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At least 1,567 records · Page 87

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DOE OSTI2026

Nb 3 Sn coating of SRF cavity by cosputtering from a composite target

Here, we deposited an Nb 3 Sn film on the inner surface of a 2.6 GHz Nb superconducting radio frequency cavity by cosputtering using a composite of Nb and Sn tube targets in a DC cylindrical magnetron sputtering system, followed by the thermal annealing of the coated cavity. An aluminum mockup cavity, replicating a 2.6 GHz Nb SRF cavity geometry, was utilized to optimize deposition parameters, resulting in cosputtered Nb–Sn films with an Sn content of 32–42 at. % on the beam tubes and equator positions. Several annealing conditions were investigated to improve the surface homogeneity of the Nb 3 Sn film. The best cosputtered Nb–Sn film was achieved after annealing at 600 °C for 6 h, followed by annealing at 950 °C for 1 h. The best process was applied to a Nb cavity, which was RF tested in a cryogenic dewar. RF testing of the Nb 3 Sn-coated cavity demonstrated a superconducting transition temperature of 17.78 K. The Nb 3 Sn cavity underwent light Sn recoating, followed by additional RF testing, resulting in the enhancement of the RF performance, primarily due to the improved surface homogeneity of the Nb 3 Sn coating.

Nb3Sn film↗

DOE OSTI2020

Improved Capacity Retention of Lithium Ion Batteries under Fast Charge via Metal-Coated Graphite Electrodes

A primary barrier preventing repetitive fast charging of Li-ion batteries is lithium metal plating at the graphite anode. One approach toward mitigating Li metal deposition is the deliberate modification of the graphite anode surface with materials demonstrating high overpotentials unfavorable for Li metal nucleation, such as Ni or Cu nanoscale films. This research explores Ni and Cu surface coatings at different areal loadings (3 or 11 μg cm -2 ) on the electrochemistry of graphite/LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC622) type Li-ion batteries. Extended galvanostatic cycling of control and metal-coated electrodes in graphite/NMC622 pouch cells are conducted under high rate conditions. Based on the overpotential of Li deposition on metal foil, both Ni and Cu treatments were anticipated to result in reduced lithium deposition. The higher metal film loadings of 11 μg cm -2 Ni- or Cu-coated electrodes exhibit the highest capacity retention after 500 cycles, with mean improvements of 8% and 9%, respectively, over uncoated graphite electrodes. Li plating quantified by X-ray diffraction indicates that the metal films effectively reduce the quantity of plated Li compared to untreated electrodes, with 11 μg cm -2 Cu providing the greatest benefit.

25 ENERGY STORAGE↗

DOE OSTI2023

Thermodynamic analysis of heat transfer reduction in spark ignition using thermal barrier coatings

This work uses a 0D thermodynamic engine model coupled to a 1D surface temperature solver to study the potential of low thermal inertia thermal barrier coatings (TBCs) on combustion chamber surfaces to increase the efficiency of spark ignition engines. Under ideal conditions, coating the piston crown, head, and valve faces with a TBC with a thermal inertia of 640 J/m 2 K s 1/2 resulted in less than a 1% relative improvement in efficiency. Despite using a low thermal inertia coating to avoid open cycle charge heating, the reduction in closed cycle heat transfer, which is the pathway to increasing efficiency, increased knock propensity. Therefore, any efficiency gain through closed cycle heat transfer reduction in spark ignition is offset by the need to retard spark timing to counter knock. An exergy analysis of completely blocking heat transfer for a 10 crank-angle degree window showed that on a low compression engine, like those used for stoichiometric gasoline spark ignition, the maximum efficiency gain achievable was limited compared to a higher compression ratio engine. Furthermore, the high gas temperatures of stoichiometric operation mean that even state-of-the-art TBCs cannot elevate surface temperatures enough purely through temperature swing to achieve a significant reduction in heat transfer near top dead center, where work availability is highest. Overall, these results indicate that low thermal inertia TBCs are ill-suited for achieving an efficiency benefit in spark ignition through a heat transfer reduction pathway. Instead spark ignition TBC research should explore ways to use low thermal inertia TBCs to achieve open cycle charge cooling to reduce knock propensity.

Engineering↗

DOE OSTI2019

Stress compensation by deposition of a nonuniform corrective coating

Surface deformation by coating stress is compensated by prefiguring the substrate with a radially nonuniform layer of dense silica. Stresses in the compensation layer and reflector are modeled using finite element analysis to determine the optimal thickness profile, with the deposited coating reducing the surface deformation by 90%. As a result, this process is intended to allow implementation of both the compensation layer and the traditional multilayer coating in a single vacuum cycle.

36 MATERIALS SCIENCE↗

DOE OSTI2021

High laser fluence ITO coatings utilizing a Fabry-Perot thin film filter to reduce effective absorption

Laser-induced damage threshold of transparent conductors, such as Indium Tin Oxide (ITO), is limited by their high optical absorption due to free carriers. However, the effective absorption of a transparent conductor thin film can be reduced by an order of magnitude, without changing the electrical characteristics of the film, when placed in a low electric field section of a multilayer coating. A Fabry-Perot thin film interference filter has both high transmittance and low electric field positions, so it is an ideal thin film structure for this application. Although Fabry-Perot interference filters are not known as particularly high laser-induced damage resistant coatings due to their resonant characteristics, a laser-induced damage threshold (LIDT) improvement of up to 8× was observed with this technique compared to single layer ITO coatings fabricated using either radio frequency magnetron sputtering or electron-beam deposition. Additionally, an approximately 4× LIDT improvement for a Fabry-Perot interference filter has been observed by the addition of ITO into the multilayer structure.

47 OTHER INSTRUMENTATION↗

DOE OSTI2026

Analysis of vapor diffusion Nb$^{3}$Sn coating at Fermilab: Minimizing impurities using TOF-SIMS

Nb₃Sn demonstrates steady advancements nowadays offering reduced power cost in superconducting radio-frequency cavities due to its high critical temperature, quality factor, and achieved accelerating gradient. However, theoretical estimates of its radio-frequency parameters have not been achieved due to several potentially limiting mechanisms: tin spots, patchy regions, defects, thermal impedance, and impurities. While some of these limitations have been intensively studied, impurity analysis in Nb$_3$Sn coatings have received less attention. We report an investigation of impurities in several vapor-diffused Nb₃Sn coated samples using time-of-flight secondary ion mass spectroscopy (TOF-SIMS) and show allowable impurity levels in view of superconducting cavity performance. Challenges and lessons learned in maintaining clean Nb$_3$Sn coatings are also discussed.

Tagdulang, Nikki [Fermilab]↗

DOE OSTI2025

First Results from a Nb3Sn-Coated 1.5-Cell 650 MHz SRF Cavity for Cryogen-Free Industrial Accelerators

First Results from a Nb3Sn-Coated 1.5-Cell 650 MHz SRF Cavity for Cryogen-Free Industrial Accelerators ABSTRACT = Fermilab is advancing the development of a compact, high-power electron beam accelerator using superconducting radio frequency (SRF) technology as a non-radioactive alternative to traditional radiological sources. The current design targets continuous-wave (CW) operation at \SI{1.6}{MeV} and \SI{20}{kW}. To ensure suitability for industrial environments, the system is being designed for cryogen-free operation, driving the adoption of a novel Nb$_3$Sn-coated 1.5-cell SRF cavity operating at \SI{650}{MHz}. This contribution reports on the fabrication, surface preparation, and Nb$_3$Sn coating process of the cavity, as well as first results from vertical test stand (VTS) measurements performed in a liquid helium bath. These initial tests mark a key milestone toward demonstrating the viability of conduction-cooled Nb$_3$Sn SRF cavities for industrial-scale deployment.

Tagdulang, N. [Fermilab]↗

DOE OSTI2023

INVESTIGATION OF THE MULTILAYER SHIELDING EFFECT THROUGH NbTiN-AlN COATED BULK NIOBIUM

Superconducting radio frequency (SRF) cavities, composed of bulk niobium (Nb), are extensively utilized in particle accelerators. To optimize their performance and extend their operational range, thin films of superconducting materials are applied to the Nb surfaces. This study focuses on investigating the magnetic field penetration characteristics of NbTiN-AlN coating on bulk niobium. The experimental setup involves measuring the magnetic field penetration across flat superconducting samples at cryogenic temperatures. One key parameter of interest is the field just before the first flux penetration, Bp which enables the observation of the multilayer shielding effect on bulk niobium under high magnetic fields. The study reveals a significant enhancement in Bp of the NbTiN-AlN coated Nb samples compared to bare Nb samples. This property holds critical importance for achieving high field performance in SRF cavities. Furthermore, the study explores the relationship between coating thickness and Bp corroborating the theoretical predictions.

Senevirathne, I. H.↗

DOE OSTI2023

FIRST RESULTS FROM Nb3Sn COATINGS OF 2.6 GHz Nb SRF CAVITIES USING DC CYLINDRICAL MAGNETRON SPUTTERING SYSTEM

A DC cylindrical magnetron sputtering system has been commissioned and operated to deposit Nb3Sn onto 2.6 GHz Nb SRF cavities. After optimizing the deposition conditions in a mock-up cavity, Nb-Sn films are deposited first on flat samples by multilayer sequential sputtering of Nb and Sn, and later annealed at 950 °C for 3 hours. X-ray diffraction of the films showed multiple peaks for the Nb3Sn phase and Nb (substrate). No peaks from any Nb-Sn compound other than Nb3Sn were detected. Later three 2.6 GHz Nb SRF cavities are coated with ~1 µm thick Nb3Sn. The first Nb3Sn coated cavity reached close to Eacc = 8 MV/m, demonstrating a quality factor Q0 of 3.2 × 108 at Tbath = 4.4 K and Eacc = 5 MV/m, about a factor of three higher than that of Nb at this temperature. Q0 was close to 1.1 × 109, dominated by the residual resistance, at 2 K and Eacc = 5 MV/m. The Nb3Sn coated cavities demonstrated Tc in the range of 17.9 ? 18 K. Here, we present the commissioning experience, system optimization, and the first results from the Nb3Sn fabrication on flat samples and SRF cavities.

Shakel, M.S.↗

DOE OSTI2020

Further Support of the Development of Advanced Multilayer Optics Coatings for X-Ray Imaging

The Smithsonian Astrophysical Observatory (SAO) is working with Lawrence Livermore National Laboratory (LLNL) to develop Wolter-I optics for x-ray imaging applications at energies of 15-50 keV and above for National Nuclear Security Administration (NNSA) facilities. SAO work includes R&D on advanced multilayer coatings as well as fabrication and testing of Wolter multilayer coated optics. It also includes delivery of custom 3.05-meter focal length Wolter optics with response at energies of interest to Sandia National Laboratories and LLNL. The optics are fabricated using an electroform nickel replication technique which has been used to fabricate optics for X-ray astronomy satellites over the past two decades. This technique starts with a figured, polished mandrel from which the optics are replicated. To carry this technique over to fabricate optics for NNSA facilities, several additional barriers had to be overcome to deposit multilayer coatings on integral optics with radii as small as 25 mm. These breakthroughs allow fabrication of optics which meet the spatial and spectral specifications required by NNSA facilities. During this present contract period SAO delivered four custom optics to LLNL with spectral response at or near the Kα line of silver, 22.16 keV.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

Hydrogenated and Carbon-coated Na2Ti6O13 Nanowires as High-Rate Anode Materials for Lithium Ion Batteries

The main disadvantage for sodium titanate as an anode material for LIBs is its low electronic conductivity, resulting in poor rate capability. Several approaches have been taken in an attempt to improve the electronic conductivity of sodium/lithium titanate, such as electronic material coating/mixing, ionic doping, comminution, etc.; but as of yet there has been no uniform carbon coating reported on sodium titanate for LIBs. In this work, we detail a facile technique to create uniform thin carbon coating layers on Na2Ti6O13 nanowires (NTO-C). In addition, we also explored self-doped Ti3+ on carbon coated Na2Ti6O13 nanowires (H-NTO-C) in an effort to further improve its electronic conductivity. The detailed results of the synthesis, characterization, and electrochemical performance of the NTO-based materials (NTO, NTO-C and H-NTO-C) will be presented.

25 ENERGY STORAGE↗

DOE OSTI2022

Advanced Integrated Reticular Sorbent-Coated System to Capture CO 2 from the Atmosphere (AIR2CO2)

GE Research Center (GRC) and the University of California, Berkeley (UCB) executed an 15-month, $1.0 MM program to develop a lab-scale material system to extract CO 2 from ambient air using UCB’s pioneering sorbent technology and GRC’s composite coating expertise. The primary objective of this project was to develop an “Advanced Integrated Reticular Sorbent-Coated System to Capture CO 2 from the Atmosphere (AIR2CO2)” at a Technology Readiness Level (TRL) of 3. The AIR2CO2 concept relies on two key innovations: 1) advanced sorbent architectures with high capacity and rapid sorption kinetics that enable effective CO 2 capture at low concentrations, and 2) tailored MOF-binder slurry formulations and coating processes that enable sorbent integration into a novel additively-manufactured contactor.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Fuel Performance Analysis of Chromium-Coated Cladding under Burst Conditions

To reduce the oxidation of zirconium-based alloy cladding at high temperatures, accident tolerant fuel systems have been proposed. Of the concepts identified, chromium-coated cladding has been shown to slow oxidation without greatly impacting the fuel system geometry or neutronic performance. To determine how coated-cladding tubes will perform under high-temperature accident conditions, pressurized-tube burst tests have been performed using the Severe Accident Test Station at Oak Ridge National Laboratory. To begin modeling these tubes to better understand how the coating will impact cladding behavior, these burst tests were simulated with the BISON fuel performance code. Cladding tube surface temperatures for the burst test were developed by fitting thermocouple data into axial and azimuthal profiles, while pressure data were compared until cladding failure. The temperatures at failure and the pressure evolution show relatively good agreement between the simulation and experiment results. This is the first step of a larger effort to simulate the cladding deformation process under high-temperature transient conditions and assess the cladding margin to failure more accurately.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

First Results From Nb3Sn Coatings of 2.6 GHz Nb SRF Cavities Using DC Cylindrical Magnetron Sputtering System

A DC cylindrical magnetron sputtering system has been commissioned and operated to deposit Nb3Sn onto 2.6 GHz Nb SRF cavities. After optimizing the deposition conditions in a mock-up cavity, Nb-Sn films are deposited first on flat samples by multilayer sequential sputtering of Nb and Sn, and later annealed at 950 °C for 3 hours. X-ray diffraction of the films showed multiple peaks for the Nb3Sn phase and Nb (substrate). No peaks from any Nb- Sn compound other than Nb3Sn were detected. Later three 2.6 GHz Nb SRF cavities are coated with ~1 μm thick Nb3Sn. The first Nb3Sn coated cavity reached close to Eacc = 8 MV/m, demonstrating a quality factor Q0 of 3.2 × 108 at Tbath = 4.4 K and Eacc = 5 MV/m, about a factor of three higher than that of Nb at this temperature. Q0 was close to 1.1 × 109, dominated by the residual resistance, at 2 K and Eacc = 5 MV/m. The Nb3Sn coated cavities demonstrated Tc in the range of 17.9 – 18 K. Here we present the commissioning experience, s ystem optimization, and the first results from the Nb3Sn fabrication on flat samples and SRF cavities.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2023

FIRST RESULTS FROM Nb3Sn COATINGS OF 2.6 GHz Nb SRF CAVITIES USING DC CYLINDRICAL MAGNETRON SPUTTERING SYSTEM

Shakel, M. S.↗

DOE OSTI2024

Mechanical creep testing and characterization of Cr coated Zircaloy

Zirconium based cladding has been developed for use in light water reactor fuel applications due to the material’s desirable low neutron scattering cross section. To help improve corrosion resistance in accident conditions, such as a loss of coolant accident (LOCA), a chromium coating can be applied to the outer diameter of the Zircaloy tube. Cladding strength at reactor relevant temperatures is important for the structural performance. Stress relaxation creep testing was performed on Cr coated Zircaloy-4 to measure strain rate as a function of stress for 350 and 650°C. These were performed at both 5 ± 1 % and 7.5 ± 1 % strain. The lower temperature provides results near normal operating temperature, while the higher temperature provides results relevant to off-normal conditions where recrystallization will take place. Characterization was also performed to analyze the structure of the Cr coating and Zircaloy-4 as well as the interface between the two.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Monitoring the corrosion resistance of cold-spray coatings with membrane-based sensors

In this presentation, the MBES shows the ability to detect the change in exposed environment even with cold-spray coatings. Corrosion rates from the cold-spray coating were comparable to a 316 stainless steel sample. Defects in the coating did not impact sensor performance in terms of corrosion rate or water content detection. Energy dispersive X-ray spectroscopy was used to document ion migration into the membrane.

Rendon, Arnaldo↗

DOE OSTI2023

Self-assembled Seashell Like Coatings for Large Area Robust Debris Shields for Next Generation Pulsed Power Drivers

During this LDRD project, our team developed a technology which enables the fabrication of novel nanostructures replicating seashell – “nature’s toughest material”. The resulting coatings exhibit high thermal stability up to 1650°C, which exceeds the hardness of Spectra® by ~44%, as well as the compressive strength of aluminum by ~57%. Coatings made with this technology are stronger, environmentally friendly, more sustainable, and more versatile than other comparable materials. Beryllium wafers, the current, most favorable shielding material in terms of thermal and mechanical properties, are very toxic and cost hundreds of times more than the new material developed in this project. The coatings on silicon wafer and stainless steel, respectively, have been tested as ride-along on the Z machine and clearly outperform the bare substrate. Use of this technology will have a profound global impact for pulsed power and fusion energy development, debris mitigation for spacecraft and satellites, durability of drill bits used in deep well drilling and tunnel boring operations, thermal protection of aircraft and manned spacecraft, and various other thermal and mechanical protection applications.

36 MATERIALS SCIENCE↗