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Laser micro-machining and damage testing of rounded shadow cone blockers on silica glass for arresting laser damage growth by redirection of light
Structured conical blockers manufactured on optical input surfaces are being used to shadow, and thereby, arrest growth of exit surface damage on large optics for applications in high-energy laser systems to extend their lifetime usage. However, as the size of the Shadow Cone Blocker (SCB) is increased, the deflected light must be carefully managed to prevent consequential damage from downstream intensification. Here, we design and fabricate a distinct input SCB geometry to alleviate this problem, enabling larger damage site mitigation. The demonstrated ~1 mm diameter SCB was manufactured with a convergent approach using a CO 2 pulsed laser ablative scanning sequence on a fused silica window. The SCB design was refined to maximize resistance to both input and exit surface damage initiations on 1 cm thick fused silica windows when exposed to 351 nm irradiation and validated with laser damage testing. The design showed to prevent damage onset to the exit surface for incident fluences on the SCB of 10.7 ± 1.3 J·cm -2 and is resistant to damage on the input surface exceeding 30 J·cm -2 input fluence.
8 Ft Vessel Refinishing Contract Introduction [Slides]
LANL utilizes spherical vessels for numerous basic science, materials, and system performance experiments. The 8 ft vessel was fabricated in the early 2000s to ASME B&PVC Section VIII Division 1 using HSLA-100 material. This vessel was not used operationally due to programmatic change in direction. Years of improper maintenance and storage has resulted in deterioration of sealing surfaces and bolt hole threads. New mission needs call for expanded capabilities in terms of vessel sizes, therefore refinishing the 8ft vessel is crucial.
High Pressure and Two-Sided Mold Surface Solutions (CRADA Final Report)
This project provided surface solutions for highly loaded precision tooling relevant to the automotive industry. Previous development work in coatings for Big Area Additive Manufacturing (BAAM) has produced commercialized coatings for low temperature Acrylonitrile Butadiene Styrene (ABS) tools (TD Coat RT) as well as a soft coating for high temperature applications (TD Seal HT). The team developed these coatings and commercialized them during a prior Manufacturing Demonstration Facility (MDF) technical collaboration (NFE-15-05793). During the prior collaboration, commercialization testing was successfully performed by the Boeing and NAVAIR and resulted in an Awards for Composites Excellence (ACE), award at CAMX – The Composites and Advanced Materials Expo 2016. While this work was clearly successful, gaps in the technology were identified, that prevent widespread adoption of large-scale additive manufacturing in high pressure tooling applications prevalent in the automotive industry. In this project we focused on development of surface solutions for two-sided, compression molding tooling printed on a large-scale polymer AM system in an arbitrary build orientation. We have printed a single cavity extrusion compression molding mold using Polyphenylene sulfide/carbon fiber (PPS/CF) materials, 50% by weight CF samples. These processes are commonly used by Original Equipment Manufacturers (OEM) and Tier 1 suppliers for high volume automotive applications. Several OEMs have identified the need for such technology, indicating significant time and monetary savings could be possible if commercially available surface solutions for high pressure Additive Manufacturing (AM) tooling existed.
Optimal Geometry for Focused Ion Beam-Milled Samples for Direct-Pull Micro-Tensile Testing Performed In Situ in a Scanning Electron Microscope
A thorough procedure was developed to efficiently manufacture dogbone samples using focused ion beam (FIB) milling for micro-tensile testing. A Bruker PI 89 PicoIndenter, Billerica, MA, USA, was used as a case study, although the analysis and results are applicable to other micro-mechanical testing systems capable of mounting a standard, Ø12.7 mm × Ø3.2 mm pin, scanning electron microscopy (SEM) pin stub (Ted Pella, Redding, CA, USA). Nine dogbones were made from an Fe-45Cu alloy additively manufactured using powder-fed laser-directed energy deposition (DED-LB). Testing showed that fracture was confined to the gauge section for all dogbones and that the fracture mode, ductile vs. brittle, was entirely dependent on the grain orientation relative to the loading direction. The analysis showed that the measured plastic strain to failure can vary from >11% (optimal geometry) to <1% (non-optimal geometry) in micro-tensile testing of high-tensile-strength (>1 GPa) metallic materials. Subsequently, a finite element analysis (FEA) was conducted to identify the improved dogbone geometries. A total of ten thousand dogbone geometries were tested, and their dimensions were defined by a set of four adjustable parameters (corner radius, load surface angle, load surface length, and dogbone head length). The gauge width and gauge length were fixed to 4 µm and 10 µm, respectively. Three-dimensional surface plots of the stress concentration as a function of two parameters were used to identify the optimal ranges of parameter values. The addition of maximum width and length constraints, measuring 25 µm and 30 µm, respectively, allowed us to identify an optimal geometry at load surface angles of 30° and 45°. Their respective dimensions (corner radius, load surface length, and dogbone head length) are, in µm, 12, 6, and 7 and 10, 7, and 7. Testing these two optimal geometries with a range of gauge lengths from 4 to 20 µm showed that smaller gauge lengths only slightly reduced the detrimental stress concentration outside the gauge section. However, smaller gauge lengths will notably improve the FIB surface polishing step as tapering is reduced with smaller dogbone lengths.
[Presentation Slides] Code-to-Code Benchmark Study for Thermal Stress Modeling and Preliminary Analysis of the High-temperature Single Heat-Pipe Experiment
In the heat-pipe-cooled microreactor, heat pipes remove heat from the reactor core as a passive heat-transfer device, so the fluid circulation is not required for cooling, which can substantially simplify the overall reactor design. However, given the extremely high temperatures in the core region and potentially large temperature gradients across the structure materials, thermal stresses need to be well-analyzed to ensure structural integrity during normal operations and accident scenarios. This presentation slides discuss finite element method-based thermal-stress analysis for the high-temperature single heat-pipe test article in the Single Primary Heat Extraction and Removal Emulator (SPHERE) facility at Idaho National Laboratory (INL), using two commercial software packages, Abaqus and Star-CCM+. A code-to-code benchmark study was performed to crosscheck the model setup and capability of each code and to gain preliminary insights into the potential thermal stress concerns from the current experimental setup. It is observed the significant thermal stresses happen at the inner surface of the heat pipe hole surrounded by electric heaters where the largest temperature gradients appear. The temperature fields have good agreements between Abaqus and Star-CCM+, while the induced thermal stresses show modest deviations probably due to differences of meshing engines used in these two codes. It is found that the local maximum thermal stresses may reach close to the ultimate tensile strength and yield strength of structural material depending on the heater power. Ultimately, the coupled thermal-structural analysis will help guide the current experimental plan and ensure the facility safety for future experimental study.
Final Technical Report
The project goal is to demonstrate low-cost, interlocking, and carbon-storing insulation materials with thermal insulation of R5/inch, flexural modulus > 10 MPa, low material price < $ 0.5/ft2 wall area (materials cost for ½” thick panel), and net embodied carbon of 0.8t net CO2e/t (60% reduction compared to gypsum), respectively, which can meet the cost and performance targets of department of energy (DOE)’s 2050 climate target. To achieve this goal, the project plans three tasks, and each has a specific objective: 1) Modular design and engineering analysis of interlocking insulation panel blocks using biogenic materials (cellulose, straw, etc.): with the consideration of potential assembling and recycling. 2) Scalable manufacturing of biogenic-based interlocking insulation panels: scale up the modular panel production using ambient pressure drying and surface superhydrophobic modification at 1ft*1ft with the potential for further scalable mass production of 4ft*4ft. 3) Code-compliant testing, recycling and carbon footprint analysis of manufactured interlocking insulation panels examined using ASTM standards of thermal insulation (ASTM C518), mechanical properties (ASTM C1161), and water vapor transmission (ASTM E96).
Nuclear fusion powered Titan aircraft
This paper discusses a system for Titan exploration enabled by nuclear fusion power. Titan is one of the most interesting locations in the solar system with a thick atmosphere, surface oceans, under-ice oceans and complex terrain. This paper provides a conceptual design of a fusion-powered system to explore many parts of Titan and enable the use of high-power instruments. The design includes a fusion-powered orbital transfer vehicle and an electric Titan science aircraft. A Direct Fusion Drive (DFD) propulsive engine could bring a sizable spacecraft to Titan orbit in less than two years. A second fusion reactor, configured as a closed-loop power generator, would be used for an electric Titan science aircraft. Both reactors are based on the Princeton Field-Reversed Configuration (PFRC) concept which combines an FRC with a magnetic mirror. PFRC uses a novel radio-frequency plasma heating system and deuterium-helium-3 fuel. A lower temperature plasma flows around the closed-field FRC region removing the fusion products. In the DFD propulsive configuration, this secondary flow permits direct and variable thrust and exhaust velocity. The science aircraft would do a powered entry to Titan and then have the capability to fly anywhere on the moon at subsonic speeds. The DFD-powered transfer vehicle would allow the in-orbit transfer stage to change inclination as needed to cover different areas of the surface.
Evaluating software defined networking solutions to reduce the digital attack surface of nuclear security systems
Most nuclear security systems used today were not designed for today’s threat environment. Systems that were intended to be stand alone are now interconnected. Devices that have a single purpose are built on multi-purpose platforms and communication protocols that, while effective, have no ability to authenticate authorized versus unauthorized commands. These attributes provide an attacker significant ability to affect the system, pivot throughout the interconnected networks, and remain undetected if he/she is able to compromise a single node. Software defined networking (SDN) has been used for years by information technology (IT) cloud service providers to quickly provision or remove servers or other systems to meet changing demand. The same concept has recently been applied to operational technology (OT) systems to enable very fast failover on critical systems that have stringent and deterministic (<5ms) transmit/receive times. By carefully engineering the communication flows through a network using preplanned routes and specific pathways it is possible to achieve deterministic and extremely reliable message delivery even when components fail. This engineering approach to network design has added security benefits including securing the networking control plane, eliminating network scanning and mapping, inhibiting ARP spoofing and host masquerading, eliminating unauthorized network pivoting and enabling greater situational awareness on the network. SDN in OT environments is new but early testing in electrical power and other critical infrastructure has shown it to be a very powerful tool for building reliable networks and reducing the digital attack surface of the network. The authors tested a software defined network switch on a simple physical protection system with components commonly found in nuclear security systems and found improved mitigations to denial of service attacks, lateral movement and network reconnaissance. The paper details the tests and their results.
Structural studies of the IFNλ4 receptor complex using cryoEM enabled by protein engineering
Abstract IFNλ4 has posed a conundrum in human immunology since its discovery in 2013, with its expression linked to complications with viral clearance. While genetic and cellular studies revealed the detrimental effects of IFNλ4 expression, extensive structural and functional characterization has been limited by the inability to express and purify the protein, complicating explanations of its paradoxical behavior. In this work, we report a method for robust production of IFNλ4. We then use yeast surface display to affinity-mature IL10Rβ and solve the 72 kilodalton structures of IFNλ4 (3.26 Å) and IFNλ3 (3.00 Å) in complex with their receptors IFNλR1 and IL10Rβ using cryogenic electron microscopy. Comparison of the structures highlights differences in receptor engagement and reveals a distinct 12-degree rotation in overall receptor geometry, providing a potential mechanistic explanation for differences in cell signaling, downstream gene induction, and antiviral activities. Further, we perform a structural analysis using molecular modeling and simulation to identify a unique region of IFNλ4 that, when replaced, enables secretion of the protein from cells. These findings provide a structural and functional understanding of the IFNλ4 protein and enable future comprehensive studies towards correcting IFNλ4 dysfunction in large populations of affected patients.
Material and Interface Engineering Strategies to Mitigate Decoherence in Superconducting Qubits
While significant strides have been made to increase the coherence time of superconducting qubits, further advancements are essential for realizing scalable quantum computing. Decoherence is often a result of loss and noise stemming from two-level systems and excess quasiparticles, arising due to material defects, fabrication processes, and ambient exposure, particularly at surfaces and interfaces. Our recent efforts to mitigate these decoherence mechanisms have employed a variety of strategies, including low-loss surface encapsulation materials, advanced substrate preparation techniques, modifications to metal film growth, and the development of novel fabrication processes. The structural and chemical properties of materials, surfaces, and interfaces are studied using scanning probe microscopy, electron microscopy, photoelectron spectroscopy, mass spectrometry, and X-ray diffraction, which is correlated to device performance metrics, including superconducting resonator internal quality factor and qubit T1 time. This information is used to identify and understand material sources of loss and their origins in the device fabrication process. Through multi-institution efforts within SQMS we have identified the loss mechanism of interstitial hydrogen in niobium-based devices and shown how standard fabrication processes introduce these hydrides, developing strategies to mitigate their formation.1 Furthermore, we have characterized the metal-substrate interface, including the loss of niobium-silicides formed at that interface, and developed silicon surface treatments that reduce atomic scale roughness and oxygen content at the metal-substrate and Josephson junction interfaces.2-4 By developing the connection between materials properties and the overall performance of superconducting quantum circuitry, we can develop fabrication strategies to mitigate material losses, thus supporting the ongoing efforts to enhance coherence time in superconducting quantum devices. 1. Torres-Castanedo, C. G.*, Goronzy, D. P.*, et al., Adv. Funct. Mater., 2401365 (2024) 2. Lu, X., et al., Phys. Rev. Materials 6, 064402 (2022) 3. Berti, G., Appl. Phys. Lett. 122, 192605 (2023) 4. Kopas, C. J., Goronzy, D. P., et al., arXiv:2408.02863 (2024)
Investigation of NO adsorption and desorption phenomena on a Pd/ZSM-5 passive NO x adsorber
Pd-based zeolite materials have gained significant attention as passive NO x adsorbers (PNAs) for diesel-engine cold-start NO x mitigation due to their ability to store NO x at low temperatures. Pd/ZSM-5 is a promising PNA candidate, however, the NO adsorption mechanism over this material is not well understood. This study combines flow reactor experiments and surface spectroscopy to investigate NO adsorption under a variety of conditions. Furthermore, the state of hydration of the Pd cations played an important role in determining the impact of H 2 O and CO concentration on the PNA performance. Below 150 °C, the inhibition effect of H 2 O on NO adsorption was mitigated by CO. Due to dehydration, neither H 2 O nor CO had an impact on NO uptake at 150 °C, where maximum NO storage capacity of the PNA was also observed. The observed gas composition and temperature effects on NO adsorption and formation of surface intermediates ultimately inform a proposed mechanism.
Isoform- and ligand-specific modulation of the adhesion GPCR ADGRL3/Latrophilin3 by a synthetic binder
Adhesion G protein-coupled receptors (aGPCRs) are cell-surface proteins with large extracellular regions that bind to multiple ligands to regulate key biological functions including neurodevelopment and organogenesis. Modulating a single function of a specific aGPCR isoform while affecting no other function and no other receptor is not trivial. Here, we engineered an antibody, termed LK30, that binds to the extracellular region of the aGPCR ADGRL3, and specifically acts as an agonist for ADGRL3 but not for its isoform, ADGRL1. The LK30/ADGRL3 complex structure revealed that the LK30 binding site on ADGRL3 overlaps with the binding site for an ADGRL3 ligand – teneurin. In cellular-adhesion assays, LK30 specifically broke the trans-cellular interaction of ADGRL3 with teneurin, but not with another ADGRL3 ligand – FLRT3. Our work provides proof of concept for the modulation of isoform- and ligand-specific aGPCR functions using unique tools, and thus establishes a foundation for the development of fine-tuned aGPCR-targeted therapeutics.
Learning heterogeneous reaction kinetics from X-ray videos pixel by pixel
Reaction rates at spatially heterogeneous, unstable interfaces are notoriously difficult to quantify, yet are essential in engineering many chemical systems, such as batteries and electrocatalysts. Experimental characterizations of such materials by operando microscopy produce rich image datasets, but data-driven methods to learn physics from these images are still lacking because of the complex coupling of reaction kinetics, surface chemistry and phase separation. Here we show that heterogeneous reaction kinetics can be learned from in situ scanning transmission X-ray microscopy (STXM) images of carbon-coated lithium iron phosphate (LFP) nanoparticles. Combining a large dataset of STXM images with a thermodynamically consistent electrochemical phase-field model, partial differential equation (PDE)-constrained optimization and uncertainty quantification, we extract the free-energy landscape and reaction kinetics and verify their consistency with theoretical models. We also simultaneously learn the spatial heterogeneity of the reaction rate, which closely matches the carbon-coating thickness profiles obtained through Auger electron microscopy (AEM). Across 180,000 image pixels, the mean discrepancy with the learned model is remarkably small (<7%) and comparable with experimental noise. Our results open the possibility of learning nonequilibrium material properties beyond the reach of traditional experimental methods and offer a new non-destructive technique for characterizing and optimizing heterogeneous reactive surfaces.
Residual strain-stress in manganese steel railway crossing determined by synchrotron and laboratory X-rays
The residual stress within the nose of a worn manganese steel railway crossing was investigated. The macroscopic residual stress at the running surface was determined in areas with and without visual faults by laboratory X-rays. To get information about the penetration depth of the residual stress, synchrotron X-ray diffraction was used to map the distribution of local (within grain) residual strains below the running surface. The laboratory X-ray measurements revealed significant compressive stress on the rail running surface. The synchrotron measurements documented that local strains exist through the entire depth investigated. Relations between residual stress, plastic deformation, and crack formation are analysed, leading to a discussion on potentials/limitations of the two experimental methods for investigations of residual stress in large engineering components.
Performance analysis of photodetectors based on 2D materials and heterostructures
The unprecedented demand for sophisticated, self-powered, compact, ultrafast, cost-effective, and broadband light sensors for a myriad of applications has spurred a lot of research, precipitating in a slew of studies over the last decade. Apart from the photosensing ability of an active element in the light sensor, the device architecture is crucial in terms of photoinduced charge carrier generation and separation. Since the inception of graphene and the subsequent research growth in the atomically thin 2D materials, researchers have developed and adapted different families of 2D materials and device architectures, including single element 2D, 0D/2D, 2D/2D, 1D/2D stacked structures, and so on. Here this review discusses the recent reports on the light-sensing properties of various 2D materials, their heterostructures, and characteristics applicable to the ultraviolet-near infrared (UV-NIR), short-wave IR (SWIR), mid-wave IR (MWIR), long-wave IR (LWIR), and terahertz (THz) spectral ranges. It highlights the novelty of the burgeoning field, the heightened activity at the boundaries of engineering and materials science, particularly in the generation of charge carriers, their separation, and extraction, and the increased understanding of the underpinning science through modern experimental approaches. Devices based on the simultaneous effects of the pyro-phototronic effect (PPE) and the localized surface plasmon resonance (LSPR) effect, the photothermoelectric effect (PTE)-assisted photodetectors (PDs), waveguide-integrated silicon-2D PDs, metal-2D-metal PDs, and organic material PDs are examined rigorously. Theoretical treatment utilizing various computational approaches to investigate 2D materials and heterostructures for photodetection applications is also briefly discussed. At the end, current challenges and solutions to enhance the figures of merit of photodetectors are proposed.
Low-Cost, Scalable Sorbents with Balanced Capacity-Kinetics-Thermodynamics for H2 Storage
The goal of this project is to utilize cutting-edge materials science, chemistry, and process engineering to demonstrate the feasibility of a new class of scalable sorbents with unprecedented balance of capacity-kinetics-thermodynamics for H 2 storage in fossil fuel power plants . The core fabrication leverages the unique exotic properties (e.g., high H 2 affinity, ultrahigh surface area, and exceptional thermal, mechanical and chemical stability) of the emerging 2D materials i.e. hexagonal boron nitride (hBN) followed by strategic coupling with alkali metals (Li, Na) dopants and optimal interlayer distance to deliver a stable, long-term energy storage for the grid. Figure 1 shows how this technology works.