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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.

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At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Exploring mounting solutions for cryogenically cooled thin crystal optics in high power density x-ray free electron lasers

This study investigates three mounting methods—clamping, soldering, and a hybrid clamping–soldering approach—for cryogenically cooled thin diamond crystals crucial to stable operation of X-ray Free Electron Laser (XFEL) systems. While clamping methods exhibit temperature resilience and flexibility, meticulous design is required to prevent stress-induced warping and reduce thermal contact area. Soldering methods offer reliable mechanical and thermal bonding but encounter challenges due to the coefficient of thermal expansion mismatch at cryogenic temperatures. The hybrid method, integrating clamping and soldering with strain relief cuts, effectively mitigates overall distortion caused by mounting and XFEL thermal loads. These findings offer a novel mounting solution for high-performance x-ray optics in XFEL research and applications, ensuring stability and optimal functionality in cryogenic conditions.

Instruments & Instrumentation↗
DOE OSTI2025

Structured light approaches in laser-based plasma diagnostics

There is a growing demand for plasma diagnostics suitable for industrial plasma reactors employed in semiconductor nanofabrication, especially relevant to microelectronics and quantum information systems. Such reactors typically have limited optical access and pose considerable diagnostic challenges, including intense background emission, significant thermal loads, and contamination of optical viewports. In this study, we outline research into structured light techniques (laser beams with tailored spatial, temporal, or phase characteristics) that effectively overcome these issues using laser-induced fluorescence (LIF) as an example. The focus of presented diagnostics is on ion kinetics analysis within an industrial plasma source, although this approach is broadly applicable to other plasma systems and diagnostic contexts. We present a confocal LIF implementation using an axicon-generated Bessel annular beam, achieving spatial resolutions of approximately 5 mm at a focal distance of 300 mm, with potential improvements to about 1 mm. This approach matches conventional orthogonal LIF performance but requires only one optical port. Wavelength-modulation LIF employs nonlinear laser wavelength tuning to measure spectral line derivatives, suppressing background emission and enhancing details of spectral line shape. Additionally, we present new results on applying vortex beams (laser beams carrying orbital angular momentum, OAM) for LIF measurements in an industrial plasma device. These measurements enable simultaneous axial and tangential velocity determination using a single laser beam and have been tested with xenon ion transition. Initial quantification of results was performed. Together, these structured-light approaches provide robust, background-resilient, multi-dimensional diagnostics for complex plasma environments.

Romadanov, Ivan [Princeton Plasma Physics Laborato↗
DOE OSTI2022

Multiphysics Analyses of the Bottom Components of the 3D Printed Transformational Challenge Reactor

This research presents multi-physics analyses on the bottom components of the Transformational Challenge Reactor (TCR) facility. These components include the bottom axial reflector and the steel exit cone. The bottom axial reflector is made of pure silicon carbide elements hosting helium cooling channels These elements are 3D printed and therefore can host any arbitrary shape of the helium cooling channels. The design of the bottom reflector considers the neutronics and thermo-fluid dynamics performances as well as the manufacturing process optimization. More precisely, the best design of the bottom reflector reduces neutron leakage by avoiding straight cylindrical helium channels that facilitate neutron leakage, minimizes the helium flow pressure drop, and reduces the number of 3D printed silicon carbide pieces. The exit cone steel structure collects the hot helium from the bottom fuel assemblies and channels the cold helium to the top of the fuel assemblies. The steel simultaneous contact with hot and cold helium flows sets a large thermal gradient. Different designs of the exit cone are proposed to reduce the steel equivalent stress from the helium thermal load. The multi-physics analyses have been performed using Ansys Fluent, Ansys Mechanical, STAR-CCM+, and Serpent computer programs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Technoeconomic Design Optimization for Fast Reactors. Part I: Workflow Development and Case Study for Small LFR District Energy Application

The nuclear industry is developing small reactor designs that can target a variety of deployment locations and energy products. Smaller nuclear designs have traditionally struggled to handle the steep trade-offs between size and cost that have historically incentivized large reactors. This motivates computational optimization of small reactors to minimize costs and quantify the trade-off between size and cost. In this paper, the cost/size trade-off for a small fast reactor is derived using a multi-objective genetic algorithm optimization, with steady-state, transient, and cost analysis of the fast reactor being performed. Specifically, the method is demonstrated on a small 10- to 120-MW(thermal) U-Pu-Zr–fueled lead-cooled fast reactor with a 10-year core life for district energy applications, which can have a thermal load compatible with this range. The results reinforced that fast reactor cores at the lower end of this power range suffer cost penalties due to critical mass considerations. It was found that high power density cores with strong reactivity swings and many control rods were favored over designing to minimize reactivity swing. Furthermore, this contrasts with some traditional configurations designed using engineering judgment and demonstrates that optimizers can find nontraditional but realistic solutions, along with demonstrating the value of incorporating cost functions into whole-reactor design optimization.

Fast reactor↗
DOE OSTI2021

Structural Analysis of the US ITER ECH Transmission Line System

The electron cyclotron heating (ECH) and current drive system is one of the main plasma heating systems for ITER. It uses high-power microwave beams with the power deposition location steerable across the plasma cross section. Microwave power is conveyed via transmission lines (TLs) that run from the gyrotrons in the radio frequency building through the assembly hall and tokamak building to the ECH launchers within the tokamak vacuum vessel. The ECH system includes a vast array of interconnected TL waveguides, in-line components, and support structures.Finite element (FE) modeling provides an essential means of simulating the system, applying loads and determining deflections, rotations, forces, moments, and stresses in order to evaluate various structural and microwave transmission performance metrics. A representative FE model of the overall ECH TL system is developed in ANSYS®. This top-level model defines the centerline of the waveguide system. Waveguide segments are represented by line elements (beams and pipes) with equivalent section properties, and support structures are represented by boundary conditions. A systematic approach is used to model each ECH component with lumped masses and structurally equivalent stiffness matrices or ANSYS superelements.The top-level TL FE model is used to evaluate the various loads (thermal, vacuum, seismic, etc.) and operating scenarios. The top-level model directly calculates stresses in the straight aluminum waveguide segments. The model provides the forces and moments acting on the in-line components for detailed submodel assessments. Displacement results from the top-level analysis feed into a separate microwave performance model to help determine operational efficiency. All TL performance and thermal-structural requirements are met, as specified by the applicable codes and standards, and successfully documented in numerous technical reports and demonstrated at the final design review.

Shanmugasundaram, Aravind↗
DOE OSTI2021

Impact of soil model complexity on the long-term thermal performance prediction of a new shallow bore ground heat exchanger

Shallow bore ground heat exchangers have been investigated in recent years because they have the potential to reduce the initial cost of the ground source heat pump system. Correctly modeling the transient heat transfer between the ground heat exchanger and the surrounding soil is essential for predicting a ground heat exchanger's performance. Simplification of the soil model could increase computation speed but sacrifice accuracy. This study investigates the impact of the soil model complexity on the annual performance prediction of a new shallow bore ground heat exchanger, the underground thermal battery (UTB). A simple 1D soil model and a more detailed 2D soil model were implemented, and they were validated against a 3D soil model. Overall, the resulting predictions of the UTB’s response from the 1D and 2D models to a given thermal load in different climates were compared. The results show that the root mean square differences between the hourly temperatures of the UTB during a year predicted using the two soil models range from 1.17°C to 3.39°C. As a result, the difference in the annual power consumption of the heat pump was between 0.7% and 3.4%. Furthermore, the dimensions of the UTB affected its performance, and a longer UTB was less sensitive to the soil models.

42 ENGINEERING↗
DOE OSTI2022

Enhanced critical axial tensile strain limit of CORC ® wires: FEM and analytical modeling

Abstract Conductor on Round Core (CORC ® ) cables and wires are composed of spiraled high-temperature superconducting (HTS) rare-earth barium copper oxide (REBCO) tapes, wound in multiple layers, and can carry very high currents in background magnetic fields of more than 20 T. They combine isotropic flexibility and high resilience to electromagnetic and thermal loads. The brittle nature of HTS tapes limits the maximum allowable axial tensile strain in superconducting cables. An intrinsic tensile strain above about 0.45% will introduce cracks in the REBCO layer of straight HTS tapes resulting in irreversible damage. The helical fashion at which the REBCO tapes are wound around the central core allows tapes to experience only a fraction of the total axial tensile strain applied to the CORC ® wire. As a result, the critical strain limit of CORC ® wires can be increased by a factor of more than 10 that of REBCO tapes. Finite element (FE) and analytical models are developed to predict the performance of CORC ® wires under axial tensile strain. A parametric analysis is carried out by varying the winding angle, the Poisson’s ratio of the CORC ® wire core, the core diameter, and the tape width. The results show that a small variation in winding angle can have a significant impact on the cable’s axial tensile strain tolerance. While the radial contraction of the helically wound tapes in a CORC ® wire under axial tensile strain depends on its winding angle, it is mostly driven by the Poisson’s ratio of the central core, affecting the tape strain state and thus its performance. Contact pressure from multiple layers within the CORC ® wire also affects the CORC ® wire performance. The FE model can be used to optimize the cable design for specific application conditions, resulting in an irreversible strain limit of CORC ® cables and wires as high as 7%.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

Positron sources: from conventional to advanced accelerator concepts-based colliders

Positron sources are the key elements for the future and current lepton collider projects such as ILC, CLIC, SuperKEKB, FCC-ee, Muon Collider/LEMMA, etc., introducing challenging critical requirements for high intensity and low emittance beams in order to achieve high luminosity. In fact, due to their large production emittance and constraints given by the target thermal load, the main collider parameters such as the peak and average current, the emittances, the damping time, the repetition frequency and consequently the luminosity are determined by the positron beam characteristics. In this work, the conventional positron sources and their main properties are explored for giving an indication to the challenges that apply during the design of the advanced accelerator concepts. The photon-driven positron sources as the novel approach proposed, primarily for the future linear colliders, are described highlighting their variety and problematic.

47 OTHER INSTRUMENTATION↗
DOE OSTI2026

High-bandwidth frequency domain multiplexed readout of transition-edge sensors for neutrinoless double beta decay searches

The next-generation of cryogenic neutrinoless double-beta decay experiments require increasingly fast readout in order to improve background discrimination. These experiments, operated as cryogenic calorimeters at ∼ 10 mK, are usually read out by high-impedance neutron transmutation doped (NTD) thermistors, which provide good energy resolution, but are limited by ∼ 1 ms response times. Superconducting detectors, such as transition-edge sensors (TESs) with a time resolution of ∼ 100 μs, offer superior timing performance over NTD semiconductor bolometers. To make this technology viable for an application to a thousand or more channels, multiplexed readout is necessary in order to minimize the thermal load and radioactive contamination induced by the readout. Frequency-domain multiplexing readout (fMUX) for TESs, previously developed at Berkeley Lab and McGill University, is currently in use for mm-wave telescopes with detector sampling rates in the order of 100 Hz. We demonstrate a new readout system, based on the McGill/Berkeley digital fMux readout, to satisfy the higher bandwidth and noise requirements of the next generation of TES-instrumented cryogenic calorimeters. Each multiplexing readout module comprises 10 superconducting resonators in the 1–5 MHz range and a DC superconducting quantum interference device (DC-SQUID), interfaced to high-speed field programmable gate array (FPGA)-based electronics for digital signal processing and low-latency SQUID feedback. The new readout samples detectors at 156 kHz, three orders of magnitude faster than its cosmology-oriented predecessor, and demonstrates a stable feedback bandwidth of 3 kHz in a real TES-based system.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Metamorphic Tunnel Junctions Grown Via MOCVD Designed for GaAs 0.75 P 0.25 /Si Tandem Solar Cells

A high-performance metamorphic Al 0.2 Ga 0.8 As 0.75 P 0.25 /GaAs 0.75 P 0.25 heterojunction tunnel junction structure was developed for application to monolithic epitaxial GaAs 0.75 P 0.25 /Si 1.7 eV/1.1 eV bandgap tandem solar cells produced via metal-organic chemical vapor deposition. Doping optimization focused on both bulk doping concentrations and mitigating the transient incorporation effects that otherwise causes non-abrupt doping profiles in the Te doped layer. Furthermore, these efforts resulted in a fully-relaxed metamorphic tunnel diode at the target lattice constant having a peak tunneling current density (JP) of 279.1 A·cm –2 and a zero-bias resistance area product (RA) of 3.0×10 –4 Ω·cm 2 . After post-growth annealing to emulate the thermal load of the GaAs 0.75 P 0.25 top cell growth and elimination of the performance enhancing carbon activation anneal, the device achieved JP = 13.1 A·cm –2 and RA = 1.5×10 –3 Ω·cm 2 . These worst-case values are very promising as they enable the operation of GaAs 0.75 P 0.25 /Si tandems under one-sun AM1.5G illumination with negligible series resistance and at AM1.5D concentrations up to 240 suns with only 0.1% absolute efficiency loss.

14 SOLAR ENERGY↗
DOE OSTI2020

sMF-BO-2CoGP: A sequential multi-fidelity constrained Bayesian optimization framework for design applications

Bayesian optimization (BO) is an effective surrogate-based method that has been widely used to optimize simulation-based applications. While the traditional Bayesian optimization approach only applies to single-fidelity models, many realistic applications provide multiple levels of fidelity with various levels of computational complexity and predictive capability. In this work, we propose a multi-fidelity Bayesian optimization method for design applications with both known and unknown constraints. The proposed framework, called sMF-BO-2CoGP, is built on a multi-level CoKriging method to predict the objective function. An external binary classifier, which we approximate using a separate CoKriging model, is used to distinguish between feasible and infeasible regions. Finally, the sMF-BO-2CoGP method is demonstrated using a series of analytical examples and a flip-chip application for design optimization to minimize the deformation due to warping under thermal loading conditions.

42 ENGINEERING↗
DOE OSTI2021

Liquid-Cooled Heat Sink Optimization for Thermal Imbalance Mitigation in Wide-Bandgap Power Modules

Power semiconductor die placement on substrates used in high-power modules is generally optimized to minimize electrical parasitic (e.g., stray inductance, common-mode capacitance), taking into account the minimum spacing between semiconductor dies for thermal decoupling. The layout assumes sufficient heat spreading and transfer from dies to the cooling structure. Insulated metal substrate-based power module designs may lead to asymmetrical thermal resistance across the dies, which may cause significant temperature differences among the devices. Such unintentional thermal asymmetries can lead to oversizing the cooling system design or underusing the semiconductor power processing capability. This article proposes a thermal imbalance mitigation method that uses evolutionary optimized liquid-cooled heat sinks to improve the thermal loading among devices.

42 ENGINEERING↗
DOE OSTI2026

TEC (ThermoElastoCreep) [SWR-25-167]

This repository provides a Python script to simulate the thermomechanical behavior of Concentrating Solar Power (CSP) receivers under periodic thermal loading. The simulation couples elastic and creep strains to predict stress relaxation, fatigue, and rupture life of the receiver structure. The work was done under the project Light Trapping Planar Cavity Receiver (LTPCR) funded by U.S. Department of Energy. All other relevant work and publications from LTPCR project can be found at https://github.com/NatLabRockies/LTPCR-Public

He, Xin [National Laboratory of the Rockies (NLR),↗
DOE OSTI2024

Waste Tank Structural Assessment

This chapter describes the single and double shell tanks at Hanford, analysis of record and static and thermal loads analysis.

Grant, Christopher L.↗
DOE OSTI2020

Adaptive shape control of wavefront-preserving X-ray mirrors with active cooling and heating

This article describes the development and testing of a novel, water cooled, active optic mirror system (called “REAL: Resistive Element Adjustable Length”) that combines cooling with applied auxiliary heating, tailored to the spatial distribution of the thermal load generated by the incident beam. This technique is theoretically capable of sub-nanometer surface figure error control even at high power density. Tests conducted in an optical metrology laboratory and at synchrotron X-ray beamlines showed the ability to maintain the mirror profile to the level needed for the next generation storage rings and FEL mirrors.

42 ENGINEERING↗
DOE OSTI2020

Cryogenic C-band wavelength division multiplexing system using an AIM Photonics Foundry process design kit

Cryogenic environments make superconducting computing possible by reducing thermal noise, electrical resistance and heat dissipation. Heat generated by the electronics and thermal conductivity of electrical transmission lines to the outside world constitute two main sources of thermal load in such systems. As a result, higher data rates require additional transmission lines which come at an increasingly higher cooling power cost. Hybrid or monolithic integration of silicon photonics with the electronics can be the key to higher data rates and lower power costs in these systems. We present a 4-channel wavelength division multiplexing photonic integrated circuit (PIC) built from modulators in the AIM Photonics process development kit (PDK) that operate at 25 Gbps at room temperature and 10 Gbps at 40 K. We further demonstrate 2-channel operation for 20 Gbps aggregate data rate at 40 K using two different modulators/wavelengths, with the potential for higher aggregate bit rates by utilizing additional channels.

42 ENGINEERING↗
DOE OSTI2022

Simultaneous single-shot rotation–vibration non-equilibrium thermometry using pure rotational fs/ps CARS coherence beating

Here, we report the development of a simple and sensitive two-beam hybrid femtosecond/picosecond pure rotational coherent anti-Stokes Raman scattering (fs/ps CARS) method to simultaneously measure the rotational and vibrational temperatures of diatomic molecules. Rotation–vibration non-equilibrium plays a key role in the chemistry and thermalization in low-temperature plasmas as well as thermal loading of hypersonic vehicles. This approach uses time-domain interferences between ground state and vibrationally excited N 2 molecules to intentionally induce coherence beating that leads to apparent non-Boltzmann distributions in the pure rotational spectra. These distortions enable simultaneous inference of both the rotational and vibrational temperatures. Coherence beating effects were observed in single-shot fs/ps CARS measurements of a 75 Torr N 2 DC glow discharge and were successfully modeled for rotational and vibrational temperature extraction. We show that this method can be more sensitive than a pure rotational fs/ps CARS approach using a spectrally narrow probe pulse. Lastly, we experimentally measured the beat frequencies via Fourier transform of the time-domain response and obtained excellent agreement with the model.

42 ENGINEERING↗
DOE OSTI2023

Investigation of modified uni-traveling carrier photodiode for cryogenic microwave photonic links

Quantum devices present the potential for unparalleled computing and communications capabilities; however, the cryogenic temperatures required to successfully control and read out many qubit platforms can prove to be very challenging to scale. Recently, there has emerged an interest in using microwave photonics to deliver control signals down to ultracold stages via optical fiber, thereby reducing thermal load and facilitating dense wavelength multiplexing. Photodetectors can then convert this optical energy to electrical signals for qubit control. The fidelity of the quantum operations of interest therefore depend heavily upon the characteristics of the photodiode, yet experimental demonstrations of fiber-coupled photodetection systems at low temperatures are relatively few in number, leaving important open questions regarding how specific detectors may perform in real-world cryogenic settings. In this work, we examine a highly linear modified uni-traveling carrier photodiode (MUTC-PD) under C-band illumination (1530–1565 nm) at three temperature regimes (300 K, 80 K, and ∼4 K) and multiple bias conditions. Our findings of reduced responsivity but preserved bandwidth are consistent with previous studies, while our saturation tests suggest a variety of potential applications for MUTC-PDs in cryogenic microwave photonics with and without electrical bias. Overall, our results should provide a valuable foundation for the continued and expanding use of this detector technology in quantum information processing.

47 OTHER INSTRUMENTATION↗