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DOE OSTI2023

Fusion Materials Research at Oak Ridge National Laboratory in FY22

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Fusion Materials Research at Oak Ridge National Laboratory in Fiscal Year 2023

The materials science challenge of providing a suite of suitable materials to satisfy the technology to achieve fusion energy is addressed in this ORNL program. The inability of currently available materials and components to withstand the harsh fusion nuclear environment requires development of new materials, and an understanding of their response to the fusion environment. The overarching goal of the ORNL Fusion Materials program is to provide the applied materials science support and materials understanding to underpin the ongoing DOE Office of Science—Fusion Energy Sciences program, in parallel with developing the materials for fusion power systems. In this effort the program continues to be integrated both with the larger U.S. and international fusion materials communities and with the U.S. and international fusion design and technology communities. The excitement of this program comes from the priorities given to this subject in the two recent fusion reviews, by the FESAC and NAS committees. An important element of those recommendations is the support for pivoting the national R&D emphasis to the Fusion Materials and Technologies (FM&T), the long-advocated Fusion Prototypic Neutron Source, and for the Fusion Pilot Plant study that will help focus program direction and efforts. Furthermore, the surge of venture capital investment into the private fusion industry start-ups over the last few years is anticipated to help accelerate all aspects of the fusion energy development. This twelfth annual report of the ORNL (Oak Ridge National Laboratory) Fusion Reactor Materials Program summarizes the accomplishments in Fiscal Year 2023 (FY2023). The year was the first to return to full post-COVID-restriction operations, with students and international assignees no longer impacted by COVID restrictions, as in FY20-21-22. Following the pattern of planning used in this program, work for the year FY2023 focused on having the data and productivity to support a strong presence at the International Conference on Fusion Reactor Materials (ICFRM) 21, organized by Spain and occurred in October 2023. Twenty-nine ORNL-led abstracts were submitted, with all accepted. Four were invited presentations, nine contributed oral, fourteen posters, and two withdrawn due to unforeseen circumstances. Additionally, nine external abstracts with ORNL contributing authors were presented. These will be reported in the FY24 report next year.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Toward fusion plasma scenario planning for NSTX-U using machine-learning-accelerated models

One of the most promising devices for realizing power production through nuclear fusion is the tokamak. To maximize performance, it is preferable that tokamak reactors achieve advanced operating scenarios characterized by good plasma confinement, improved magnetohydrodynamic (MHD) stability, and a largely non-inductively driven plasma current. Such scenarios could enable steady-state reactor operation with high \emph{fusion gain} --- the ratio of produced fusion power to the external power provided through the plasma boundary. Precise and robust control of the evolution of the plasma boundary shape as well as the spatial distribution of the plasma current, density, temperature, and rotation will be essential to achieving and maintaining such scenarios. The complexity of the evolution of tokamak plasmas, arising due to nonlinearities and coupling between various parameters, motivates the use of model-based control algorithms that can account for the system dynamics. In this work, a learning-based accelerated model trained on data from the National Spherical Torus Experiment Upgrade (NSTX-U) is employed to develop planning and control strategies for regulating the density and temperature profile evolution around desired trajectories. The proposed model combines empirical scaling laws developed across multiple devices with neural networks trained on empirical data from NSTX-U and a database of first-principles-based computationally intensive simulations. The reduced execution time of the accelerated model will enable practical application of optimization algorithms and reinforcement learning approaches for scenario planning and control development. An initial demonstration of applying optimization approaches to the learning-based model is presented, including a strategy for mitigating the effect of leaving the finite validity range of the accelerated model. The approach shows promise for actuator planning between experiments and in real-time.

machine learning↗

DOE OSTI2023

Accelerated kinetic model for global macro stability studies of high-beta fusion reactors

The field reversed configuration (FRC), such as studied in the C-2W experiment at TAE Technologies, is an attractive candidate for realizing a nuclear fusion reactor. In an FRC, kinetic ion effects play the majority role in macroscopic stability, which allows global stability studies to make use of fluid-kinetic hybrid (also referred to as Ohm's law) models wherein ions are treated kinetically while electrons are treated as a fluid. The development and validation of such a hybrid particle-in-cell algorithm in the Exascale Computing Project code WarpX are reported here. Implementation of this model in the WarpX framework benefits from the numerical efficiency of WarpX as well as its scalability on large HPC systems and portability to different architectures. Performance benchmarks of the new algorithm for large, 3-dimensional, full device simulations from the Perlmutter supercomputer are presented. Results of a series of FRC simulations are discussed in which the impact of two-fluid effects on the tilt-mode growth rate was studied. It was observed that, in agreement with previous Hall-MHD studies, two-fluid effects have a stabilizing impact on the tilt mode.

Physics↗

DOE OSTI2020

Advancement of LANSCE accelerator facility as a 1-MW Fusion Prototypic Neutron Source

The Fusion Prototypic Neutron Source (FPNS) is considered to be a testbed for scientific understanding of material degradation in future nuclear fusion reactors (Zinkle and Moeslang, 2013; Summary Report on the FPNS Workshop, 2018; Pitcher et al., 2019). The primary mission of FPNS is to provide a damage rate in iron samples of 8-11 dpa/calendar year with He/dpa ratio of 10 appm in irradiation volume of 50 cm 3 or larger with irradiation temperature 300–1000 °C and flux gradient less than 20%/cm in the plane of the sample. The Los Alamos Neutron Science Center (LANSCE) is an attractive candidate for the FPNS project. The Accelerator Facility was designed and operated for an extended period as a 0.8-MW Meson Factory. The existing setup of the LANSCE accelerator complex can nearly fulfill requirements of the fusion neutron source station. The primary function of the upgraded accelerator systems is the safe and reliable delivery of a 1.25-mA continuous proton beam current at 800-MeV beam energy from the switchyard to the target assembly to create 1 MW power of proton beam interacting with a solid tungsten target. The present study describes existing accelerator setup and further development required to meet the needs of FPNS project.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS2018

Preliminary Analysis of the Gradient Field Imploding Liner Fusion Propulsion Concept

The advancement of human deep space exploration requires the continued development of energetic in-space propulsion systems, advancing from current chemical engines to nuclear thermal rockets to future high energy concepts such as nuclear fusion. This paper presents the initial results of a NASA Innovative Advanced Concepts (NIAC) Phase I study funded to investigate the feasibility of a new pulsed fusion propulsion concept based on the rapid implosion of a fuel target injected at high velocity into a strong stationary magnetic field. The proposed concept takes advantage of the significant advances in terrestrial magneto-inertial fusion designs while attempting to mitigate the most common engineering impediments to in-space propulsion applications. A semi-analytic numerical model used to estimate target compression physics and energy release is presented, leading to estimates for engine performance. A preliminary vehicle design concept is outlined, and representative trajectory analyses for rapid Mars and Saturn missions are provided. The paper concludes with an overview of proposed next steps for theoretical and experimental validation of the concept.

Propulsion↗

NASA NTRS2000

High Energy Plasma Space Propulsion

In order to meet NASA's challenge on advanced concept activity in the propulsion area, we initiated a new program entitled "High Energy Plasma Space Propulsion Studies" within the current cooperative agreement in 1998. The goals of this work are to gain further understanding of the engine of the AIMStar spacecraft, a concept which was developed at Penn State University, and to develop a prototype concept for the engine. The AIMStar engine concept was developed at Penn State University several years ago as a hybrid between antimatter and fusion technologies. Because of limited amounts of antimatter available, and concurrently the demonstrated ability for antiprotons to efficiently ignite nuclear fusion reactions, it was felt that this was a very good match. Investigations have been made concerning the performance of the reaction trap. This is a small Penning-like electromagnetic trap, which is used to simultaneously confine antiprotons and fusion fuels. Small DHe3 or DT droplets, containing a few percent molar of a fissile material, are injected into the trap, filled with antiprotons. We have found that it is important to separate the antiprotons into two adjacent wells, to inject he droplet between them and to simultaneously bring the antiprotons to the center of the trap, surrounding the droplet. Our previous concept had the droplet falling onto one cloud of antiprotons. This proved to be inefficient, as the droplet tended to evaporate away from the cloud as it interacted on its surface.

Wu, S. T.↗

DOE OSTI2023

New Developments and Verification of the Fusion Blanket Simulation Capabilities in the MOOSE Framework

This poster contains new developments and updates in the Multiphysics Object-Oriented Simulation Environment (MOOSE) framework related to fusion modeling and simulation, and forms the basis for an on-going effort in modeling whole fusion devices at Idaho National Laboratory using MOOSE. In this work, a slice of the midplane of a proposed ceramic breeder blanket design for the Fusion Nuclear Science Facility is simulated using a combination of neutronics, 1D system level thermal hydraulics for helium, 3D heat conduction, and tritium transport. Previous work focused on the engineering scale full assembly of a blanket sector, but the simulations here form the basis for software quality and verification efforts to increase confidence as the large scale simulations continue. This poster was presented at the Idaho National Laboratory Intern Poster Session 2023.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Thermal-Mechanic Modeling of Fusion Components Using The MOOSE Framework

With fusion energy rapidly developing, there is a great need for an open source tool that can rapidly model different fusion tokamak designs. The open-source codes Multiphysics Object Oriented Simulation Environment (MOOSE), Tritium Migration Analysis Program Version 8 (TMAP8) , and Fusion ENergy Integrated Multiphysi-X (FENIX) are being used to demonstrate thermal-mechanic modeling of fusion components. In this study, an analysis is done on the fusion nuclear science facility (FNSF) blanket, and ITER toroidal magnet and diverter mono block. This study will lay the groundwork for fusion component analysis in the MOOSE framework and FENIX program.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Double Shell Inertial Confinement Fusion X-Ray Spectral Analysis

At the National Ignition Facility (NIF), lasers are used to compress a double shell capsule with deuterium and tritium in order to create nuclear fusion processes. The lasers aim at the inside of a gold hohlraum which excite electrons which further release photons in the range of 0~20keV. The photons randomly disperse, ultimately either going towards the fuel capsule or back out the laser entrance holes. The photons that go towards the fuel capsule work towards the compression of the multi-shell capsule whereas the photons that leave the hohlraum have a chance at being picked up by the Lawrence Livermore National Lab’s ‘Dante’ photon detector. ‘Dante’ analyzes photon data by having 18 planar vacuum x-ray diodes (XRD) behind unique filters to differentiate data amongst various photon energies. The goal of the project was to analyze the characteristics of low and high energy photons released by the gold shell.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Microstructure and Elevated Temperature Flexure Testing of Tungsten Produced by Electron Beam Additive Manufacturing

Abstract Due to their superior high-temperature thermomechanical capabilities, sputter erosion durability, and excellent resistance to hydrogen isotopes, tungsten materials have garnered significant interest in fusion nuclear applications. However, low room-temperature ductility and complex machining strategies present significant challenges for traditional fabrication. Electron beam powder bed fusion (EB-PBF) shows promise in manufacturing pure tungsten via high thermal energy input, elevated build temperature, and a tightly controlled high-vacuum environment. This work explores the process, structure, and property relationship of pure tungsten fabricated by EB-PBF, where 99.8% relative density was achieved with reduced cracking by isolating the build substrate and optimizing the print parameter suite. Optical and electron imaging revealed that the microstructure contained equiaxed grains along the build direction, with subgrains present in all inspected grains. Flexural testing at ambient and elevated temperatures demonstrated high ductility at 900°C and flexural strength of 470 MPa at room temperature of additively manufactured tungsten.

Zhang, Haozhi↗

DOE OSTI2026

Data readiness pipeline patterns for scientific AI at scale: Insights from climate, fusion, life sciences, and materials

This article examines how data readiness for AI principles apply to large scientific datasets used to train foundation models. We analyze archetypal workflows across four representative domains—climate, nuclear fusion, life sciences, and materials—to identify common preprocessing patterns and domain‐specific constraints. We introduce a two‐dimensional readiness model that combines canonical preprocessing patterns with a five‐level operational readiness scale, both tailored to high‐performance computing (HPC) environments. This construct helps outline key challenges in transforming large‐scale scientific data into formats suitable for scalable AI training. Together, these dimensions form a conceptual maturity matrix that characterizes scientific data readiness and guides infrastructure development toward standardized, cross‐domain support for scalable and reproducible AI for science. Finally, we evaluate this maturity matrix in the context of case studies including ClimaX (climate), AFLOW (materials), OpenFold (proteomics), and DIII‐D fusion disruption‐prediction workflows, from which we distill lessons learned and provide recommendations to guide practitioners in developing robust AI‐readiness pipelines. Finally, we discuss remaining cross‐cutting challenges that persist across scientific domains.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Rapid extraction of short-lived isotopes from a buffer gas cell for use in gas-phase chemistry experiments, Part II: On-line studies with short-lived accelerator-produced radionuclides

We report a novel combination of advanced gas-chromatography and detection systems coupled to a buffer-gas cell was characterized on-line to allow gas-phase chemical studies of accelerator-produced short-lived α -decaying mercury, francium, and astatine isotopes. These were produced in 40 Ar- and 48 Ca-induced nuclear fusion–evaporation reactions, subsequently isolated in the recoil separators MARS at Texas A&M University, USA, and TASCA at GSI Darmstadt, Germany, before being thermalized in a buffer-gas-stopping cell. From the latter, the nuclear reaction products were extracted into gas-phase chromatographic systems, suitable for registering α-decaying short-lived radionuclides, such as isotopes of superheavy elements. Efficiencies of 21(3)% for 204-209 Fr were reached for the extraction into the optimized miniCOMPACT gas-chromatography setup, indicating that this technique enables the identification of isotopes of volatile as well as non-volatile elements. These studies guide the path towards chemical investigations of superheavy elements beyond flerovium, which are out of reach with currently used setups.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2025

Radiation damage effects in beryllium for next generation neutrino beam targetry (Final Technical Report)

Current and future high-power accelerators put severe requirements on materials used for target and beam windows and target facilities have been recognized as a critical challenge in development of future particle accelerators. In accelerators, window and target materials are exposed to extreme conditions, which include bombardment with very high energy protons (1- 100 GeV) and thermomechanical shock waves. Radiation can cause direct damage in the material, and it leads to production of transmutation products (especially helium), both phenomena having a potential adverse effect on the stability and durability of the target/window material. At high enough temperatures, He can aggregate to form gas bubbles, which in turn cause significant dimensional changes (swelling), enable easy crack propagation, and eventually cause failure by fracture. On the other hand, if the temperature is too low, radiation damage accumulates in the form of internal defects (e.g., dislocations), leading to hardening and a decreased ductility of the material. In this project, we will focus on beryllium since it is considered to be one of the candidate materials for beam windows and targets in the next-generation proton accelerators, e.g., the Long Baseline Neutrino Facility (LBNF). Radiation effects in Be have been studied in the context of nuclear fusion reactor applications. However, key differences exist between reactor and accelerator conditions, including neutron vs. proton irradiation, continuous vs. pulsed beam flux, much higher energies of bombarding particles in accelerators, and higher operating temperatures for typical reactors. For example, the impact of beam pulsing on the radiation damage and the He bubble kinetics is largely unknown. While results obtained on Be from fusion research might not be directly transferrable to understanding target materials, there is an opportunity to bring state-of-the-art tools from materials research in nuclear reactors to aid design of target and beam window materials in high-power accelerators. To this end, the overarching goal of this project are to develop an experimentally-validated computational framework capable of predicting radiation damage evolution in beryllium relevant to beam window and target conditions, focusing on He bubble formation and growth as a function of irradiation temperature. Our model will be based on the cluster dynamics formalism, where size distribution of defects and He bubbles is simulated as a function of time, temperature, and radiation dose. Parameters for the model will be taken from published experiments and from high-fidelity atomistic simulations proposed in this project. In addition, we will carry out a series of targeted ex-situ and in-situ dual-beam experiments using low-energy protons to provide critical data for validation of the model on the effects of radiation on He clustering, He bubble distribution, and dislocation loop density/size in proton irradiated Be.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Explainable tokamak-agnostic forecasting of fusion plasma instability via megahertz turbulent fluctuations

Scientific applications of artificial intelligence (AI) often remain limited by device-specific training and unexplained “black-box” approaches, creating fundamental barriers to cross-system generalization. This challenge is critical for nuclear fusion, where future reactors will have limited operational data for AI training. Here, we demonstrate that our neural network, trained solely on megahertz-scale turbulence measurements from one machine (DIII-D), forecasts Type-I edge localized mode (ELM) onsets in a different tokamak (KSTAR) through zero-shot weight transfer following physics-consistent preprocessing without device-specific retraining. Through an explainable AI framework combining gradient-weighted class activation mapping with physics validation, we reveal that our network can internalize physics relationships governing the ELM instabilities rather than memorizing device-specific patterns. The network perceives spatiotemporal features that correlate consistently with independently calculated instability growth rates, magnetohydrodynamic stability limits, and pedestal structure dynamics. Statistical analyses of dimensionally-reduced saliency features reveal the identical triangular features between the saliency representations, instability growth rates, and prediction probability across tokamaks, providing evidence that our forecasting system can show tokamak-agnostic generalization. This work contributes to a foundation for explainable scientific AI systems, where cross-system developments are essential for transcending traditional domain-specific constraints.

AI↗

DOE OSTI2024

Instabilities and Mixing in Inertial Confinement Fusion

By imploding fuel of hydrogen isotopes, inertial confinement fusion (ICF) aims to create conditions that mimic those in the Sun's core. This is fluid dynamics in an extreme regime, with the ultimate goal of making nuclear fusion a viable clean energy source. The fuel must be reliably and symmetrically compressed to temperatures exceeding 100 million degrees Celsius. After the best part of a century of research, the foremost fusion milestone was reached in 2021, when ICF became the first technology to achieve an igniting fusion fuel (thermonuclear instability), and then in 2022 scientific energy breakeven was attained. A key trade-off of the ICF platform is that greater fuel compression leads to higher burn efficiency, but at the expense of amplified Rayleigh–Taylor and Richtmyer–Meshkov instabilities and kinetic-energy-wasting asymmetries. In extreme cases, these three-dimensional instabilities can completely break up the implosion. Even in the highest-yielding 2022 scientific breakeven experiment, high-atomic-number (high-Z) contaminants were unintentionally injected into the fuel. Here we review the pivotal role that fluid dynamics plays in the construction of a stable implosion and the decades of improved understanding and isolated experiments that have contributed to fusion ignition.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Nested Pebble Bed Blanket (NesPeB)

Recent advances in magnetic confinement fusion technology have attracted billions of dollars of investments in startups from venture capitals and corporations, resulting in the development of devices aiming to demonstrate net energy gain in a self-heated burning plasma, such as SPARC (under construction) and others. However, future fusion power plants must operate in regimes that will require technologies far beyond current experience. According to a National Academies of Science, Engineering, and Medicine report, to have nuclear fusion power plants contributing in a timely manner to the planned reduction of atmospheric carbon dioxide, a pilot plant should be built by 2035, and it should demonstrate fusion power production and the performance of the tritium fuel system (requiring a high enough tritium breeding) by 2040. A recognized key technology gap by [26] is the fusion first wall and blanket since no current blanket concept is considered satisfactory or has been built and proven. The first wall and blanket in magnetic fusion reactors form a vital and complex system, as it must satisfy different functions such as power extraction, tritium breeding, plasma containment, radiation shielding, and safety. The list of design requirements is even longer: high enough tritium production for fusion self-sufficiency, low material activation, decay heat and shutdown dose rates, high thermal efficiency, high-capacity factor, high magnets-divertor-vacuum vessel-first wall life, low corrosion, low cost, and intrinsically safe (requiring minimal licensing). Despite fifty-plus years of research, the first wall and blanket concepts proposed suffer from fundamental technical problems and immaturity (TRL=2-3) that jeopardize the timely delivery of a commercial fusion power plant. A fusion first-wall blanket has never been built nor tested, and a "winning", practical functioning design requires enough engineering margins (high enough tritium breeding considering the uncertainty, etc.), manufacturing simplicity, ease of continuous operation, maintenance, and low cost. A new, groundbreaking blanket concept called "Nested Pebble Bed Blanket" (NesPeB) was developed at ORNL under the successful ARPA-E GAMOW FERMI project (patent application allowed by the USPTO). The NesPeB blanket concept addresses current blanket concepts' shortcomings and technical immaturity, paving the way for accelerated delivery of fusion power plants. NesPeB is based on nested pebbles, which are binary-sized lithium-ceramic pebbles enclosed in "Beryllide" perforated and coated spherical shells, which are also binary-sized, stacked on top of each other, forming a "bed" and cooled by Nitrogen gas also "sweeping" the Helium and Tritium generated by the neutron irradiation of Lithium; the vacuum vessel plasma facing material is Molybdenum-96 and -97 with the first wall cooled by Helium while the divertor armor is made of Tungsten. The simulations of the NesPeB blanket using Fusion Reactors Models Integrator (FERMI) are encouraging as they estimate a tritium breeding ratio (TBR) greater than 1.2 using natural Lithium, acceptable pressure drop, and excellent heat transfer properties. Furthermore, the NesPeB blanket is not limited by magneto-hydro-dynamics (MHD) effects, is designed for online refueling, relies on existing tritium extraction technologies, has a simple construction, and limits the corrosion and chemical reactivity problems. NesPeB has the potential to be transformational and disruptive since it can solve all the main, challenging technical problems of fusion device blankets and accelerate a pilot plant delivery for 10 or more years.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Investigating the possible existence of hyper-heavy nuclei in a neutron-star environment

The synthesis of hyper-heavy elements is investigated under conditions simulating neutron star environment. The constrained molecular dynamics approach is used to simulate low energy collisions of extremely n-rich nuclei. A new type of the fusion barrier due to a “neutron wind” is observed when the effect of neutron star environment (screening of Coulomb interaction) is introduced implicitly. When introducing also a background of surrounding nuclei, the nuclear fusion becomes possible down to temperatures of 10 8 K and synthesis of extremely heavy and n-rich nuclei appears feasible. A possible existence of hyper-heavy nuclei in a neutron star environment could provide a mechanism of extra coherent neutrino scattering or an additional mechanism, resulting in x-ray burst or a gravitational wave signal and, thus, becoming another crucial process adding new information to the suggested models on neutron star evolution.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗