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DOE OSTI2023

Room Temperature Electrorefining of Rare Earth Metals from End-of-use Nd-Fe-B Magnets

Recovering rare earth elements (REE) from used permanent magnets, which contains about 30 wt.% of rare earth elements, has been persistent technological challenge. Current recycling methods relies on pyrometallurgical or hydrometallurgical processes which are energy- and chemical- intensive and not economically and environmentally viable for rare earth containing magnets. Enabling efficient and simplistic recovery and refining of REEs contained in End-of-Use (EoU) products, such as Neodymium-Iron-Boron (Nd-Fe-B) based magnets will play an important and complementary role in the total supply of REEs in the future. We designed a new electrochemical method and demonstrated a room temperature one-pot process that concurrently separates and electroplates REE from commercial Nd-Fe-B magnets. By establishing selective oxidation and reductive potential as electrochemical control parameter along with electrochemically compatible non-aqueous electrolyte system, we demonstrated selective electroleaching of lanthanides (Nd and Preseodymium (Pr)) from anode and concurrent plating as alloy at Pt cathode. The morphological and chemical evolution of the Nd-Fe-B magnets during electroleaching reveals the electrochemical stimuli and rate of dissolution depends on microstructural complexities of the Nd-Fe-B magnet. The concomitant electroplating process leads to Nd-Pr based alloy which can be used as raw metallic alloy for manufacturing new permanent magnet and other devices. Our study demonstrates a scalable separation and refining methodology, based on widely available organic electrolyte system and without any consumptive chemical use, for selective lanthanide recovery from waste magnets.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1992

Deformation mechanisms of NiAl cyclicly deformed near the brittle-to-ductile transformation temperature

One of the ongoing challenges of the aerospace industry is to develop more efficient turbine engines. Greater efficiency entails reduced specific strength and larger temperature gradients, the latter of which means higher operating temperatures and increased thermal conductivity. Continued development of nickel-based superalloys has provided steady increases in engine efficiency and the limits of superalloys have probably not been realized. However, other material systems are under intense investigation for possible use in high temperature engines. Ceramic, intermetallic, and various composite systems are being explored in an effort to exploit the much higher melting temperatures of these systems. NiAl is considered a potential alternative to conventional superalloys due to its excellent oxidation resistance, low density, and high melting temperature. The fact that NiAl is the most common coating for current superalloy turbine blades is a tribute to its oxidation resistance. Its density is one-third that of typical superalloys and in most temperature ranges its thermal conductivity is twice that of common superalloys. Despite these many advantages, NiAl requires more investigation before it is ready to be used in engines. Binary NiAl in general has poor high-temperature strength and low-temperature ductility. On-going research in alloy design continues to make improvements in the high-temperature strength of NiAl. The factors controlling low temperature ductility have been identified in the last few years. Small, but reproducible ductility can now be achieved at room temperature through careful control of chemical purity and processing. But the mechanisms controlling the transition from brittle to ductile behavior are not fully understood. Research in the area of fatigue deformation can aid the development of the NiAl system in two ways. Fatigue properties must be documented and optimized before NiAl can be applied to engineering systems. More importantly though, probing the deformation mechanisms operating in fatigue will lead to a better understanding of NiAl's unique characteristics. Low cycle fatigue properties have been reported on binary NiAl in the past year, yet those studies were limited to two temperature ranges: room temperature and near 1000 K. Eventually, fatigue property data will be needed for a wide range of temperatures and compositions. The intermediate temperature range near the brittle-to-ductile transition was chosen for this study to ascertain whether the sharp change occurring in monotonic behavior also occurs under cyclic conditions. An effort was made to characterize the dislocation structures which evolved during fatigue testing and comment on their role in the deformation process.

Antolovich, Stephen D.↗

DOE OSTI2023

Integrated Operations for Nuclear: Work Reduction Opportunity Demonstration Strategy

EXECUTIVE SUMMARY The Light Water Reactor Sustainability Program Plant Modernization Pathway has been working with industry for a number of years to leverage digital technology to extend the life and improve the performance of the existing fleet through modernized technologies and improved processes for plant operation and power generation. This includes development of modernization solutions to improve reliability and economic performance while addressing US nuclear industry’s aging and obsolescence challenges. The objective of these efforts is to deliver a sustainable business model that enables US nuclear industry to remain competitive. Digital Infrastructure (DI) research has established a technical foundation for these efforts. This effort began with technical analysis and support for a safety-related instrumentation and control (I&C) pilot upgrade being performed at Constellation Energy Generation’s Limerick Nuclear Plant. The following publicly available reports were produced as part of this effort. • INL/EXT-20-61079, Vendor-Independent Design Requirements for a Boiling Water Reactor Safety System Upgrade [1] • INL/EXT-20-59371, Business Case Analysis for Digital Safety-Related Instrumentation & Control System Modernizations [2] • INL/EXT-20-59809, “Safety-Related Instrumentation and Control Pilot Upgrade: Initial Scoping Phase Implementation Report and Lessons Learned [3] • INL/RPT-23-72105, Safety-Related Instrumentation and Control Upgrade: Conceptual – Detailed Design Phase Report and Lessons Learned [4]

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2024

Design of the Electromagnetic Particle Injector (EPI) for Tokamak Deployment

Both predicting and controlling disruptions are critical and urgent issues for ITER as some disruptions with a short warning time may be unavoidable. For these cases, a rapid response disruption mitigation system (DMS) referred to as the electromagnetic particle injector (EPI) is being developed. The primary advantages of the EPI are its fast response time and high velocity, which have been demonstrated in offline experiments (Raman et al., 2021). The EPI is capable of accelerating a metallic sabot electromagnetically using a rail gun to the required velocities ( > 2 km/s) within 2 ms. Two high-field racetrack magnets able to generate fields over 2 T are positioned above and below the rails to permit high velocity at low rail currents, a requirement to minimize electrode erosion. At the end of the acceleration phase, a sabot capture mechanism retains the spent sabot inside the vacuum chamber that houses the EPI. At this point, it releases well-defined microspheres, or a shell pellet, of a radiative payload into the disrupting plasma. A remotely operated sabot loading system positioned behind the injector contains several pre-equipped sabots that can be loaded by an operator from the tokamak control room. The injector is interfaced to the tokamak through a guide tube attached to the front of the EPI vacuum chamber. Finally, the advantages of the EPI system over other DMSs under consideration are described in conjunction with the details of an EPI system designed for near-term test on an existing large tokamak.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1971

Control of microbial contamination.

Two specific applications are discussed of microbial contamination control in planetary quarantine. Under the first concept, using the clean room to control environmental microorganisms, the objective is to reduce the microbial species and keep the numbers of microorganisms within an enclosure at a low level. The clean room concept is aimed at obtaining a product that has a controlled and reduced level of microbial contamination. Under the second concept, using the microbiological barrier to control microbial contamination of a specific product, the barrier techniques are designed to prevent the entry of any microorganisms into a sterile work area. Thus the assembly of space flight hardware within the confines of a microbiological barrier is aimed at obtaining a sterile product. In theory and practice, both approaches are shown to be applicable to the planetary quarantine program.

Mcdade, J. J.↗

NASA NTRS1992

Superlattice barrier varactors

SBV (Single Barrier Varactor) diodes have been proposed as alternatives to Schottky barrier diodes for harmonic multiplier applications. However, these show a higher current than expected. The excess current is due to X valley transport in the barrier. We present experimental results showing that the use of a superlattice barrier and doping spikes in the GaAs depletion regions on either side of the barrier can reduce the excess current and improve the control of the capacitance vs. voltage characteristic. The experimental results consist of data taken from two types of device structures. The first test structure was used to study the performance of AlAs/GaAs superlattice barriers. The wafer was fabricated into 90 micron diameter mesa diodes and the resulting current vs. voltage characteristics were measured. A 10 period superlattice structure with a total thickness of approximately 400 A worked well as an electron barrier. The structure had a current density of about one A/sq cm at one volt at room temperature. The capacitance variation of these structures was small because of the design of the GaAs cladding layers. The second test structure was used to study cladding layer designs. These wafers were InGaAs and InAlAs layers lattice matched to an InP substrate. The layers have n(+) doping spikes near the barrier to increase the zero bias capacitance and control the shape of the capacitance vs. voltage characteristic. These structures have a capacitance ratio of 5:1 and an abrupt change from maximum to minimum capacitance. The measurements were made at 80 K. Based on the information obtained from these two structures, we have designed a structure that combines the low current density barrier with the improved cladding layers. The capacitance and current-voltage characteristics from this structure are presented.

Raman, C.↗

NASA NTRS2020

The Spaceport Command and Control System Security Assessor Project

This Summer, I worked as a National Aeronautics and Space Administration (NASA) Internships and Fellowships (NIF) intern under my mentor, Jill Giles within the Software Engineering Branch. Within this project, I worked alongside the Cyber Security branch to identify a list of Commercial Off the Shelf (COTS) software to analyze, research, and gain insight about potential vulnerabilities within the software that could become a threat of attack. After identifying the list of COTS software, my team and I used Microsoft Excel to create a worksheet to easily organize and design a questionnaire about the software. Security reports weregiven to us to identify the software used on the machines in the firing rooms. With these reports, we created a script that would populate the database with the software information to identify potential security weaknesses of COTS software.The goal of the project was to produce a final report, summarizing the most vulnerable launch control system servers and configurations and document vulnerabilities, residual risk, likelihood, and consequence. This project is important for the Cyber Security and Information Technology branches because it will identify security weaknesses and help to mitigate risk. From the Spaceport Command and Control System Security Assessor Project, I learned how to properly identify weaknesses and vulnerabilities within software and how to mitigate the risks within the software. This project also taught me how to create databases using scripts and input files.

Destani Satora Van Arsdalen↗

DOE OSTI2020

Development of an Advanced Integrated Operations Concept for Hybrid Control Rooms

The U.S. Nuclear Industry has an urgent need to reduce the operations and maintenance costs to remain economically competitive in today’s energy market. Measures to improve efficiency in operations will need to leverage technology in a way that safely transforms how plants are operated. This work describes the development of an integrated operations concept that integrates data from existing Instrumentation and Control (I&C) infrastructure, upgraded I&C systems, new sensors, and field technologies such as computer-based procedures to provide operators with centralized, streamlined instructions. The concept was developed to allow for an operator to remotely supervise many plant activities and to dramatically streamline plant operations and maintenance. This report describes the design philosophy, the analysis used to inform design, the implementation in the Human Systems Simulation Laboratory, and illustrates the design concept.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS1988

The dc power control for a liquid-fed resistojet

A simple breadboard power controller was designed and demonstrated for a new liquid-fed water resistojet. The 1-piece laboratory model thruster has an integrated vaporizer/superheater using a single heating element. Heater temperature was maintained at or near a preset reference value with the closed loop controller providing pulse width modulated (PWM) dc power into the thruster heater. A combined thruster, temperature readout, PWM transfer function was experimentally determined. This transfer function was used to design a proportional plus integral controller that demonstrated zero steady state error, conservative stability margins and adequate transient response to step changes in propellant flow rate, input voltage and temperature reference. Initial turn-on temperature overshoot from room temperature to a 650 C setpoint was 80 C. In addition, EMI was alleviated by reducing heater dI/dt and dV/dt using a simple diode-inductor-capacitor network. Based on limited initial tests, thruster preheat with no propellant flow was necessary to achieve stable system operation during startup. Breadboard power efficiency was 99 percent at 1 kW, and component mass was 0.4 kg excluding the power loss and mass of an input filter required for spacecraft integration.

Gruber, Robert P.↗

NASA NTRS1988

dc power control for a liquid-fed resistojet

Gruber, Robert P.↗

DOE OSTI2021

A hybrid coupler for directing quantum light emission with high radiative Purcell enhancement to a dielectric metasurface lens

Quantum photonic technologies such as quantum sensing, metrology, and simulation could be transformatively enabled by the availability of integrated single photon sources with high radiative rates and photon collection efficiencies. We address these challenges for quantum emitters formed from color center defect sites such as those in hexagonal boron nitride, which are promising candidates as single photon sources due to their bright, stable, polarized, and room temperature emission. We report design of a nanophotonic coupler from color center quantum emitters to a dielectric metasurface lens. The coupler is comprised of a hybrid plasmonic–dielectric resonator that achieves a large radiative Purcell enhancement and partial control of far-field radiation. We report radiative Purcell factors up to 285 and photon collection efficiencies up to 89% for a lossless metasurface, applying a continuous hyperboloidal phase-front. Our hybrid plasmonic–dielectric coupler interfacing two nanophotonic elements is a compound optical element, analogous to those found in microscope objective lenses, which combine multiple optical functions into a single component for improved performance.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2023

Coriolis force compensation and laser beam delivery for 100-m baseline atom interferometry

The Coriolis force is a significant source of systematic phase errors and dephasing in atom interferometry and is often compensated by counter-rotating the interferometry laser beam against Earth's rotation. We present a novel method for performing Coriolis force compensation for long-baseline atom interferometry, which mitigates atom-beam misalignment due to beam rotation, an effect which is magnified by the long lever arm of the baseline length. The method involves adjustment of the angle of the interferometer beam prior to a magnifying telescope, enabling the beam to pivot around a tunable position along the interferometer baseline. By tuning the initial atom kinematics and adjusting the angle with which the interferometer beam pivots about this point, we can ensure that the atoms align with the center of the beam during the atom optics laser pulses. This approach will be used in the MAGIS-100 atom interferometer and could also be applied to other long-baseline atom interferometers. An additional challenge associated with long baseline interferometry is that since long-baseline atom interferometers are often located outside of typical laboratory environments, facilities constraints may require lasers to be housed in a climate-controlled room a significant distance away from the main experiment. Nonlinear effects in optical fibers restrict the use of fiber-based transport of the high-power interferometry beam from the laser room to the experiment. We present the design of and prototype data from a laser transport system for MAGIS-100 that maintains robustness against alignment drifts despite the absence of a long fiber.

Glick, Jonah↗

NASA NTRS1989

A knowledge-based flight status monitor for real-time application in digital avionics systems

The Dryden Flight Research Facility of the National Aeronautics and Space Administration (NASA) Ames Research Center (Ames-Dryden) is the principal NASA facility for the flight testing and evaluation of new and complex avionics systems. To aid in the interpretation of system health and status data, a knowledge-based flight status monitor was designed. The monitor was designed to use fault indicators from the onboard system which are telemetered to the ground and processed by a rule-based model of the aircraft failure management system to give timely advice and recommendations in the mission control room. One of the important constraints on the flight status monitor is the need to operate in real time, and to pursue this aspect, a joint research activity between NASA Ames-Dryden and the Royal Aerospace Establishment (RAE) on real-time knowledge-based systems was established. Under this agreement, the original LISP knowledge base for the flight status monitor was reimplemented using the intelligent knowledge-based system toolkit, MUSE, which was developed under RAE sponsorship. Details of the flight status monitor and the MUSE implementation are presented.

Duke, E. L.↗

DOE OSTI2023

A reduced-order modeling of a tubular solar reactor for long duration thermochemical energy storage

The storage of solar energy in a solid form, referred to as a “solar fuel”, can be achieved through a process known as endothermic solar thermochemistry. This process transforms the absorbed solar energy into a stable and retrievable form that can be stored for extended periods of time. This paper presents a low–order heat transfer model of a counter–current tubular falling bed reactor designed to produce thermally reduced magnesium manganese oxide pellets for long duration thermochemical energy storage. The energy required for the endothermic reduction was supplied by concentrated solar energy or renewable electricity via indirect heating of the gas and solid reactants flowing in a ceramic tube. The counter-current gas flow enhances the mixing of the solid particles with the heat recuperation zone, allowing the gas and particles to enter and exit the tubular reactor close to room temperature. Further, the reactor was vertically oriented and was heated circumferentially by an adjustable level heat flux along a finite segment of its length. The temperature distribution of the reactor in response to transient changes along the tube was modeled by considering conduction, convection, and radiation heat transfer. Governing equations for the heat transfer model were solved by discretizing the reactor tube into a finite number of control volumes and using an energy balance for the heat exchange between the reactor wall, gas, and particles within the control volume. The energy absorbed during this endothermic reaction was modeled numerically by fitting the data of the chemical conversion rate with the corresponding temperature of particles in the heating zone. The numerical model has been experimentally validated using a reactor prototype made of a 121.92 cm alumina tube heated by a 7kW electric tube–furnace. The alumina tube receives magnesium manganese oxide pellets of 3.66±0.516 mm in diameter from the top, and a counter–current gas flow from the bottom. The reactor wall temperature was monitored by six thermocouples installed along the reactor tube length. The experimental procedure was numerically simulated, and the temperature variation along the reactor tube was compared with a matrix of experimental runs for a range of particles mass flowrates (0.75–1.25g/s) and corresponding gas flowrates (36–65 SLPM). The reactor system was heated gradually from room temperature to a steady state temperature of 1673K, and then cooled down to room temperature. The heating and cooling processes were simulated, and the numerical and experimental results were compared throughout processes. The numerical model showed similar trends to the experimental results, with an error of 0.69 to 7.9% for the particle inlet and 0.7 to 7.9% for the gas inlet during steady-state operation. The proposed numerical model can be implemented as a simplified physical model to design a feedback control system to regulate reactor temperature.

14 SOLAR ENERGY↗

NASA NTRS1994

Magnetically suspended stepping motors for clean room and vacuum environments

To answer the growing needs for super-clean or contact free actuators for uses in clean rooms, vacuum chambers, and space, innovative actuators which combine the functions of stepping motors and magnetic bearings in one body were developed. The rotor of the magnetically suspended stepping motor is suspended like a magnetic bearing and rotated and positioned like a stepping motor. The important trait of the motor is that it is not a simple mixture or combination of a stepping motor and conventional magnetic bearing, but an amalgam of a stepping motor and a magnetic bearing. Owing to optimal design and feed-back control, a toothed stator and rotor are all that are needed structurewise for stable suspension. More than ten types of motors such as linear type, high accuracy rotary type, two-dimensional type, and high vacuum type were built and tested. This paper describes the structure and design of these motors and their performance for such applications as precise positioning rotary table, linear conveyor system, and theta-zeta positioner for clean room and high vacuum use.

Higuchi, Toshiro↗

DOE OSTI2022

Micro-Environmental Control System (Final Report)

This project developed an innovative micro-environmental control system (µX) that enables office buildings to reduce energy used for heating and cooling by 15% or more. The µX is a compact, quiet, and ergonomic device that is designed to be installed under an office workstation; it is designed to maintain occupant comfort when room thermostat setpoints are incremented by 4°F or more (warmer in the summer and cooler in the winter) to save energy. When ambient room temperatures are outside of the usual comfort range, the µX maintains occupant comfort by delivering personalized cooling or heating locally to each office worker. The µX provides personalized cooling using a micro vapor compression system that includes a new high-performance micro-scroll compressor and a novel thermal storage unit. The vapor compression system operates at night to freeze a phase-change material (PCM). During the workday, the cooling stored in the PCM is released as a cool breeze of air to make occupants more comfortable. The micro-scroll compressor was developed specifically for this application; it is smaller than any of its type, minimizing the amount of power needed. In heating mode, the µX maintains occupant comfort using a foot heating mat with an infrared reflective box. The µX R&D project was conducted by Syracuse University in collaboration with United Technologies Research Center, Air Innovations, Bush Technical, and Cornell University. Over the course of the initial three-year project, the team developed and evaluated four versions of the unit, advancing the concept to Technology Readiness Level 6. The capabilities of individual proof-of-concept prototypes were verified in tests that were conducted with: 1) units in psychrometric chambers, 2) an instrumented manikin in a laboratory, and 3) human subjects in laboratories that simulate office environments. The tests verified that the µX prototypes met or exceeded all performance targets required to enable office buildings to reduce energy used for heating and cooling by 15% or more by maintaining occupant comfort when thermostat setpoints are incremented by 4°F or more.

25 ENERGY STORAGE↗

DOE OSTI2021

Swelling-Assisted Sequential Infiltration Synthesis of Nanoporous ZnO Films with Highly Accessible Pores and Their Sensing Potential for Ethanol

Here, we report a swelling-assisted sequential infiltration synthesis (SIS) approach for the design of highly porous zinc oxide (ZnO) films by infiltration of block copolymer templates such as polystyrene-block- polyvinyl pyridine with inorganic precursors followed by UV ozone-assisted removal of the polymer template. We show that porous ZnO coatings with the thickness in the range between 140 and 420 nm can be obtained using only five cycles of SIS. The pores in ZnO fabricated via swelling-assisted SIS are highly accessible, and up to 98% of pores are available for solvent penetration. The XPS data indicate that the surface of nanoporous ZnO films is terminated with -OH groups. Density functional theory calculations show a lower energy barrier for ethanol-induced release of the oxygen restricted depletion layer in the case of the presence of -OH groups at the ZnO surface, and hence, it can lead to higher sensitivity in sensing of ethanol. We monitored the response of ZnO porous coatings with different thicknesses and porosities to ethanol vapors using combined mass-based and chemiresistive approaches at room temperature and 90 °C. The porous ZnO conformal coatings reveal a promising sensitivity toward detection of ethanol at low temperatures. In conclusion our results suggest the excellent potential of the SIS approach for the design of conformal ZnO coatings with controlled porosity, thickness, and composition that can be adapted for sensing applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1998

Friction Stir Weld Tooling Development for Application on the 2195 Al-Cu-Li Space Transportation System External Tank

Friction Stir Welding (FSW) is a new and innovative solid-state joining process which can be applied to difficult-to- weld aluminum alloys. However, the large forces involved with the process have posed a production tooling challenge. Lockheed Martin Michoud Space Systems has overcome many of these challenges on the Super Lightweight External Tank (ET) program. Utilizing Aluminum-Copper-Lithium alloy 2195 in the form of plate and extrusions, investigations of FSW process parameters have been completed. Major loading mechanisms are discussed in conjunction with deflection measurements. Since the ET program is a cryogenic application, a brief comparison of cryogenic material properties with room temperature material properties is offered for both FSW and fusion welds. Finally, a new approach to controlling the FSW process from a load perspective is introduced. Emphasis will be put on tooling development, as well as the impact of tooling design and philosophy on Friction Stir Weld success probability.

Loftus, Zachary↗