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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Robust Data-Driven Predictive Run-to-Run Control for Automated Serial Sectioning

This letter presents a one-step predictive run-to-run controller (R2R-MPC) for the automation of mechanical serial sectioning (MSS), a destructive material analysis process. To address the inherent uncertainty and disturbances in the MSS process, a robust closed-loop approach is presented. Here, the robust R2R-MPC models the uncertainty of the MSS process using a linear differential inclusion. As an analytical model of the MSS process is unavailable, the differential inclusion is identified from historical data. The R2R-MPC is posed as an optimization problem that computes incremental changes to the control input which minimize the worst-case material removal errors. This optimization-based controller is combined with a run-to-run controller to provide integral action that rejects constant disturbances and tracks constant reference removal rates. To demonstrate the efficacy of our robust R2R-MPC, we present simulation results which compare the presented controller with a conventional non-robust R2R.

42 ENGINEERING↗
DOE OSTI2024

Final Technical Report - Rapid Surface Microanalysis using a Low Temperature Plasma

This project focused on improving our current understanding and scientific knowledge in the area of plasma-surface interactions and plasma assisted material synthesis related to advanced microelectronics and nanotechnology. Current challenges include: controlling the interaction of Low Temperature Plasma (LTP) with a single layer of atoms to manufacture integrated circuits, continued miniaturization of integrated circuits, LTP processing of material surfaces and thin films to enable industrial scale fabrication of advanced microelectronics, synthesis of new materials, nanomaterials, nanotubes, and complex materials, Technology developed in this subtopic is of value to either (i) enable scans of surfaces (~1 sq. cm area) using various microscopies (electron, optical, other) at high resolution (micron or sub-micron resolution) rapidly (hours or days rather than years to complete a high-resolution scan of such a large surface area), or (ii) enable scans of surfaces (~1 sq. cm area) using various microscopies (electron, optical, other) at relatively low resolution rapidly, then apply algorithms to select spots for micron-scale imaging. Sputtering occurs when particles of a solid material are ejected from its surface by energetic particles from a plasma. While the degradation of the solid material and the subsequent deposition of the ejected material onto vulnerable surfaces are the usual subjects of sputtering studies, plasma science has yet to be combined with sputtering to create new diagnostics devices and systems. Small changes in the design of the plasma discharge device make it possible to create broad plasma beams for rapid scanning or small plasma beams to obtain the distribution of ejected elements with micron resolution. In the high-resolution use, the ion flux is extracted from the gas-discharge plasma and focused by a spherical emission surface to micron sizes onto the target specimen, providing very local sputtering and local elemental analysis. We call this “self-focusing”. The radiation from the excited and ionized sputtered atoms is recorded by a spectrometer through a window and fiberglass cable and analyzed with standard software packages used for optical glow discharge spectroscopy. Computer simulations of beam formation were used to verify and optimize the designs to be tested. A prototype was designed, constructed, and used to start experiments of beam formation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Effect of Heat Treatment on Microstructure and Mechanical Property of 316L Stainless Steel Produced by Laser Powder Bed Fusion

The advanced non-light water reactor designs (Gen IV reactors), including molten salt/ very high temperature/ sodium-cooled and lead-cooled fast reactors, typically operate at higher temperatures and more extreme radiation conditions than light water reactors. An intrinsic part of the deployment and progress of Gen IV reactor designs is selecting the most suitable structural material for a specific application. Additive manufacturing (AM), a fairly new process of making physical, three-dimensional objects from a computer design file, is going to completely change the way of design, build and certify nuclear systems. It offers a range of opportunities to produce complex geometries from existing materials, offers new routes for processing of previously difficult to process materials, allows for design of new high-performance materials, and finally facilitates hybridization of dissimilar materials. This emerging technology has successfully produced cars, wind turbine blade molds and even live cells. It could also open up big opportunities for the nuclear industry to quickly deploy technologies at a fraction of the cost. So far, AM techniques have been preliminarily applied in the field of nuclear reactors, including the classical parts such as the pressure vessel of a small reactor with 508-III steel, the bottom nozzle of a fuel assembly with 304L steel, the fuel cladding with zirconium alloy and the integrated impeller of a pump and the multi-channel valve body with 316L steel [6,7]. The AM applications for operating nuclear reactors started in auxiliary plant components and have slowly migrated to metallic reactors and core components, but many of these are not safety critical components. Although many parts used for nuclear reactors have been fabricated by AM techniques, practical applications in engineering are still a long way off due to the uncertainty factors focused on the processing, material properties, analysis methods and application standards, which feeds the safety and life-cycle of the nuclear reactor. Due to rapid, repeated heating and cooling during production, a high dislocation density was present in the AM material. This microstructure feature is unstable at elevated temperature while high temperature is one of the typical operation environments for nuclear reactors. Thus, it is important to understand the thermal effect on the microstructure of AM material. The objectives of this study are to investigate the effect of heat treatment on the microstructure and mechanical properties of 316L stainless steel produced by laser powder bed fusion additive manufacturing, and to determine an appropriate heat treatment practice that will be applied to the lightweight AM lattice-structured material with the same chemistry. The heat treatment study consisted of annealing the samples at a temperature range of 800 to 1200 oC with a 50 oC increment for different times (1-24 hours), followed by vacuum or air cooling. Microstructural characterization was carried out by Scanning Electron Microscope (SEM). Grain size and crystallographic orientation were investigated by Electron Backscatter Diffraction (EBSD). Vickers hardness tests with a 0.5 kg load were employed to determine the hardness of samples after different heat treatments. After heat treatment, the random crystallographic orientation was preserved, and the volume fraction of high-angle grain boundaries (grain boundary misorientation =15 oC) remained the same. The dislocation density decreased with annealing temperature due to recovery. The fine subgrain structures in the as-printed specimen were quite stable up to 1200 oC. Minimal recrystallization was observed up to 1200 oC. Recrystallization initiated only after 8.5 hours at 1200 oC. The SEM images did not show obvious dependence of microstructure on cooling rate. The hardness of the specimens decreased with increasing annealing temperature as a result of the decrease in dislocation density. It is interesting to note that the AM material showed very similar hardness to the wrought material when annealing at similar temperature, although the microstructures are very different. Annealing at 1050 oC for 1 hour followed by air cooling was selected as the heat treatment procedure for the lattice designed lightweight AM 316L material.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Nitridation of atomically smooth (111) diamond surfaces using a low temperature Penning plasma discharge

Diamond is a material with a wide band gap that can host a variety of isolated paramagnetic defects, called “color centers”1. These color centers have attractive optical and magnetic properties suitable for quantum applications including quantum computing, nanophotonics and quantum sensing. The most common one is the negatively charged nitrogen vacancy (NV) color center. For quantum sensing, it is desirable to reduce the distance between the NV center and the analyte by using shallow color centers in order to increase sensitivity. In this context, the diamond surface termination is especially critical. The appropriate surface termination is required to stabilize the color centers and mitigate surface magnetic noise. The nitrogen termination of diamond has been postulated as highly desirable for the NV color center. The goal of this project is to take advantage of an electron beam-generated ExB low temperature plasma developed by the Princeton Collaborative Low Temperature Plasma Research Facility (PCRF) at the Princeton Plasma Physics Laboratory (PPPL) to nitridate the surface of (100) diamond single crystals with minimal surface damage. In this reactor, the use of a magnetized plasma enables gentle processing of materials sensitive to ion damage. This is in strong contrast to radiofrequency plasma processing reactors which are known to etch and sputter the surface. XPS measurements indicate the incorporation of nitrogen and oxygen atoms at the surface in similar amounts. XAS measurements confirm the nitridation and indicate that the nitrogen termination is different from the nitrogen termination obtained using radiofrequency plasma treatment4. The combination of these results indicates the formation of amid species at the (100) diamond surface that are promising for the stabilization of NV centers for quantum sensing.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Critical statistical assessment of data in metal additive manufacturing

Obtaining high quality data reflecting the relationships between the additive manufacturing (AM) process parameters, material microstructure and mechanical properties is crucial for the use of machine learning in AM. A database of over 4,000 data entries of metal AM was created thanks to a large number of literature studies on key process parameters and indicators of build quality. Meta-analysis reveals critical biases in the literature. Firstly, majority of studies report only high quality builds, these imbalances in reporting result in weak correlation between process parameters, properties and consolidation, limiting the ability of machine learning models to generalize beyond optimized conditions. Nevertheless, the trained models accurately predict yield strength ($R^2 = 0.85$), suggesting that certain process–property relationships are effectively captured within these models. Secondly, quantitative microstructural data are largely absent, limiting the learning of the microstructure-mechanical properties relationships. Finally, current process window identification is based largely on the consolidation, despite significant uncertainty in its measurement. It is important to identify the process map on the basis of not only the consolidation, but also mechanical behaviour under loading. Such a identification shows that 316 L and Inconel have much larger process map (i.e. highly printable) in comparison to the AlSi10Mg and Ti6Al4V.

Additive manufacturing↗
DOE OSTI2025

Adsorptive denitrogenation of model aviation fuel using mesoporous silica in a packed bed adsorption system

This study aims to understand the effects of system process parameters such as flow rate, adsorbent particle size, and use of recycled adsorbent on denitrogenation performance of a model fuel using mesoporous silica gel. The goal is to reduce the nitrogen content of the model fuel from 1500 parts per million to single-digit ppm to meet ASTM specifications for drop-in fuels. This work was done with the intent of applying adsorptive denitrogenation to sustainable aviation fuel (SAF) product fractions produced via hydrothermal liquefaction (HTL). The adsorption performance of the silica is evaluated via packed column breakthrough data, with data generated from collecting from the column outlet and quantifying nitrogen content via gas chromatography. Select experiments use a significantly larger (2.5x column diameter and length) column to demonstrate linear scalability of the process. Thermogravimetric analysis data is collected to evaluate the effects of thermal calcination as a sorbent regeneration method. Effects of a more complex feed are also investigated using a known reference fuel with additional added nitrogen containing compounds. The results presented in this work successfully demonstrate up to 99.8 % removal of NCCs from a model fuel fraction at an original NCC concentration of approximately 1500 ppm to single-digit parts per million after treatment. We also examine calcination of sorbent materials to remove the adsorbed species to enable sorbent reuse and minimize waste generation and show that the calcined material can be reused up to 5 cycles with reduced adsorption capacity. Overall, this work indicates that adsorptive denitrogenation using silica gel is a viable solution to enable the integration of HTL-derived aviation fuels into existing fuel infrastructure.

Adsorption techniques↗
DOE OSTI2025

Scale-Up of Novel Li-Conducting Halide Solid State Battery Electrolyte

LBNL and project partner Saint Gobain (SG) demonstrated scalable processing of halide-based solid state batteries. SG’s innovative halide-based SSE utilized in this project is inherently scalable: it can be compressed into a dense electrolyte sheet at room temperature under moderate pressure, can be processed in dry air, and does not present any safety issues during processing or end use. The halide material forms the dense electrolyte layer, and is dispersed in the thick cathode to form a highly conductive path for Li ions. The halide also comes in contact with various environments and other materials (solvents, binders, processing equipment, etc.) throughout the battery manufacturing process, and must be stable in contact with cathode and anode materials during operation.

25 ENERGY STORAGE↗
DOE OSTI2026

Semi-Transparent Perovskite Solar Cells in a Stacked Tandem Module: Cooperative Research and Development Final Report, CRADA Number CRD-19-00810

This project seeks to develop device design, materials composition, and processing tools and parameters to fabricate semi-transparent perovskite solar cells and modules for application in stand-alone products or added to other solar cells in a mechanically stacked tandem configuration. This technology presents significant advanced manufacturing challenges and opportunities in getting to scale, including development of perovskite inks, scalable perovskite and heterojunction deposition and annealing processes, heterojunction composition, transparent electrode composition and deposition process, anti-reflection layer composition and deposition process, and cell to module integration processes. Modification 5: The proposed project seeks to develop device design, materials composition, and processing tools and parameters to fabricate semi-transparent perovskite solar cells and modules for application in stand-alone products or added to other solar cells in a mechanically-stacked tandem configuration. This technology presents significant advanced manufacturing challenges and opportunities in getting to scale, including development of perovskite inks, scalable perovskite and heterojunction deposition and annealing processes, heterojunction composition, transparent electrode composition and deposition process, passivation layers including in module scribes, anti-reflection layer composition and deposition process, and cell to module integration processes. Advanced metrology and characterization will be performed on perovskite films, cells and module. Furthermore, we will examine module or materials recycling for circular economy considerations. Modifcation 6: Gigahertz frequency microwave pump-probe spectroscopies are highly sensitive to thin film semiconductor photoconductivity of individual and stacks of layers that comprise perovskite solar cells. As such, these techniques will be used to qualify reproducibility and quality correlations during the manufacturing process. Modification 7: Mechanical adhesion of top contacts within perovskite modules significantly impacts the durability of the module when exposed to accelerated degradation testing. The adhesion between the perovskite/transport layer interface and the transport layer/top contact interface are both very sensitive small changes in processing. ALD processing conditions of the transport layer will be tuned to optimize the mechanical adhesion within the perovskite module stack.

14 SOLAR ENERGY↗
DOE OSTI2025

The Cost of Scaling Up in Large-Format Additive Manufacturing

Additive manufacturing (AM) of large objects has, over the last decade, required the scaling of existing material extrusion processes. The current generation of large-scale printers are primarily gantry robots with high-throughput extrusion systems. With workspaces approaching 50 m 3 , these printers have pushed the boundaries of achievable print volume while allowing the utilization of low-cost feedstocks, such as cementitious materials and polymer pellets, like those used in injection molding. Continued workspace expansion requires an examination of the inherent trade-offs, which impact capital and operational costs. Here, in this work, the authors examine these trade-offs to determine fundamental scaling laws for existing system architectures, survey the state of the art for alternative system configurations, and pose recommendations for future system designers to continue the evolution of large-scale AM systems.

3D printing↗
DOE OSTI2025

Volumetric Shaping of Nanoparticle-DNA Crystals by Light-Induced Milling

DNA-programmable self-assembly enables the formation of nanoparticle crystals with controlled lattice symmetry. While this approach offers the formation of complexly ordered nanostructures for optical, mechanical, and biological applications, a mesoscale control over such nanomaterials is limited. Directing the material formation process through the assembly pathway or external fields allows for modulating crystal morphology, but achieving arbitrary morphology remains challenging. Here, we present a photothermal method for shaping 3D DNA-programmable crystals of gold nanoparticles. Through local heating of nanoparticles due to plasmonic light absorption, we induce targeted volumetric dissolution of specifically defined crystal areas with micron-scale accuracy. This technique effectively prescribes crystal shaping and creates arbitrarily shaped voids within crystals. We further investigate both computationally and experimentally the key factors governing volumetric material subtraction. The developed automated light-milling platform enables the fabrication of nanomaterials exhibiting both DNA-programmable nanoscale order and custom-designed mesoscale architecture.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Recent Advances and Future Perspectives of Low-Concentration CO 2 Enrichment and Emerging Applications

Low-concentration carbon dioxide (LCCO 2 ) streams, ranging from ambient air to industrial flue gas, represent a significant yet underutilized carbon resource. This review examines recent advances in technologies for enriching LCCO 2 and enabling its integration into a wide range of applications. It covers emerging materials and processes for CO 2 capture, including immobilized amines, metal oxides, polymers, porous carbons, and zeolites, with a focus on performance metrics, regeneration strategies, and process intensification. Beyond capture, the review explores the direct utilization of LCCO 2 through reactive capture pathways enabled by novel catalysts and processes, as well as nonreactive applications, such as greenhouse cultivation, enhanced weathering, and sustainable agriculture. Additionally, this review highlights the role of LCCO 2 in enhancing critical metal recovery. Finally, the review outlines crucial future research directions necessary to fully realize LCCO 2 enrichment’s potential within circular carbon economies and critical material supply chains, paving the way toward a more energy-innovative and resource-resilient industrial sector. The findings are significant for researchers in academia, industry, and government, as well as the public interested in extending the value of LCCO 2 .

atmospheric chemistry↗
DOE OSTI2024

Compensating for Sintering Distortion in Additively Manufactured Shaped Charge Liners using Physics-Informed Machine Learning

Copper is a challenging material to process using laser-based additive manufacturing due to its high reflectivity and high thermal conductivity. Sintering-based processes can produce solid copper parts without the processing challenges and defects associated with laser melting; however, sintering can also cause distortion in copper parts, especially those with thin walls. In this study, we use physics-informed Gaussian process regression to predict and compensate for sintering distortion in thin-walled copper parts produced using a Markforged Metal X bound powder extrusion (BPE) additive manufacturing system. Through experimental characterization and computational simulation of copper’s viscoelastic sintering behavior, we can predict sintering deformation. We can then manufacture, simulate, and test parts with various compensation scaling factors to inform Gaussian process regression and predict a compensated as-printed (pre-sintered) part geometry that produces the desired final (post-sintered) part.

36 MATERIALS SCIENCE↗
DOE OSTI2024

A holistic platform for accelerating sorbent-based carbon capture

Abstract Reducing carbon dioxide (CO 2 ) emissions urgently requires the large-scale deployment of carbon-capture technologies. These technologies must separate CO 2 from various sources and deliver it to different sinks 1,2 . The quest for optimal solutions for specific source–sink pairs is a complex, multi-objective challenge involving multiple stakeholders and depends on social, economic and regional contexts. Currently, research follows a sequential approach: chemists focus on materials design 3 and engineers on optimizing processes 4,5 , which are then operated at a scale that impacts the economy and the environment. Assessing these impacts, such as the greenhouse gas emissions over the plant’s lifetime, is typically one of the final steps 6 . Here we introduce the PrISMa (Process-Informed design of tailor-made Sorbent Materials) platform, which integrates materials, process design, techno-economics and life-cycle assessment. We compare more than 60 case studies capturing CO 2 from various sources in 5 global regions using different technologies. The platform simultaneously informs various stakeholders about the cost-effectiveness of technologies, process configurations and locations, reveals the molecular characteristics of the top-performing sorbents, and provides insights on environmental impacts, co-benefits and trade-offs. By uniting stakeholders at an early research stage, PrISMa accelerates carbon-capture technology development during this critical period as we aim for a net-zero world.

Science & Technology - Other Topics↗
DOE OSTI2024

Laser-stimulated photodetachment of electrons from the negatively charged dielectric substrates

The photon-stimulated emission of bulk electrons has been extensively studied for various types of materials, while the photodetachment of surplus surface electrons has not been fully explored. The photodetachment barrier energy is commonly defined by the surface electron affinity of material, which is typically less than the work function and more pronounced for non-conducting substrates and in environments with a continuous flux of electrons to the surface, such as in gas discharge plasmas. Herein, it is experimentally shown that the photodetachment yield of surplus electrons created by plasma-induced charging of non-conductive surfaces of dielectric materials depends on the initial surface charge density and do not correlate with the tabulated affinity values of these materials under gas discharge charging conditions. In cocnclusion, this result obtained using laser-stimulated photodetachment for fused silica, boron nitride, and alumina, is critically important for the understanding of charging and discharging dynamics, secondary electron emission, and photo emission effects affecting plasma–wall interactions relevant to surface and capacitively coupled discharges, dusty plasmas, electrostatic probe diagnostics, and applications for plasma processing of materials, plasma propulsion, and gas breakdown.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Study of Helium Irradiation Effect on Al6061 Alloy Fabricated by Additive Friction Stir Deposition

Additive friction stir deposition (AFS-D) is considered a productive method of additive manufacturing (AM) due to its ability to produce dense mechanical parts at a faster deposition rate compared to other AM methods. Al6061 alloy finds extensive application in aerospace and nuclear engineering; nevertheless, exposure to radiation or high-energy particles over time tends to deteriorate their mechanical performance. However, the effect of radiation on the components manufactured using the AFS-D method is still unexamined. In this work, samples from the as-fabricated Al6061 alloy, by AFS-D, and the Al6061 feedstock rod were irradiated with He+ ions to 10 dpa at ambient temperature. The microstructural and mechanical changes induced by irradiation of He+ were examined using a scanning electron microscope (SEM), energy-dispersive X-ray spectroscopy (EDS), transmission electron microscopy (TEM), and nanoindentation. This study demonstrates that, at 10 dpa of irradiation damage, the feedstock Al6061 produced a bigger size of He bubbles than the AFS-D Al6061. Nanoindentation analysis revealed that both the feedstock Al6061 and AFS-D Al6061 samples have experienced radiation-induced hardening. These studies provide a valuable understanding of the microstructural and mechanical performance of AFS-D materials in radiation environments, offering essential data for the selection of materials and processing methods for potential application in aerospace and nuclear engineering.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Irradiation Testing of Additively Manufactured Materials for LWR Applications: Alloy 718 and 316L Stainless Steel

The objective of this NSUF Project is to assess the changes in irradiated additively manufactured (AM) material properties as compared to non-irradiated material. Type 316L stainless steel and Alloy 718 samples were produced using Direct Metal Laser Melting (DMLM) fabrication. Materials produced from this fabrication method have several potential applications within the nuclear industry as reactor internal repair parts, fuel debris resistant filters, or fuel spacers within existing light water reactors (LWRs). AM materials have been shown to achieve equivalent mechanical behavior in simulated reactor environments as compared to wrought materials, but have significantly more flexibility when it comes to unique design features. The increased component design flexibility makes these AM materials an attractive choice for both current LWR applications as well as for small modular reactor (SMR) designs. Prior to use of these materials in reactor fleet operation, the industry as a whole must evaluate the effects of irradiation on their material properties. Standard 0.4 inch thick Compact Tension specimens and SSJ3 type tensile bars were neutron irradiated at the Advanced Test Reactor to ~1 dpa for the purpose of performing a variety of mechanical tests in a range of simulated environments applicable to LWRs. For the ductile austenitic Type 316L stainless steel, the irradiated data will be used to confirm that the AM process produces materials with properties that are equivalent to wrought materials under testing conditions applicable to LWR operation. Transmission electron microscopy analysis was also performed in order to understand microstructural and microchemical changes induced in each material in response to neutron irradiation. If possible, data collected from these AM 316L samples will be used to remove fluence limits from specifications of ASME code cases for this alloy, which will give vendors much more flexibility in building future components.

36 - MATERIALS SCIENCE↗
DOE OSTI2025

Alloy 625 Qualification Pathway for ASME Section III Division 5 Class A construction

The American Society of Mechanical Engineers Boiler and Pressure Vessel Code Section III Division 5 provides construction and inspection rules to ensure the safety of nuclear components operating at elevated temperatures, defined as those operating above 700°F (370°C) or 800°F (425°C), depending on the material type. At present, there are six materials approved for Class A (high safety significance) component construction under ASME BPVC Section III Division 5. Out of these six materials, five materials are steels or iron-based alloys and one material, Alloy 617, is a nickel alloy. Nickel alloys are stronger than steels; however, Alloy 617 consists of 10-15% cobalt, and activation is a concern under irradiation. Therefore, there is a need to qualify new nickel alloy with lower cobalt content. Alloy 625 is one candidate which has similar mechanical properties at elevated temperature compared to Alloy 617 and has a maximum of 1% cobalt. Although Alloy 625 material properties have been developed in the past to support allowable stress development under ASME Section II, new test results would be needed to qualify this material for elevated temperature component construction under ASME Section III Division 5. The purpose of this report is to describe a path towards developing a Nuclear Code Case to qualify Alloy 625 (UNS N06625; Grade 1 and Grade 2) for elevated temperature nuclear use in accordance with the ASME BPVC rules. This report reviews the existing database on Alloy 625, presents proposed test campaign, and discusses potential paths for accelerating the accelerated material qualification process.

36 - MATERIALS SCIENCE↗
DOE OSTI2024

Materials Science of the Interstitial Doping Process

Particle accelerators are an increasingly important tool for frontier science. Growing initial and operating costs are a significant barrier for upgrades and for new machines. While everything matters, the major cost contributor is the SRF cavities and their ancillary facilities (e.g., cryoplant). Accordingly, the accelerator science community devotes much R&D effort to improving their energy efficiency (increased Q o ) and gradient (E acc ). While improved gradient is at the forefront for certain machines (ILC), improved quality factor has broader impact, benefitting all SRF applications. An important opportunity for accelerator science and technology to move forward arose in the course of building the LCLS-II, the second generation Linac Coherent Light Source at SLAC. At more or less the same time, researchers at Fermilab discovered that introducing a small amount of nitrogen to the niobium surface could improve the mid-range quality factor as much as three-fold. A firm resolution of how nitrogen confers its benefit attracts much current research interest. The key elements of the “nitrogen doping” process were vacuum bake at 800 °C, brief exposure to mTorr of nitrogen at several hundred degrees followed by electropolish (EP) to remove several microns from the surface to eliminate unwanted nitrides: While the process as a whole was novel, the comprising unit operations are familiar to the accelerator community. It was judged reasonable to adopt it as a cost-reduction technology for LCLS-II. Researchers carried out a program of varying process parameters and measuring performance in single-cell cavities, leading to a consensus stable protocol for the project. The transition to vendor fabrication and multiple niobium sources has presented unforeseen challenges of performance variation evidently not connected to anything that could be incorporated in a purchase specification. Moving beyond the high temperature N-doping process above, researchers reported a simplified process consisting entirely of tens of hours anneal in a N atmosphere at low temperatures (~120°C – 160°C) after 800 °C UHV bake. These processes typically yield a few-nm doped layer while the high temperature process yields at least a few to many micron doped layer. Even more recently, oxygen has been used to dope instead of nitrogen which leaves a few-µm O-alloyed layer upon vacuum annealing for 300 °C for ~3 hours. The investigation of these materials is just beginning, but the process simplification they may offer is surely attractive. The very low quantity of material that appears to be significant in the “infusion” process indicates the need for very careful control of gas species available for diffusion into the surface during low temperature treatment, both for process control and research to characterize the underlying dynamics. Oxygen alloying offers the further opportunity to utilize the decomposition of the surface native oxide as the dopant source. It is necessary to understand and (thus) manage this process. We have been supported by the Department of Energy Offices of High Energy Physics and Nuclear Physics to pursue this goal.

36 MATERIALS SCIENCE↗