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At least 145 records · Page 8

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DOE OSTI2026

Metal additively manufactured wavy fin cold-plate architecture for improved thermal-hydraulic performance

Rapid growth in artificial intelligence and data center workloads demands high-performance liquid cooling to manage increasing chip power. This study presents two metal-additive-manufactured cold plates with sinusoidal fins, constant-amplitude wavy fins and linearly variable-amplitude wavy fins and compares them against metal-additive-manufactured straight fins using experiments conducted at 1 kW heat dissipation as well as high-fidelity 3D conjugate computational fluid dynamic simulations. The cold plates were printed in AlSi10Mg material and underwent design using a Python-automated workflow prior to manufacture and testing. The experiments show that wavy fins reduce the normalized thermal resistance by 35 to 45 % at water flow rates from 1 to 4 LPM. At a fixed 20 kPa pressure drop, the variable-waviness design lowered peak surface temperature by 9 °C and thermal resistance by 51 %, while edge-channel maldistribution in the constant wavy fin design limited gains. A thermal resistance breakdown revealed that 55–63 % of the total thermal resistance in wavy designs comes from base heat conduction, 27–33 % from fin heat conduction, and 9–13 % from fin heat convection, indicating the need to address conduction bottlenecks. Parametric sweeps identify a 3 mm fin pitch as optimal, and that horizontal inlet/outlet manifolds further reduce pressure drop by 30–60 % and thermal resistance by 9–16 % relative to vertical inlet-outlet manifolds. The results yield comprehensive guidelines for fin geometry, manifold alignment, material selection and additive-manufacturing constraints to realize high-performance liquid-cooled cold plates for power-dense electronics.

3d printing↗

DOE OSTI2025

Integrated process-structure–property–performance optimization of cold-sprayed zinc coatings on AZ91 magnesium alloy

High-pressure die cast (HPDC) AZ91 magnesium alloy is widely used in automotive components such as transmission housings and brackets for its excellent strength-to-weight ratio. Zinc-based cold spray coatings can be applied selectively to vulnerable areas to enhance corrosion resistance, minimize galvanic coupling with dissimilar metals, and eliminate the need for full-surface oxide coatings, making the process more efficient and targeted. A comprehensive evaluation of 16 combinations of nitrogen carrier gas temperatures and pressures led to the identification of an optimal range of process parameters, yielding Zn coatings with porosity <0.5 % by area, wear rates reduced by a factor of two compared to uncoated AZ91, and adhesion strengths up to 35 MPa. The enhanced mechanical performance of the coating is attributed to the low porosity and the formation of a metallurgical bond at the coating-substrate interface. Corrosion studies using macroscale potentiodynamic polarization (PDP) and electrochemical impedance spectroscopy (EIS) revealed a significant decrease in corrosion rate and a shift to more noble corrosion potentials (ZCP) for coated substrates. Furthermore, the Zn cold-sprayed samples exhibited significantly lower corrosion-induced evolved hydrogen content compared to the base AZ91 substrate and AZ91 coated with industrial coatings, demonstrating that the Zn layer effectively protects the substrate from the corrosive environment. Overall, cold spray Zn coatings significantly improve the mechanical and corrosion performance of AZ91 Mg alloys, addressing key material challenges and enabling their broader use in automotive applications.

Corrosion performance↗

DOE OSTI2026

Improving creep resistance of Al-0.27Zr-0.08Sn (wt%) via cold swaging while maintaining high electrical conductivity

This study investigates the effect of mechanical cold work (0, 50, and 90% cross-sectional area reduction via swaging) on the creep properties of cast aluminum alloys with high electrical conductivity including high-purity Al (HP-Al), Al-0.15Zr (Al-Zr), and Al-0.27Zr-0.08Sn (Al-Zr-Sn, wt%). The Al-Zr alloy is strengthened by Zr in solid solution while the Al-Zr-Sn alloy is additionally strengthened by Al3Zr nanoprecipitates (8 nm diameter). After 90% cold swaging, the alloys exhibit grains elongated along the swaging direction with their widths ranging between 8 and 152 μm perpendicular to the swaging direction. Creep testing at 200 °C shows that the minimum creep rate of all 90% swaged alloys shows high sensitivity to stress, which can be modeled via a threshold stress σth. Increasing swaging magnitude from 0 to 50 to 90% in Al-Zr-Sn improves the creep resistance without reducing electrical conductivity. The formation of subgrains, increased dislocation density, and columnar grain structure in swaged alloys all enhance creep resistance. HP-Al swaged to 90% exhibits much lower creep resistance (σth = 18 MPa) due to subgrain coarsening and the absence of precipitates compared to Al-Zr (σth = 40 MPa) and Al-Zr-Sn (σth = 40 MPa), which maintain stable subgrain structures and benefit from solid solution strengthening and Al3Zr nanoprecipitates, respectively. Although Al3Zr precipitates are known to stabilize the deformed microstructure by pinning grain-boundaries, this work demonstrates that Zr in solid solution alone can effectively stabilize the deformed microstructure resulting in enhanced creep resistance. This effect of Zr solute on stabilizing grain boundaries for creep performance was not previously well-defined in the literature. Despite similar creep performances of Al-Zr and Al-Zr-Sn, the latter shows 70% higher room-temperature microhardness and slightly improved electrical conductivity (56%IACS (International Annealed Copper Standard) vs. 57%IACS, respectively). This work provides new insights into creep mechanisms of cold-worked Al–Zr alloys that will guide the design of heat-resistant Al conductors for high-demand applications.

Coello ramirez, Ismael [Northwestern University,]↗

DOE OSTI2025

Visualizing Stereodynamics in Cold Collisions through Shape Resonance Wavefunctions

Shape resonances in cold collisions are often strongly affected by stereodynamics. These resonances can sometimes be assigned by single-channel quantization along the scattering coordinate. However, sensitive steric control of collision implies strong anisotropy of the interaction potential energy surface, which usually leads to coupling among multiple scattering channels in the strongly interacting region. Hence, the resonances might be the result of quantization in a multidimensional space. Using the cold rotationally inelastic collision between para-H 2 (v 1 = 1, j 1 = 2) and HF (v 2 = 0, j 2 = 0) as an example, we analyze four low-lying shape resonances via diagonalization of the full-dimensional Hamiltonian with a stabilization method. While some resonances can indeed be assigned with a single partial wave, others apparently involve more than one scattering channel. Furthermore, a new model based on these resonance wavefunctions is developed to better understand the stereodynamics through shape resonances in cold collisions.

Collisions↗

DOE OSTI2026

Understanding cold electron impact on parallel-propagating whistler chorus waves via moment-based quasilinear theory

Earth's magnetosphere hosts a wide range of collisionless particle populations that interact through various wave-particle processes. Among these, cold electrons, with energies below 100 eV, often dominate the plasma density but remain poorly characterized due to measurement challenges such as spacecraft charging and photoelectron contamination. Understanding the contribution of these cold populations to wave–particle interaction is of significant interest. Recent kinetic simulations identified a secondary drift-driven instability, in which parallel-propagating whistler-mode chorus waves excite oblique electrostatic whistler waves near the resonance cone and Bernstein-mode turbulence. These secondary modes enable a new channel of energy transfer from the parallel-propagating whistler wave to the cold electrons. In this work, we develop a moment-based quasilinear theory of the secondary instabilities to quantify such energy exchange. Our results show that these secondary instabilities persist for a wide range of parameters and, in many cases, lead to nearly complete damping of the primary wave. Such secondary instability might limit the amplitude of parallel-propagating whistler waves in Earth's magnetosphere and might explain why high-amplitude oblique whistler or electron Bernstein waves are rarely observed simultaneously with high-amplitude field-aligned whistler waves in the inner magnetosphere.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Unveiling the Interplay: Cold Work, Recrystallization, and Flux Expulsion in SRF Cavities

The fabrication of SRF cavities from sheet materials includes deep-drawing, electron beam welding, chemical and mechanical polishing, high-temperature heat treatment, and material diffusion. The performance of these cavities is frequently limited by magnetic flux trapping giving rise to additional rf loss. In this presentation, we thoroughly examine how recrystallization influences flux expulsion in SRF cavities, using cold-worked niobium sheets from various suppliers. Our findings reveal that cold-worked sheets enhance flux expulsion, especially at lower heat treatment temperatures, by promoting improved recrystallization. In particular, a traditionally fabricated Nb cavity half-cell from an annealed poly-crystalline Nb sheet after an 800 C heat treatment leads to a bi-modal microstructure that ties in with flux trapping and inefficient flux expulsion. This non-uniform microstructure is related to varying strain profiles along the cavity shape. A novel approach to prevent this non-uniform microstructure is presented by fabricating a 1.3 GHz single cell Nb cavities with a cold-worked sheet and subsequent heat treatment leading to better flux expulsion after 800 C/3h

Dhakal, P. [Old Dominion Univ., Norfolk, VA (Unite↗

DOE OSTI2024

Mark-18A Cold Runs

The Savannah River National Laboratory (SRNL) is tasked by the National Nuclear Security Administration (NNSA) to recover highly valued isotopes from irradiated Mark-18A (Mk-18A) targets. The Savannah River Site (SRS) has sixty-five Mk-18A targets available for the recovery of the high valued materials. The sixty-five Mk-18A targets are currently stored in the L-Area Basin and will be removed one at a time and individually transported to SRNL. Upon receipt at SRNL, the Mk-18A target material will be removed from the confinement, dissolved, chemically separated, and calcined to a stable oxide. The flowsheet is designed to recover the plutonium as well as the trivalent actinides. The remaining unrecovered material will be discarded to the high activity drain (HAD) system in SRNL. A specially designed cask was procured for transport of the targets from L-Area to SRNL. Once received at SRNL, the targets will be loaded into the back of Cell 7 and resized as they enter the cell. The resized targets (1/4 lengths) will then be processed one at a time through the following processes: caustic dissolution and filtration; acidic dissolution and filtration, Reillex anion exchange, diglycolamide (DGA) cation exchange; and DGA calcination. This processing will result in two product streams. The first is an aqueous plutonium solution which will be removed from the shielded cells and taken to a glovebox for further purification and conversion to an oxide. The second is a calcined oxide containing the Am and Cm as well as other lanthanide fission products which will be removed from the shielded cells using a bagless transfer system. Both materials will be packaged for shipment to Oak Ridge National Laboratory (ORNL). All equipment to carry out this process was designed, procured or fabricated, and installed in a mock-up facility (716-4A) at SRS to allow for simulation testing in a non-radioactive area. This equipment was then dismantled and transferred from 716-4A to 773-A and installed in the SRNL Shielded Cells. After installation in the shielded cells facility testing was performed using water followed by surrogates and cold chemicals. Issues were identified during these evaluations, including equipment issues as well as technical challenges. Many of the issues were rectified during performance of the cold runs, and the remaining have a resolution identified. Table ES-1 provides a summary of all issues identified during the cold run operations, as well as the status and identified resolutions to outstanding issues.

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2025

Warm to cold correlations and other test results of the MQXFA Low-Beta Quadrupole magnets for the High-Luminosity Large Hadron Collider

The production of the MQXFA low-beta quadrupole magnets for the High Luminosity LHC (HL-LHC) is quite advanced with about 20 magnets cold tested in vertical cryostat. The MQXFA magnets are fabricated by the US HL-LHC Accelerator Upgrade Project (AUP) and are being used in the Q1 and Q3 Inner Triplet (IT) elements of the HL-LHC, whereas CERN is fabricating similar magnets for Q2a and Q2b IT elements. These large-aperture, high-gradient quadrupole magnets are first-of-the-kind accelerator magnets introducing Nb_3Sn conductor to High Energy Physics colliders. At this point of MQXFA production there is sufficient data to look at warm to cold correlations for the HL-LHC and for future use of Nb_3Sn magnets in particle accelerators. Examples of warm-cold correlations discussed in this paper are: field quality (including the use of magnetic shims for low-order harmonics correction), magnetic length, magnetic axis and magnetic field angle. A summary of main test data will also be presented and discussed.

Kurian, F. [Brookhaven]↗

NASA NTRS1972

CO2 laser cold cathode study

The procedure for evaluating reliable sputter-free cold cathodes for carbon dioxide lasers is discussed. The purpose of the development is to obtain cold cathodes with service life in excess of 10,000 hours. Discharge tubes are used to eliminate the materials which would be unsatisfactory for use as a cold cathode. A description of the facility for producing the discharge tubes is described. The gas monitoring technique for determining discharge tube performance is examined. Discharge characteristics of tubes with various metals for cathode material are presented in chart form.

Hochuli, U.↗

NASA NTRS1972

Cold sea survival.

Two prototype three-man life rafts were evaluated during the winter months in Arctic waters off Kodiak Island, Alaska, to assess potential survival problems and determine tolerance limits. Each raft incorporated thermal characteristics specifically designed for cold water. Water and air temperatures varied from 0 to +2 C and -5 to +4 C respectively. All subjects were removed upon reaching subjective tolerance. The results showed that none of the clothing assemblies was adequate to maintain a person in comfort even with dry boarding. No significant biochemical shifts in the blood or urine were found. The TUL raft was found to be superior in its thermal characteristics and afforded better subject protection. General tolerance for cold water immersion, wet and dry, and cold water raft exposures are depicted graphically, based on previously reported data.

Veghte, J. H.↗

NASA NTRS1980

Cold shivering activity after unilateral destruction of the vestibular apparatus

The bioelectric activity of muscles (flexors and extensors of the forelimbs and hindlimbs) during cold shivering after unilateral destruction of the vestibular apparatus. It was found, that unilateral delabyrinthing produces bilateral facilitation of cold shivering in the flexor extremities more pronounced on the ipsilateral side. In the extensor muscles there was an absence of bioelectric activity both before and after delabyrinthing. Enhancement of cold shivering in the flexor extremities following intervention was evidently conditioned by removal of the inhibiting effect of the vestibulary apparatus on the function of special centers.

Kuzmina, G. I.↗

NASA NTRS1980

Variations in the Nimbus-7 scanning multichannel microwave radiometer cold reference antenna signals and temperatures during two orbital periods

The observed effects of solar radiance on the Nimbus 7 scanning multichannel microwave radiometer (SMMR) cold reference signal are discussed. Unexpected diurnal responses in this signal sometimes larger than the typical cold reference signal resulted from acquisition of the solar disc. Solar heating of the SMMR components as a function of orbital locations was correlated with the cold reference radiances for two sets of sequential orbit six months apart.

Gloersen, P.↗

NASA NTRS1979

Magnetospheric electrostatic emissions and cold plasma densities

A synoptic study of electric wave, magnetometer, and plasma data from Imp 6 has been carried out for times when banded electrostatic waves are observed between harmonics of the electron gyrofrequency in the earth's outer magnetosphere. Four separate classes of such waves have previously been identified by us. The spatial and temporal occurrences of waves in each class are summarized here, as are correlations of occurrence with geomagnetic activity. Most importantly, associations between the observations of waves of different classes and the relative portions of cold and hot electrons present at the position of the spacecraft are established. The cold to hot ratio varies in accordance with the predictions of our previous theoretical work, which models the emission as arising unstably from a hot loss cone distribution existing simultaneously with a cold isotropic electron component. Finally, evidence for the signature of the loss cone is sought in the plasma data.

Hubbard, R. F.↗

NASA NTRS1981

Method of cold welding using ion beam technology

A method for cold welding metal joints is described. In order to remove the contamination layer on the surface of the metal, an ion beam generator is used in a vacuum environment. A gas, such as xenon or argon, is ionized and accelerated toward the metal surface. The beam of gas effectively sputters away the surface oxides and contamination layer so that clean underlying metal is exposed in the area to be welded. The use of this method allows cold welding with minimal deformation. Both similar and dissimilar metals can be cold welded with this method.

Sater, B. L.↗

NASA NTRS1983

Io's atmosphere - Pressure control by regolith cold trapping and surface venting

A new model for the basal pressure of Io's atmosphere is developed. This model takes into account the previously ignored fact that much of Io's surface has very high porosity, typically about 90 pct. Such porosity allows efficient subsurface cold trapping of atmospheric gases which tends to keep ambient surface pressures very low. SO2 is the only gas identified on Io, and the basal pressures for atmospheric models are usually pegged to local surface temperature via the SO2 vapor pressure equilibrium curve. Near Io's subsolar point the pressure in equilibrium with a surface SO2 frost deposit is about 1/10,000,000th bar. Porous surface models of the type developed invoke equilibrium with the colder, subsurface permafrost (at about 3-cm depth) and yield pressures of about 1/10 to the 12th bar. The subsurface cold trapping model explains many but not all observations relevant to Io's atmosphere. The new subsurface cold trapping model and the earlier surface frost equilibrium model, when taken together, provide lower and upper limits, respectively, on the basal SO2 pressure of Io's atmosphere.

Matson, D. L.↗

NASA NTRS1983

Gifford-McMahon refrigerator with split cold head

Leybold-Heraeus Co. have developed, built and successfully tested a Gifford-McMahon cryocooler with splitted cold head for cooling a cryopump. The refrigerating part of the cold head and the gas flow control device have been separated (splitted cold head) and the distance between them is bridged by only two thin lines for carrying the working gas. Due to this separation the size of the refrigerating part is virtually defined only by the size of the displacers whilst the gas flow control device can be of any desired design. It has been shown that dimensioning of the connecting lines and the corresponding losses became less critical with increasing size of the expander, but additional cooling in proportion to the refrigerating capacity is required.

Forth, H. J.↗

NASA NTRS1984

Temporal evolution of whistler growth in a cold plasma injection experiment

The evolution of whistler mode turbulence and particle participation in a cold plasma release are studied experimentally as part of the Active Magnetospheric Particle Tracers Explorer (AMPTE) program. The investigation used a simple time dependent cold plasma density model, and an atypical ambient radiation belt was assumed. It is shown that a cold lithium injection in the AMPTE parameter range can give rise to whistler mode turbulence with significant gain to the wave amplitude in a single pass through a flux tube. Whistler mode growth results in the pitch angle diffusion of energetic electrons, which are in turn precipitated. The rate of power input into the ionosphere from these precipitating electrons is roughly estimated at 2 ergs per sq cm/s. It is found that this value of the precipitated power is large enough to continue producing a visible aurora until the injected plasma in the flux tube is lost or destroyed by magnetospheric convection or other processes.

Ganguli, G.↗

NASA NTRS1984

The structure and energetics of midlatitude disturbances accompanying cold-air outbreaks over East Asia

The evolution of extratropical transient waves as they propagate eastward from the Eurasian land mass toward the Pacific during selected cold surge events in the winter Monsoon Experiment (MONEX) is studied. The outstanding cold surge episodes during MONEX are first identified, and the salient synoptic features related to these events are described using composite streamline charts. The structure of rapidly varying disturbances accompanying the cold surges and the associated energetics are examined, and the behavior of those fluctuations over relatively longer time scales is addressed.

Lau, N.-C.↗