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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Prediction of DIII-D Pedestal Structure From Externally Controllable Parameters

The sharp increase of pressure at the edge of a high confinement mode (H-mode) plasma, the pedestal, strongly impacts overall plasma performance. Predicting the pedestal is a necessity to control and optimize tokamak operations. Here, an experimental data-driven machine learning (ML) approach is presented that predicts the pedestal heights and widths of electron density (n e ) and electron temperature (T e ) profiles as well as the separatrix ne from externally controllable parameters such as the plasma shape, heating method and power, and gas puff rate and integrated gas puff. The OMFIT framework was used with DIII-D data to efficiently, robustly, and automatically build a database of pedestal parameters to train machine learning models. Database creation was enabled by the search engine tool for DIII-D data, TokSearch, which parallelizes data fetching, enabling fast searches through basic signals of thousands of DIII-D shots and selection of relevant time intervals. Principal Component Analysis (PCA) separated the database into three clusters that represent classes of plasma shapes that are regularly used in DIII-D. The most important parameters for setting the pedestal structure were plasma current (I p ), toroidal magnetic field (B Φ ), neutral beam heating power (P NBI ) and shaping quantities. The Deep Jointly Informed Neural Networks (DJINN) algorithm was applied to identify suitable neural network (NN) architectures that appropriately capture the features of the pedestal database. Separate NNs were implemented for each pedestal parameter, and ensembling methods were used to improve the prediction accuracy and allowed estimation of the prediction uncertainty. The pedestal predictions of the test dataset lie within the measurement uncertainties of the pedestal parameters. The NN outperformed simple Linear Regression (LR) analysis, indicating non-linear dependencies in the pedestal structure. The presented achievements illustrate a promising path for future research, using feature extraction to infer experimental trends and thereby improve pedestal models as well as deploying NN for a fast pedestal prediction in DIII-D scenario development.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Measurement of the energy dependence of the e+e- → $ B\overline{B} $, $ B{\overline{B}}^{\ast } $ and $ {B}^{\ast }{\overline{B}}^{\ast } $ exclusive cross sections

We report the first measurement of the exclusive cross sections e + e - → $B\overline{B}$, e + e - → $B{\overline{B}}^{\ast }$, and e + e - → ${B}^{\ast }{\overline{B}}^{\ast }$ in the energy range from 10.63 GeV to 11.02 GeV. The B mesons are fully reconstructed in a large number of hadronic final states and the three channels are identified using a beam-constrained-mass variable. The shapes of the exclusive cross sections show oscillatory behavior with several maxima and minima. The results are obtained using data collected by the Belle experiment at the KEKB asymmetric-energy e + e - collider.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

A Replacement Cold Neutron Guide System for HFIR (Conceptual Design Report)

The design of a replacement cold neutron guide system for the High Flux Isotope Reactor (HFIR) is presented. The proposed six-channel design uses the latest technologies and is optimally designed to account for operational and site constraints. These include the design of the cold source and the beam tube, the size and shape of the penetrations in the reactor confinement boundary, and the shape and orientation of the guide hall. The existing user instruments are a macromolecular diffractometer (IMAGINE), an IMAGING station, two small-angle neutron scattering (SANS) instruments (Bio-SANS and GP-SANS), and a cold triple-axis spectrometer (C-TAX). These instruments will all be reinstalled at end-of-guide positions with improved performance, and a position for a new high-performance neutron spin echo instrument will be created. The proposed guide design requires an extension to the guide hall toward the south. The calculated flux gain for a typical experiment is between a factor of 1.3 and 3 for all instruments, with the exception of the C-TAX instrument, which stands to gain a factor of >30 in flux at the sample. The new guide system will also offer additional performance gains, such as an increase in Q-range on Bio-SANS. The stated performance gains do not take into account any potential performance gains resulting from renewal and realignment of the guide system. The design of the guide system in the common sections up to about 25 m from the source is considered to be complete and ready for engineering design, while the designs of the instrument-specific guides are in some cases still a work in progress. The present report describes the current status of those designs.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

ARPA-E PNDIODES "PN Junctions by Ion Implantation" Project (Final Report)

Electricity accounts for nearly 40% of the energy generated in the United States, of which 65% is lost to electrical system inefficiency before reaching end-use sectors. Power electronics will play a growing role in this distribution and end-use, with up to 80% of electricity estimated to pass through power electronics from generation to consumption by 2030. This gives technical improvements in power electronics enormous potential to drive efficiency gains throughout the U.S. economy. Current Si-based power architectures including MOSFETs and IGBTs are limited by high losses, low switching frequency, and poor high-temperature performance. Given the material properties of GaN, devices can exhibit a given turn-on resistance and breakdown voltage with a minute fraction of the area of a Si device—all with higher switching speeds. While n-type doping of III-nitrides has reached a high level of maturity and integration into commercialized products, p-type doping presents distinct challenges that requires continued research. The success of the next generation of GaN-based power devices depends in large part on the ability to form selective-area p-type regions, which can be accomplished by ion implantation of the prevailing acceptor dopant, Mg. This approach is relatively inexpensive and is a fab-ready processing step for creation of current-generation power electronic devices including BJTs, IGBTs, and diode rectifiers. However, ion implantation induces lattice damage and creates point defects within the material, which negatively impacts dopant activation annealing. These forms of damage may be removed by high-temperature annealing, however short annealing time and higher pressures are required to prevent decomposition of the material. We approach this challenge through an innovative combination of approaches toward obtaining high-conductivity p-type GaN. By the novel employment of a gyrotron, a microwave source that can be shaped into a highly localized beam to dissipate very high power in a semiconductor target, a wafer of GaN can be annealed in short (<2 s) ‘pulses’ at temperatures of 1450 °C (2640 °F) to achieve p-type activation without appreciable surface degradation. The p-type activation of Mg-implanted GaN can be further aided by co-implantation with N, believed to enhance the removal of point defects that compensate the acceptors dopant. Elevation to such high temperatures for even a short time induces degradation of GaN-to overcome, we have implemented additional measures to retain high-quality crystalline GaN while removing implant damage and activating Mg dopant. A bilayer cap of AlN is deposited by a combination of chemical and physical vapor deposition to protect the GaN surface. To prevent decomposition of GaN loss of N during annealing, a custom vessel—to contain pressurized N while allowing injection of microwave energy—is employed. By detailed study of the interaction of various measures that are implemented to protect the sample surface (GaN), activate the implanted dopants, and mitigate damage of the lattice heating damage during annealing, we are able to achieve p-type GaN and observe recovery of the crystal and removal of substantial density of defects created during the implantation process.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

L-H transition trigger physics in ITER-similar plasmas with applied n = 3 magnetic perturbations

The L–H transition power threshold PLH is observed to increase with applied n = 3 resonant magnetic perturbations (RMP) in ITER-similar-shape plasmas with balanced neutral beam torque injection in DIII-D. The increase is most pronounced with added electron–cyclotron heating: PLH increases with decreasing edge plasma collisionality as PLH/PLH-08 ~ (ν*)−0.5, where PLH-08 is the 2008 ITPA multi-machine power threshold scaling. This result raises concerns for H-mode access at low edge collisionality in ITER, where RMP may have to be applied before the L–H transition to safely suppress the first edge-localized mode. Non-axisymmetric modifications with RMP include a simultaneous reduction of the radial electric field (Er) well depth and E × B shear. This can be attributed to increasing edge toroidal co-current rotation, and is consistent with substantially increased local long-wavelength turbulence (measured via beam emission spectroscopy). At high RMP perturbation strength the edge electric field Er reverses sign locally (becomes positive), with changes in dominant turbulence modes. Edge magnetic stochasticity provides an attractive explanation of the observed modifications, and the observed changes in toroidal rotation and Er are consistent with a simple fluid model describing radial electron current flow along stochastic fieldlines. The observed collisionality dependence of the L-mode edge electric field with applied RMP is also qualitatively consistent with this model. Reflectometry data indicate a significant reduction of the normalized L-mode radial density gradient a/Ln at high RMP field with simultaneous increase in radial particle flux and electron thermal flux from power balance analysis. We conjecture that the increase of PLH with RMP results from the combined effects of reduced E × B flow shear (increasing turbulent transport levels) and toroidal/poloidal flow modulation due to edge stochasticity. Initial experiments indicate that non-resonant n = 3 magnetic perturbations lead only to relatively small changes in Er, E × B shear and fluctuation characteristics, and have less impact on the L–H transition power threshold. This motivates further exploration of the RMP spectrum dependence of PLH for possible mitigation of the observed threshold increase.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Design of inertial fusion implosions reaching the burning plasma regime

One of the last remaining milestones in fusion research before reaching ignition is creating a burning plasma state, where alpha particles from deuterium-tritium (DT) fusion reactions redeposit their energy as the dominant source of heating in the plasma. The indirect-drive inertial confinement fusion approach at the National Ignition Facility (NIF) uses a laser-generated radiation cavity (hohlraum) to spherically implode DT fuel to high temperatures and densities in a central ”hot spot”. Here, we deliver more energy to the hot spot than ever before, while maintaining the extreme pressures required for inertial confinement, by increasing the size of the implosion compared to previous experiments. We develop more efficient hohlraums, to drive these larger implosions within NIF’s current laser energy and power capability and control symmetry by moving energy between laser beams and by changing the shape of the hohlraum. These designs resulted in record fusion powers of 1.5 petawatts, greater than the input power of the laser, and 170 kJ of fusion energy. Radiation hydrodynamics simulations show alpha particle heating as the dominant term in the hot spot energy balance, e.g. a burning plasma state. This work is expected to motivate future studies of burning plasmas and improve predictive capability by providing a benchmark for modeling used to understand the proximity to ignition.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Erratum to: Soft- and reactive landing of ions onto surfaces: concepts and applications

Soft- and reactive landing of mass-selected ions is gaining attention as a promising approach for the precisely-controlled preparation of materials on surfaces that are not amenable to deposition using conventional methods. A broad range of ionization sources and mass filters are available that make ion soft-landing a versatile tool for surface modification using beams of hyperthermal (<100?eV) ions. The ability to select the mass-to-charge ratio of the ion, its kinetic energy and charge state, along with precise control of the size, shape, and position of the ion beam on the deposition target distinguishes ion soft landing from other surface modification techniques. Soft- and reactive landing have been used to prepare interfaces for practical applications as well as precisely-defined model surfaces for fundamental investigations in chemistry, physics, and materials science. For instance, soft- and reactive landing have been applied to study the surface chemistry of ions isolated in the gas-phase, prepare arrays of proteins for high-throughput biological screening, produce novel carbon-based and polymer materials, enrich the secondary structure of peptides and the chirality of organic molecules, immobilize electrochemically-active proteins and organometallics on electrodes, create thin films of complex molecules, and immobilize catalytically active organometallics as well as ligated metal clusters. In addition, soft landing has enabled investigation of the size-dependent behavior of bare metal clusters in the critical subnanometer size regime where chemical and physical properties do not scale predictably with size. The morphology, aggregation, and immobilization of larger bare metal nanoparticles, which are directly relevant to the design of catalysts as well as improved memory and electronic devices, have also been studied using ion soft landing. This review article begins in section 1 with a brief introduction to the existing applications of ion soft- and reactive landing. Section 2 provides an overview of the ionization sources and mass filters that have been used to date for soft landing of mass-selected ions. A discussion of the competing processes that occur during ion deposition as well as the types of ions and surfaces that have been investigated follows in section 3. Section 4 discusses the physical phenomena that occur during and after ion soft landing, including retention and reduction of ionic charge along with factors that impact the efficiency of ion deposition. The influence of soft landing on the secondary structure and biological activity of complex ions is addressed in section 5. Lastly, an overview of the structure and mobility as well as the catalytic, optical, magnetic, and redox properties of bare ionic clusters and nanoparticles deposited onto surfaces is presented in section 6. © 2015 Wiley Periodicals, Inc. Mass Spec Rev 35:439–479, 2016.

Johnson, Grant E.↗
DOE OSTI2023

Development of high-performance long-pulse discharge in KSTAR

High-performance long-pulse plasma operation is essential for producing economically viable fusion energy in tokamak devices. To achieve such discharges in KSTAR, firstly, the rapid increase in the temperature of plasma-facing components was mitigated. The temperature increase of the poloidal limiter, especially, was associated with beam-driven fast ion orbit loss and the discrepancy of the equilibrium reconstructed with heated magnetic probes of signal drift. The fast ions lost to the poloidal limiter were reduced by optimizing the plasma shape and the composition of neutral beam injection (NBI). This nonlinear signal drift was successfully reduced by a new thermal shielding protector on the magnetic probes. Secondly, a lower loop voltage approach was implemented to reduce a poloidal flux consumption rate. A plasma current of 400 kA and a line-averaged electron density of ~2.0 × 10 19 m –3 were chosen by considering the L–H power threshold, fast ion orbit loss, and beam shine-through power loss for low loop voltage in KSTAR. In addition, the application of electron cyclotron heating also helped maintain the plasma with low loop voltage (~25 mV) by enhancing the NBI-driven current and achieving a high poloidal beta (β P ) state. KSTAR has achieved a long pulse (~90 s) operation with the high performance of β P $\leqslant$ 2.7, thermal energy confinement enhancement factor (H 98y2 ) ~ 1.1, and fraction of non-inductive current (f NI ) $\leqslant$ 0.96. Still, gradual degradation of the plasma performance has been observed over time in the discharges. In one of the long-pulse discharges, β P reduced by ~18% over the time of ~8τ R (current relaxation time, τ R ~5 s) and ~1067τ E,th (thermal energy confinement time, τ E,th ~45 ms). The degradation may be closely associated with weak, yet growing, and persistent toroidal Alfvén eigenmodes and their effect on fast ion confinement.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Shadow of a laser beam

Light, being massless, casts no shadow; under ordinary circumstances, photons pass right through each other unimpeded. Here, we demonstrate a laser beam acting like an object — the beam casts a shadow upon a surface when the beam is illuminated by another light source. We observe a regular shadow in the sense it can be seen by the naked eye, it follows the contours of the surface it falls on, and it follows the position and shape of the object (the laser beam). Specifically, we use a nonlinear optical process involving four atomic levels of ruby. We are able to control the intensity of a transmitted laser beam by applying another perpendicular laser beam. We experimentally measure the dependence of the contrast of the shadow on the power of the laser beam, finding a maximum of approximately 22%, similar to that of a shadow of a tree on a sunny day. We provide a theoretical model that predicts the contrast of the shadow. This work opens new possibilities for fabrication, imaging, and illumination.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Improved optical standing-wave beam splitters for dilute Bose–Einstein condensates

Bose–Einstein condensate (BEC)-based atom interferometry exploits low temperatures and long coherence lengths to facilitate high-precision measurements. Progress in atom interferometry promises improvements in navigational devices like gyroscopes and accelerometers, as well as applications in fundamental physics such as accurate determination of physical constants. Previous work demonstrates that beam splitters and mirrors for coherent manipulation of dilute BEC momentum in atom interferometers can be implemented with sequences of non-resonant standing-wave light pulses. While previous work focuses on the optimization of the optical pulses’ amplitude and duration to produce high-order momentum states with high fidelity, we explore how varying the shape of the optical pulses affects optimal beam-splitter performance, as well as the effect of pulse shape on the sensitivity of optimized parameters in achieving high fidelity in high-momentum states. Here, in simulations of two-pulse beam splitters utilizing optimized square, triangle, and sinc-squared pulse shapes applied to dilute BECs, we, in some cases, reduce parameter sensitivity by an order of magnitude while maintaining fidelity.

74 ATOMIC AND MOLECULAR PHYSICS↗
DOE OSTI2025

Non-circular electron beam spot welds in stainless steel alloys

Circularly symmetric-shaped spot welds are desirable for welding applications as they relate to heat and fluid flow conditions in the melt pool with predictable weld penetrations and repeatable results. Non-circular spot welds on the other hand result in undesirable and unpredictable weld penetrations or non-bridging of the liquid melt pool across the joint. Two known causes for non-circular melt pools occur when welding dissimilar metals, or when welding with skewed electron or laser beams that are not perpendicular to the surface. A largely unexplored additional factor, shown here, is an asymmetric power density distribution within the beam that can create non-circular melt pools even though the beam dimensions are much smaller than the melt pool itself.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Plasma Focused Ion Beam Milling of High-Aspect-Ratio Holes in Diamond

Plasma focused ion beam (PFIB) technology has a great potential for applications requiring rapid micro-machining of high-aspect-ratio features. Here, we use 30-keV Ar, Xe, and O 2 ion beams to study PFIB milling of high-aspect-ratio circular holes in polycrystalline diamond. Our results show that Xe and O 2 ion beams have the highest milling efficiency for low-aspect-ratio and high-aspect-ratio hole milling, respectively. Each ion beam species produces holes with its characteristic shape and wall surface morphology. In conclusion, based on these results, we demonstrate a “hybrid” hole milled in a two-step process with Xe and O 2 ion beams with the geometry and wall morphology attractive for the attachment of a fuel fill tube to the inertial confinement fusion capsule.

ICF targets↗
DOE OSTI2022

A Quantitative Method for In Situ Pump-Beam Metrology in 4D Ultrafast Electron Microscopy

In this work, we report a method for measuring spot size and focusing conditions of the femtosecond (fs) excitation laser in situ at the specimen location in 4D ultrafast electron microscopy (UEM). The method makes use of threshold laser ablation behaviors of thin amorphous carbon membranes. For Gaussian beam profiles and for ablation threshold fluence values, we analytically derive expressions describing the relationship between ablated hole size and the actual laser spot size. Using these expressions, we developed experimental procedures for characterizing the shape and spot size of the pump beam at the specimen. We demonstrate the viability of the approach for incident excitation wavelengths of 343 nm and 515 nm, thus illustrating the applicability of the method to a range of optical wavelengths without modification. Further, we show that by measuring ablated hole size as a function of focusing condition, a full metrological characterization of the Gaussian beam propagation properties can be performed. Finally, we find good agreement for spot sizes determined with this method and with those determined by extrapolation from measurements taken outside the microscope column. Overall, this method is a simple, cost-effective means for accurate and precise determination of key pump-beam parameters in situ at the specimen location in UEM experiments.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Laser additive manufacturing for infrastructure repair: A case study of a deteriorated steel bridge beam

As our transportation infrastructure ages, its deterioration is becoming a growing concern. Rapid and effective methods for repair can reduce the need for time-and cost-intensive replacement of structures such as roadway bridges. In this work, laser-based additive manufacturing (AM) was developed for the re-pair of damaged beams in steel bridges. A corroded structural beam of low-carbon A36 steel was selected for this case study and 316L stainless steel was used for repair due to its excellent mechanical properties and corrosion resistance. Simulated repair experiments were performed on specimens extracted from the beam, and prepared with various groove shapes (Rectangular, Trapezoidal, and U-shaped). More in-depth parametric and microstructural studies were carried out with a series of U-shaped specimens repaired with the linear laser input energy varied from 19.5 to 30.0 J mm -1 . The tensile properties of the repaired specimens and interface structures were also investigated in detail. It was found that the repaired specimens had a slightly higher tensile strength despite a reduction in tensile elongation compared to the A36 steel base metal. The influence of interfacial microstructure and heterogeneity on the mechanical proper-ties of the repaired specimens was discussed. Furthermore, our work suggests the promising potential to employ AM for structural repair and provides fundamental insights into processing-structure-property relationships in laser AM-repaired materials.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Control of ternary alloy composition during remote epitaxy on graphene

Understanding the sticking coefficient σ, i.e., the probability of an adatom sticking to a surface, is essential for controlling the stoichiometry during epitaxial film growth. However, σ on monolayer graphene-covered surfaces and its impact on remote epitaxy are not understood. Here, using molecular-beam epitaxial growth of the magnetic shape memory alloy Ni 2 MnGa, we show that the sticking coefficients for metals on graphene-covered MgO (001) are less than one and are temperature and element dependent, as revealed by ion backscattering spectrometry and energy-dispersive x-ray spectroscopy. This lies in stark contrast with most transition metals sticking on semiconductor and oxide substrates, for which σ is near unity at typical growth temperatures (T < 800°C). By initiating growth below 400°C, where the sticking coefficients are closer to unity and wetting on the graphene surface is improved, we demonstrate the epitaxy of Ni 2 MnGa films with controlled stoichiometry that can be exfoliated to produce freestanding membranes. Straining these membranes tunes the magnetic coercive field. Finally, our results provide a route to synthesize membranes with complex stoichiometries whose properties can be manipulated via strain.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Toward high laser power beam manipulation with nanophotonic materials: evaluating thin film damage performance

Nanophotonic materials enable unprecedented control of light-matter interactions, including the ability to dynamically steer or shape wavefronts. Consequently, nanophotonic systems such as metasurfaces have been touted as promising candidates for free-space optical communications, directed energy and additive manufacturing, which currently rely on slow mechanical scanners or electro-optical components for beam steering and shaping. However, such applications necessitate the ability to support high laser irradiances (> kW/cm 2 ) and systematic studies on the high-power laser damage performance of nanophotonic materials and designs are sparse. Here, we experimentally investigate the pulsed laser-induced damage performance (at λ ∼ 1 µm) of model nanophotonic thin films including gold, indium tin oxide, and refractory materials such as titanium nitride and titanium oxynitride. We also model the spatio-thermal dissipation dynamics upon single-pulse illumination by anchoring experimental laser damage thresholds. Our findings show that gold exhibits the best laser damage resistance, but we argue that alternative materials such as transparent conducting oxides could be optimized to balance the tradeoff between damage resistance and optical tunability, which is critical for the design of thermally robust nanophotonic systems. We also discuss damage mitigation and ruggedization strategies for future device-scale studies and applications requiring high power beam manipulation.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Diagnostics for PSR Upgrade

This report discusses the diagnostics upgrade plan for the PSR. The PSR diagnostics under discussion include beam position and phase monitor (BPPM), wirescanners, wall current monitors, bunch shape monitors, laser notchers, and diamond array detectors. Existing diagnostics at the PSR include beam position monitors (BPM), a wirescanner, and a wall current monitor. All existing diagnostics need modernization, as part of the PSR upgrade plan. Meanwhile, we will introduce minor changes to improve the existing setups, which will enhance the performance and the longevity of the diagnostics equipment and components in the upgraded PSR operation. On the other hand, new, advanced, and available diagnostic technologies at a high technology readiness level (TRL) can also be considered for implementation for the PSR upgrade. In this note, we go through all types of diagnostics, introducing their basic principle, operating status, and plans for the PSR upgrade.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Non-Rare Earth Magnesium Bumper Beams

Magna will team with the Pacific Northwest National Laboratory (PNNL) to develop Shear Assisted Processing and Extrusion (ShAPE™) of rectangular and multi-zoned extrusion profiles using non-RE Mg. It is envisioned that the ShAPE™ process, developed during this project for non-circular profiles, will serve as the foundation for fabrication of full-scale bumper beams of the future where near net-shapes are extruded directly from castings in a single step, without the need for costly rare earth additives. In this project, the ShAPE™ process will be developed for a rectangular profile measuring 1” x 2” with a 0.06” wall thickness. Successful extrusion of rectangular cross sections is a critical step along the path toward profiles with multiple zones. With the process established for a rectangular profile, the project will then make advancements toward multi-zoned cross sections. A magnesium alloy bumper beam offers a 35% weight savings compared to aluminum alloys and 60% compared to high strength steels. The bumper beam was chosen as the first component to target because the geometry can have a fairly simple 0.6-0.12 inch wall/web thickness, generally compatible with PNNL’s knowledge base and equipment capability surrounding ShAPE™. The bumper component offers commercial value by providing mass reduction in the front of the vehicle along with ride and handling benefit. PNNL has demonstrated the ability to ShAPE™ process non-RE Mg tubing with high strength, ductility and energy absorption. It has been shown that ShAPE™ extruded ZK60 and Mg2Si tubing with 0.30 inch diameter and 0.03 inch wall thickness have similar energy absorption to AA6061-T6. This is due to significant grain refinement, breakdown and dispersion of second phases, and the ability to eliminate anisotropy in compressive/tensile strength by aligning texture 45 degrees to the extrusion axis. Scalability of the ShAPE™ process has been demonstrated in ZK60 by fabricating 2.0 inch diameter tubing with 0.06 and 0.12 inch wall thicknesses having concentricity as tight as 1.3%. These tubes exhibit an ultimate tensile strength of 260-300 MPa and room temperature ductility of >20% parallel, perpendicular and 45 degrees to the extrusion axis. Aluminum bumpers represent approximately 54% of the NA light vehicle market. If the research effort is successful, providing a 30% mass reduction at equal cost relative to aluminum bumpers, it is anticipated that 25% market penetration would be realized over the next 5 year and 50% market share by 2030. 100% of the aluminum automotive bumpers are sourced from the tier network, providing resourcing opportunity based on equal performance, reduced mass and cost equivalent lower than aluminum bumpers. Due to the relatively low vehicle content, magnesium components are currently shredded and 100% recycled with aluminum content in the US, presenting a positive life cycle impact.

42 ENGINEERING↗