 dpa in a commercial Pressurized Water Reactor

Two flux thimble tubes (FTT) made of 15% cold-worked 316 stainless steel (SS) were harvested from Ringhals Pressurized Water Reactor (PWR) Unit 2, with peak damages of 76 and 100 displacements per atom (dpa) after 29 and 34 years’ service, respectively. Specimens sectioned from parent tubes were comprehensively characterized with nominal damage levels of ~0, ~41, ~74, 76, and 100 dpa at a nominal temperature range of 285-323 °C. Both FTTs contained helium and hydrogen gases as transmutation products. The helium follows a production rate of ~9.8 appm/dpa, while environmental factors complicate hydrogen production obscuring an exact H/dpa ratio. Irradiation-induced dislocation loops, nano-cavities, solute clusters, and microsegregation were all observed. The dislocation loops and nano-cavities indicated saturation at 41 dpa. The solute clusters continued to evolve with Ni-Si clusters formed at 41 dpa, and Ni-Si-Mn-P clusters formed at 74 and 100 dpa, but neither clusters exhibited distinct diffraction patterns at any damage levels. Solute clusters were observed to frequently be co-located with dislocation loops, but fully decorated loops were rarely detected. Significant radiation-induced segregation (RIS) was observed around grain boundaries at all damage levels. The modified inverse Kirkendall (MIK) model captured the RIS behavior of major elements. Large cavities within or around an Mn-S rich region were observed for the first time. Through all the damage levels, void swelling is always below 0.05%, making significant dimensional change unlikely in core internals when used at similar conditions. Meanwhile, the role of overwhelming nanocavities, presumably helium bubbles, should be considered in other potential degradation mechanisms, including irradiation-assisted stress corrosion cracking, embrittlement, and loss of fracture toughness, which remain the concerns for extended operation of nuclear power plants.

Post Irradiation Examination, Isotope Dilution Mas↗
DOE OSTI2022

Porous Colloidal Nanoparticles as Injectable Multimodal Contrast Agents for Enhanced Geophysical Sensing

Injecting fluids into underground geologic structures is crucial for the development of long-term strategies for managing captured carbon and facilitating sustainable energy extraction operations. Here, we have previously reported that the injection of metal–organic frameworks (MOFs) into the subsurface can enhance seismic monitoring tools to track fluids and map complex structures, reduce risk, and verify containment in carbon storage reservoirs because of their absorption capacity of low-frequency seismic waves. Here, we demonstrate that water-based Cr/Zn/Zr MOF colloidal suspensions (nanofluids) are multimodal geophysical contrast agents that enhance near-wellbore logging tools. Based on experimental fluid-only measurements, MIL-101(Cr), ZIF-8, and UiO-66 nanofluids have distinct complex conductivity and/or low-field nuclear magnetic resonance (NMR) signatures that are relevant to field-deployed technologies, implying the potential to enhance near-wellbore monitoring of CO 2 injection and associated processes with downhole logging tools. Small- and wide-angle X-ray scattering characterization of ~0.5 wt % MIL-101(Cr) suspensions confirmed phase stability and provided insight into the fractal nature of colloidal nanoparticles. Finally, low-field (2 MHz) NMR measurements of MIL-101(Cr) nanofluid injection into a prototypical Berea sandstone demonstrate how paramagnetic high-surface area MOFs may dominate the relaxation times of hydrogen-bearing fluids in porous geologic matrices, enhancing the mapping of near-surface and near-wellbore transport pathways and advancing sustainable subsurface energy technologies.

NMR↗
DOE OSTI2021

Experimental investigation on thermal inertia characterization of commercial buildings for demand response

Characterizing the thermal inertia of commercial buildings is of great importance in quantifying demand flexibility. Experimental tests can be used to investigate the thermal inertia of commercial buildings. However, existing studies tend to be qualitative and have limited scope. In this study, a comprehensive field test has been performed to assess the thermal inertia of commercial buildings. In this field test, six buildings are selected with different sizes, vintages, and types of heating, ventilation, and air conditioning (HVAC) systems to represent the majority of the U.S. commercial building stock. We quantify the thermal inertia with building operation data collected under various thermostat excitation signals. We then studied the relationship between thermal inertia and intrinsic properties, such as floor area, HVAC system, etc., as well as the operation condition indicators such as outdoor air temperature, zone temperature, and occupancy. The testing results indicate that the median values of the normalized charge response time and the normalized discharge response time of the five buildings are 1~5 hr/ °C and -5~-1 hr/ °C, respectively. The results also show that the thermal inertia of commercial buildings may be sensitive to the HVAC system type but not the floor area or location of zones, i.e., core vs. perimeter. Finally, our results suggest that the relationships between the charging/discharging normalized response time and the zone/outdoor temperature may vary among zones and be highly nonlinear.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

GBCGE Subsurface Database Explorer and APIs

This submission defines a DOI for the Great Basin Center for Geothermal Energy's (GBCGE) Subsurface Database Explorer web application and underlying data services, and acknowledges the INGENIOUS project as a major source of funding for data compilation and quality assurance. The GBCGE Subsurface Database Explorer is an interactive web mapping application that provides public access to the GBCGE Subsurface Database, and its collection of datasets pertinent to geothermal exploration, oil and gas exploration, critical mineral exploration, and other subsurface characterization for the Great Basin Region, western US. This is a living database, and will be continuously updated with new data and datasets as funding and motivations allow. The underlying database views that populate the web application are on an automated refresh schedule. Data sources and acknowledgements: We thank our partners with the Nevada Division of Minerals (NDOM), the Southern Methodist University (SMU), and Great Basin State Geological Surveys for their active efforts in data curation, schema design, and quality assurance. We also thank contributors among the USGS, Oregon Institute of Technology, State Divisions of Water Resources, State Divisions of Oil, Gas, and Minerals, and State Geological Surveys for open data availability and direct contributions made under the National Geothermal Data System (NGDS).

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

MAPPRAISER: A massively parallel map-making framework for multi-kilo pixel CMB experiments

Forthcoming cosmic microwave background (CMB) polarized anisotropy experiments have the potential to revolutionize our understanding of the Universe and fundamental physics. The sought-after, tale-telling signatures will be however distributed over voluminous data sets which these experiments will collect. These data sets will need to be efficiently processed and unwanted contributions due to astrophysical, environmental, and instrumental effects characterized and efficiently mitigated in order to uncover the signatures. This poses a significant challenge to data analysis methods, techniques, and software tools which will not only have to be able to cope with huge volumes of data but to do so with unprecedented precision driven by the demanding science goals posed for the new experiments. A keystone of efficient CMB data analysis is solvers of very large linear systems of equations. Such systems appear in very diverse contexts throughout CMB data analysis pipelines, however they typically display similar algebraic structures and can therefore be solved using similar numerical techniques. Linear systems arising in the so-called map-making problem are one of the most prominent and common ones. In this work we present a massively parallel, flexible and extensible framework, comprised of a numerical library, MIDAPACK, and a high level code, MAPPRAISER, which provide tools for solving efficiently such systems. Here, the framework implements iterative solvers based on conjugate gradient techniques: enlarged and preconditioned using different preconditioners. We demonstrate the framework on simulated examples reflecting basic characteristics of the forthcoming data sets issued by ground-based and satellite-borne instruments, executing it on as many as 16,384 compute cores. The software is developed as an open source project freely available to the community at: https://github.com/B3Dcmb/midapack.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2024

Reconstruction of the 4D beam matrix

The widely used transverse parameters characterizing particle beams are the Twiss parameters. These parameters can be measured experimentally but they do not fully characterize the beam since they do not account for possible correlations in particle distribution between two transverse coordinates. These correlations may occur due to uncompensated magnetic field at the cathode or misalignment of focusing quadrupoles in the transport beamline. We test a novel diagnostic for diagnosing full 4D beam matrix which may be used to identify such imperfections. The diagnostic is based on transporting the beam through the beamline which includes a quadrupole and a skew quadrupole magnets and measuring the resulting 2D beam distribution at the screen downstream. Such a measurement can be viewed as measuring a 2D projection of the 4D distribution. Different settings of the quads provide measurements of different slices of the phase space. The reconstruction of the original beam matrix from a number of measurements is done using machine learning algorithm, which provides a fast and reliable way of reconstruction for an arbitrary configuration of the scanning beamline. In August 2024, we set up the diagnostic beamline to perform a quadrupole scan of the beam. The setup includes a skew quadrupole, a regular quadrupole, and a screen. The images on the screen were post-processed to remove experimental artifacts and enhance contrast by eliminating background noise outside the core of the distribution=. The rms parameters of the distribution were then calculated and used as inputs for the reconstruction algorithm. This algorithm attempts to determine the initial beam matrix that produces expected images on the screen closely matching the observed images across all quadrupole settings. The algorithm found a solution in which the expected rms parameters closely align with the observations. Validation of the results is planned for FY25.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

A Non-Invasive Approach for Elucidating the Spatial Distribution of In-Situ Stress in Deep Subsurface Geologic Formations Considered for CO 2 Storage (Task 3 Report Laboratory Characterization of Stress Dependent Wavespeed)

This report presents a summary of Task 3 (Laboratory Experimental Characterization of Stress Dependent Wavespeed in Rocks and Application for In-Situ Stress Estimation) of the project titled “A Non-Invasive Approach for Elucidating the Spatial Distribution of In-Situ Stress in Deep Subsurface Geologic Formations Considered for CO 2 Storage”. The main objective of this component of the project was to employ non-destructive techniques to determine how compressional (P)-wave and shear (S)-wave propagation velocities are related to triaxial-stress conditions in laboratory test samples of targeted reservoir rocks. The overarching principle is that such laboratory measurements can provide a basis whereby field measurements of wave-propagation velocities in rocks can be used to ascertain the stress state that would be expected to generate the observed wave-propagation behavior.

58 GEOSCIENCES↗
DOE OSTI2021

Excited-State Bond Contraction and Charge Migration in a Platinum Dimer Complex Characterized by X-ray and Optical Transient Absorption Spectroscopy

Interactions between metal centers in dimeric transition metal complexes (TMCs) play important roles in their excited-state energetics and pathways, and, thus, affect their photophysical properties relevant to their applications, e.g., photoluminescent materials and photocatalysis. In this study, we report electronic and nuclear structural dynamics studies of two photoexcited pyrazolate-bridged [Pt(ppy)(µ-R 2 pz)] 2 -type Pt(II) dimers (ppy = 2-phenylpyridine, µ-R 2 pz = 3,5-substituted pyrazolate): [Pt(ppy)(µ-H 2 pz)] 2 (1) and [Pt(NDI-ppy)(µ-Ph 2 pz)] 2 (2, NDI = 1,4,5,8-naphthalenediimide), both of which have distinct ground state Pt-Pt distances. X-ray transient absorption spectroscopy at the Pt L III -edge revealed a new d-orbital vacancy due to the one-electron oxidation of the Pt centers in 1 and 2. However, while a transient Pt-Pt contraction was observed in 2, such an effect was completely absent in 1, demonstrating how the excited states of these complexes are determined by the overlap of the Pt (d z 2 ) orbitals, which is tuned by steric bulk of the pyrazolate R-groups in the 3- and 5-positions. In tandem with analysis of the Pt-Pt distance structural parameter, we observed photoinduced charge separation in 2 featuring a covalently linked NDI acceptor on the ppy ligand. The formation and subsequent decay of the NDI radical anion absorption signals were detected upon photoexcitation using optical transient absorption spectroscopy. The NDI radical anion decayed on the same timescale, hundreds of picoseconds, as that of the d-orbital vacancy signal of the oxidized Pt-Pt core observed in the XTA measurements. The data indicated ultrafast formation of the charge-separated state and subsequent charge recombination to the original Pt(II-II) species.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

High-Resolution Computed Tomography Dataset of Mount Simon Sandstone

The Illinois Basin is a critical structure for subsurface energy related activities and their implementation in the United States. The Mount Simon Sandstone has been identified as a storage target for permanent and transient storage of fluids in the basin. Known for its exceptional thickness, depth, porosity, and sealing properties of overlying formations, this saline reservoir is crucial for long-term subsurface energy efforts. We present an extensive Computed Tomography (CT) dataset on a high porosity and permeability zone in the lower Mount Simon Sandstone available on the Energy Data eXchange® (EDX). This publicly accessible database comprises over 500 GB of high-resolution CT scans of six core samples, with resolutions ranging from 14.8 µm to 0.7 µm per pixel. The scans include both dry sandstone samples and those saturated with multiple fluids, allowing for comparative analyses across different conditions and resolutions. Coarser scans capture the bedding structure of the sandstone, while finer resolutions reveal detailed pore infill and throat characteristics. Metadata on location, depth, and saturation state enhance usability, enabling quick identification and cross-sample comparisons. By providing a robust resource for research and collaboration, the database contributes to domestic energy advancement by supporting continued progress in the use of the subsurface for energy solutions.

characterization↗
DOE OSTI2024

Effect of Heat Treatment on Microstructure and Mechanical Property of 316L Stainless Steel Produced by Laser Powder Bed Fusion

The advanced non-light water reactor designs (Gen IV reactors), including molten salt/ very high temperature/ sodium-cooled and lead-cooled fast reactors, typically operate at higher temperatures and more extreme radiation conditions than light water reactors. An intrinsic part of the deployment and progress of Gen IV reactor designs is selecting the most suitable structural material for a specific application. Additive manufacturing (AM), a fairly new process of making physical, three-dimensional objects from a computer design file, is going to completely change the way of design, build and certify nuclear systems. It offers a range of opportunities to produce complex geometries from existing materials, offers new routes for processing of previously difficult to process materials, allows for design of new high-performance materials, and finally facilitates hybridization of dissimilar materials. This emerging technology has successfully produced cars, wind turbine blade molds and even live cells. It could also open up big opportunities for the nuclear industry to quickly deploy technologies at a fraction of the cost. So far, AM techniques have been preliminarily applied in the field of nuclear reactors, including the classical parts such as the pressure vessel of a small reactor with 508-III steel, the bottom nozzle of a fuel assembly with 304L steel, the fuel cladding with zirconium alloy and the integrated impeller of a pump and the multi-channel valve body with 316L steel [6,7]. The AM applications for operating nuclear reactors started in auxiliary plant components and have slowly migrated to metallic reactors and core components, but many of these are not safety critical components. Although many parts used for nuclear reactors have been fabricated by AM techniques, practical applications in engineering are still a long way off due to the uncertainty factors focused on the processing, material properties, analysis methods and application standards, which feeds the safety and life-cycle of the nuclear reactor. Due to rapid, repeated heating and cooling during production, a high dislocation density was present in the AM material. This microstructure feature is unstable at elevated temperature while high temperature is one of the typical operation environments for nuclear reactors. Thus, it is important to understand the thermal effect on the microstructure of AM material. The objectives of this study are to investigate the effect of heat treatment on the microstructure and mechanical properties of 316L stainless steel produced by laser powder bed fusion additive manufacturing, and to determine an appropriate heat treatment practice that will be applied to the lightweight AM lattice-structured material with the same chemistry. The heat treatment study consisted of annealing the samples at a temperature range of 800 to 1200 oC with a 50 oC increment for different times (1-24 hours), followed by vacuum or air cooling. Microstructural characterization was carried out by Scanning Electron Microscope (SEM). Grain size and crystallographic orientation were investigated by Electron Backscatter Diffraction (EBSD). Vickers hardness tests with a 0.5 kg load were employed to determine the hardness of samples after different heat treatments. After heat treatment, the random crystallographic orientation was preserved, and the volume fraction of high-angle grain boundaries (grain boundary misorientation =15 oC) remained the same. The dislocation density decreased with annealing temperature due to recovery. The fine subgrain structures in the as-printed specimen were quite stable up to 1200 oC. Minimal recrystallization was observed up to 1200 oC. Recrystallization initiated only after 8.5 hours at 1200 oC. The SEM images did not show obvious dependence of microstructure on cooling rate. The hardness of the specimens decreased with increasing annealing temperature as a result of the decrease in dislocation density. It is interesting to note that the AM material showed very similar hardness to the wrought material when annealing at similar temperature, although the microstructures are very different. Annealing at 1050 oC for 1 hour followed by air cooling was selected as the heat treatment procedure for the lattice designed lightweight AM 316L material.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Impact of Molten Gallium on the Microstructure and Corrosion Behavior of Aluminum and Uranium-Aluminum Alloys for Used Nuclear Fuel Reprocessing

Test reactors around the world utilize highly enriched uranium fuel to achieve high neutron fluxes for materials testing. Once spent, the remaining uranium is a valuable resource for subsequent fuel fabrication. However, some of these test reactor cores consist of curved plate-type fuel elements, fabricated using aluminum alloy 6061 (AA6061) cladding to encapsulate a uranium-aluminum alloy (UAlx) fuel matrix. These assemblies require non-standard reprocessing approaches for uranium recovery, as aluminum dissolves readily in acidic solutions, generating large volumes of waste and complicating downstream chemical separations. In this work, we investigate a novel chemical decladding strategy based on the interaction between AA6061/UAlx and molten gallium (Ga). Ga is known to induce severe degradation of aluminum metal through liquid metal embrittlement (LME), even at relatively low Ga concentrations. By penetrating the aluminum crystal lattice, Ga disrupts grain cohesion and facilitates fracture or dissolution of the aluminum matrix. Thermodynamic analysis of the Al–Ga binary phase diagram suggests that Ga may offer a viable pathway to selectively weaken or dissolve the AA6061 cladding, and potentially the aluminum component of the UAlx fuel matrix within. To this end, parametric experiments were performed at 50 °C and 100 °C across a range of Al–Ga atomic fractions. At lower Al fractions, the AA6061 was completely molten after 2 hours of exposure to the Ga metal. In contrast, samples with higher Al fractions (0.9 Al, 0.1 Ga) contained residual solids after 2 hours, which were characterized by microstructural examination using electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM). These Al-Ga compositions were also evaluated using FactSage thermodynamic modeling to further elucidate the relationship between phase diagram behavior and LME.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗