Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “target fabrication”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Fabrication of Nb3Sn by Magnetron Sputtering for Superconducting Radiofrequency Application

Particle accelerators are considered as an important device that has wide applications in cancer treatment, sterilizing waste, preserving foods, ion implantation in semiconductor industry, and in production of isotopes for medical applications. Superconducting radiofrequency (SRF) cavities are the building blocks of a linear particle accelerator. Current particle accelerators use niobium (Nb) superconductors as the sheet material to fabricate a single SRF cavity for particle acceleration. With better superconducting properties (critical temperature Tc ~ 18.3 K, superheating field Hsh~ 400 mT), Nb3Sn is considered a potential candidate in SRF technology. Magnetron sputtering is a promising deposition method to fabricate Nb3Sn thin films inside SRF cavities. Superconducting Nb3Sn films were fabricated on Nb and sapphire substrates by magnetron sputtering from a single stoichiometric Nb3Sn target, by multilayer sputtering of Nb and Sn followed by annealing, and by co-sputtering of Nb and Sn followed by annealing. The variation of morphological and superconducting properties was investigated for different substrate temperatures, annealing temperatures, annealing durations, and thicknesses. The film properties were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), atomic force microscopy (AFM), and energy dispersive X-ray spectroscopy (EDS). The films had crystalline Nb3Sn structure without any presence of poor superconducting Nb6Sn5 and NbSn2 phases. The highest Tc of the films fabricated from the stoichiometric target, multilayer sputtering and co-sputtering were 17.44, 17.93, and 17.66 K respectively. Finally, a cylindrical sputter coater with two identical magnetrons was designed and commissioned to fabricate Nb3Sn films inside a 2.6 GHz SRF cavity. The magnetrons were installed facing opposite to each other in a custom designed vacuum chamber and multilayers of Nb and Sn films on 1 cm2 Nb substrates replicating the beam tubes and equator locations of the cavity and the coated multilayered films were annealed at 950 °C for 3 h. The XRD of the as?deposited and annealed films confirmed the formation of Nb3Sn after the annealing. The dissertation discusses the fabrication process, characterized results of the fabricated films, the design of the cylindrical sputter coater and the preliminary data obtained from the sputter coater.

Sayeed, Md Nizam↗
DOE OSTI2023

Correcting Hohlraum Drive Asymmetry with Glow Discharge Polymerization Coated Capsule Shims

In inertial confinement fusion target design, the shape discrepancy between the cylindrical hohlraum and the spherical capsule creates a low mode asymmetry in the implosion. One way to correct such asymmetry is to shim the target capsule surface with extra mass in specific locations following a 3D P4 Legendre mode. Previously, the desired surface pattern was precision machined out of the capsule. The resulting 2DConA experiments that investigated the implosion’s shape demonstrated the shimming method’s success. However, machining leaves large defects on the capsule surface which will degrade neutron yield in a DT implosion. An alternative shimming approach is to grow the pattern on the capsule surface using a glow discharge polymerization coating process in a stencil lithography application. In this study, we discuss the fabrication, characterization and challenges of making shimmed target capsules with this new method.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Characterization of mechanical properties and deformation behavior of highly irradiated 316L stainless steel from target modules at the Spallation Neutron Source using digital image correlation analysis

Tensile specimens with irradiation doses ranging from approximately 0.7 to 7.6 displacements per atom (dpa) were fabricated from 316L samples removed from Spallation Neutron Source (SNS) target vessels after service. Tensile tests were performed in conjunction with digital image correlation (DIC) characterization, which permitted detailed analysis of the strain distribution and deformation behavior of the specimen gauge sections during testing. The results show, while considerable hardening (500–700 MPa increase in yield strength) occurred in the 316L SNS target material with increasing dose, appreciable ductility (19–23% total elongation) remained in the material after irradiation to 7.6 dpa in the mixed neutron/proton environment of the SNS target region. The DIC data showed the strain distribution and deformation behavior of all irradiated specimens were nonuniform during testing. Strain localization in the form of deformation bands or “hotspots” was observed during testing, and in some specimens, the bands propagated as deformation waves along the gauge section. The “traveling wave” deformation behavior affected the amount of elongation each specimen achieved, and the scatter in the elongation data was attributed to the large variation in deformation behavior observed among different specimens. Bands of localized strain, or deformation bands, oriented at specific angles were observed in two-dimensional plots of the strain distribution in the gauge sections of some specimens. Overall, this paper describes the experimental procedures, results, and deformation behavior of tensile specimens from SNS targets after service and illustrates the value of DIC characterization during tensile testing of irradiated materials.

36 MATERIALS SCIENCE↗
NASA NTRS2026

Artemis Suit Material Effects of Calendaring Woven Fabrics on Dust Resistance

This paper presents one element of an ongoing NASA technology-infusion effort to design, fabricate, and test a new outer shell fabric for a lunar Extravehicular Activity (EVA) space suit, a critical component of sustained lunar exploration. A primary challenge for suit textiles is preventing lunar dust, which is highly abrasive, electrostatically charged, and capable of infiltrating even tightly woven fabrics from penetrating the Environment Protection Garment (EPG) and compromising suit durability and astronaut safety. To enhance dust-blocking performance, the Artemis Suit Materials Team investigated calendaring, a continuous roll to roll mechanical finishing process in which fabric passes through heated rollers under high pressure to compress and flatten the weave, thereby reducing pore size and modifying surface texture without significantly affecting other properties. Targeted testing of calendared Teflon™ T-162 and Ortho Fabric samples provides new insight into how calendaring influences dust resistance, informing future material development and advancing EVA suit technology for long-duration lunar missions.

Dust↗
NASA NTRS2026

Artemis Suit Material Effects of Calendaring Woven Fabrics on Dust Resistance

This paper presents one element of an ongoing NASA technology-infusion effort to design, fabricate, and test a new outer shell fabric for a lunar Extravehicular Activity (EVA) space suit, a critical component of sustained lunar exploration. A primary challenge for suit textiles is preventing lunar dust, which is highly abrasive, electrostatically charged, and capable of infiltrating even tightly woven fabrics from penetrating the Environment Protection Garment (EPG) and compromising suit durability and astronaut safety. To enhance dust-blocking performance, the Artemis Suit Materials Team investigated calendaring, a continuous roll to roll mechanical finishing process in which fabric passes through heated rollers under high pressure to compress and flatten the weave, thereby reducing pore size and modifying surface texture without significantly affecting other properties. Targeted testing of calendared Teflon™ T-162 and Ortho Fabric samples provides new insight into how calendaring influences dust resistance, informing future material development and advancing EVA suit technology for long-duration lunar missions.

Dust↗
DOE OSTI2024

Use of a Lignin-Based Admixture for Tailoring the Rheological Properties of Mortars for 3D Printing: Preprint

Efforts toward decarbonizing construction materials and industrial processes related to cement and concrete can be aided via multifaceted approaches that target alternative admixtures as well as precision control of fabrication. Chemical admixtures for water reduction have played a crucial role in the development of advanced concrete mixtures. Newer biomass processing techniques developed for aviation fuel production from corn stover biomass produce a more reactive lignin byproduct that is suitable for chemical modifications to mimic the properties of polycarboxylate ether admixtures with a smaller carbon footprint. The present study examines the use of lignin-based water-reducing admixture in cement pastes and mortar mixtures for 3D printing. The experimental program explores the use of different dosages of lignin-based admixture to produce 3D-printed samples with appropriate extrudability and buildability. The rheological characterization was performed to determine the flow curve of various mixtures. Finally, the heat of hydration of cement pastes was monitored via isothermal calorimetry to assess the impact of lignin-based admixtures on the hydration process of cement. The results of this study indicate that the use of biomass by-products, such as lignin-based admixtures have great potential to effectively control the fresh-state properties of cement-based materials.

bio-based admixtures↗
DOE OSTI2025

Challenges and Optimization of Mu2e Proton Target Design with Radiative Cooling

Mu2e, the Muon-to-Electron Conversion Experiment, aims to identify physics beyond the Standard Model, namely, the conversion of muons to electrons without the emission of neutrinos. The muons are produced from pions generated in a production target when it is hit by an 8 GeV proton beam from the Fermilab Booster/Main Injector. The proton target design space is strongly constrained by a one-year operating lifetime and the need for radiative cooling in a vacuum environment. Uncertainties in the lifetime of the existing baseline design – a monolithic, segmented tungsten target – are large, particularly due to unknown impacts of radiation damage at the very high proton fluences expected in the experiment. We have begun evaluation of a new design utilizing Inconel 718 over the WL10 used in the existing target design. As a result, the structural design of the target has evolved significantly. This evolution focuses on lowering the target temperature, minimizing obstruction to muons, increasing structural stability, maximizing fatigue lifetime, simplifying the fabrication process, and more. The thermal management, structural stability and fatigue lifetime are emphasized here. These optimizations have led to a promising new target design for the Mu2e experiment.

Liu, Z. [Fermilab]↗
DOE OSTI2025

Historic and modern nuclear graphite impurities: Pathways to improved waste strategies

Graphite has been used in large volumes as a structural material and neutron moderator since the earliest days of nuclear fission. However, no international consensus exists on the disposal of irradiated graphite, leaving much of the historic radioactive graphite inventory in interim vault or silo storage. With several new graphite-moderated reactors planned or under construction, the issue of graphite waste management is becoming increasingly urgent. This paper reviews and quantifies impurities in both historic and modern nuclear graphite, with emphasis on nitrogen—responsible for much of the 14 C inventory—and chlorine, which plays a critical role in repository performance and design. Modern graphites, benefitting from stringent quality-control measures developed for non-nuclear industries, meet or exceed the ASTM Ultra-High Purity nuclear standards, even without halide purification. Both chlorine and nitrogen concentrations have declined over time. For chlorine, identified as a key impurity influencing U.S. waste repository design, we propose a target of 0.1 appm in as-fabricated billets as a reasonable benchmark. Nitrogen sources are traced throughout the graphite production process, with surface and bulk concentrations characterized for all materials studied. Modern graphites commonly exhibit nitrogen levels below 5 appm, with values approaching 1 appm achievable. Using such reduced-nitrogen grades is critical to keeping graphite-induced radioactivity below the greater-than-Class-C waste threshold, thereby avoiding disposal cost penalties of nearly an order of magnitude.

Chlorine↗
DOE OSTI2021

Oxygen Vacancies Enriched Bi Based Catalysts for Enhancing Electrocatalytic CO2 Reduction to Formate

The practical application of CO2 conversion through electrochemical reduction is still hindered by the lack of high performance and cost-effective catalysts. It is thus imperative to explore feasible strategies for scalable fabrication of catalysts for CO2 reduction to targeting products with high efficiency. Herein, for the first time, a hybrid of BiOx encapsulated in carbon thin layer is developed as high active electrocatalyst for CO2 conversion, which is synthesized by pyrolysis using Bi MOF as precursor and sacrificial template. The carbon layer overcoating BiOx catalyst exhibits superior performance for CO2 reduction to formate, achieving a maximum Faradaic efficiency of 89.3 % and a maximum current density of 37.8 mA cm-2. It is found that the as-prepared BiOx catalyst is enriched with oxygen vacancies stabilized by the encapsulating carbon layer. Both the carbon layer and oxygen vacancies improve the charge transfer of the catalyst, in favor of the high formate current density. The defects of oxygen vacancies play a vital role in CO2 adsorption and activation and thereby further enhancing the electrocatalytic ability for formate production.

oxygen vacancy, bismuth, carbon coating, CO2 elect↗
DOE OSTI2024

Technoeconomic analysis of perovskite/silicon tandem solar modules

Tandem photovoltaic (PV) modules offer an opportunity to improve the efficiency and energy yield of available solar resources compared with single-junction devices. Here, we present a cost model and sensitivity analysis of perovskite/silicon (Si) tandem modules to understand how design choices impact overall module costs. We find a minimum sustainable price (MSP) of $\$$0.428/W DC for our baseline two-terminal design and $\$$0.423/W DC for our baseline four-terminal design, each at a module efficiency of 25% and module production of 3 GW per year in the United States. We find that the choice of Si cell architecture, overall module efficiency, and factory throughput have the most significant impacts on cost and competitiveness. The dynamic model provided is designed for researchers, companies, and interested individuals to use and edit as needed to better understand the trade-offs among PV module technologies and enable targeted research to improve module design and fabrication.

14 SOLAR ENERGY↗
DOE OSTI2025

Machine learning-driven design and self-sensing capabilities of automotive bumper lattices for adaptive impact response

We present a novel approach to design an automotive bumper energy absorber using carbon fiber reinforced polymer composites, optimized to meet conflicting performance requirements for two distinct impact scenarios. The design must satisfy both a low-speed (2.5 mph) pendulum intrusion test, simulating vehicle-to-vehicle collisions, and a high-speed (25 mph) leg flexion test, replicating pedestrian impacts. These tests demand opposing deformation characteristics: high flexibility (deformation < 85 mm) for the former and high stiffness (deformation < 22 mm) for the latter. To address these contradictory requirements, we developed a machine learning (ML) framework for inverse optimization of lattice designs and material selection. Unlike traditional iterative design processes, our ML model directly outputs optimal design parameters and material choices based on target performance inputs. The energy absorber was fabricated using advanced additive manufacturing techniques, including extrusion deposition and digital light processing. The integration of carbon fibers provides multifunctionality to the bumper structure, enabling self-sensing capabilities through changes in electrical resistivity under compression. This electrical response demonstrates high repeatability under multiple cycles at 2% compression and exhibits distinct signatures during crack formation under high deformation. This research offers adaptive performance through innovative design methodologies and smart material integration. The approach has potential applications in various fields requiring adaptive energy absorption and real-time structural health monitoring.

Chawla, Komal [ORNL] (ORCID:0000000190327565)↗
DOE OSTI2022

Design and characterization of “flow-cell” integrated-flow active cooling for high-average-power ceramic optics

We used COMSOL Multiphysics to design a prototype actively cooled “flow-cell” substrate targeted at high-average-power applications, fabricated the prototype from cordierite ceramic, and tested the substrate under load in our thermal loading test stand. Sub-aperture testing revealed average-power handling up to 3.88-W/cm 2 absorbed power density, in excellent agreement with model predictions. Gratings fabricated on 2-in.-diam cordierite coupons were subjected to laser-damage testing and showed a damage threshold of 250 mJ/cm 2 .

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Acceptance Testing of the Scorpius Sweep Magnet

A beam-dump magnet for Scorpius has been defined by LANL and designed and built by Radiabeam Technologies. Initial verification of the Radiabeam design used a magnetic field model provided by Radiabeam and analyzed by LANL tools during September 2021. Simulations indicated that the design was sufficient to meet deflection requirements to protect sensitive equipment in the case of a failed target. In January 2022, the magnet was fabricated and Radiabeam conducted measurements of the magnetic field as a function of position. The measurements deviate somewhat from the simulation. In particular, the peak magnetic field is 10-15% smaller in magnitude than expected from simulation. This note compares the magnetic field measurements to simulation and to measurements of the existing DARHT magnet, which was designed for the same purpose. We show a comparison of the measured beam deflection performance between Scorpius and DARHT and show updated results of LANL’s electron beam tracking code using the Scorpius measurements. Using field measurements we find that the DARHT magnet will deflect a 19.6 MeV electron beam by 46.6° and the Scorpius magnet will deflect by 44.6°. These results show that the as-built Scorpius magnet has met design requirements for beam deflection.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRS2003

NASA Tech Briefs, August 2003

Topics covered include: Stable, Thermally Conductive Fillers for Bolted Joints; Connecting to Thermocouples with Fewer Lead Wires; Zipper Connectors for Flexible Electronic Circuits; Safety Interlock for Angularly Misdirected Power Tool; Modular, Parallel Pulse-Shaping Filter Architectures; High-Fidelity Piezoelectric Audio Device; Photovoltaic Power Station with Ultracapacitors for Storage; Time Analyzer for Time Synchronization and Monitor of the Deep Space Network; Program for Computing Albedo; Integrated Software for Analyzing Designs of Launch Vehicles; Abstract-Reasoning Software for Coordinating Multiple Agents; Software Searches for Better Spacecraft-Navigation Models; Software for Partly Automated Recognition of Targets; Antistatic Polycarbonate/Copper Oxide Composite; Better VPS Fabrication of Crucibles and Furnace Cartridges; Burn-Resistant, Strong Metal-Matrix Composites; Self-Deployable Spring-Strip Booms; Explosion Welding for Hermetic Containerization; Improved Process for Fabricating Carbon Nanotube Probes; Automated Serial Sectioning for 3D Reconstruction; and Parallel Subconvolution Filtering Architectures.

Source record↗
DOE OSTI2023

Confirmation and Quantification of Gas Flow into Capsules

Inertial confinement fusion experiments require a fuel filled target. At the National Ignition Facility (NIF), these targets are filled through a capsule fill tube assembly (CFTA). While fabricating these assemblies, it is possible to plug the fill tube with glue, which would render the CFTA and eventual target unusable. Historically, this plugging was first detectable in a finished target after considerable resources had been expended. Herein, this paper presents a method for not only detecting a plug in the fill tube before the CFTA is assembled into a target, but also characterizing gas flow through the fill tube, which can help NIF operations prepare to expend each target.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Simulation Study of Monoenergetic Photon Source LiDAR System Performance for Emergency Response Applications

The following report summarizes the results of a Monte Carlo simulation and modeling study of the Lawrence Berkeley National Laboratory’s (LBL) Monoenergetic Photon Source (MPS) as part of a high-energy LiDAR system for use in emergency response applications. A set of image quality indicators (IQI) and nonsensitive phantoms or generalized surrogates for search targets have been identified for use in the planned measurement campaign at the Berkeley Lab Laser Accelerator (BELLA) Center toward the end FY2023. These items were modeled and the time-of-flight (TOF) spectral responses following irradiation were calculated for a set of varying operating conditions. The goal of this study was to both predict the LiDAR system performance as well as determine if minor modifications to the IQI and phantom designs were required before fabrication. It was found that the IQI and target designs both overlap and extend towards the limit of performance of the system and are thus suitable for the final project measurement campaign.

43 - PARTICLE ACCELERATORS↗
DOE OSTI2020

High-Throughput Characterization of (Fe x Co 1–x ) 3 O 4 Thin-Film Composition Spreads

In this study, thin-film continuous composition spreads of Fe–Co–O were fabricated by reactive cosputtering from elemental Fe and Co targets in reactive Ar/O 2 atmosphere using deposition temperatures ranging from 300 to 700 °C. Fused silica and platinized Si/SiO 2 strips were used as substrates. Ti and Ta were investigated as adhesion layer for Pt and the fabrication of the Fe–Co–O films. The thin-film composition spreads were characterized by high-throughput electron-dispersive X-ray spectroscopy, X-ray diffraction, X-ray photoelectron spectroscopy, atomic force microscopy, scanning electron microscopy, and optical transmission spectroscopy. The Fe-content ranged from 28 to 72 at. %. The spinel phases Fe 2 CoO 4 and FeCo 2 O 4 could be synthesized and stabilized at all deposition temperatures with a continuous variation in spinel composition in between. The dependence of the film surface microstructure on the deposition temperature and the composition was mapped. Moreover, the band gap values, ranging from 2.41 eV for FeCo 2 O 4 to 2.74 eV for Fe 2 CoO 4 , show a continuous variation with the composition.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Discovery, Design, Synthesis and Testing of High Performance Structural Alloys (Final Technical Report)

The overarching goal of this project is to understand the phase stability and mechanical behavior of non-stoichiometric multi-principal element alloy (MPEA) materials. In order to identify suitable alloys, we plan to use a combinatorial thin film screening approach, in collaboration with scientists at Lawrence Berkeley National Laboratory who are performing computational work as well as complementary experimental work. Specific tasks within the scope of this project include the fabrication, using thin film deposition from six sputtering targets, of combinatorial samples with multi-dimensional gradients in composition and microstructure. These samples are studied to screen MPEA systems for promising candidate alloys with specific composition(s), based on characterization of composition, structure and mechanical behavior across the thin film. We want to produce single-phase MPEAs with chemical homogeneity in a given thin film region, simple grain structures, and no intermetallic phases present. Gradient films facilitate first-pass screening for desirable characteristics and inform the next stage of work that involves fabrication of bulk MPEA specimens for (tensile) mechanical testing and characterization. To make the bulk alloys, metal (elemental) pieces are melted to form MPEAs, followed by heat treatment to homogenize the composition and microstructure. A subset of alloys is also cast, using vacuum arc melting, to yield larger samples (diameter ~1 cm and length ~5-10 cm) and these allow us to assess viability of scale-up for the alloys in structural applications. Further processing plans include rolling and heat treatment to recrystallize selected bulk MPEAs and grow grains to different extents, in order to investigate size effects in the mechanical behavior of MPEAs. Microspecimen testing will be performed (primarily in tension) to assess the mechanical behavior over a range of temperatures. The deformation microstructure of mechanically tested alloys will be characterized using transmission electron microscopy (TEM) to provide a scientific basis for understanding the structure-property relationships in MPEA mechanical behavior.

36 MATERIALS SCIENCE↗