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DOE OSTI2022

National Smart Manufacturing Strategic Plan: To Facilitate More Rapid Development, Deployment and Adoption of Smart Manufacturing Technologies

Smart manufacturing technologies provide real-time data and insight to improve the productivity, efficiency, and competitiveness of U.S. manufacturing, creating the potential for new jobs in the manufacturing sector. These technologies can support U.S. manufacturers’ ability to increase throughput and energy efficiency, and decrease waste, defects, and costs. A wide range of manufacturing and industrial subsectors, particularly energy-intensive and energy-dependent industries, have the potential to benefit from smart manufacturing technologies. There are technical improvements still needed to reduce the costs and barriers (trained workforce and upskilling, software-hardware integration, cost, and technical barriers to deployment of advanced sensors, computing, and communication technologies for existing manufacturing assets) to the adoption of smart manufacturing technologies, especially to small and medium-sized manufacturers, and subsequently, increase the overall adoption rate of smart manufacturing technologies. This report outlines the Department of Energy’s (DOE) strategic plan to accelerate the development and implementation of smart manufacturing technologies in the United States and the actions DOE has taken to use these technologies in smart manufacturing for the United States. DOE’s plan to facilitate more rapid development, deployment and widespread adoption of smart manufacturing technologies derive from the 2018 Strategy for American Leadership in Advanced Manufacturing. The strategy outlines a vision for America’s leadership in advanced manufacturing including the development of intelligent manufacturing systems to optimize manufacturing facilities and support the manufacturing of transformative materials. DOE’s Clean Energy Smart Manufacturing Innovation Institute (CESMII), a Manufacturing USA Institute, focuses on accelerating the development and adoption of advanced sensors, controls, platforms, and models needed for smart manufacturing. The objective is to enhance U.S. manufacturing productivity and global competitiveness through the research and development of these technologies. Smart manufacturing has the potential to improve the overall performance, energy productivity, and efficiency of manufacturing, fostering the economic competitiveness of the manufacturing sector.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2021

Future Battery Material Demand Analysis Based on U.S. Department of Energy R&D Targets

The U.S. Department of Energy’s Vehicle Technologies Office (VTO) supports research, development, and deployment of efficient, sustainable transportation technologies that will improve energy efficiency and fuel economy, and enable America to use less petroleum. To accelerate the development and adoption of new technologies, VTO has developed specific targets for a wide range of powertrain components, including the energy storage system. In this study, we use Autonomie, Argonne National Laboratory’s (Argonne’s) vehicle system simulation tool to evaluate future energy storage requirements (power, energy, etc.) for different vehicle classes, powertrains, component technologies and timeframes. BatPac, Argonne’s tool dedicated to energy storage pack design and costs, is then used to quantify the materials required for each pack. Market penetrations are then used to estimate the overall material demand worldwide and in the United States, with or without recycling. The results demonstrate that the positive impact of VTO research and development will lead to significant reduction in material compared to business-as-usual due to new anode and cathode designs, along with acceleration in battery cell chemistry penetrations. In terms of material demands, it is observed that lithium demand reaches about 80,000 tons (by a factor of 42–45), nickel demand reaches about 500,000 tons (by a factor of 47–56), manganese demand reaches about 30,000–50,000 tons (by a factor of 20–34), and cobalt demand reaches about 30,000 tons (by a factor of 13–28) in the future by 2050. The individual material demand per unit energy, however, decreases significantly in the future due to advances in VTO research and development activities. The increase in battery material demands is mostly driven by increased electrified vehicle fleet penetration in the markets.

25 ENERGY STORAGE↗

DOE OSTI2023

End-to-end AI framework for interpretable prediction of molecular and crystal properties

We introduce an end-to-end computational framework that allows for hyperparameter optimization using the DeepHyper library, accelerated model training, and interpretable AI inference. The framework is based on state-of-the-art AI models including CGCNN, PhysNet, SchNet, MPNN, MPNN-transformer, and TorchMD-NET. We employ these AI models along with the benchmark QM9, hMOF, and MD17 datasets to showcase how the models can predict user-specified material properties within modern computing environments. We demonstrate transferable applications in the modeling of small molecules, inorganic crystals and nanoporous metal organic frameworks with a unified, standalone framework. We have deployed and tested this framework in the ThetaGPU supercomputer at the Argonne Leadership Computing Facility, and in the Delta supercomputer at the National Center for Supercomputing Applications to provide researchers with modern tools to conduct accelerated AI-driven discovery in leadership-class computing environments. We release these digital assets as open source scientific software in GitLab, and ready-to-use Jupyter notebooks in Google Colab.

36 MATERIALS SCIENCE↗

DOE OSTI2024

DuraMAT: Building a Consortium to Accelerate the Photovoltaic Module Reliability Learning Cycle

Durable and reliable photovoltaic (PV) modules are critical to enabling an efficient transition to sustainable energy generation. The rate at which new module designs and materials are developed and deployed currently outpaces the rate at which we can identify failure mechanisms and understand degradation rates. Increasing the service life of PV modules, and our ability to predict performance over time, requires more durable materials and designs, better durability testing, more extensive material characterization, robust modeling, and methods to cross-examine historical performance data to extract meaningful results. This is a multidisciplinary challenge that requires expertise from a broad range of fields and, therefore, benefits significantly from a collaborative approach. In this Perspective, we outline the approach taken by the Durable Module Materials Consortium (DuraMAT), present a few case studies where our approach was successful, and provide an outlook on where this approach might be applied as the PV technology landscape continues to rapidly evolve. Published by the American Physical Society 2024

14 SOLAR ENERGY↗

DOE OSTI2015

Evaluation of Aluminum-Boron Carbide Neutron Absorbing Materials for Interim Storage of Used Nuclear Fuel

The objective of this work was to understand the corrosion behavior of Boral® and Bortec® neutron absorbers over long-term deployment in a used nuclear fuel dry cask storage environment. Corrosion effects were accelerated by flowing humidified argon through an autoclave at temperatures up to 570°C. Test results show little corrosion of the aluminum matrix but that boron is leaching out of the samples. Initial tests performed at 400 and 570°C were hampered by reduced flow caused by the rapid build-up of solid deposits in the outlet lines. Analysis of the deposits by XRD shows that the deposits are comprised of boron trioxide and sassolite (H 3 BO 3 ). The collection of boron- containing compounds in the outlet lines indicated that boron was being released from the samples. Observation of the exposed samples using SEM and optical microscopy show the growth of new phases in the samples. These phases were most prominent in Bortec® samples exposed at 570°C. Samples of Boral® exposed at 570°C showed minimal new phase formation but showed nearly the complete loss of boron carbide particles. Boron carbide loss was also significant in Boral samples at 400°C. However, at 400°C phases similar to those found in Bortec® were observed. The rapid loss of the boron carbide particles in the Boral® is suspected to inhibit the formation of the new secondary phases. However, Material samples in an actual dry cask environment would be exposed to temperatures closer to 300°C and less water than the lowest test. The results from this study conclude that at the temperature and humidity levels present in a dry cask environment, corrosion and boron leaching will have no effect on the performance of Boral® and Bortec® to maintain criticality control.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

In Cell Thermal Creep Frames for Demonstration Project Preparations

The thrust of advanced nuclear reactor demonstrations demands the accelerated qualification of in-core materials to enable licensing processes and developing the performance data. Due to the high-operating temperatures of such reactors, long-term mechanical behavior under constant load is essential to determine the geometrical and mechanical integrity of in-core components during operation and off-normal conditions. Therefore, the thermal creep behavior of neutron-irradiated advanced reactor materials must be determined. The feasibility of using subsize specimens for the irradiation campaigns and the limited available infrastructure challenge the assessment of thermal creep behavior of advanced reactor materials. Therefore, the U.S. Department of Energy Office of Nuclear Energy (DOE-NE) National Reactor Innovation Center (NRIC) prioritizes the development of a thermal creep testing infrastructure for multiple subsize specimens to accelerate the demonstration and deployment of advanced reactor concepts. This report describes the activities for the construction of a thermal creep testing capability at Idaho National Laboratory (INL). The overall project consists of conceptual design, out-of-cell demonstration, and in-cell demonstration phases. During fiscal year (FY)-2021, the team finished the conceptual design of a thermal creep test facility that can test multiple subsize specimens. This conceptual design consisted of the determination of technical and functional requirements, the determination of the design space, and the preparation of the technical drawings. Technical and functional requirements were categorized as required and desired capabilities and the conceptual design was performed to meet all the required capabilities with the flexibility to achieve the desired capabilities. The design space identified the operational capacity of the creep frame for different advanced reactor relevant materials with the consideration of the feasible operation in the hotcell at the Fuels and Applied Science Building (FASB) at INL. Based on the requirements and design space, the multiple specimen creep frame was designed. The official INL engineering drawing process was started and the procurement of materials for construction was initiated. For FY-2022, the out-of-cell demonstration and final installation of the multiple creep frame is planned.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Performance and Reliability of Bonded Interfaces for High-Temperature Packaging

Sintered silver has proven to be a promising candidate for use as a die-attach and substrate-attach material in automotive power electronics components. It holds promise of greater reliability than lead-based and lead-free solders, especially at higher temperatures (>200 degrees C). Accurate predictive lifetime models of sintered silver need to be developed and its failure mechanisms thoroughly characterized before it can be deployed as a die-attach or substrate-attach material in wide-bandgap device-based packages. Mechanical characterization tests that result in stress-strain curves and accelerated tests that produce cycles-to-failure result will be conducted. Also, we present a finite element method (FEM) modeling methodology that can offer greater accuracy in predicting the failure of sintered silver under accelerated thermal cycling. A fracture mechanics-based approach is adopted in the FEM model, and J-integral/thermal cycle values are computed.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2019

Initial growth of tin on niobium for vapor diffusion coating of Nb 3 Sn

Nb 3 Sn offers significant potential to exceed the performance of niobium for superconducting radio frequency accelerator cavities. The most promising path toward deployment is by tin vapor diffusion coating of Nb cavity interiors via a two step nucleation-then-growth sequence. Reported here is a materials science study of the nucleation process. We manipulated the accessible range of process variables and determined the effect on composition and microstructure using an array of materials characterization tools. Broadly, nucleation deposits tin as a thin surface phase and, under some conditions, as near-micron sized particles as well, resembling Stranski–Krastanov growth. Conditions that impair nucleation promote the formation of defects, such as patches, in subsequent coating growth. Furthermore no significant effect on the subsequently grown coating was found for structures produced during nucleation.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Graduating Sustainable Industrial Decarbonization Solutions from the Laboratory to Real-World Deployments

Accelerating innovation and integration of industrial decarbonization technology solutions is crucial for achieving industry-wide net-zero greenhouse gas emissions targets. This can be accomplished in various ways through increased utilization of low-embodied carbon materials and the adoption of advanced manufacturing techniques in construction practices. At the National Renewable Energy Laboratory (NREL), we facilitate dialogue and action across all sectors to uncover industry needs to inform innovation, and explore ways we can help with implementation of emerging solutions in the real world. As an applied laboratory, NREL sits between academia and industry to fully bridge the gap from foundational science research to examining the feasibility of market applications. Integration of innovative technologies and solutions that are efficient, resilient, and grid-interactive will play a pivotal role in supporting a clean energy future. However, it is imperative that these solutions prioritize equitable outcomes, addressing the challenges faced by all communities. By embracing decarbonization, the construction industry can revolutionize itself, promoting sustainability, reducing carbon emissions, conserving resources, while enhancing performance and durability - all major steps toward a greener and more sustainable future.

cement↗

DOE OSTI2025

Investigation into Scalable and Detection-Enhanced Satellite Conjunction Assessment

Imaging opportunities (viewable conjunctions) of Resident Space Objects (RSOs) by satellites are not continuously discovered. We propose to continuously produce and report viewable conjunctions among objects in orbit. Viewable conjunctions are events in space and time when a satellite may favorably view a Resident Space Object (RSO). Favorability is defined by a set of constraints, e.g., solar illumination, distance between observer and target, orbital location for viewable event. Computing viewable conjunctions requires calculation of orbital propagation while considering constraints based on the state vectors of position, velocity, with covariance for both satellite and RSO. We propose two parallel lanes of effort: acceleration and research. The objective of acceleration is to avoid missed opportunities and reduce latency for satellite maneuver requests through continuous prediction and reporting of viewable conjunctions. The effort will begin by deploying currently available software on dedicated systems and continue with optimizing the code for high performance computing hardware. The research lane aims to expand RSO inspection and modeling capabilities. Among our current research ideas are spectral characterization of RSO materials and planning multiple observations to recover RSO 3D form. Computing resources at Oak Ridge National Laboratory (ORNL) are available for the acceleration work. Laika, Maxar conjunction prediction dashboard software, and Bluesim, Maxar orbital propagation software, are expected to be the first software in the acceleration lane. Laike and Bluesim are to be provided by the sponsor, and output will be made accessible through its dashboard. Deliverables will follow a gated schedule to the sponsor. ORNL will provide progressively more robust viewable conjunction assessments from both modelled and actual ephemerides.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2026

Agentic workflow enables the recovery of critical materials from complex feedstocks via selective precipitation

We present a multi-agentic workflow for critical materials recovery that deploys a series of AI agents and automated instruments to recover critical materials from produced water and magnet leachates. This approach achieves selective precipitation from real-world feedstocks using simple chemicals, accelerating the development of efficient, adaptable, and scalable separations to a timeline of days, rather than months and years.

Ritchhart, Andrew J.↗

DOE OSTI2024

SERAPH: Dark Matter Searches with SRF Cavities and Transmon Qubits

The Superconducting Quantum Materials and Systems Center, led by Fermi National Accelerator Laboratory, is one of five research centers funded by the U.S. Department of Energy as part of a national initiative to develop and deploy the world s most powerful quantum computers and sensors. SQMS will also apply the same technologies used for quantum computing, such as SRF cavities and superconducting qubits, to search for fundamental physics. This presentation will focus on the SERAPH experiment, a family of superconducting haloscopes being developed by SQMS to search for wavelike dark matter like axions and dark photons. In this presentation, I will focus on the progress of the current phase of SERAPH, which will search dark photon dark matter using a widely-tunable SRF cavity (4-7 GHz) with Q>10^8. In parallel, SQMS has recently developed superconducting transmon qubits with leading coherence times. I will report new results for SQMS dark matter searches implementing these qubits to subvert the Standard Quantum Limit noise.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2023

Advanced Reactor Supply Chain Assessment (GAIN Report)

Several net-zero scenario evaluations predict a rapid ramp up of nuclear energy in the coming decades. If this materializes, it will most likely strain the supply chains associated with the potential advanced reactor concepts awaiting deployment. To help assess the current and potential capacities of the various advanced reactor supply chains, the Gateway for Accelerated Innovation in Nuclear (GAIN) conducted a survey of companies able to produce components for advanced reactors in the near future (namely for sodium, gas-cooled, and molten salt reactors). Using an aggressive nuclear deployment scenario, the objective was to assess the ability of the various supply chains to meet the considerable demand projections for certain key components (vessels, heat exchangers, pumps, graphite, and sensors) and identify potential challenges. While individual companies were unable to meet the most optimistic nuclear deployment rate projections, it was found that on aggregate, a United States-based supply chain projected that expansion could be ramped up to meet a larger future demand of these components. However, meeting projected demand for several more complex items (namely gas or salt heat exchangers) was found to be more challenging. Deploying new reactors at scale necessitates the production of more and more supply chain components, requiring a ramp up in production. Supply chain companies were surveyed, and respondents appeared less able to meet short term demand (next year) versus longer-term demand projections (5 and 10 years). This reflects the need to obtain orders with adequate lead times (can range from 3 to 30 months). Future demand will need to be met by expanding existing capacity. These expansions will require suppliers to raise capital or secure other types of support (federal loans or grants) to invest in facilities, equipment, and workforce. Individual suppliers indicated financial investments could be in the range of $\$ $100 million to $\$ $1 billion for their own facilities (depending on the type of facility). The biggest risk, according to respondents, related to general uncertainties surrounding the future nuclear industry and whether the potential demand projections will materialize into real demand that is actionable from a business perspective. Businesses do not seem willing to take investments risks without clear orders. If businesses are not able to invest to expand the supply, it will either delay the deployment of advanced nuclear technology, or the supply chain will be met by suppliers outside of the United States. This report only focuses on the domestic supply chain’s ability to meet the various projections stipulated here for the specific assessed components (vessels, heat exchangers, pumps, graphite, and sensors). The report does not cover all reactor designs or all components that may ultimately be needed for any one reactor design. It also does not address whether any specific aspect of the supply chain will be cost competitive in the global market, nor how potential state-backed entities could affect the expansion of a United States-based supply chain. The largest challenges in ramping up capacity among respondents appear to be workforce related. This includes workforce availability, experience, training, and turnover. In addition to facility investment, suppliers will also need to invest heavily in long-term workforce training to meet production goals. This issue is not nuclear-specific, and the expansion of any supply chain will likely face similar challenges. While suppliers evaluated expected normal business demand from other markets outside of nuclear, it is possible that other market segments could expand more than predicted and compete for the same suppliers. One potential market that may compete for the same supplier resources is the United States military, as many of these suppliers support both the commercial nuclear sector as well as the Navy with reactors and components. In summary, suppliers in the United States believe that there is a way to increase production in order to begin meeting the demand which will exist for advanced reactors—as long as appropriate investments can be made in the supply chain in an appropriate timeframe. Based on the capacity projections and lead times, investment will be needed to meet the 5-year and 10-year production targets. Therefore, if significant nuclear deployment is to occur in the 2030s, investment and ramp up of the advanced nuclear supply chain will need to begin in the near future for the United States to successfully deploy these advanced reactors with domestic supply chains.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Impact of breech geometry and propellant flow on the release of large pellets for the ITER disruption mitigation system

Studies have been performed on the release mechanism for large pellets using high pressure gas in a shattered pellet injector. Typically, pellets are dislodged from the cryogenic surface and accelerated down a barrel using high pressure gas delivered by a fast-acting propellant valve. The pellets impact an angled surface which shatters the pellet into many small fragments before entering the plasma. This technique was initially demonstrated on DIII-D (Commaux et al 2016 Nucl. Fusion 56 046007) and is now deployed on JET, KSTAR, ASDEX-Upgrade, and other tokamaks around the world in support of ITER's disruption mitigation system design and physics basis. The large hydrogen, 28.5 mm diameter, 2 length-to-diameter ratio, pellets foreseen for ITER SPI operation have low material strength and low heat of sublimation, which cause the pellets to be fragile and highly reactive to the impact of warm propellant gas. Due to the size of the pellets, significantly more propellant gas is required to dislodge and accelerate them. This creates a potentially significant propellant gas removal issue as 2–6 bar-L of gas is expected to be required for release and speed control. The research presented in this paper is an in-depth exploration of the parameters that are keys to reliable pellet release and speed control. Computational fluid dynamics (CFD) modeling of propellant flows through various breech designs was conducted to determine the force generated on the back surface of a pellet. These simulations assumed the use of the ORNL designed flyer plate valve. CFD modeling combined with experimental measurements provide adequate insight to determine a path to an optimal valve and breech design for ITER SPI pellet release and speed control while minimizing propellant gas usage.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Material efficiency technologies in the food and beverage industry

The U.S. food and beverage (F&B) sector is a major contributor to manufacturing gross domestic product and supports substantial employment and economic activity, while exerting significant pressures on land and water resources. At the same time, the industry faces growing expectations to balance its resource-intensive operations without compromising cost competitiveness. Material inefficiencies across the F&B value chain, particularly in raw material use and product loss/waste, lead to substantial financial losses and resource depletion. Thus, the F&B sector requires adoption of solutions and measures to avoid food wastage, reduce raw material consumption and valorize waste to high-value added products. This work presents a comprehensive understanding of the various technology solutions available for the F&B sector. The following two research questions are addressed: “What are the mid-to-high Technology Readiness Level technologies or measures to reduce material use and enable waste valorization in the F&B sector? What are the barriers to their commercial deployment? Additionally, what targeted research and development efforts are needed to overcome these barriers and accelerate their scale-up?” The findings are intended to support evidence-based decision-making, guide strategic investment, and help stakeholders strengthen resilience and competitiveness across the F&B sector.

Nain, Preeti [ORNL] (ORCID:0000000258358959)↗

DOE OSTI2022

Topical Group on Application and Industry Community Engagement Frontier Snowmass 2021 (Summary Report)

HEP community leads and operates cutting-edge experiments for the DOE Office of Science which have challenging sensing, data processing, and computing requirements that far surpass typical industrial applications. To make necessary progress in the energy, material, and fundamental sciences, development of novel technologies is often required to enable these advanced detector and accelerator programs. Our capabilities include efficient co-design, which is a prerequisite to enable the deployment of advanced techniques in a scientific setting where development spans from rapid prototyping to robust and reliable production scale. This applies across the design spectrum from the low level fabrication techniques to the high level software development. It underpins the requirement for a holistic approach of innovation that accelerates the cycle of technology development and deployment. The challenges set by the next generation of experiments requires a collaborative approach between academia, industry and national labs. Just a single stakeholder will be unable to deliver the technologies required for the success of the scientific goals. Tools and techniques developed for High Energy Physics (HEP) research can accelerate scientific discovery more broadly across DOE Office of Science and other federal initiatives and also benefit industry applications.

43 PARTICLE ACCELERATORS↗

DOE OSTI2019

Development of an accelerator-based diagnostic for plasma-facing surfaces in magnetic confinement devices

The focus of this work was the development of the Accelerator-based In-situ Material Surveillance (AIMS) diagnostic. The understanding of plasma-material interaction processes in fusion devices has been greatly hampered by the lack of ability to measure the surface ~micron layers of solid surfaces that are in contact with and greatly modified by the boundary fusion plasma. AIMS was the first diagnostic developed and deployed that allowed non-destructive surface measurements with adequate spatial and time resolution. The deployment was primarily carried out on the Alcator C-Mod tokamak. AIMS diagnostic goal is to remotely generate isotopic concentration maps on a plasma shot-to-shot timescale that cover a large fraction of the plasma-facing surface inside of a magnetic fusion device without the need for vacuum breaks or physical access to the material surfaces. The diagnostic used a compact (~ 1 m), high-current (~ 1 milliamp) radio-frequency quadrupole accelerator to inject 0.9 MeV deuterons into the Alcator C-Mod tokamak. The tokamak magnetic fields were controlled – in between plasma shots – to steer the deuterons to material surfaces where the deuterons cause high-Q nuclear reactions with low-Z isotopes up to 5 microns into the material. The induced neutrons and gamma rays are measured with scintillation detectors; energy spectra analysis provides quantitative reconstruction of surface compositions. Experimental validation showed that low-Z isotopes such as deuterium and boron can be quantified on the material surfaces, and that magnetic steering provides access to different measurement locations. AIMS measurements of D retention on inner wall PFCs were acquired during diverted and limited plasma operations and during wall conditioning experiments om Alcator C-Mod. Intershot measurements demonstrate the local erosion and co-deposition of boron films on PFC surfaces with a constant D-B ratio. This is consistent with previous results suggesting that D co-=deposition with boron is insufficient to account for the net retention observed in Alcator C-Mod. Changes in deuterium concentration during boronization, electron cyclotron and glow cleanings were also measured. These initial results were limited to studying low-Z surface properties, because the Coulomb barrier precludes nuclear reactions between high-Z elements and the ~1 MeV AIMS deuteron beam. In order to measure the high-Z erosion of interest in Alcator C-Mod and future fusion devices, a new technique using deuteron-induced gamma emission and a low-Z depth marker was developed using implanted depth markers as a method of measuring bulk erosion and redeposition. This method is dubbed DEA: Depth marker Erosion with AIMS. DEA simulations and experiments were used to validate this technique, both in the laboratory and via experiments in the EAST tokamak. Based on these results, the DEA technique, using ion beam implanted depth markers as a reference to the surface in order to monitor surfaces for erosion and redeposition, is a viable option as a diagnostic, both in and ex situ. These markers show stability to temperature, the tokamak environment, and multiple probing beams. The ex-situ (eDEA) method, which uses resonances in the cross sections of gamma producing reactions to track the surface, was used to successfully measure erosion in samples that were exposed in the EAST tokamak. The in-situ (iDEA) method, which uses the gamma yield ratio to monitor changes to the surface, was used to differentiate between markers implanted to different depths. Both techniques were successfully simulated, and both presented unique challenges experimentally and in data analysis. In particular, the eDEA probing beam was found to have energy variations leading to initial experimental uncertainty, and the iDEA gamma spectra had conflicting gamma peaks which make data analysis difficult. However, the end result is a promising framework for a diagnostic technique that supplements the abilities of AIMS and expands the possibilities of surface diagnostics in fusion devices. While the results of this work are overwhelmingly encouraging for further development of AIMS in general, and the DEA technique specifically, several areas require significant development before this diagnostic is as robust and widely applicable as a surface diagnostic ought to be. Recommended future work includes the development of a cross section/yield measurement database, erosion tests with secondary verification of results using a fiducial mark from a focused ion beam, and acquiring a new accelerator with a more reliable high energy proton and deuterium beam The project resulted in 14 publications, including the PhD theses of three MIT graduate students, cited in the included bibliography.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Microstructure and 77K mechanical properties of electron beam welded Cu101- Inconel 625 joints

In developing large-scale next-generation superconducting radio frequency (SRF) linear accelerators using superconducting films on Cu, the design and development of dissimilar welding and joining metals, such as Cu to Inconel, stainless steel, and Nb, are essential. In this talk, we present the development of procedures for electron-beam welding of Cu¿Inconel 625 and evaluation of the microstructure and 77K mechanical properties of the weld and base material in the welded condition and heat treatments in the 750°C ¿950°C heat treatment range. The results will be presented in the context of developing joining techniques for low-temperature applications where high conductivity and strength, vacuum hygiene, and magnetic properties of the material need consideration. The methods presented here are being deployed to thin film SRF Cu cavities at Jefferson Lab. Acknowledgment: This material is based upon work supported by the U.S. Department of Energy, Office of Science, Office of Nuclear

Khanal, Bashu↗