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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 OSTI2021

Nondiffractive beam shaping for enhanced optothermal control in metal additive manufacturing

High thermal gradients and complex melt pool instabilities involved in powder bed fusion–based metal additive manufacturing using focused Gaussian-shaped beams often lead to high porosity, poor morphological quality, and degraded mechanical performance. We show here that Bessel beams offer unprecedented control over the spatiotemporal evolution of the melt pool in stainless steel (SS 316L) in comparison to Gaussian beams. Notably, the nondiffractive nature of Bessel beams enables greater tolerance for focal plane positioning during 3D printing. We also demonstrate that Bessel beams significantly reduce the propensity for keyhole formation across a broad scan parameter space. High-speed imaging of the melt pool evolution and solidification dynamics reveals a unique mechanism where Bessel beams stabilize the melt pool turbulence and increase the time for melt pool solidification, owing to reduced thermal gradients. Consequently, we observe a distinctively improved combination of high density, reduced surface roughness, and robust tensile properties in 3D-printed test structures.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Decoupling the capacity fade contributions in polymer electrolyte-based high-voltage solid-state batteries

Polymer electrolyte (PE)-based solid-state batteries (PE-SSBs) made with high-voltage cathodes are known to suffer from severe capacity fade, stemming primarily from the poor oxidative stability of most PEs under high-voltage cycling conditions. PEs also suffer from greater ion-transport limitations compared to liquid or solid electrolytes. However, often, these limitations are collectively stated to be responsible for the observed capacity fade, and it is challenging to decouple the contributions of different factors. Herein, a tunable cell fabrication platform was developed to systematically investigate and decouple the two primary capacity fade drivers (cell impedance growth and kinetic limitations), while keeping the other cell parameters constant. Three PE types with distinct transport characteristics were compared. By utilizing a voltage profile analysis method, the contribution of the cell's internal impedance growth was quantitatively decoupled from the kinetic limitations stemming from the high concentration gradient in the polymer catholyte and slow charge transfer reactions. We demonstrate that the high interfacial impedance did not necessarily correlate with the high capacity fade rate. Kinetic limitations that are not reflected by impedance measurements can play a dominant role in causing cumulative capacity decay.

Ock, Ji-young [Oak Ridge National Laboratory (ORNL↗
DOE OSTI2026

Correlating Surface Processing of Nb Superconducting RF Cavities with the Evolution of Surface Electronic States

Superconducting-radio frequency (RF) cavities provide an efficient way to accelerate particle beams with extremely high acceleration gradients while generating very small power dissipation. The few nanometers of the surface play a critical role in defining the RF performance of superconducting Nb based cavities. Over the past two decades, several pioneering surface treatment and processing methods have emerged, enabling remarkable improvements in superconducting cavity performance by simultaneously achieving high quality factors with increasing maximum acceleration gradients. These processing approaches include chemical polishing, distinct multi-step thermal treatments under ultra-high vacuum (UHV) conditions over low to high temperature regimes, as well as high-temperature treatments under controlled nitrogen atmospheres. Beyond their macroscopic impact on RF performance, these methods produce distinct surface oxide configurations characterized by different valence states, oxide thicknesses, chemical uniformity, and oxygen concentration profiles extending into the near-surface bulk of niobium. In this work, we are trying to understand how the surface-processing methods and the resulting oxide/oxygen profiles affect the electronic structure of surface and the mechanism of superconductivity. Using a combination of X-ray photoemission and X-ray absorption spectroscopies, we investigate how the valence-band structure and the electronic density of states (DoS) near the Fermi level evolve under different surface treatments. By employing tunable photon energies across multiple elemental absorption edges, we use resonant photoemission to disentangle and identify the elemental contributions to specific valence-band features. Our observations show that different surface-processing methods lead to distinct temperature evolutions of the DoS and valence-band states near the Fermi level. Our results suggest variations in different Nb-O orbital hybridizations in distinct processes and point towards the possibility of different underlying mechanisms of superconductivity governed by surface chemistry and oxide configuration. We also correlate these distinct superconducting mechanisms with RF cavity performance, specifically focusing on measured surface resistance, the nature of the Q-slope, and quench fields observed in superconducting RF measurements. These results will enable us to identify the potential limiting factors and relevant controllable parameters that can be further optimized to improve the performance of superconducting RF cavities.

Tripathi, Malvika [Fermilab] (ORCID:00000001989251↗
DOE OSTI2021

High Efficiency Uniform Wakefield Acceleration of a Positron Beam Using Stable Asymmetric Mode in a Hollow Channel Plasma

Plasma wakefield acceleration in the blowout regime is particularly promising for high-energy acceleration of electron beams because of its potential to simultaneously provide large acceleration gradients and high energy transfer efficiency while maintaining excellent beam quality. However, no equivalent regime for positron acceleration in plasma wakes has been discovered to date. We show that after a short propagation distance, an asymmetric electron beam drives a stable wakefield in a hollow plasma channel that can be both accelerating and focusing for a positron beam. A high charge positron bunch placed at a suitable distance behind the drive bunch can beam-load or flatten the longitudinal wakefield and enhance the transverse focusing force, leading to high efficiency and narrow energy spread acceleration of the positrons. Three-dimensional quasistatic particle-in-cell simulations show that an over 30% energy extraction efficiency from the wake to the positrons and a 1% level energy spread can be simultaneously obtained. Further optimization is feasible.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Machine Learning for Well Log Analysis in Uranium Mining

This project explores the use of Artificial Intelligence (AI) and Machine Learning (ML) techniques to automate well log analysis for uranium mining. Geophysical log data—spontaneous potential, resistivity, and gamma ray—were used to classify lithology, correlate well logs and identify roll front zonation patterns, which are critical for locating uranium ore bodies. Supervised ML algorithms such as eXtreme Gradient Boosting (XGBoost), Categorical Boosting (CatBoost), and Random Forest were trained to classify lithology with high accuracy. Gradient Boosting Machines (GBM), XGBoost, Random Forest, and Neural Networks were also used for role front zone identification. Moreover, a Fast Dynamic Time Warping (FastDTW) algorithm was employed for well log correlation. Additionally, sample lag was addressed using dynamic programming. Results demonstrate the potential of AI and ML to streamline well log analysis and enhance uranium exploration workflows.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Si-Cr-Al-Mn Alloy for High Specific Resistivity

Laboratory material produced in budget period one met the target resistivity, mechanical and magnetic requirements for the Go/No-Go decision to move to industrial trials. The chosen chemistry settled on a high Cr strategy, with moderate Mn and Al additions, providing a good comprise on core loss and induction with minimal impact on mechanical properties, important to successful downstream processing. Industrial trials began in budget period two with the chosen chemistry, referred to as Alloy X. Difficulties occurred during initial hot rolling trials. Reheating the material using the standard NOES practice caused slab cracking from high thermal gradients in areas exposed to the roof burners, this was solved using a modified reheat practice. High Cr caused poor dynamic recrystallization during hot rolling, which was solved using a modified hot rolling practice. The high Cr content of the steel also caused poor decarburization during final annealing, which necessitated lowering the melt carbon aim for the final heat, together with a modified decarburization practice. Steel was finished to final thicknesses of 0.20 – 0.50 mm and evaluated for magnetic and mechanical properties. Although the target core loss for the 0.25 and 0.35 mm material was not achieved, significant reductions in high frequency core loss were measured, compared to equivalent commercially available material. Alloy X at 0.35 mm showed a 26 % and 23 % improvement at 400 HZ and 1000 Hz respectively, over Cliffs’ M-19 (0.35 mm) commercially available NOES. At 0.25 mm, Alloy X showed a 23 % and a 26 % improvement at 400 HZ and 1000 Hz respectively, over Cliffs’ HF-10 (0.25 mm) commercially available NOES. The 0.25 mm product was chosen for motor efficiency evaluation. ORNL collaborated with Cleveland-Cliffs (CC) to build, assemble, and test two 5HP motors: a baseline motor with M19 steel and a motor made with high efficiency steel (Alloy X) developed for the project. Overall, results were as expected with comparable performance at low speeds, and with more than 8% efficiency improvement for high speeds. Increased motor steel efficiency at high frequencies not only results in direct efficiency improvements but can yield reductions in motor size and cost by facilitating higher operation speeds, or by increasing the number of poles in the machine. This allows the production of more power-dense motors which are sometimes avoided with conventional material due to increased core losses. The material developed on this project provides more viable options for achieving improved motor efficiency or reduced motor size and cost.

36 MATERIALS SCIENCE↗
DOE OSTI2022

On possibility of low-emittance high-energy muon source based on plasma wakefield acceleration

We report plasma wakefield acceleration (PWA) channels are characterized by very high accelerating gradients and very strong focusing fields. We propose to employ these properties for effective production of low emittance high energy muon beams, consider muon beam dynamics in the PWFA cell and analyze various options and potential of the PWA-based muon sources.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Enhancing water and oxygen transport through electrode engineering for AEM water electrolyzers

Anion-exchange membrane water electrolyzers (AEMWEs) can accelerate the deployment of more efficient and affordable hydrogen production solutions. Here, electrode structure is shown to affect water back-diffusion and oxygen transport, which, in return, governs overpotential behaviors in AEMWEs. Measurements indicate that electrode with copious catalytic sites produces water close to the AEM, creating a higher water gradient and driving water back-diffusion, which improves membrane hydration and mass transport. In situ measurement reveals a high pH gradient near the anode surface, which affects anode kinetics. Operando measurement shows reduced oxygen accumulation when decoupling oxygen production and transport on anode. Catalyst ink rheology and stability are tuned with additives to realize scalable fabrication of electrodes with enhanced transport features, allowing AEMWE to operate at 2 A cm−2 for over 1,000+ h at a 2.3 μV h−1 degradation rate. Analysis during and post-durability provides insights into degradation mechanisms. This work demonstrates an electrode design strategy for efficient and durable AEMWEs.

AEM↗
DOE OSTI2022

Thermoacoustic Soret separation

In a fluid mixture in a channel with an axial time-averaged temperature gradient, high-amplitude oscillating flow can greatly increase the axial flux of thermal diffusion (Soret) separation of the components of the mixture. The enhancement occurs when the oscillating lateral temperature gradient greatly exceeds the axial gradient, causing a large oscillating concentration that can be favorably time-phased with the oscillating flow. This process can occur even with a negligible pressure oscillation or with a negligible temperature response to pressure, as is the case in most liquid solutions. The thermal boundary condition imposed by realistic solids on thermoacoustic liquids is imperfect, adding mathematical complications that are absent for typical gases, for which the solid surface is temporally isothermal. Compared with gas mixtures, the high Lewis number in typical liquid solutions reduces the separation flux associated with the time-averaged temperature gradient, but it also reduces the remixing associated with the time-averaged mole-fraction gradient. For large enough channels, the second-law separation efficiency is only slightly reduced from that of steady liquid Soret separation.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Mo-100 Disk Structural Integrity Tests I

The NorthStar pressed and sintered 29 mm diameter, 0.5 mm thick Mo-100 disks will be subjected to large temperature gradients when in beam during production. The beam preferentially heats the disk center, while the aggressive cooling by the helium keeps areas outside the beam spot relatively cool. The result is a temperature gradient of up to 900°C over the radial distance of 14.5 mm. To test the disk integrity with this high temperature gradient, a special holder for a single disk was made such that proper cooling can be applied as in the design target and the disk heating can be replicated with induction heating. NorthStar press and sintered disks were used for these tests.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Dual‐Gradient Construction on Li‐Rich Cathodes for High Stability Lithium Battery

Abstract The practical applications of high‐energy Li‐rich layered oxides (LLOs) have been hindered by the severe performance degradation including voltage decay and capacity fading. The gradient construction toward high‐activity interior and high‐stability exterior, typically realized by gradually changed transition metal (TM) gradient in LLOs, can alleviate the performance degradation to certain degrees. In this study, a gradient design of Al/Mg dopants is demonstrated for the TM‐gradient LLOs to further harmonize the high‐activity interior and high‐stability exterior, thereby forming the dual (TM and doping) gradient. As a result, superior capacity retention of 86% and a minor voltage decay of 0.54 mV cycle −1 are achieved at 1 C after 300 cycles. The improved electrochemical stability of the dual‐gradient LLO is attributed to the enhanced surface stability and suppressed bulk structure degeneration of LLOs upon electrochemical cycling. The dual‐gradient design serves as an important approach to fabricate high‐performance bulk LLOs toward applications.

Wu, Tianhao↗
DOE OSTI2020

DPM: A deep learning PDE augmentation method with application to large-eddy simulation

A framework is introduced that leverages known physics to reduce overfitting in machine learning for scientific applications. The partial differential equation (PDE) that expresses the physics is augmented with a neural network that uses available data to learn a description of the corresponding unknown or unrepresented physics. Training within this combined system corrects for missing, unknown, or erroneously represented physics, including discretization errors associated with the PDE's numerical solution. For optimization of the network within the PDE, an adjoint PDE is solved to provide high-dimensional gradients, and a stochastic adjoint method (SAM) further accelerates training. Additionally, the approach is demonstrated for large-eddy simulation (LES) of turbulence. High-fidelity direct numerical simulations (DNS) of decaying isotropic turbulence provide the training data used to learn sub-filter-scale closures for the filtered Navier–Stokes equations. Out-of-sample comparisons show that the deep learning PDE method outperforms widely-used models, even for filter sizes so large that they become qualitatively incorrect. It also significantly outperforms the same neural network when a priori trained based on simple data mismatch, not accounting for the full PDE. Measures of discretization errors, which are well-known to be consequential in LES, point to the importance of the unified training formulation's design, which without modification corrects for them. For comparable accuracy, simulation runtime is significantly reduced. A relaxation of the typical discrete enforcement of the divergence-free constraint in the solver is also successful, instead allowing the DPM to approximately enforce incompressibility physics. Since the training loss function is not restricted to correspond directly to the closure to be learned, training can incorporate diverse data, including experimental data.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2021

Analytical gradients for molecular-orbital-based machine learning

We report molecular-orbital-based machine learning (MOB-ML) enables the prediction of accurate correlation energies at the cost of obtaining molecular orbitals. Here, we present the derivation, implementation, and numerical demonstration of MOB-ML analytical nuclear gradients, which are formulated in a general Lagrangian framework to enforce orthogonality, localization, and Brillouin constraints on the molecular orbitals. The MOB-ML gradient framework is general with respect to the regression technique (e.g., Gaussian process regression or neural networks) and the MOB feature design. We show that MOB-ML gradients are highly accurate compared to other ML methods on the ISO17 dataset while only being trained on energies for hundreds of molecules compared to energies and gradients for hundreds of thousands of molecules for the other ML methods. The MOB-ML gradients are also shown to yield accurate optimized structures at a computational cost for the gradient evaluation that is comparable to a density-corrected density functional theory calculation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

History of gradient advances in SRF

Radio frequency (RF) superconductivity has become a key technology for many modern particle accelerators. One of its most salient features of this technology is the ability of superconducting RF cavities to deliver high accelerating gradients in continuous-wave and long-pulse modes of operation. However, reaching the current state of the technology was not an easy fit. Over many years scientists and engineers had to overcome several serous performance limitations. In this paper, I attempt to the best of my knowledge to trace the history of accelerating gradients evolution in the field of superconducting radio frequency. I will restrict the scope to primary innovations along with some of the ensuing developments in developing cavities made of bulk niobium. But I will not cover all the many applications and findings over the subsequent decades of progress that were based on the primary discoveries and inventions. I will also not cover a number of other important topics in the history of cavity developments, such as the drive for higher Q values, or the push for lower cavity costs via Nb/Cu cavities or large grain Nb cavities.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

High flux boiling heat transfer enhancement using triangle shaped vertical walls in two-phase microchannel heat exchangers

Two-phase heat exchangers allow heat loads to be dissipated with lower fluid flow rates without inducing thermal gradients, and high surface area microchannels further reduce the thermal resistance of these heat exchangers. However, there are many practical limits that prevent widespread use of two-phase microchannel heat exchangers. Many authors have looked to address these practical limits by treating the channel floors or creating artificial nucleation sites. Few works look to enhance heat transfer in the walls of channels with hydraulic diameters below 200 μm. This work is aimed at increasing the efficacy of high aspect ratio silicon microchannels that use R134a as the working fluid. The 125 parallel channels are 40 μm wide, 200 μm deep, and 2 mm long and contain a 15 μm wide, 150 μm long restriction at each inlet. The thermal resistance and dryout characteristics of traditional, plain-walled channels are compared to channels with 2 area enhancement patterns each of which increases the area available for heat transfer by 41%. Furthermore, a resistance to dryout is seen in both area-enhanced test sections, and a 15.5% reduction in thermal resistance is shown for the area-enhanced part with a 6 μm triangular pitch. Only a 7.8% performance increase is seen in the test section with a 3 μm pitch. Both area enhancement patterns induce an average 27% increase in pressure drop for all tests. Heat transfer characteristics are solved for using a finite element analysis (FEA) model. By examining heat transfer coefficients and local heat fluxes, it is postulated that the area enhancement reduces heat transfer coefficients and the performance increase is caused by increasing the number of active nucleation sites.

42 ENGINEERING↗
DOE OSTI2020

High-Brightness Continuous-Wave Electron Beams from Superconducting Radio-Frequency Photoemission Gun

Continuous-wave photoinjectors operating at high accelerating gradients promise to revolutionize many areas of science and applications. They can establish the basis for a new generation of monochromatic x-ray free electron lasers, high-brightness hadron beams, or a new generation of microchip production. In this Letter we report on the record-performing superconducting rf electron gun with CsK 2 Sb photocathode. The gun is generating high charge electron bunches (up to 10 nC / bunch ) and low transverse emittances, while operating for months with a single photocathode. As such, this achievement opens a new era in generating high-power beams with a very high average brightness.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Dynamic realization of emergent high-dimensional optical vortices

The dimensionality of vortical structures has recently been extended beyond two dimensions, providing additional topological complexity and robustness for high-capacity information processing and turbulence control. The generation of high-dimensional vortical structures has mostly been demonstrated in classical systems through the complex interference of fluidic, acoustic, or electromagnetic waves. However, natural materials rarely support three- or higher-dimensional vortical structures and their physical interactions. Here, we experimentally demonstrate a high-dimensional gradient thickness optical cavity (GTOC) in which the optical coupling of planar metal-dielectric multilayers implements topological interactions across multiple dimensions. At non-trivial topological phases, high-dimensional GTOC induces high-dimensional vortical structures in generalized parameter space in three, four dimensions, and beyond. These emergent high-dimensional vortical structures are observed under electro-optic tomography as optical vortex dynamics in two-dimensional real-space, employing the optical thicknesses of dielectric layers as synthetic dimensions. Our findings hold significant promise for emulating high-dimensional physics and developing active topological photonic devices.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Shock wave formation from head-on collision of two subsonic vortex rings

Vortex ring collisions have attracted intense interest in both water and air studies (Baird in Proc R Soc Lond Ser Math Phys Sci 409:59–65, 1987, Poudel et al. in Phys Fluids 33:096105, 2021, Lim and Nickels in Nature 357:225, 1992, New et al. in Exp Fluids 57:109, 2016, Suzuki et al. in Geophys Res Lett 34, 2007, Yan et al. in J Fluids Eng 140:054502, 2018, New et al. in J Fluid Mech 899, 2020, Cheng et al. in Phys Fluids 31:067107, 2019, Hernández and Reyes in 29:103604, 2017, Mishra et al. in Phys Rev Fluids, 2021, Zednikova et al. in Chem Eng Technol 42:843–850, 2019, Kwon et al. in Nature 600:64–69, 2021). These toroidal structures spin around a central axis and travel in the original direction of impulse while spinning around the core until inertial forces become predominant causing the vortex flow to spontaneously decay to turbulence (Vortex Rings, https://projects.iq.harvard.edu/smrlab/vortex-rings). Previous studies have shown the collision of subsonic vortex rings resulting in reconnected vortex rings, but the production of a shock wave from the collision has not been demonstrated visibly (Lim and Nickels in Nature 357:225, 1992, Cheng et al. in Phys Fluids 31:067107, 2019). Here we present the formation of a shock wave due to the collision of explosively formed subsonic vortex rings. As the vortex rings travel at Mach 0.66 toward the collision point, they begin to trap high pressure air between them. Upon collision, high pressure air was imploded and released radially away from the axis of the collision, generating a visible shock wave traveling through and away from the colliding vortices at Mach 1.22. Our results demonstrate a pressure gradient with high pressure release creating a shock wave. We anticipate our study to be a starting point for more explosively formed vortex collisions. For example, explosives with different velocities of detonation could be tested to produce vortex rings of varying velocities.

42 ENGINEERING↗