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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 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Neutron irradiation & thermomechanical experiment (NITE) - design

For the reliable long-term operation of fusion power plants, it is crucial to understand and predict the lifetime of materials in use. These materials include all structural and functional materials utilized at the first wall, blanket, magnets, and shielding. The key challenge is, that the harsh environment including high heat fluxes, high thermal stress and stress cycling, neutron irradiation, and sputtering on such materials should not be viewed separately. Currently, the synergistic loads cannot be evaluated experimentally because of the lack of adequate facilities. The purpose of that work is to design a synergetic Neutron Irradiation and Thermomechanical Experiment (NITE) for fusion materials. This design will leverage the existing Advanced-Test-Reactor (ATR), a fission reactor at the Idaho National Laboratory. We also acknowledge that with existing fission reactors the exact fusion condition cannot be created, and the limitations are critically discussed. The combination of neutron irradiation with a high heat flux is the focus. This is realized with an irradiation capsule design that includes a TRISO fueled region inside the capsule to enable a steady-state heat flux on one side of the specimen. In conclusion, the experimental design modeling showed that steady-state heat fluxes of 2.4 MW/m 2 with a thermal gradient of above 250°C can be achieved in a 5 mm thick specimen.

70 - PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Thermodynamic assessment of the quaternary WTaCrV refractory high entropy alloy as a means to guide experimental approaches

The deployment of fusion energy poses challenges for materials in plasma facing components to withstand high temperatures and thermal gradients, particle implantation and neutron damage. The current material of choice is tungsten, although property degradation limits its consideration in future fusion reactors. Hence, materials with better resistance to harsh environments need to be developed for fusion energy to become a reality. High entropy alloys are being explored as potential candidates with some compositions showing good radiation resistance to defect cluster formation. One of these materials is the WTaCrV system, although only one composition has been tested under ion irradiation. In this work, we study the thermodynamic properties of the entire quaternary alloy composition range. Coupling first principles calculations, cluster expansion approaches, and Monte Carlo methods, we access the free energy functionals, short-range ordering as a function of temperature, and atomic configurations that can be compared to experimental observations. We use this data to inform experiments into compositions with higher propensity to form solid solutions, instead of phase separating. With this formalism we have developed thermodynamic database (TDB) files that can be used to plot quaternary phase diagrams.

Cluster Expansion↗
DOE OSTI2024

Microphysics of shock-grain interaction for inertial confinement fusion ablators in a fluid approach

Ablator materials used for inertial confinement fusion, such as high-density carbon (HDC) and beryllium, have grain structure which may lead to small-scale density nonuniformity and the generation of perturbations when the materials are shocked and compressed. Here, we use a combination of a linear theory of shock interaction with density nonuniformity [Velikovich et al., Phys. Plasmas 14, 072706 (2007)] and numerical simulations to study shock interaction with a model representation of HDC grains. While the shock-grain interaction is nonlinear, the linear theory shows some key features of the shock-grain interaction, which also hold for the (nonlinear) simulations. The postshock perturbations are made up of sonic reflections off of grain boundaries and vorticity deposition along them, with the latter dominating the perturbed energy content. The mean (per mass) postshock perturbed kinetic energy decreases with increasing grain size, but energy will be deposited at increasing spatial scale. From the perspective of the postshock perturbed energy, the detailed linear theory largely supports a proposed method [S. Davidovits et al., Phys. Plasmas 29, 112708 (2022)] for deresolving the grains (in a similar grains model) that treats the grains statistically. Finally, our simulation results highlight the influence of thermal conduction on the perturbation dynamics at grain scales.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Investigating Fast Scanning Calorimetry and Differential Scanning Calorimetry as Screening Tools for Thermoset Polymer Material Compatibility with Laser-Based Powder Bed Fusion

As additive manufacturing (AM) technology has developed and progressed, a constant topic of research in the area is expanding the library of materials to be used with these techniques. Among AM methods that utilize polymers, laser-based powder bed fusion (PBF-LB) has preferentially used thermoplastic polymers as its starting materials, but the deposition and material joining method employed in PBF-LB may also be compatible with powdered thermoset polymer precursors as feedstocks. To assess the compatibility of candidate thermosetting polymers and PBF-LB, characterization techniques and protocols that link fundamental material behavior to material behavior in the processing environment are needed. Therefore, the objectives of this work are to compare the curing behavior measured with two different calorimetry techniques that can operate in different heating rate regimes, differential scanning calorimetry (DSC) and fast scanning calorimetry (FSC), and to assess the capabilities of these techniques to act as materials screening tools for PBF-LB. A commercial polyester powder coating is used as a model material to evaluate the potential of obtaining complimentary information for material screening through a combination of calorimetry methods, and its non-isothermal curing behavior is measured at heating rates between 5 °C/min and 7500 °C/min. Curing exotherms are observed with both calorimetry techniques, and comparing the enthalpy associated with curing shows that incomplete curing occurs at higher heating rates, with relative conversion values of approximately 30%. The curing data are fit with two isoconversional models, Friedman and Starink, which show a reduced activation energy at higher heating rates as well, signifying a lower barrier to curing at the conditions used in the FSC experiments. Overall, the results of this work indicate that using these two calorimetry techniques as tiered screening tools can provide valuable information about how curing may proceed in PBF-LB and inform materials selection and design activities for additive manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Thermohydraulic Design Analysis of the Target Assembly in the Material Plasma Exposure Experiment Facility

The Material Plasma Exposure eXperiment (MPEX) project seeks to design a steady-state linear plasma facility at Oak Ridge National Laboratory that will be used to study plasma-material interactions (PMIs) at fusion prototypic levels, supporting the evaluation and development of materials for the next generation of fusion devices. This study is focused on PMI exposure of small-size neutron-irradiated specimens, which are clamped onto an actively cooled component. A thermohydraulic evaluation of a new MPEX target assembly design to assess the appropriate operation during MPEX operation is presented. To further guide the design and assess the structural integrity of the components under expected loads, preliminary thermomechanical stress analyses were also conducted. To ensure good thermal contact between the components, thermal interface materials, such as silver flexible graphite, were used in the assembly. It was found that the maximum target temperatures of 1572, 1463, and 1315 K were obtained for Grafoil thicknesses of 0.61, 0.38, and 0.25 mm, respectively. The distribution of the axial deformation at high heat fluxes showed that there are no gaps between components, indicating good contact at material interfaces. Moreover, the contact pressure between the target and other components indicated that very good contact was established at these interfaces. Furthermore, the stress-strain conditions for the target will be further used to assess the appropriate operation during MPEX experiments and gain insight into materials science phenomena during PMI experiments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Nonlinear optics in 2D materials: From classical to quantum

Nonlinear optics has long been a cornerstone of modern photonics, enabling a wide array of technologies, from frequency conversion to the generation of ultrafast light pulses. Recent breakthroughs in two-dimensional (2D) materials have opened a frontier in this field, offering new opportunities for both classical and quantum nonlinear optics. These atomically thin materials exhibit strong light–matter interactions and large nonlinear responses, thanks to their tunable lattice symmetries, strong resonance effects, and highly engineerable band structures. In this paper, we explore the potential that 2D materials bring to nonlinear optics, covering topics from classical nonlinear optics to nonlinearities at the few-photon level. We delve into how these materials enable possibilities, such as symmetry control, phase matching, and integration into photonic circuits. The fusion of 2D materials with nonlinear optics provides insights into the fundamental behaviors of elementary excitations—such as electrons, excitons, and photons—in low-dimensional systems and has the potential to transform the landscape of next-generation photonic and quantum technologies.

2D materials↗
DOE OSTI2024

Gas pore correlations in laser powder bed fusion of Al6061

Additive manufacturing (AM) of metal materials based on powder bed fusion technology is widely used now in many industries. A known limitation of this type of manufacturing is the formation of gas pores in the bulk material. Here we present a combined X-ray imaging and mid-infrared pyrometry study of pore formation in side-by-side tracks of Al6061 for different processing conditions using both in-situ and post-processing analysis. By carefully quantifying the distributions and correlations of pore positions, we show that an existing pore in one track often catalyzes the formation of another pore in an adjacent track. In a raster scan strategy commonly used to construct bulk material, this phenomenon has the result of forming subsurface perforations, or lines of pores transverse to the scanning direction in a rastered patch. If controlled, this effect can be eliminated to improve the yield strength of the build, or exploited to create programmable failures for specific purposes.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Modeling ablator grain structure impacts in ICF implosions

High-density carbon is a leading ablator material for inertial confinement fusion (ICF). This and some other ablator materials have grain structure which is believed to introduce very small-scale (~nm) density inhomogeneity. In principle, such inhomogeneity can affect key ICF metrics like fuel compression and yield, by, for example, acting as a seed for instabilities and inducing mix between ablator and fuel. However, assessments of such effects are uncertain due to the difficulty of modeling this small-scale structure in ICF simulations, typically requiring reduced-resolution modeling that scales these features. We present a grain model and show both the impact of de-resolving grains and the complex mixing dynamics such structures can induce. We find that different methods for de-resolving grains can yield both different total deposition of kinetic energy perturbations and different fuel–ablator mixing. We then show a simple-to-implement approach for approximately conserving the deposition of perturbed kinetic energy and demonstrate that, for the present grain model and test cases, this approach yields a reasonably matched time history of mix width between less and more resolved grain models. The simulations here also demonstrate the complex interaction history between grain-induced mixing and instability around the fuel–ablator interface, showing, for example, that the grain-induced perturbations typically trigger instability of conduction-driven density gradients in the DT fuel, enhancing mix penetration early in the acceleration of the shell. Furthermore simulating both microscale and nanoscale grains, we find initial evidence for larger mixing in the microscale case of the present model, despite smaller deposited kinetic energy perturbation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Improving Predictions Under Uncertainty of Material Plasma Device Operations

Understanding the properties of materials when exposed to various plasma temperatures and fluxes is essential to the building and operating of fusion reactors. The Material Plasma Exposure eXperiment (MPEX) is an instrument currently being developed by the Department of Energy (DOE) for this purpose. MPEX is expected to come online in stages over the next five years. Proto-MPEX, the predecessor to MPEX, operated from 2014 to 2021, and was designed to understand the generation of plasma temperatures and fluxes at orders of magnitude below what will be obtained by MPEX. This work uses the recently developed stochastic neural network (SNN), a machine learning technique capable of operating under uncertainty to provide a surrogate model for the Proto-MPEX device. We demonstrate that SNN outperforms Bayesian neural network (BNN), a standard in the field of machine learning with uncertainty. The development of a robust surrogate of the Proto-MPEX will aid in the commissioning and operation of the MPEX device.

Archibald, Rick↗
DOE OSTI2025

Simulation Tools for Characterizing Stress Distribution in Laser Welded Dissimilar Joints

This project focuses on developing a thermo-metallurgical-mechanical modeling method to accurately predict the microstructural evolution and residual stress in laser welding between dissimilar metals, such as HSLA steel and high carbon equivalent (CE) gear steel. The method leverages a comprehensive material database to model the temperature and rate dependent phase transformations, along with their associated effects on material properties, such as thermal expansion and flow stress, throughout the welding process. A key innovation is the incorporation of phase transformation and phase-specific properties, which enhances the accuracy of residual stress predictions. The mixture material in the fusion zone due to the dissimilar metals will also be addressed in the numerical model. This is especially critical in scenarios involving phase transformations in the fusion zone and heat-affected zone (HAZ), where the phase changes can induce substantial residual stress variations. The material database has been generated using JMatPro. The modeling approach is implemented through a custom User Material (UMAT) subroutine, executed with the commercial finite element software Abaqus.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Simulation Tools for Characterizing Stress Distribution in Laser Welded Dissimilar Joints

This project focuses on developing a thermo-metallurgical-mechanical modeling method to accurately predict the microstructural evolution and residual stress in laser welding between dissimilar metals, such as HSLA steel and high carbon equivalent (CE) gear steel. The method leverages a comprehensive material database to model the temperature and rate dependent phase transformations, along with their associated effects on material properties, such as thermal expansion and flow stress, throughout the welding process. A key innovation is the incorporation of phase transformation and phase-specific properties, which enhances the accuracy of residual stress predictions. The mixture material in the fusion zone due to the dissimilar metals will also be addressed in the numerical model. This is especially critical in scenarios involving phase transformations in the fusion zone and heat-affected zone (HAZ), where the phase changes can induce substantial residual stress variations. The material database has been generated using JMatPro. The modeling approach is implemented through a custom User Material (UMAT) subroutine, executed with the commercial finite element software Abaqus.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Investigation of interfacial strength in nacre-mimicking tungsten heavy alloys for nuclear fusion applications

Abstract Tungsten heavy alloys have been proposed as plasma facing material components in nuclear fusion reactors and require experimental investigation in their confirmation. For this purpose, a 90W–7Ni–3Fe alloy has been selected and microstructurally manipulated to present a multiphase brick-and-mortar structure of W-phase ‘bricks’ surrounded by a ductile ‘mortar’. This work draws inspiration from nature to artificially imitate the extraordinary combination of strength and stiffness exhibited by mollusks and produce a nacre-mimicking metal matrix composite capable of withstanding the extremely hostile environment of the reactor interior and maintaining structural integrity. The underlying mechanisms behind this integrity have been probed through high-resolution structural and chemical characterization techniques and have revealed chemically diffuse phase boundaries exhibiting unexpected lattice coherency. These features have been attributed to an increase in the energy required for interfacial decohesion in these systems and the simultaneous expression of high strength and toughness in tungsten heavy alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Report on the Second MPEX User Research Forum

The Material Plasma Exposure eXperiment (MPEX) User Research Forum (MURF), a 2 day workshop, was held virtually on September 13–14, 2021, to seek community input for MPEX, a new high-power linear plasma device that is currently being built at Oak Ridge National Laboratory (ORNL). This was the second MURF workshop. The first MURF workshop was held in October 2019 in La Jolla, California, and focused exclusively on the definition of the surface analysis station for MPEX. MPEX is designed to address crucial R&D gaps in plasma material interactions (PMI) for future fusion reactors. The MPEX plasma source and heating systems will allow plasma exposures of plasma-facing materials and components to prototype fusion reactor divertor plasma conditions. The MPEX design accommodates the introduction of previously neutron-irradiated materials for fusion reactor-relevant plasma exposures. This capability will be unique worldwide. The US fusion program has advocated for such a device in numerous community reports in recent years, and now ORNL is building this new device. MPEX is a Major Item of Equipment project executed by the US Department of Energy’s Office of Science Fusion Energy Sciences.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

An Overview of the Hybrid Illinois Device for Research and Applications Material Analysis Test-stand (HIDRA-MAT)

The Hybrid Illinois Device for Research and Applications (HIDRA) at the University of Illinois at Urbana-Champaign is a toroidal plasma device that enables fusion plasma-material interaction testing with both stellarator and tokamak plasmas. HIDRA’s long-pulse steady state stellarator plasmas provide a testbed for plasma facing component (PFC) plasma exposures. The HIDRA Material Analysis Test-stand (HIDRA-MAT) is a material characterization module attached to HIDRA that is being designed and fabricated to include thermal desorption spectroscopy and laser induced breakdown spectroscopy systems for in-vacuo PFC characterization. A specialized rotatable sample holder positions the sample for liquid metal droplet application from a liquid metal droplet injector on HIDRA-MAT. Early experiments look to investigate the effect liquid lithium has on porous tungsten samples’ retention of H, D, and He after plasma exposure. Preliminary results from a dual residual gas analyzer system show the ability to differentiate D2 and He in HIDRA-MAT. Finally, this work aims to advance the understanding of liquid metal PFCs and further the design and development of new fusion PFCs and technologies.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Neutron irradiation-enhanced grain growth in tungsten and tungsten alloys

Herein, to understand the microstructural stability of candidate plasma-facing materials under fusion-relevant environments, neutron irradiation of W and W-3%Re alloys with and without K and La dopants was performed in the mixed-spectrum High Flux Isotope Reactor at nominal temperatures of ~850 °C and ~1100 °C to calculated doses between 0.42 and 0.47 dpa. To the best of our knowledge, this study presents the first experimental evidence of radiation-enhanced recrystallization in W and undoped W–Re alloys at ~850 °C, conditions where thermal annealing does not cause any grain growth in a similar timescale. Potassium- or lanthanum-doped tungsten alloys showed more resistance to radiation-enhanced grain growth. We explain the acceleration of grain growth by analyzing the self-diffusion constant under atomic displacement environments. The microstructural observations of the studied W variants suggest that La doping is more effective than K doping for mitigating recrystallization. This study also found that radiation-enhanced recrystallization is an important consideration when designing and applying W to plasma-facing components in future nuclear fusion reactors.

36 MATERIALS SCIENCE↗