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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 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

2022 Annual Site Environment Report, Princeton Plasma Physics Laboratory

This report provides the U.S. Department of Energy (DOE) and the public with information on the level of radioactive and non-radioactive pollutants (if any) that are added to the environment as a result of Princeton Plasma Physics Laboratory’s (PPPL) operations. This report fulfills the annual public reporting requirements of DOE Order 231.1B. The results of PPPL’s 2022 environmental surveillance and monitoring program are presented and discussed. The report also summarizes environmental initiatives, assessments, and community involvement programs that were undertaken in 2022. PPPL’s on-site operations started to be restored in 2022, following curtailments in 2020 and 2021 for the global coronavirus (COVID-19) pandemic. PPPL has engaged in fusion energy research since 1951 and at its current locations since 1958. The Laboratory’s mission is to develop the scientific knowledge and advanced engineering to enable fusion to power the U.S. and the world, and to develop the understanding of plasmas from the nano- to the astrophysical scale. PPPL’s primary experiment, the National Spherical Torus Experiment-Upgrade (NSTX-U) is a collaboration among national laboratories, universities, and national and international research institutions and is a major element in the US Fusion Energy Sciences Program. Its design tests the physics principles of spherical torus (ST) plasmas, playing an important role in the development of smaller, more economical fusion reactors. Due to previous operational issues, NSTX-U did not operate in 2022. PPPL is engaged in a project to replace key NSTX-U components and systems to enable the operation of this international magnetic fusion user facility. In 2022, PPPL’s radiological environmental monitoring program measured tritium in the air at onsite sampling stations. Using highly sensitive air monitors, PPPL is capable of detecting small changes in the ambient levels of tritium. The operation of monitors located on D-site is used to demonstrate compliance with the National Emission Standard for Hazardous Air Pollutants (NESHAPs) regulations. Also included in PPPL’s radiological environmental monitoring program, are water monitoring – ground, surface, and waste waters. PPPL’s radiological monitoring program characterized the background levels of tritium in the environment and those data are presented in this report. Ground water monitoring continued under New Jersey Department of Environmental Protection’s (NJDEP) Site Remediation Program regulations. PPPL monitored for non-radiological contaminants, mainly volatile organic compounds (components of common degreasing solvents). In 2022, PPPL complied with permit limits for surface water and sanitary wastewater discharges. PPPL was honored with an award for EPEAT-certified electronics purchasing from the Global Electronics Council.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Performance Comparison of Helium and sCO 2 as Coolants for Modular Finger-Type Divertors

Several studies at the Georgia Institute of Technology have evaluated the thermal and fluids performance of the helium-cooled modular divertor with multiple jets (HEMJ) over the past decade. This finger-type divertor was studied both experimentally at nearly prototypical conditions and numerically at fully prototypical operating conditions using experimentally validated simulations. Recently, supercritical carbon dioxide (sCO 2 ) has been studied as the primary coolant in power cycles and other applications in various systems, in part because CO 2 achieves the high densities typical of supercritical fluids at relatively low temperatures and pressures, with a critical point of (7.38 MPa, 31°C). This density makes it possible to realize very compact and efficient sCO 2 power cycles. The feasibility of sCO 2 as a coolant for plasma-facing components, specifically the divertor, was therefore evaluated as part of the Fusion Energy System Studies design study activities. This work compares the thermal-fluid performance of helium and sCO 2 in the HEMJ divertor geometry using numerical simulations at prototypical conditions: inlet temperatures T i = 600°C to 700°C, pressures p ≈ 10 MPa, and steady-state incident heat fluxes on the tile q″ < 17 MW/m 2 . The performance is quantified here as the maximum heat flux that can be accommodated by the plasma-facing tile, the pumping power fraction, defined as the ratio of the coolant pumping power to the incident thermal power, and the operating stress limits based on ASME pressure vessel criteria. As expected, helium requires lower mass flow rates and pumping power fractions within imposed maximum temperature limits for the HEMJ pressure boundary. However, it also appears that neither helium nor sCO 2 can remove 10 MW/m 2 of incident heat flux while meeting ASME pressure vessel criteria. Finally, the numerical modeling reveals that sCO 2 may remove slightly higher incident heat fluxes than helium due to the imposed stress limits due to the sCO 2 coolant resulting in smaller local temperature gradients, albeit at a considerably higher pumping power fraction.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Processing of tungsten through electron beam melting

Additive manufacturing (AM) presents a new design paradigm for the manufacture of engineering materials through the layer-by-layer approach combined with welding theory. In the instance of difficult to process materials such as tungsten and other refractory metals, AM offers an opportunity for radical redesign of critical components for next-generation energy technologies including fusion. In this work, electron beam powder bed fusion (EB-PBF) is applied to process pure tungsten to study the influence of process parameters on the defect density of the material. Here, an in-situ image analysis algorithm is applied to pure tungsten for the first time, and is used to visualize the defect structure in AM tungsten. Finally, a cracking mechanism for AM tungsten is proposed, and suggestions for suppression of cracks in pure tungsten are offered.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Irradiation effects in tungsten—From surface effects to bulk mechanical properties

Advanced materials such as tungsten fibre-reinforced composites allow to overcome severe weaknesses of the baseline materials for plasma-facing components — copper and tungsten. The effect of the fusion environment on the mechanical properties of these materials, e.g. the embrittlement by neutron irradiation, plays a key role for the development of future fusion reactors. To simulate this effect, high-energy ions are used as a substitute for the displacement damage by neutrons. We propose the use of very fine tungsten wire as a possibility of studying the influence of irradiation damage on the mechanical properties. This is possible as they allow full-depth irradiation of almost the entire volume despite the limited penetration depth of ions. Geometrical size effects are mitigated due to the nanoscale microstructure of the wire. In addition, similar wire is used in tungsten fibre-reinforced composites. Thus, the investigation of irradiated wire can directly be used for the prediction of the bulk composite properties. For the proof of this concept tungsten wire with a diameter of 16 μm was electrochemically thinned to 5 μm and irradiated with 20.5 MeV W 6+ ions. The mechanical properties were subsequently determined by macroscopic tensile testing. Irradiation to 0.3, 1 and 9 dpa did not lead to a change of the mechanical behaviour. Both strength and ductility, the latter indicated by the reduction of area, were similar to the as-fabricated state.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Toward an integrated multi-gigahertz ionizing particle diagnostic

Needs arising at both current and future accelerator facilities call for the development of radiation-hardened position-sensing diagnostics that can operate with multi-GHz repetition rates. Such instruments are likely to also have applications in the diagnosis of rapid plasma behavior. Here, building on the recent work of our Advanced Accelerator Diagnostics Collaboration, we are exploring the development of integrated multi-GHz ionizing particle detection systems based on chemical-vapor deposition diamond sensors, with the initial goal of producing a quadrant detector that can determine the intensity and centroid position of a particle beam at a repetition rate between 5 and 10 GHz. Results from our initial high-speed characterization work are presented, including those from a single-channel sensor with a GHz response. Approaches to achieving multi-GHz (5–10 GHz) rate capability, including the design of a dedicated Application Specific Integrated Circuit and the use of 3D RF-solver computer aided design software, are presented and discussed in more detail. 3D RF simulations suggest clean pulses of duration less than 250 ps (FWHM less than 125 ps) can be achieved with the approaches developed by this work.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

BeyondFingerprinting: AI-guided discovery of robust materials & processes

BeyondFingerprinting was a 2021-2024 Sandia Grand Challenge LDRD exploring the potential to develop new resilient materials and manufacturing processes by taking an artificial-intelligence (AI)-guided approach that integrates human-subject-matter expertise with algorithms enriched with physics-based constraints to unearth process-structure-property correlations. Such algorithms, trained on high-throughput experiments and simulations, are shown to serve as surrogate models that efficiently detect key “fingerprints” in materials data, prognose material performance, and guide effective process improvements. To accelerate broader adoption across mission areas, this AI-guided approach was demonstrated with three complex process-centric exemplars: electroplating, physical vapor deposition, and laser powder bed fusion. Together, these exemplars impact nearly every hardware component relevant to DOE and NNSA national security missions.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Predictive process mapping for laser powder bed fusion: A review of existing analytical solutions

One of the main challenges in the laser powder bed fusion (LPBF) process is making dense and defect-free components. These porosity defects are dependent upon the melt pool geometry and the processing conditions. Power-velocity (PV) processing maps can aid in visualizing the effects of LPBF processing variables and mapping different defect regimes such as lack-of-fusion, under-melting, balling, and keyholing. This work presents an assessment of existing analytical equations and models that provide an estimate of the melt pool geometry as a function of material properties. The melt pool equations are then combined with defect criteria to provide a quick approximation of the PV processing maps for a variety of materials. Finally, the predictions of these processing maps are compared with experimental data from the literature. Here, the predictive processing maps can be computed quickly and can be coupled with dimensionless numbers and high-throughput (HT) experiments for validation. The present work provides a boundary framework for designing the optimal processing parameters for new metals and alloys based on existing analytical solutions.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Conceptual design of HTS magnets for fusion nuclear science facility

Second-generation high temperature superconductors (HTS) are available for producing >20 T at the magnet bore compared to 13–16 T for lower temperature superconducting (LTS) toroidal field magnets proposed in recent fusion energy systems studies (FESS) of Fusion Nuclear Science Facility (FNSF). HTS may enable higher fusion power density and smaller device size. High current density cables of multi-layered REBCO tapes have achieved >10 kA at 4–20 K operation in short sample tests for fusion. High current density cables are required for engineering design of FNSF to allow space for interior plasma components. High current density HTS magnets are particularly attractive in reducing the size of a fusion device, beneficial for compact tokamaks, due to their space constraints. Successful HTS magnet development may enable the design of smaller and cheaper fusion pilot plants with a mission of demonstrating net electricity. It may also offer significant cost and performance advantages in non-fusion applicants such as nuclear magnetic resonance (NMR) and magnetic resonance imaging (MRI). Furthermore, we developed HTS magnet design concepts for a compact FNSF radial build in order to define the coil size, winding pack mechanical loading and engineering requirements. Partnering with vendors in the US, PPPL is also testing high current cable prototypes aiming at enabling low cost cable technology toward 100 A/mm 2 engineering current density over the winding pack desired in high field model coil development for compact fusion pilot plants.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Sensitive search for near-symmetric and super-asymmetric fusion-fission of the superheavy element Flerovium (Z=114)

Measurements of mass and angular distributions have been made for fission-like outcomes in reactions forming isotopes of flerovium (Z=114), using 48 Ca, 50 Ti, and 54 Cr projectiles. The dominant fast quasifission process, which masks the presence of fusion-fission, has minimum yield at the most backward angles, where the sensitivity to fusion-fission is thus highest. In fitting the backward angle mass spectra, only weak evidence for a component of super-asymmetric fission was found, but a near-symmetric fission component was consistently required for the 48 Ca + 244 Pu reaction, giving upper limit to the fusion probabilities P CN of ~10 -2 , ~5 times lower than previous results. P CN for the 50 Ti reaction was lower than 48 Ca, whilst no evidence of fusion-fission was found for the 54 Cr reaction.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2024

LLNL FESP Theory Highlights: August 2024

The 2024 ABOUND SciDAC and BOUT++ combined workshop was held August 5-9 th 2024 at the University of California Livermore Collaboration Center (UCLC) in Livermore. Bringing together leading scientists and researchers from across the globe, this pivotal event focused on advancing plasma physics and boundary plasma dynamics within the context of fusion energy research. Key discussions throughout the meeting highlighted significant advancements in the BOUT++ framework, including enhanced simulations of small Edge Localized Modes (ELMs) and the initiation of integrating the integration of the 5D GEM gyrokinetic turbulence core code with the 2D SOLPS-ITER boundary transport code. These developments are crucial for managing heat loads in fusion reactors and supporting the longevity of plasma-facing components. The event also featured a session on Inter-SciDAC Collaborations, where principal investigators from multiple U.S. FES SciDAC tokamak projects explored opportunities for cross-collaboration. Additionally, the meeting showcased cutting-edge advancements in GPU acceleration and AI/ML technologies, poised to drive the next generation of fusion research. In his closing remarks, Dr. Xueqiao Xu emphasized the importance of the collaborative efforts and discussions that took place, noting their potential to shape future breakthroughs in fusion energy. The event underscored the global nature of the BOUT++ collaboration, with contributions from over 57 institutions worldwide. The 2024 BOUT++ and ABOUND Joint Hybrid Meeting continues to drive forward the research and innovations needed to achieve fusion energy, setting the stage for future collaboration and discovery.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Long plasma duration operation analyses with an international multi-machine (tokamaks and stellarators) database

Combined high-fusion performance and long-pulse operation is one of the key integration challenges for fusion energy development in magnetic devices. Addressing these challenges requires an integrated vision of physics and engineering aspects with the purpose of simultaneously increasing time duration and fusion performance. Significant progress has been made in tokamaks and stellarators, including very recent achievement in duration and/or performance. This progress is reviewed by analyzing the experimental data (109 plasma pulses with a total of 3200 data points, i.e. on average 29 data per pulse) provided by ten tokamaks (in alphabetical order: Axially Symmetric Divertor Experiment Upgrade, DIII-D, Experimental Advanced Superconducting Tokamak, Joint European Torus, JT-60 Upgrade, Korea Superconducting Tokamak Advanced Research, tokamak à configuration variable, Tokamak Fusion Test Reactor, Tore Supra, W Environment in Steady-State Tokamak) and two stellarators (Large Helical Device and Wendelstein 7-X) expanding the pioneering work of Kikuchi (Kikuchi M. and Azumi M. 2015 Frontiers in Fusion Research II: Introduction to Modern Tokamak Physics (Springer)). Data have been gathered up to January 2022 and coordination has been provided by the recently created International Energy Agency-International Atomic Energy Agency international Coordination on International Challenges on Long duration OPeration group. By exploiting the multi-machine international database, recent progress in terms of injected energies (e.g. 1730 MJ in L-mode, 425 MJ in H-mode), durations (1056 s in L-mode, 101 s in H-mode), injected powers, and sustained performance will be reviewed. Progress has been made to sustain long-pulse operation in tokamaks and stellarators with superconducting coils, actively cooled components, and/or with metallic walls. The graph of the fusion triple products as a function of duration shows a dramatic reduction of, at least two orders of magnitude when increasing the plasma duration from less than 1 s to 100 s. Indeed, long-pulse operation is usually reached in dominant electron-heating modes at reduced density (current drive optimization) but with low ion temperatures ranging from 1 to 3 keV for discharges above 100 s. Difficulties in extending the duration may arise from coupling high heating powers over long durations and the evolving plasma-wall interaction towards an unstable operational domain. Possible causes limiting the duration and critical issues to be addressed prior to ITER operation and DEMO design are reported and analyzed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Comparative Mechanical Properties Analysis of Triple Ion-Beam Irradiated and Neutron Irradiated Potential Plasma Facing Components

Abstract Several classes of materials are being proposed for use in fusion reactors including oxide dispersion strengthened (ODS) and reduced activation ferritic-martensitic (RAF/M) steels to withstand the severe and harsh conditions. In this work, the mechanical properties of a Fe-16Cr-4Al-2W-0.3Ti-0.3Y 2 O 3 (K3) (ODS) ferritic steel and a Fe-8.9Cr-1.1W-0.47Mn-0.2V-0.14Ta-0.11C (Eurofer 97) (RAF/M) steel) after triple ion beam irradiation were locally evaluated utilizing in-situ micro-pillar compression tests, and continuous stiffness/quasi-static nanoindentation. No change in mechanical properties was observed in the K3 ODS steel. However, the Eurofer 97 RAF/M steel exhibited radiation-induced effects via increases in yield strength. Micro-pillar techniques were expanded to neutron-irradiated materials via an in-situ testing technique employing lift-out methods on Fe-14Cr-0.9Ti-0.3Mo-0.25Y 2 O 3 (MA957) ODS ferritic steel. Both the non-irradiated and irradiated compressive yield stresses of the MA 957 micro-pillars were in good agreement with bulk yield stress values reported in the literature, suggesting that the lift-out micro-pillar compression testing technique is a promising method. The demonstration of these techniques on ion beam and neutron irradiated ODS steels and ion beam RAF/M steels gives information to inform models of the material degradation during use in a fusion device.

alloys↗
DOE OSTI2020

Static and dynamic properties of multi-ionic plasma mixtures

Complex plasma mixtures with three or more components are often encountered in astrophysics or in inertial confinement fusion (ICF) experiments. For mixtures containing species with large differences in atomic number Z, the modeling needs to consider at the same time the kinetic theory for low-Z elements combined with the theory of strongly coupled plasma for high-Z elements, as well as all the intermediate situations that can appear in multi-component systems. For such cases, we study the pair distribution functions, self-diffusions, mutual diffusion and viscosity for ternary mixtures at extreme conditions. These quantities can be produced from first principles using orbital free molecular dynamics at the computational expense of very intensive simulations to reach good statistics. Utilizing the first-principles results as reference data, we assess the merit of a global analytic model for transport coefficients, "Pseudo-Ions in Jellium" (PIJ), based on an iso-electronic assumption (iso-n e ). With a multi-component hypernetted-chain integral equation, we verify the quality of the iso-n e prescription for describing the static structure of the mixtures. This semi-analytical modeling compares well with the simulation results and allows one to consider plasma mixtures not accessible to simulations. Further, applications are given for the mix of materials in ICF experiments. A reduction of a multicomponent mixture to an effective binary mixture is also established in the hydrodynamic limit and compared with PIJ estimations for ICF relevant mixtures.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Modified bacterial microcompartment shell proteins

The present invention provides for a fusion protein comprising (1) a bacterial microcompartment (BMC) shell protein comprising one or more subunit, and (2) a first component of a specific-binding pair, operably linked to the BMC shell protein such that the first component faces (i) a lumen (inside) side, or (ii) outside of a BMC shell formed incorporating the fusion protein and the fusion protein does not disrupt or prevent the folding of the BMC shell protein or the ability of the BMC shell protein to integrate with other BMC shell proteins into a BMC shell; wherein the first component is capable of forming a stable or irreversible interaction with a second component of the specific-binding pair.

Hagen, Andrew R.↗
DOE OSTI2024

Modified bacterial microcompartment shell protein

The present invention provides for a fusion protein comprising (1) a bacterial microcompartment (BMC) shell protein comprising one or more subunit, and (2) a first component of a specific-binding pair, operably linked to the BMC shell protein such that the first component faces (i) a lumen (inside) side, or (ii) outside of a BMC shell formed incorporating the fusion protein and the fusion protein does not disrupt or prevent the folding of the BMC shell protein or the ability of the BMC shell protein to integrate with other BMC shell proteins into a BMC shell; wherein the first component is capable of forming a stable or irreversible interaction with a second component of the specific-binding pair.

Hagen, Andrew R.↗
DOE OSTI2022

Developing ductile and isotropic Ti alloy with tailored composition for laser powder bed fusion

Laser powder bed fusion (LPBF) is an advanced technology to create metallic components with complex geometry. Ti-6Al-4V (Ti64) is one of the most frequently used materials for LPBF. The intrinsic high cooling rates and ultra-high directional thermal gradient of melt, however, lead to a hierarchical structure composed of fine martensitic alpha' within columnar prior-beta grains in LPBF Ti64. This microstructure results in poor ductility and strong mechanical anisotropy in as-built Ti64 components, which largely limit their applications. Here, we report that the above shortcomings can be overcome by tailoring the alloy composition. Specifically, by reducing the aluminum content from 6 wt% to 4 wt%, the resultant LPBF Ti-4Al-4V (Ti44) alloy exhibits substantially improved ductility and mechanical isotropy. These improvements are attributed to grain refinement during solidification and the activation of multiple slip modes and twinning in the as-built material during deformation. This work offers a simple strategy to design new titanium alloys for LPBF with significantly improved ductility and isotropy.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Process and feedstock driven microstructure for laser powder bed fusion of 316L stainless steel

Here in the pursuit of improving additively manufactured (AM) component quality and reliability, fine-tuning critical process parameters such as laser power and scan speed is a great first step toward limiting defect formation and optimizing the microstructure. However, the synergistic effects between these process parameters, layer thickness, and feedstock attributes (e.g. powder size distribution) on part characteristics such as microstructure, density, hardness, and surface roughness are not as well-studied. In this work, we investigate 316L stainless steel density cubes built via laser powder bed fusion (L-PBF), emphasizing the significant microstructural changes that occur due to altering the volumetric energy density (VED) via laser power, scan speed, and layer thickness changes, coupled with different starting powder size distributions. This study demonstrates that there is not one ideal process set and powder size distribution for each machine. Instead, there are several combinations or feedstock/process parameter ‘recipes’ to achieve similar goals. This study also establishes that for equivalent VEDs, changing powder size can significantly alter part density, GND density, and hardness. Through proper parameter and feedstock control, part attributes such as density, grain size, texture, dislocation density, hardness, and surface roughness can be customized, thereby creating multiple high-performance regions in the AM process space.

316L stainless steel↗