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At least 145 records · Page 8

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DOE OSTI2022

Passive heat removal in horizontally oriented micro-HTGRs

There are novel, horizontally oriented high-temperature gas-cooled micro-reactor (HTGR) designs under consideration because of their portability, simplicity, and reliable operation. These features of the micro-HTGR design can meet the fission battery attributes, such as economic, standardize, installed, unattended and reliable. Although there have been HTGR related safety studies, micro-HTGRs when horizontally oriented are expected to exhibit significantly different thermal physics. During the unavailability of helium circulation, the internal reactor core is designed to cool by block-to-block conduction and radiation, and the reactor vessel surface is cooled by the ambient air. This scenario is anticipated during the transport of the micro-HTGR in a shipping container. The conduction and radiation between the prismatic micro-HTGR blocks in the core can be influenced by variances in the thermal contacts. This work investigated the conduction within a simulated horizontal HTGR core. An experimental setup was used to validate a numerical model. The experimental setup consisted of a hexagonal assembly with scaled prismatic blocks placed within a high-temperature vacuum environment. The gaps between the blocks were well controlled and monitored. The experimental setup was designed in such a way that the temperature variation in the axial direction was minimal, such that the experiment could be observed as a 2D (r, ) heat transfer problem. The pressurized tube was equipped with Infra-Red (IR) transparent windows, and an IR camera was used to capture the spatio-temporal temperature evolution in the hexagonal block assembly during the cooldown experiments. The experimental scenario was computationally modeled with a finite element analysis (FEA) program. Once validated, the computational model was used to investigate the impact of gap conductance on overall decay heat removal. Using a conservative estimate for gap conductance value (100 W/m 2 -K) between the prismatic blocks, there is a negligible increase in temperature observed during decay heat generation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Residual stress accumulation in large-scale Ti-6Al-4V wire-arc additive manufacturing

Large-scale additive manufacturing (AM) is of interest in the manufacturing industry to produce components of dimensions on the order of hundreds of millimeters to meters in scale. Wire-arc AM (WAAM) of Ti-6Al-4V (Ti64) is an attractive technique for large-scale AM in the aerospace industry, give the high strength-to-weight ratio of the material and high deposition rate of the process. However, due to the large scale, significant distortion and residual stresses are developed in the material during deposition and cooling, potentially leading to part failure. WAAM of a prototypical large-scale Ti64 machine tool component is studied in this work via finite element analysis (FEA). Element activation/deactivation technique is employed to simulate deposition and the resulting distortion and residual stress (RS) predictions are analyzed to evaluate the possibility of crack formation. Significant distortion (∼10 mm) and RS (>1300 MPa) is predicted, suggesting the formation of cracks and possible crack propagation into the build region. Incorporation of fillets significantly reduces RS concentration regions, thus reducing the possibility of part failure. Material deposition sequence also affects the RS pattern in the build.

Mathews, Ritin↗

DOE OSTI2026

Thermomechanical analysis and modeling of a high-temperature light trapping planar cavity solar receiver

The development of durable particle-based high-temperature solar receivers is critical for advancing concentrating solar-thermal (CST) technologies to enable high-efficiency power generation and industrial process heat. Here, this study presents a computational framework to evaluate the thermomechanical performance of a proposed enclosed light-trapping planar cavity receiver designed for particle-based thermal energy systems. The receiver incorporates absorptive cavities and fluidized particle-bed channels to enhance heat capture and reduce thermal losses. Finite element analysis (FEA) is employed to assess stress, strain, and creep-fatigue behavior under concentrated solar flux using realistic thermal boundary conditions derived from coupled system models and experimental assembly parameters. The analysis investigates the influence of particle-to-wall heat transfer coefficients (HTC) ranging from 800 to 1800 W/m 2 .K on the thermomechanical response of six candidate high-temperature alloys: Alloy 740H, Alloy 282, Alloy 617, 316H, Alloy 230, and 800H. Results show that increasing HTC reduces thermal gradients, leading to lower stresses and strains and extended minimum predicted creep life. While all materials satisfy fatigue life requirements under the investigated conditions, significant differences in creep resistance are observed. Alloy 740H consistently exhibits the longest minimum predicted creep life and the most favorable durability margins, followed by Alloy 282, with the remaining materials showing reduced creep resistance under identical loading. The reported creep lives are conservative lower-bound estimates intended for comparative material evaluation. This framework highlights the critical roles of material selection and geometry optimization in improving mechanical durability and reliability of solar-thermal receivers, forming a foundation for future experimental validation and design optimization.

14 SOLAR ENERGY↗

DOE OSTI2023

Probing Phosphorus Solubility and Its Effect on Critical Temperature ( T c ) in the Helical Superconducting Magnet RbEuFe 4 As 4– x P x

RbEuFe 4 As 4 exhibits a rare combination of high-temperature superconductivity and noncollinear magnetism, originating from the FeAs and Eu layers, respectively. In order to fine-tune its superconducting and magnetic properties, we studied P-doped RbEuFe 4 As 4–x P x . To determine the value of x for which RbEuFe 4 As 4–x P x exists, members of the series have been synthesized in the form of relatively large-sized single crystals by a high-temperature flux growth technique using RbAs flux as well as polycrystalline powder by direct combination reactions between RbFe 2 As 2 and EuFe 2 As 2–x P x . The flux crystal growth reactions indicate that RbEuFe 4 As 4–x P x forms with the values of x ≤ 0.12, which is corroborated by the Rietveld refinement analysis on the products obtained from direct combination reactions. The solubility limit exists primarily due to the preferential site As(2) occupation by P in the RbEuFe 4 As 4 crystal structure. Finally, as x increases in RbEuFe 4 As 4–x P x , magnetization measurements reveal that the superconducting critical transition temperature (T c ) decreases, while the magnetic ordering temperature (T N ) remains almost unchanged in comparison to undoped RbEuFe 4 As 4 .

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Suppression of Superconductivity and Nematic Order in Fe 1–y Se 1–x S x (0 ≤ x ≤ 1; y ≤ 0.1) Crystals by Anion Height Disorder

Connections between crystal chemistry and critical temperature T c have been in the focus of superconductivity, one of the most widely studied phenomena in physics, chemistry and materials science alike. In most Fe-based superconductors materials chemistry and physics conspire so that T c correlates with the average anion height above the Fe plane, i.e. with the geometry of the FeAs 4 or FeCh 4 (Ch = Te, Se, S) tetrahedron. Here, by synthesizing Fe 1-y Se 1-x S x (0 ≤ x ≤ 1, y ≤ 0.1) we find that in alloyed crystals T c is not correlated with the anion height as most other Fe superconductors. Instead, changes in T c (x) and tetragonal-to-orthorombic (nematic) transition T s (x) on cooling are correlated with disorder in Fe vibrations in direction orthogonal to Fe planes, along the crystallographic c-axis. The disorder stems from the random nature of S substitution, causing deformed Fe(Se,S) 4 tetrahedra with different Fe-Se and Fe-S bond distances. Our results provide evidence of T c and T s suppression by disorder in anion height. The connection to local crystal chemistry may be exploited in computational prediction of new superconducting materials with FeSe/S building blocks.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2023

The breakdown of both strange metal and superconducting states at a pressure-induced quantum critical point in iron-pnictide superconductors

Here we report the first observation of the concurrent breakdown of the strange metal (SM) normal state and superconductivity at a pressure-induced quantum critical point in Ca 10 (Pt 4 As 8 )((Fe 0.97 Pt 0.03 ) 2 As 2 ) 5 superconductor. We find that, upon suppressing the superconducting state, the power exponent (α) changes from 1 to 2, and the slope of the temperature-linear resistivity per FeAs layer (A $\Box$ ) gradually diminishes. At a critical pressure, A $\Box$ and superconducting transition temperature (T c ) go to zero concurrently, where a quantum phase transition from a superconducting state with a SM normal state to a non-superconducting Fermi liquid state occurs. Scaling analysis reveals that the change of A $\Box$ with T c obeys the relation of T c ~ (A $\Box$ ) 0.5 , similar to what is seen in other chemically doped unconventional superconductors. These results suggest that there is a simple but powerful organizational principle of connecting the SM normal state with the high-T c superconductivity.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2024

Transient behavior of oxide fuels with controlled microstructure and Cr2O3 additive

Abstract Microstructure and Cr 2 O 3 doping profoundly impact the thermal-mechanical properties and fracture of oxides fuels. It is a challenge to study the transient behavior of nuclear fuels under loss-of-coolant-event (LOCA). In this study, the crack behavior of UO 2 pellets with controlled grain structure and Cr 2 O 3 doping was tested with rapid power ramping (300−900 °C per min) mimicking a prototypical LOCA heating profile. Dense micron-sized UO 2 pellets display well-maintained integrity without cracking with the ramping up to 1500 °C at a heating rate of 8 °C per second. Fracture occurs in both pure and Cr 2 O 3 -doped dense nano-sized UO 2 pellets. The Cr 2 O 3 doped oxide fuel pellet with a larger grain size (~ 22.2 μm) displays the best performance under LOCA testing due to its highest thermal conductivity under high temperature. FEA calculations suggest a temperature gradient across the fuel pellet during transient testing, resulting in residual stress and cracking, which can be correlated with their thermal-mechanical properties.

Zhao, Dong (ORCID:0000000191377257)↗

DOE OSTI2020

Enhanced surface superconductivity in Ba(Fe 0.95 Co 0.05 ) 2 As 2

We present direct evidence for an enhanced superconducting Tc on the surface of cleaved single crystals of Ba(Fe 0.95 Co 0.05 ) 2 As 2 . Transport measurements performed on samples cleaved in ultra-high vacuum show a significantly enhanced superconducting transition when compared to equivalent measurements performed in air. Deviations from the bulk resistivity appear at 21 K, well above the 10 K bulk Tc of the underdoped compound. We demonstrate that the excess conductivity above the bulk Tc can be controllably suppressed by application of potassium ions on the cleaved surface, indicating that the enhanced superconductivity is strongly localized to the sample surface. Additionally, we find that the effects of the potassium surface dosing are strongly influenced by the presence of residual gas absorbates on the sample surface, which may prevent effective charge transfer from the potassium atoms to the FeAs plane. This further supports the conclusion that the effects of the dosing (and enhanced superconductivity) are localized within a few layers of the surface.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2021

3D simulations of vertical displacement events in tokamaks: A benchmark of M3D-C 1 , NIMROD, and JOREK

In recent years, the nonlinear 3D magnetohydrodynamic codes JOREK, M3D-C1, and NIMROD developed the capability of modeling realistic 3D vertical displacement events (VDEs) including resistive walls. In this paper, a comprehensive 3D VDE benchmark is presented between these state-of-the-art codes. The simulated case is based on an experimental NSTX plasma but with a simplified rectangular wall. There are differences between the physics models and numerical methods, and the VDE evolution leads to sensitivities on the initial conditions that cannot be avoided as can be done in edge localized modes (ELM) and sawtooth simulations (due to the non-cyclical nature of VDEs). Nonetheless, the comparison serves to quantify the level of agreement in the relevant quantities used to characterize disruptions, such as the 3D wall forces and energy decay. The results bring confidence regarding the use of the mentioned codes for disruption studies, and they distinguish aspects that are specific to the models used (e.g., reduced vs full MHD models). Here, the simulations show important 3D fea- tures for a NSTX plasma, such as the self-consistent evolution of the halo current and the origin of the wall forces. In contrast to other reduced MHD models based on an ordering in the aspect ratio, the ansatz-based JOREK reduced MHD model allows capturing many aspects of the 3D dynamics even in the spherical tokamak limit considered here.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Surface coating by mechanofusion modulates bulk charging pathways and battery performance of Ni-rich layered cathodes

Ni-rich layered oxides as high-capacity battery cathodes suffer from degradation at high voltages. Here, we utilize a dry surface modification method, mechanofusion (MF), to achieve enhanced battery stability. The simplicity, high yield, and flexibility make it cost-effective and highly attractive for processing at the industrial scale. The underlying mechanisms responsible for performance improvement are unveiled by a systematic study combining multiple probes, e.g., 3D nano-tomography, spectroscopic imaging, in situ synchrotron diffraction, and finite element analysis (FEA). MF affects the bulk crystallography by introducing partially disordered structure, microstrain, and local lattice variation. Furthermore, the crack initiation and propagation pattern during delithiation are regulated and the overall mechanical fracture is reduced after such surface coating. We validate that MF can alter the bulk charging pathways. Such a synergic effect between surface modification and bulk charge distribution is fundamentally important for designing next-generation battery cathode materials.

25 ENERGY STORAGE↗

DOE OSTI2024

Design of Muon Campus full flow purifier for varying operational conditions and horizontal shipping

Constant ingress of impurities in Muon Campus g-2 experiment at Fermilab has resulted in reduction of efficiency of cryogenic expanders and occasional undesired downtime to flush the impurities. Due to insufficiency of current 0.06 kg/s mobile purifier, a full flow purifier is designed to be used in Muon Campus which purifies 0.24 kg/s of Helium throughput of 4 compressors through charcoal bed at 80 K and returns ambient Helium back to the system. The purifier is designed to be operated near liquid Nitrogen temperature during cold operations and up to 400 K during regeneration. Both warm and cold operational range of the purifier has required use of appropriate clearances in design due to expansion and contraction. The vessel of around 5.5 m height which is designed to be operated vertically is to be shipped horizontally. The asymmetrical position of heavy stainless steel heat exchanger in the purifier support frame and 5g vertical load design consideration for shipping has required use of shipping supports and heat exchanger rotational stops to comply with design requirements. FEA of purifier system is performed in cold, warm and shipping cases to verify that the purifier satisfies the design requirements.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

Measurement and Simulation of the Magnetic Fields from a 555 Timer Integrated Circuit Using a Quantum Diamond Microscope and Finite-Element Analysis

Quantum diamond microscope (QDM) magnetic field imaging is an emerging interrogation and diagnostic technique for integrated circuits (ICs). To date, the ICs measured with a QDM have been either too complex for us to predict the expected magnetic fields and benchmark the QDM performance or too simple to be relevant to the IC community. In this paper, we establish a 555 timer IC as a “model system” to optimize QDM measurement implementation, benchmark performance, and assess IC device functionality. To validate the magnetic field images taken with a QDM, we use a spice electronic circuit simulator and finite-element analysis (FEA) to model the magnetic fields from the 555 die for two functional states. Furthermore, we compare the advantages and the results of three IC-diamond measurement methods, confirm that the measured and simulated magnetic images are consistent, identify the magnetic signatures of current paths within the device, and discuss using this model system to advance QDM magnetic imaging as an IC diagnostic tool.

74 ATOMIC AND MOLECULAR PHYSICS↗

DOE OSTI2025

Rapid Prototyping Techniques for Organic Direct-Bonded-Copper Power Modules

Organic Direct-Bonded-Copper (ODBC) is a novel packaging technology for power modules which allows higher flexibility in layout design. In this work, a set of rapid prototyping techniques are developed for ODBC modules based on a polyimide dielectric material. These techniques enable fast and low-cost fabrication of modules with 3-Dimensional (3D) layout features. An example half-bridge (HB) silicon carbide (SiC) metal oxide semiconductor field effect transistor (MOSFET) module is designed and prototyped using the proposed techniques aiming at ultra-low power loop inductance. Finite element analysis (FEA)-circuit co-simulations results and experimental results validate an approximately 0.71nH power loop inductance for the example module design.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Thermal Design and Optimization of High- Power Wireless Charging System

In this paper, the thermal design and optimization of a high-power wireless charging system (WCS) is proposed. An integrated electromagnetic and thermal co-optimization is essential to design a high power-density WCS pad. This study presents the thermal analysis and the potential optimization scopes for a polyphase WCS pad. The coil and core causes most of the power losses of a WCS pad and causes thermal hotspot in the pad. In this paper, the thermally conductive epoxy is introduced to balance the effective volumetric loss density in the pad and mitigate the thermal hotspots in the coil and core. The proposed design is simulated through finite element analysis (FEA) and tested experimentally for a 50 kW three-phase WCS. Simulation and experimental results show that the conventional design has localized hotspots in the coil and core. The proposed thermal design mitigates the thermal hotspots without increasing the coil or core volume.

Mohammad, Mostak↗

DOE OSTI2024

Thermal Analysis of a 100 kW Polyphase Wireless Power Transfer System

Charging Electric Vehicles (EVs) fast and safely has a crucial role in the future of the EV technology. High-power Wireless Power Transfer (WPT) helps to significantly decrease the charging time. However, when the power transfer levels increase, thermal management becomes a significant challenge. The thermal design of the WPT systems needs more consideration in the design and implementation steps. This paper presents a thermal analysis of a 100 kW high-power WPT system. The thermal performance of the proposed design was evaluated at different power levels by considering the magnetic design and loss analysis. Finite Element Analysis (FEA) of the proposed design was performed and the thermal images of the implemented system were taken to prove the simulation results. The results show that, a liquid cooling design is needed for a high-power WPT systems for the long-time continuous operations of the charging pads.

Aydin, Emrullah↗

DOE OSTI2025

Capacitor Design for Self-Resonant Coils for Long-Distance Wireless Power Transfer System

In this paper, an integrated capacitor design is proposed for higher-order resonant tank topologies for self-resonant coils, such as series, parallel, LCC, LLC, etc. The capacitor is one of the large, lossy, and thermally vulnerable components of a high-frequency resonant tank, and designing a high-voltage, thermally stable resonant capacitor can be highly challenging. Designing the extremely high-voltage capacitor as an integral part of the coil reduces the size and complexity of the coil assembly. This paper proposes a low-loss PCB-based high-voltage capacitor design to achieve that target, which can be implemented as an integral part of the coil. The proposed capacitor designs are simulated using Multiphysics FEA and tested experimentally. A 23 kV, 133 pF capacitor prototype was built and tested as part of a 1 kW long-distance wireless charging system. The test results verify the capacitor’s voltage, current, and thermal resiliency performance.

Mohammad, Mostak [ORNL] (ORCID:0000000256388783)↗

DOE OSTI2026

Optimal Litz Wire Design for High-Power Wireless Charging System

In this study, an optimized Litz wire and polyphase coil winding design is proposed for high-power wireless charging systems operating at 85 kHz frequency. Litz wire in a wireless charging system contributes to more than half of the losses of the system, making it a critical design component. Here, the Litz wire is optimized through Finite Element Analysis (FEA) considering electrical and mechanical design aspects and the design was validated through experimental tests on different Litz wires with various strand-diameters, twisting ratio, and number of strands. The proposed optimal Litz wire maximizes the system efficiency considering the tradeoff between coil resistance and mutual inductance. The optimal Litz wire shows that Litz wire constructed with the 63µm strands significantly outperform the traditionally used Litz wire with 100µm strand diameter. Additionally, the coil with optimal Litz wire design shows 60% reduction in the copper volume for the same loss, and at the same time increase the coil-to-coil efficiency by more than 2% by increasing the mutual inductance and reducing coil current. The optimized Litz wire was implemented in a 22-kW wireless charging system achieving 94.7% efficiency.

Aydin, Emrullah [ORNL]↗

DOE OSTI2020

Design of an Axial Flux Machine With an Integrated Hydraulic Pump for Off-Highway Vehicle Electrification

Axial flux machines offer an inherent torque density advantage over conventional radial flux machines and are increasingly being considered for transportation electrification applications. Electrification of off-highway vehicles is notoriously challenging due to extreme power density requirements. This paper investigates the use of axial flux machines for off-highway vehicle electrification. To maximize the power density, a hydraulic pump is integrated with the axial flux machine, resulting in a single modular, electric/hydraulic machine. This paper first compares three popular axial flux machine variants using an FEA-based design optimization approach. The single rotor, single stator variant is identified to be the most promising for integration with the hydraulic pump. Next, a multi-physics framework of the complete integrated hydraulic pump and axial flux machine is developed to search the design space. The results indicate promising potential for this concept to realize efficiency over 85% and power density over 5kW/kg for the complete machine (electric machine, hydraulic pump, and thermal management system), while utilizing conventional materials (thin gauge silicon steel, N45 magnets, and magnet wire)

Off-highway vehicles, Axial flux machines, Multi-p↗