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DOE OSTI2023

Diffractive Multiplexing for High-Throughput Roll-to-Roll Laser Patterning of Flexible Organic Photovoltaic Modules (Final Report)

The purpose of this project is to demonstrate a cost-effective, high-throughput roll-to-roll (R2R) process for patterning of flexible, semitransparent organic photovoltaic (OPV) modules by developing diffractive optics-based laser multiplexing (DOL Multiplexing). DOL Multiplexing allows a single, high-powered laser source to perform parallel scribing across the R2R web width in a manner compatible with high process speeds. Such a process could have enormous benefits in terms of increased process speeds and reduced costs, both up-front capital costs, and long-term operational costs, over galvanometer-based step and scan methods or many-laser systems.

14 SOLAR ENERGY↗

NASA NTRS2001

CTE Measurements of Carbon Fibers in ESEM

The strong appeal of carbon fiber reinforced ceramic matrix and carbon-carbon composites arises from their promising high temperature performance within laboratory-simulated nozzle, leading edge and combustor environments. The main drawback in these systems are two fold; namely oxidation affinity and CTE mismatch. To date the emphasis has been on axial CTE mismatch with the push on estimating (component) laminate level data. However, in heterogeneous and anisotropic systems, all failure mechanisms are at micro or nano scales. This paper will report plans and progress on single carbon fibers efforts in order to develop its temperature dependent, anisotropic thermophysical and thermomechanical properties using combination of x-ray spectroscopy and environmental scanning electron microscopy to capture circumferential expansion from 20-900 C in within the SEM chamber. Surface roughness measurements were also determined. Crystallinity was also determined by the quality of the electron diffraction (ED) patterns.

Effinger, Michael↗

NASA NTRS1974

Development of improved amorphous materials for laser systems

Crystallization calculations were performed in order to determine the possibility of forming a particular type of laser glass with the avoidance of devitrification in an outer space laboratory. It was demonstrated that under the homogenuous nucleating conditions obtainable in a zero gravity laboratory this laser glass may be easily quenched to a virtually crystal-free product. Experimental evidence is provided that use of this material as a host in a neodymium glass laser would result in more than a 10 percent increase in efficiency when compared to laser glass rods of a similar composition currently commercially available. Differential thermal analysis, thermal gradient oven, X-ray diffraction, and liquidus determination experiments were carried out to determine the basics of the crystallization behavior of the glass, and small-angle X-ray scattering and splat-cooling experiments were performed in order to provide additional evidence for the feasibility of producing this laser glass material, crystal free, in an outer space environment.

Neilson, G. F.↗

DOE OSTI2022

Highly ordered graphite (HOPG) to hexagonal diamond (lonsdaleite) phase transition observed on picosecond time scales using ultrafast x-ray diffraction

Here, the response of rapidly compressed highly oriented pyrolytic graphite (HOPG) normal to its basal plane was investigated at a pressure of ~80 GPa. Ultrafast x-ray diffraction using ~100 fs pulses at the Materials Under Extreme Conditions sector of the Linac Coherent Light Source was used to probe the changes in crystal structure resulting from picosecond timescale compression at laser drive energies ranging from 2.5 to 250 mJ. A phase transformation from HOPG to a highly textured hexagonal diamond structure is observed at the highest energy, followed by relaxation to a still highly oriented, but distorted graphite structure following release. We observe the formation of a highly oriented lonsdaleite within 20 ps, subsequent to compression. This suggests that a diffusionless martensitic mechanism may play a fundamental role in phase transition, as speculated in an early work on this system, and more recent static studies of diamonds formed in impact events.

58 GEOSCIENCES↗

DOE OSTI2021

Tracking the phase changes in micelle-based NiGa nanocatalysts for methanol synthesis under activation and working conditions

The hydrogenation of CO 2 into high energy density fuels such as methanol, where the required H 2 is obtained from renewable sources, is of utmost importance for a sustainable society. In recent years, NiGa alloys have attracted attention as promising catalyst material systems for the hydrogenation of CO 2 into methanol at ambient pressures. They thus represent an energy-saving alternative to the Cu-based catalysts employed in today's catalytic industry that require high pressures for the CO 2 hydrogenation. However, the underlying reaction mechanisms for the NiGa system are still under debate. One of the challenges here is to unravel the evolution and coexistence of the different species in the heterogeneous NiGa catalyst system under activation and reaction conditions. To shed light on their evolution under activation in H 2 and their catalytic roles under CO 2 hydrogenation working conditions on well-defined Ni 3 Ga 1 and Ni 5 Ga 3 nanoparticle (NP) catalysts, we employed a multi-probe approach in this study. It included advanced machine learning-based analysis of operando X-ray absorption spectroscopy data combined with operando powder X-ray diffraction and near ambient pressure X-ray photoelectron spectroscopy measurements, as well as reactivity studies using bed-packed mass flow reactors. In addition, we employed atomic force microscopy and scanning transmission electron microscopy for structural characterization. Under H 2 activation at 1 bar total pressure, we concluded the formation of metallic Ni, starting for Ni 3 Ga 1 at 300 °C, and for Ni 5 Ga 3 at 400 °C. At higher temperatures, the formation of NiGa alloys follows. The α'-Ni 3 Ga 1 alloy phase is predominantly formed for the Ni 3 Ga 1 NPs, while the coexistence of α'-Ni 3 Ga 1 , δ-Ni 5 Ga 3 and Ga 2 O 3 phases is observed for the Ni 5 Ga 3 NPs after the H 2 activation. The formation of the Ga 2 O 3 phase also results in the presence of excess metallic Ni. Under CO 2 hydrogenation reaction conditions, Ga partially oxidizes again to form a Ga 2 O 3 -rich particle shell for both NP compositions, yet, to a larger extent for the Ni 3 Ga 1 NPs, which, in turn, feature a higher amount of excess Ni. We reveal that metallic Ni is responsible for the high selectivity of the Ni 3 Ga 1 NPs towards the production of methane in our catalytic tests. In contrast, the Ni 5 Ga 3 NPs display a strong selectivity toward methanol production (>92%), more than one order of magnitude higher than that for the Ni 3 Ga 1 NPs, which we ascribe to the presence of the δ-Ni 5 Ga 3 phase.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2026

Direct observation of diamond formation in a shock-compressed high explosive

Understanding the formation timescale and structure of carbonaceous reaction products is critical for modeling the high-pressure equation-of-state of organic materials. We use the National Ignition Facility to shock-compress polycrystalline TATB (C 6 H 6 N 6 O 6 ) samples to ~70–130 GPa and ~4000–5500 K, employing in situ nanosecond X-ray diffraction to probe reaction products and velocimetry to measure transmitted compression wave profiles. Our diffraction data is consistent with the formation of diamond over timescales less than ~60 ns. This represents carbon condensation from a molecular explosive on timescales three times faster than previously reported and the earliest observation of diamond produced from reacting TATB. Reactive flow simulations with explicit chemistry reproduce the observed temporal structure within wave profiles to inform the distribution of P-T states. These findings provide direct evidence of ultrafast diamond formation in a reactive system at extreme conditions and provide new constraints for models of shock and detonation chemistry.

Clarke, Samantha M. [Lawrence Livermore National L↗

DOE OSTI2020

Accelerator physics at NSLS-II: research accomplishments in 2020

NSLS-II accelerator physicists provide scientific support for user operations, as well as for improvements and developments of the accelerator systems. This work includes optimization of the NSLS-II performance with high beam current and low vertical emittance, improvement of the beam stability, development of new software tools for operations and beam studies. The accelerator physicists productively worked on a number of research activities such as the conceptual design of NSLS-II accelerator upgrade; design and optimization of advanced low-emittance lattices; development of novel methods to study nonlinear beam dynamics; ultrafast electron diffraction and microscopy. The physicists also contributed to the BNL electron-ion collider project, to the APS and ALS upgrade projects. Research accomplishments achieved in 2020, are summarized in this report.

43 PARTICLE ACCELERATORS↗

DOE OSTI2022

Ultrafast perturbation of magnetic domains by optical pumping in a ferromagnetic multilayer

Ultrafast optical pumping of systems with spatially nonuniform magnetic textures is known to cause far-from-equilibrium spin transport effects, such as the broadening of domain-walls. Here, we study the dynamics of labyrinth domain networks in ferromagnetic CoFe/Ni multilayers subject to a femtosecond optical pump and find an ultrafast domain dilation by 6% within 1.6 ps. This surprising result is based on the unambiguous determination of a harmonically-related shift of ultrafast magnetic X-ray diffraction for the first- and third-order rings. Domain dilation is plausible from conservation of momentum arguments, whereby inelastic scattering from a hot, quasi-ballistic, radial current transfers momentum to the magnetic domains. Our results suggest a potentially rich variety of unexpected physical phenomena associated with far-from-equilibrium inelastic electron-magnon scattering processes in the presence of spin textures.

36 MATERIALS SCIENCE↗

NASA NTRS1989

Center for the development of commercial crystal growth in space

The second year of operation of the Center for Commercial Crystal Growth in Space is described. This center is a consortium of businesses, universities and national laboratories. The primary goal of the Center's research is the development of commercial crystal growth in space. A secondary goal is to develop scientific understanding and technology which will improve commercial crystal growth on earth. In order to achieve these goals the Center's research is organized into teams by growth technique; melt growth, solution growth, and vapor growth. The melt growth team is working on solidification and characterization of bulk crystals of gallium arsenide and cadmium telluride. They used high resolution X-ray topography performed at the National Synchrotron Light Source at Brookhaven National Laboratory. Streak-like features were found in the diffraction images of semi-insulating undoped LEC GaAs. These were shown to be (110) antiphase boundaries, which have not been reported before but appear to be pervasive and responsible for features seen via less-sensitive characterization methods. The results on CdTe were not as definitive, but indicate that antiphase boundaries may also be responsible for the double peaks often seen in X-ray rocking curves of this material. A liquid encapsulated melt zone system for GaAs has been assembled and techniques for casting feed rods developed. It was found that scratching the inside of the quartz ampoules with silicon carbide abrasive minimized sticking of the GaAs to the quartz. Twelve floating zone experiments were done.

Wilcox, William R.↗

NASA NTRS1993

Fabricating binary optics: An overview of binary optics process technology

A review of binary optics processing technology is presented. Pattern replication techniques have been optimized to generate high-quality efficient microoptics in visible and infrared materials. High resolution optical photolithography and precision alignment is used to fabricate maximally efficient fused silica diffractive microlenses at lambda = 633 nm. The degradation in optical efficiency of four-phase-level fused silica microlenses resulting from an intentional 0.35 micron translational error has been systematically measured as a function of lens speed (F/2 - F/60). Novel processes necessary for high sag refractive IR microoptics arrays, including deep anisotropic Si-etching, planarization of deep topography and multilayer resist techniques, are described. Initial results are presented for monolithic integration of photonic and microoptic systems.

Stern, Margaret B.↗

NASA NTRS2016

Ceres Revealed in a Grain of Salt

Introduction: Zag and Monahans (1998) are H chondrite regolith breccias containing 4.5 giga-year-old halite crystals which contain abundant inclusions of aqueous fluids, solids and organics. These all originated on a cryo-volcanically-active C class asteroid, probably 1 Ceres; the halite was transported to the regolith of the H chondrite parent asteroid, potentially 6 Hebe. Detailed analysis of these solids will thus potentially reveal the mineralogy of Ceres. Mineralogy of solids in the Monahans Halite Solid grains are present in the halites, which were entrained within the mother brines during eruption, including material from the interior and surface of the erupting body. The solids include abundant, widely variable organics that could not have been significantly heated (which would have resulted in the loss of fluids from the halite). Our analyses by Raman microprobe, SEM/EDX, synchrotron X-ray diffraction, UPLC-FD/QToF-MS, C-XANES and TEM reveal that these trapped grains include macromolecular carbon (MMC) similar in structure to CV3 chondrite matrix carbon, aliphatic carbon compounds, olivine (Fo99-59), high- and low-Ca pyroxene, feldspars, phyllosilicates, magnetite, sulfides, metal, lepidocrocite, carbonates, diamond, apatite and zeolites. Conclusions: The halite in Monahans and Zag derive from a water and carbon-rich object that was cryo-volcanically active in the early solar system, probably Ceres. The Dawn spacecraft found that Ceres includes C chondrite materials. Our samples include both protolith and aqueously-altered samples of the body, permitting understanding of alteration conditions. Whatever the halite parent body, it was rich in a wide variety of organics and warm, liquid water at the solar system's dawn.

Zolensky, M. E.↗

DOE OSTI2023

Excited State Dynamics of a Conformationally Fluxional Copper Coordination Complex

The conversion of solar energy into chemical fuel represents a capstone goal of the 21st century and has the potential to supply terawatts of power in a globally distributed manner. However, the disparate time scales of photodriven charge separation (~fs) and steps in chemical reactions (~μs) represent an inherent bottleneck in solar-to-fuels technology. Here to address this discrepancy, we are developing earth-abundant coordination complexes that undergo light-induced conformational rearrangements such that charge separation (CS) is hastened, while charge recombination (CR) is slowed. To these ends, we report the preparation and characterization of a new series of conformationally fluxional copper coordination complexes that contain a twisted intramolecular charge transfer (TICT) fluorophore as part of their ligand scaffold. Structural and spectroscopic characterization of the Cu(I) and Cu(II) complexes formed with these ligands in their ground states establish oxidation state-dependent conformational dynamicity, while time-resolved emission and transient absorption spectroscopies define the photopysical parameters of photo-induced excited states. Building on initial reports with a related set of molecules, the improved ligand design presented here greatly simplifies the observed photophysics, effectively shutting down unwanted ligand-centered excited states previously observed. Finally, time-dependent density functional theory (TDDFT) analyses reveal an unusual metal-to-TICT electronic transition only reported once before, and though the formation of a CS state is not observed directly through experiments, TDDFT geometry optimizations in the excited states support the formation of transient Cu(II) CS species, lending credence to the potential success of our approach. These studies establish a clear model for the excited state dynamics at play in proof-of-concept systems and clarify key design parameters for future optimizations toward achieving long-lived CS via photoinduced conformational gating.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Understanding the Benefit of Hybrid Electrolytes towards Vanadium Dissolution Suppression and Improved Capacity Retention in Zinc‐Aqueous Batteries Using NaV 3 O 8 Cathodes

Vanadate cathodes used in aqueous Zn-ion batteries with ZnSO 4 are hindered by capacity loss from V dissolution into the electrolyte. However, studies pinpointing the onset of dissolution as a function of electrochemical redox state and quantifying the amount of associated active material are lacking. To prevent dissolution of the NaV 3 O 8 active material, Na + ions are introduced into the electrolyte. Specifically, a hybrid ZnSO 4 + Na 2 SO 4 electrolyte is investigated in concert with NaV 3 O 8 (NVO) cathodes of varied crystallinity to determine the resulting impacts on cathode dissolution and functional electrochemistry. The use of Na + -containing hybrid electrolyte shows no significant change in Zn 2+ diffusion coefficients yet improved capacity retention. Time-resolved quantitative optical emission spectroscopy demonstrates the suppression of V dissolution with the hybrid electrolyte in both pristine and cycled electrodes. Operando synchrotron X-ray diffraction and absorption provide mechanistic insights. Hydrated NVO with wider interplanar spacing exhibits much higher H + /Zn 2+ capacity, while the Na 2 SO 4 mitigates the formation of irreversible side products. Furthermore, this study demonstrates that the use of hybrid electrolytes and control of crystallite size in the parent material can significantly improve electrochemical behavior of layered V-based cathodes in Zn-ion batteries, providing a general strategy toward safe and resilient aqueous battery systems.

36 MATERIALS SCIENCE↗

DOE OSTI2025

High-Speed and High-Quality Field Welding Repair Based on Advanced Non-Destructive Evaluation and Numerical Modeling

Creep strength-enhanced ferritic (CSEF) steels such as Grade 91 (9Cr-1Mo-V) and Grade 92 (Fe-9Cr-2W-0.5Mo) steels are widely used in the fossil-fuel-fired and nuclear power plants. The weld integrity of these steels is crucial for power plants' safe and reliable operations. Due to harsh service conditions, the steel weld can become susceptible to environmental degradation. Field welding repair is used to restore the degraded weld’s performance where a controlled temper-bead welding technique is commonly used to temper the freshly formed martensite during welding. However, knowledge of weld repairability is limited and experimental trial and error optimization to achieve desired microstructure and joint properties is expensive and time-consuming. Many existing computational models, e.g., finite element models, are limited to solving heat conduction equation and ignoring convective heat transfer due to molten metal flow. These models can result in over-prediction of peak temperatures of weld pool and heat-affected zone (HAZ), which in turn can affect the accuracy of tempering prediction. Moreover, these finite element models require an input of the deposit profiles in advance and thus limits the usability of these models. Here, a molten pool-based, multi-pass multi-layer model has been developed based on computational fluid dynamics (CFD) approach with the Volume of Fluid (VOF) method. The model calculates the bead formation, thereby eliminating the need for pre-determined bead profiles required by finite element models. For computational efficiency, a coordinate system attached to the moving heat source is utilized. A subroutine is developed to convert the temperature profiles in the reference frame stationary to the heat source to that stationary to the workpiece. The converted thermal cycles are then imported into a microstructure model to compute the tempering kinetics and resultant hardness using a Johnson-Mehl-Avrami-Kolmogorov (JMAK), and modified Grange-Baughman parameter. The modeling approach is first developed and validated on single- and multi-pass deposition of stainless steel filler metal onto a SA-533 high strength steel substrate. The models are then applied to a multi-pass V-groove repair weld of Grade 91 steel plate as well as directed energy deposition of Grade 92 steel. Non-destructive characterization of microstructures was performed on Grade 91 and 92 steel welds. Two welding processes, cold metal transfer (CMT) and flux-cored arc welding (FCAW), were investigated for the Grade 91 steel weld samples. For the Grade 92 weld samples, three different heat inputs (low, medium, and high) of gas tungsten arc welding (GTAW) were utilized to replicate traditional field welding processes. The non-destructive evaluation (NDE) method used for this research was immersion ultrasonic testing (UT) using a micro-resolution ultrasonic imaging methodology specifically designed to operate in the through-transmission configuration operating at 20 MHz of frequency. The system used a focused ultrasonic beam spot size diameter between 250-300 μm, and a 6 μm laser vibrometer spot size for detection, to produce highly defined images with longitudinal and mode-converted shear waves. From the micro-resolution ultrasonic C-scan images, three microstructural regions, i.e., weld metal (WM), HAZ, and base metal (BM), were clearly identifiable. Various levels of ultrasonic amplitudes distributed over the three regions were correlated with electron beam backscattered diffraction (EBSD) images using grain size, grain boundaries, and dislocation densities. The results showed that areas with relatively higher ultrasonic amplitude levels were associated with smaller grains and higher dislocation densities, while areas with lower amplitude levels were associated with larger grains and lower dislocation densities. In addition, ultrasonic velocity data obtained across the three different weld microstructural regions of Grade 91 test samples were correlated with optical metallographic images and hardness measurements. The results showed distinctive decreases in ultrasonic velocity and hardness over the HAZ region, where weld failures often occur during service.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Controlled Conversion of Sodium Metal From Nuclear Systems to Sodium Chloride

A series of three bench-scale experiments was performed to investigate the conversion of sodium metal to sodium chloride via reactions with non-metal and metal chlorides. Specifically, batches of molten sodium metal were separately contacted with ammonium chloride and ferrous chloride to form sodium chloride in both cases along with iron in the latter case. Additional ferrous chloride was added to two of the three batches to form low melting point consolidated mixtures of sodium chloride and ferrous chloride, whereas consolidation of a sodium-chloride product was performed in a separate batch. Samples of the products were characterized via X-ray diffraction to identify attendant compounds. The reaction of sodium metal with metered ammonium chloride particulate feeds proceeded without reaction excursions and produced pure colorless sodium chloride. The reaction of sodium metal with ferrous chloride yielded occasional reaction excursions as evidenced by temperature spikes and fuming ferrous chloride, producing a dark salt-metal mixture. This investigation into a method for controlled conversion of sodium metal to sodium chloride is particularly applicable to sodium containing elevated levels of radioactivity—including bond sodium from nuclear fuels—in remote-handled inert-atmosphere environments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1988

ORFEUS focal plane instrumentation: The Berkeley spectrometer

A spectrograph for the ORFEUS mission that incorporates four varied line-space, spherically figured diffraction gratings was designed. The ORFEUS, a 1-m normal incidence telescope is equipped with 2 focal plane spectrographs. The Berkeley spectrograph was developed with an optimizing raytracing computer code. Each grating accepts the light from 20 percent of the aperture of the telescope primary mirror and has a unique set of characteristics to cover a sub-bandpass within the 390 to 1200 A spectral range. Two photon-counting detectors incorporating a time delay readout system are used to record the spectra from all four gratings simultaneously. The nominal design achieves a spectral resolution (FWHM) in excess of 5500 at all wavelengths within the bandpass. The resolution is limited primarily by the detector spatial resolution. The 1 sigma astigmatism of this design varies between 13 and 150 micrometer on the same focal surface. An independent, direct imaging system tracks the drift of the target within the spectrometer aperture and allows measurement of the misalignment between the telescope optical axis and that of the external star tracker. The resolution and astigmatism achievable with this design are superior to those of a standard Rowland spectrograph designed with the same constraints.

Hurwitz, Mark↗

NASA NTRS2015

Space Telescope Design to Directly Image the Habitable Zone of Alpha Centauri

The scientific interest in directly imaging and identifying Earth-like planets within the Habitable Zone (HZ) around nearby stars is driving the design of specialized direct imaging missions such as ACESAT, EXO-C, EXO-S and AFTA-C. The inner edge of Alpha Cen A&B Habitable Zone is found at exceptionally large angular separations of 0.7" and 0.4" respectively. This enables direct imaging of the system with a 0.3m class telescope. Contrast ratios on the order of 10(exp 10) are needed to image Earth-brightness planets. Low-resolution (5-band) spectra of all planets may allow establishing the presence and amount of an atmosphere. This star system configuration is optimal for a specialized small, and stable space telescope that can achieve high-contrast but has limited resolution. This paper describes an innovative instrument design and a mission concept based on a full Silicon Carbide off-axis telescope, which has a Phase Induced Amplitude Apodization coronagraph embedded in the telescope. This architecture maximizes stability and throughput. A Multi-Star Wave Front algorithm is implemented to drive a deformable mirror controlling simultaneously diffracted light from the on-axis and binary companion star. The instrument has a Focal Plane Occulter to reject starlight into a high precision pointing control camera. Finally we utilize a Orbital Differential Imaging (ODI) post-processing method that takes advantage of a highly stable environment (Earth-trailing orbit) and a continuous sequence of images spanning 2 years, to reduce the final noise floor in post processing to approximately 2e-11 levels, enabling high confidence and at least 90% completeness detections of Earth-like planets.

Low-resolution (5-band) spectra↗

NASA NTRS2019

In-situ Mechanical Neutron Diffraction Loading Characteristics of GRCop-84 Fabricated by SLM

GRCop-84 is a precipitation strengthened alloy composed of Cu-8Cr-4Nb at % with Cr2Nb precipitates that provide dispersion and precipitation strengthening characteristics and limited solubility in the Cu matrix. The particle role of Cr2Nb(C15Laves) is unusual only contributing 1/3 of strengthening at high temperatures while the matrix provides the remainder. The particles mechanically and thermally stabilize the matrix retaining purity and preventing coarsening and loss of strength. At high temperatures (50-85%TmCu), GRCop-84 provides the best thermal and mechanical properties of available alloys. GRCop-84 is currently in development for reusable launch vehicles including the Space Launch System (SLS) with a focus on fabrication with additive manufacturing (AM) techniques. GRCop-84 is an optimal material for consolidating with AM. The base material is costly, the production times are long, and more geometry control can considerably improve cooling efficiency. Development of AMGR Cop-84 with selective laser melting (SLM) has rapidly progressed due to ease of printing and limited operator adjustment between builds, but the necessary knowledge-base of thermal history and stress state during builds is still under development.

Minneci, R.↗