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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Temperature Evolution of the Activation Barriers Leads to Meyer−Neldel Rules for Structural Relaxation and Transport in Polymers

Understanding activation barriers controlling structural relaxation in glass-forming liquids, molecular transport, and ionic conductivity in amorphous polymers is a grand challenge of fundamental scientific and materials engineering interest across disciplines. Over decades, intriguing but puzzling empirical correlations between the elementary time scale of activated barrier crossing and the apparent Arrhenius activation energy, the so-called Meyer−Neldel (MN) rules, have been discovered in diverse liquids and glasses. Here, in this study, we formulate and successfully apply a new experimental analysis and an explicitly dynamical theoretical framework which provides an understanding of the origin, validity, and failure of such correlations, that bridge and unify the three fields of structural relaxation, molecular transport, and ionic conductivity in liquids and quenched glasses. Distinct quasi-universal laws are predicted in equilibrated liquids and nonequilibrium glasses, consistent with experiments. Our analysis reveals that even if the relaxation appears Arrhenius over a limited temperature range, the physical activation barrier is generally temperature-dependent in polymeric systems even below glass transition temperature. In addition, we show that the approximate validity of classical MN rules hinges on a linear temperature dependence of this barrier and the temperature range probed in experiments. Our findings are relevant for controlling the activation barrier in functional soft polymeric materials relevant to molecular separations, barrier coatings, and charge transport, and also provide new constraints on the theoretical understanding of the mechanism underlying slow activated dynamics in glass-forming condensed matter.

Meyer-Neldel rules↗
DOE OSTI2025

Multilayer Architecture Barriers for High Temperature Nuclear Applications

Innovative thin film multilayer metal/ceramic barrier coatings have been developed by Argonne National Laboratory to protect fuel cladding against different phenomena that can be encountered under the harsh operating conditions of advanced nuclear reactors. One phenomenon is Fuel-Cladding Chemical Interaction (FCCI), which can represent a challenge to the performance of steel-clad metallic fuels in sodium-cooled fast reactors (SFRs), especially when operating to high burnups at elevated cladding temperatures, and long fuel residence time. Another phenomenon is the corrosion of zirconium-based cladding under prototypic boiling water reactor (BWR) conditions and associated cladding during off normal conditions, including loss of coolant accidents (LOCA). This work provides details of the development and testing of a thin film (few microns) multilayer metal/ceramic (CrY/Y 2 O 3 ) coatings on steel cladding and its performance against FCCI. The coating architecture evolved through systematic mechanical testing, radiation tolerance assessments, and high-temperature diffusion studies from a preliminary multilayer concept to an optimized high-performance design. The optimized structure leverages stoichiometric Y 2 O 3 for its exceptional radiation stability, chemical inertness, and ultra-low fission product diffusivity (e.g., Ce diffusivity ~10 -20 m 2 /s in irradiated Y 2 O 3 at 650 °C). This is paired with ductile chromium-rich interlayers (Cr 95 Y 5 ), which significantly enhance fracture toughness and mechanical resilience. Design refinements, including increased ceramic layer thickness and optimized Cr–Y interlayer composition, eliminated fracture propagation and preserved coating integrity under extreme mechanical stress (>10× typical reactor conditions) and prolonged radiation exposure (~300 dpa). Those conditions are well beyond expected conditions during normal operations in SFR, and cover some of the transient conditions as well. In addition, the coating deposition was demonstrated to be applied uniformly to the inner surface of steel tubes representing prototypic SFR cladding. Another phenomenon under consideration in this work is the corrosion of zirconium-based cladding under prototypic boiling water reactor (BWR) conditions and associated off normal conditions including loss of coolant accident (LOCA). Another multilayer thin film coating is considered for mitigation of this phenomenon, where a coating of yttrium aluminum and yttrium aluminum ceramic/metal thin film coating. Preliminary results on the coating performance during high temperature thermal cycling (up to 1000 C) have shown promising performance of the coating. On-going optimization of the coating will continue in FY26.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

Brownfields to Brightfields: A Sustainability Initiative at DOE'S East Tennessee Technology Park Cleanup - 16120

As DOE works toward completing their cleanup mission at the East Tennessee Technology Park (ETTP), the ultimate goal is to return property no longer needed for government use to the community for beneficial re-use. The vision for ETTP is to transform the former gaseous diffusion facility into a commercial industrial park, leveraging the site's infrastructure to attract businesses to the site. While hundreds of acres at ETTP have been transferred for re-use, areas within the former production footprint of the site have future use restricted due to the presence of residual contamination, underground structures and utilities and/or physical features that limit their reuse potential. Brownfield redevelopment with solar energy generation has proven to be an excellent option for beneficial reuse and sustainability thanks to the flexible nature of solar photovoltaic technology and design that can address the restrictions and limitations of the site. Developing a solar project on a cleanup site can be challenging due to a large number of stakeholders and regulatory compliance issues of the environmental legacy at DOE cleanup sites; however, the challenges can be offset by the available infrastructure and low cost property. The requirement for large amounts of land or surface area is a major constraint to the growth of photovoltaic solar systems. An average solar generating facility requires 2 or more hectares (5 acres) for each megawatt (MW) of power generated. Re-using land that is otherwise un-developable provides a cost effective site for renewable energy generation to innovative solar developers. At ETTP, DOE's Oak Ridge Office of Environmental Management and the community reuse organization (Community Reuse Organization of East Tennessee - CROET) supported a local small business (Restoration Services, Inc. - RSI) familiar with the site and environmental regulations to secure a power purchase agreement with the regional electric provider (Tennessee Valley Authority - TVA) for a 1 MW utility-scale photovoltaic solar facility. The solar facility, Powerhouse Six, was developed through a commercial partnership (RSI and Vis Solis, Inc.) that worked closely with the lead ETTP site cleanup contractor (URS-CH2M Oak Ridge LLC - UCOR) and the local government. The selected site at ETTP had limitations on subsurface disturbance to 10 feet below ground surface because of utility ducts and residual contamination. Near surface relics (facility foundation remnants) were also found to prohibit ground penetration. A photovoltaic solar design using a ballasted ground mount system was developed to conform to the restrictions. The ballasted system could follow existing land contours, eliminating the need for any extensive site preparation and avoiding the risk of ground penetration. The lead cleanup contractor's role in facilitating the completion of this project included making the necessary environmental assessment documentation available to obtain the construction notice to proceed from the regional electric provider. They accelerated the transfer of ETTP power lines and electric demand to the city electric department to accommodate connection to the electric grid and supplied the communication connection required for metering the electric power generation. DOE's support along with their cleanup contractor's re-industrialization program and power integration group provided regular communication with the project stakeholders for more than six months to facilitate the early transfer of the utility infrastructure. Powerhouse Six sustainability benefits: - Generates enough clean energy to power more than 100 homes or prevents pollution equivalent to removing 240 cars from the road annually (1,141 metric tons of carbon dioxide); - Provides Brownfield reuse/redevelopment at ETTP; - Eliminates the generation of wastes through excavation and saves money to cleanup other areas for re-use; - Supports regional electric provider's renewable energy initiative; - Offers community economic development/ jobs and property tax income to the City of Oak Ridge; - Demonstrates benefit of ETTP re-industrialization; - Provides long-term lease payments to the community reuse organization; - Supports DOE renewable energy goals; - Demonstrates collaboration between DOE and a public utility for renewable energy development. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Turning Normal to Abnormal: Reversing CO 2 /C2–Hydrocarbon Selectivity in HKUST–1

Metal–organic frameworks (MOFs) can efficiently purify hydrocarbons from CO 2 , but their rapid saturation, driven by preferential hydrocarbon adsorption, requires energy-intensive adsorption–desorption processes. To address these challenges, an innovative approach is developed, enabling control over MOF flexibility through densification and defect engineering, resulting in an intriguing inverse CO 2 /C2 hydrocarbon selectivity. Here, in this study, the densification process induces the shearing of the crystal lattice and contraction of pores in a defective CuBTC MOF. These changes have led to a remarkable transformation in selectivity, where the originally hydrocarbon-selective CuBTC MOF becomes CO 2 -selective. The selectivity values for densified CuBTC are significantly reversed when compared to its powder form, with notable improvements observed in CO 2 /C 2 H 6 (4416 vs 0.61), CO 2 /C 2 H 4 (15 vs 0.28), and CO 2 /C 2 H 2 (4 vs 0.2). The densified material shows impressive separation, regeneration, and recyclability during dynamic breakthrough experiments with complex quinary gas mixtures. Simulation studies indicate faster CO 2 passage through the tetragonal structure of densified CuBTC compared to C 2 H 2 . Experimental kinetic diffusion studies confirm accelerated CO 2 diffusion over hydrocarbons in the densified MOF, attributed to its small pore window and minimal interparticle voids. This research introduces a promising strategy for refining existing and future MOF materials, enhancing their separation performance.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Final Technical Report for Automated Manufacturing of Innovative CPV/PV Modules

Cogenra’s Dense Cell Interconnect system was designed to use traditional front-contact cells and string them together into high efficiency and high reliability “supercells”. This novel stringer allows one to take advantage of the ~100 GW/year of existing cell production capacity and create a solar product for the customer that will produce more power and last longer than traditional PV products. The goal for this program was for Cogenra Solar to design and develop a first-of-kind automated solar manufacturing line that produces strings of overlapping cells or “supercells” based on Cogenra’s Dense Cell Interconnect (DCI) technology for their Low Concentration Photovoltaic (LCPV) systems. This will enable the commercialization of DCI technology to improve the efficiency, reliability and economics for their Low Concentration Photovoltaic systems. In this program, Cogenra Solar very successfully designed, developed, built, installed, and started up the ground-breaking manufacturing tools required to assemble supercells. Cogenra then successfully demonstrated operation of the integrated line at high yield and throughput far exceeding expectations. The development of a supercell production line represents a critical step toward a high volume and low cost Low Concentration Photovoltaic Module with Dense Cell Interconnect technology and has enabled the evaluation of the technology for reliability and yield. Unfortunately, performance and cost headwinds on Low Concentration Photovoltaics systems including lack of diffuse capture (10-15% hit) and more expensive tracker requirements resulted in a move away from LCPV technology. Fortunately, the versatility of Dense Cell Interconnect technology allows for application to flat plate module technology as well and Cogenra has worked with the DOE to utilize the learning from this grant to commercialize DCI technology for the solar market through the on-going grant: Catalyzing PV Manufacturing in the US With Cogenra Solar’s Next-Generation Dense Cell Interconnect PV Module Manufacturing Technology. This program is now very successfully building off of this work and commercializing the technology to enable increased solar adoption.

14 SOLAR ENERGY↗
DOE OSTI2019

Advanced low-cost intermetallic coatings for molten salt pump impeller. Final report

1.0 INTRODUCTION The use of solar energy to produce steam for the generation of electricity is an established technology, with multiple designs for concentrating solar power (CSP) steam generators available commercially and a number of such units currently operating. As part of the effort to improve the overall efficiency of this technology, designers have developed thermal energy storage (TES) mechanisms that employ molten salt to capture a portion of the solar energy available during the day-time hours and make that energy available for steam generation during periods when the sun’s energy is not available. In current TES systems, nitrate salts are used extensively as the medium of energy exchange. However, due to the chemical instability of these salts at temperatures above 600ºC, they are not being considered for use in the next more efficient generation of CSP plants, in which the energy exchange fluids will be required to operate in the range 600ºC to 800ºC. At these higher temperatures, molten chloride salts, such as KCl-MgCl2, are viewed as promising alternatives to the nitrate salts, but, of course, these chloride-based salts are highly corrosive to the engineering alloys commonly used in the construction of pressure vessels, heat exchangers, pumps and piping at high temperatures. Hence, a solution to the problem of material degradation is essential if the next generation of CSP plants is to be commercially viable (Ref 1). In order to effectively address the problem of molten chloride salt corrosion at high temperatures (≥ 750ºC) and thereby to reduce the cost of molten salt tanks and related apparatus, various options have been considered, with one of the most promising being an innovative coatings system developed and applied onto low alloy ferritic or austenitic stainless material. Development of such a coating system would reduce the capital costs of thermal energy storage (TES) and increase the overall efficiency of the concentrating solar power (CSP) system. Although high strength nickel base alloys are well suited for many high temperature applications, they have significant limitations when exposed to molten chloride salt conditions and they are very expensive. Monolithic materials such as the austenitic stainless steels (e.g., SS310 and SS347) and the more common nickel base alloys (e.g., IN625 and IN800H) have exhibited high corrosion rates in molten chloride salt environments (Ref1). Molten salt corrosion of IN625 in salts containing chlorides showed a catastrophic corrosion rate of 1.111”/year at 800ºC (Ref1). Hence, an innovative coatings solution to mitigate molten chloride salt corrosion is needed. Of the many coating techniques available in the market, no one technique appears to be capable of producing effective protection from molten salt corrosion at a relatively low cost. There are thermal spray coating techniques, in particular the twin wire-arc technology, that are attractive when considering the coating of large molten salt tanks because the coatings application rate is high, the overall application cost is low and repairs to the coating can readily be made either in the shop or in the field. However, the twin wire arc coating materials currently available in the market have certain inherent limitations, including porosity and mechanical bonding to the substrate, which limit their effectiveness in providing protection against molten chloride salt corrosion at high temperatures. What is required is an approach that combines the economy and versatility of thermal spray wire-arc technology with the superior resistance of advanced alloys to effectively combat molten chloride salt corrosion at elevated temperatures. Applied Thermal Coatings, Inc. (ATC) has investigated an innovative coatings technology to produce dual layer cermet/ceramic coatings that will be dense and impervious to any corrosive molten salts/fluids, thereby resisting the effects of molten salt corrosion. Development of coatings using this technology will make it possible to fabricate the molten salt systems using a relatively low-cost base material, which will reduce the overall cost of the power generating system and enhance the commercial viability of solar power. 2.0 PROJECT OVERVIEW Of the coating technologies available for the production of a cost-effective method of protection from the effects of high-temperature chloride attack, there are two that offer specific advantages for the CSP/TES application, particularly when used in a way that effectively complements the strengths of each coating method. The first of these is electroless nickel plating, through which a nickel-rich layer is produced on the surface of a component through chemical reduction. The second coating technology is aluminizing, in which aluminum is diffused into the surface of a component and, depending on the composition of the substrate, aluminides are formed. The objective of this project has been to demonstrate the feasibility of a low- cost coating for the protection of pump impellers used for the inductive transport of molten salts. Initial interest focused on an inter-metallic nickel aluminide coating and subsequently, for economic reasons, consideration also was given to a coating composed of iron aluminides. Applying such coatings to low alloy or austenitic stainless-steel substrates will provide the superior resistance to molten chloride salt corrosion and blade tip erosion that normally can be achieved only through the use of more highly alloyed – and, therefore, more expensive - nickel-base materials and it will do so at a substantially lower cost. The coating systems evaluated were designed to take advantage either of the combined strengths of the electroless nickel plating process and the aluminizing process to produce a nickel-aluminide intermetallic coating or to rely solely on the aluminizing process to produce, in conjunction with iron from the substrate, a protective layer consisting of iron aluminides. With respect to the nickel aluminide protection, this has been achieved by first depositing a layer of nickel-rich alloy onto an austenitic stainless substrate using the electroless nickel plating process and then aluminizing the nickel- coated surface to produce the nickel aluminide coating. With respect to the iron aluminide protection, this has been achieved by aluminizing bare austenitic stainless steel. Testing has supported the conclusion that the developed coatings will resist attack by molten chloride salts at high temperatures (550°C to 750°C) and have sufficient hardness to resist blade tip erosion.The steps taken to develop either a low-cost intermetallic nickel aluminide coating using electroless nickel plating and aluminizing or a low-cost iron aluminide coating using aluminizing only, and to demonstrate the quality of the coatings and their effectiveness against molten chloride salt corrosion and erosion at high temperatures (≤ 750ºC) have been as follows: 1. Design of the optimum electroless nickel plating and aluminizing mixtures using advanced thermodynamic analysis; 2. Development of processing parameters for the electroless nickel plating and aluminizing processes, to be used either together or separately; 3. Production of specimens coated using the designated electroless nickel plating process; 4. Production of samples with intermetallic nickel aluminide coating or iron aluminide coating; 5. Investigation of the performance of the intermetallic nickel aluminide coating and the iron aluminide coating when subjected to molten chloride salts corrosion at high temperatures (≥ 750ºC); and, 6. Metallurgical characterization of the microstructure of the coatings, both prior to and after exposure to molten salt environments at elevated temperatures.

14 SOLAR ENERGY↗
DOE OSTI2022

Computational Prediction of Water Sorption in Facilitated Transport Membranes

Polymeric facilitated transport membranes (FTMs) have emerged as an innovative class of promising carbon capture technology. Studies have shown that the transport properties of an FTM are significantly influenced by its water uptake. In order to better quantify FTM performance, we herein explore the potential of computational techniques to predict the equilibrium water uptake values of FTMs. Two prediction approaches were examined. First, the water sorption was explicitly simulated by iteratively conducting grand canonical Monte Carlo (GCMC) and molecular dynamics (MD) simulations. Second, the water sorption was predicted based on the chemical potential of the adsorbed water, which was calculated using the Widom insertion or continuous fractional component Monte Carlo (CFCMC) method. The chemical potential-based approach with CFCMC demonstrated good prediction of the equilibrium water uptake values of FTMs with poly(N-vinylformamide-co-vinylamine) as fixed-site carrier and 2-(1-piperazinyl)ethylamine sarcosinate as mobile carrier. The predicted water uptake values increased with increasing mobile carrier content and were in good agreement with the experimental values. Furthermore, the higher water uptake promoted the diffusion of CO 2 , N 2 , and mobile carrier as well as slightly stifled the sorption of N 2 . Such an approach significantly contributes to a more comprehensive theoretical evaluation of FTMs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Rigidity‐Driven Structural Isomers in the NaCl–Ga 2 S 3 System: Implications for Energy Storage

Alternative energy sources require the search for innovative materials with promising functionalities. Systems with unusual chemical properties represent an insufficiently explored domain, concealing unexpected features. Using diffraction and Raman spectroscopy over a wide temperature range, supported by first‐principles simulations, a rare phenomenon is unveiled: phase‐dependent chemical interactions between binary components in the NaCl–Ga 2 S 3 system. In this unique occurrence, previously intact binary crystalline species transform upon melting into mixed liquid structural isomers, forming bonds with new partners. The chemical combinatorics appears to be fully reversible for stable crystals and liquids. Despite this, rapidly frozen glasses out of thermodynamic equilibrium remain in a metastable isomeric state, offering remarkable properties, particularly a high room‐temperature Na + conductivity, comparable to the best sodium halide superionic conductors and therefore encouraging for sodium solid‐state batteries and energy applications. A rigidity paradigm is responsible for the observed phenomenon, as the extremely constrained Ga 2 S 3 crystal lattice does not survive viscous flow, breaking up at a short‐range level. The removal of rigidity constraints and dense packing leads to a significant increase in empty space, which is the origin of high sodium diffusivity. Broadly, the rigidity‐driven structural isomerism opens up an inspiring path to the discovery of atypical materials.

25 ENERGY STORAGE↗
DOE OSTI2022

Versatile Heat Transfer Module

Development of micro-reactors that can be easily transported to remote areas for civilian or military applications is an immediate focus of U.S. nuclear industry and therefore is being pursued by multiple reactor vendors (e.g. HolosGen LLC, Westinghouse, Ultra Safe Nuclear Corporation, URENCO, etc.) and actively supported by DOE-NE, DOE-ARPA-E and by the Department Of Defense (DoD). Very-high-temperature gas-cooled (VHTR) and heat pipe cooled reactor technologies are regarded as promising concepts for microreactors applications since they enable compact power conversion systems and display beneficial inherent safety features. Development of microreactors with enhanced performance must be supported by innovations in nuclear technologies. Several technologies being developed by the microreactor industry are being revisited with material technologies developed at the Argonne National Laboratory (ANL). Innovative high-temperature compatible solutions are developed to enable advanced thermal-spectrum microreactor designs featuring improved neutronics performance at high-temperature operating conditions to enable high thermal efficiency and economic competitiveness. This report focuses on the Versatile Heat Transfer Module (VHTM) technology that is developed at ANL for heat-transfer in thermal-spectrum microreactors. This technology is built on a liquid alkali metal heat pipe concept while leveraging advanced nuclear material technologies for high-temperature applications at reduced neutronic penalty with potential improvement in inherent safety behavior. The VHTM can be applied to design high-temperature thermal-spectrum microreactor systems with reduced size, weight, uranium enrichment, or increased lifetime. The INFINIT technology deriving from the VHTM enables design of a highly compact long-life microreactor concept for fission surface power (FSP). Demonstration of multiphysics modeling capability was also completed to showcase the added inherent safety benefits obtained with this concept. The VHTM technology remain at an early development stage with low Technology Readiness Level and Manufacturing Readiness Level. The current demonstration of these technologies has focused on manufacturing capability, on performance of the hydrogen diffusion barrier under thermal cycling, while radiation tolerance demonstration is planned. The next step of the demonstration plan will be the assembly of miniature VHTM for high-temperature testing, which can be used as a prototype for future pilot scale demonstration. Such research is critical to pursue development of these technologies that have the clear potential to significantly improve the performance of currently investigated micro-reactors systems.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2017

Limits to Creation of Oxygen-Rich Atmospheres on Planets in the Outer Reaches of the Conventional Habitable Zone

Abundant free oxygen appears to be a requirement for macroflora and macrofauna. To the best of our knowledge, a general discussion of which habitable planets are conducive to oxygen has not taken place. Theories for the rise of oxygen fall into 4 categories: (i) It is governed by an intrinsic rate of biological innovation, independent of environmental factors. (ii) It is caused by mantle evolution, probably consequent to secular cooling. (iii) It is caused by hydrogen escape, which irreversibly oxidizes the Earth. (iv) It is Gaia's response to the brightening Sun, its rise prevented until reduced greenhouse gases were no longer needed to maintain a clement climate. All but the first of these make implicit astronomical predictions that can be quantified and made explicit. Here we address the third hypothesis. In this hypothesis hydrogen escape acts like an hourglass that continues until all relevant reduced mineral buffers have been oxidized (titrated, as it were) and the surface made safe for O2. The hypothesis predicts that abundant free O2 will be absent from habitable planets that have not experienced significant hydrogen escape. Where hydrogen escape is modest or insignificant, the atmosphere can be approximated as hydrostatic, which makes assessing radiative cooling by embedded molecules, atoms, and ions such as CO2 and H3+ straightforward. In particular, H2 is efficient at exciting non-LTE CO2 15 micron emission, which makes radiative cooling very effective when H2 is abundant. We can therefore map out the region of phase space in which habitable planets do not lose hydrogen, and therefore do not develop O2 atmospheres. A related matter is the power of radiative cooling by embedded molecules to enforce the diffusion limit to hydrogen escape. This matter in particular is relevant to addressing the empirical observation that rocky planets with thin or negligible atmospheres are rarely or never bigger than approx.1.6 Earth radii.

Zahnle, Kevin↗
DOE OSTI2025

Interpretation of Ion Irradiation and Neutron Irradiation Damage in Additively Manufactured 316 Stainless Steel using Multiscale Modeling

The accelerated adoption of nuclear energy necessitates advanced manufacturing technologies, such as additive manufacturing, to meet heightened supply chain requirements and support innovative reactor technologies. Due to the unique microstructural characteristics of additively manufactured materials under distinct solidification conditions, comprehensive evaluation of their performance in reactor environments is essential. The Advanced Materials and Manufacturing Technologies program under the Department of Energy's Office of Nuclear Energy focuses on understanding the irradiation performance and damage evolution of laser powder bed fusion 316 stainless steel, with an emphasis on integrating ion and neutron irradiation data to accelerate the development and qualification of materials for advanced nuclear reactor applications. While ion irradiation is a cost- and time-effective method, modeling and simulation are required to interpret the data for the broader range of irradiation conditions encountered in advanced reactors. In fiscal year 2025, integrated multiscale modeling and simulations were conducted to assess irradiation damage in additively manufactured 316 stainless steel. Key outcomes include predictions of chromium enrichment at grain boundaries, nickel enrichment at dislocation cell walls and void surfaces, and heterogeneous void evolution under ion and neutron irradiation conditions. Cluster dynamics simulations revealed the coarsening of voids at high irradiation temperatures and the suppression of void growth by high network dislocation density, while also demonstrating significant growth and coarsening of voids and self-interstitial atom loops at low dose rates. Machine learning-accelerated atomistic simulations highlighted the impact of the local environment and chromium concentration on vacancy diffusivity, providing key insights on the influence of composition on void swelling and radiation-induced segregation. Additionally, molecular dynamics simulations demonstrated the presence of defect production bias and a significant effect of carbon content on defect cluster behavior. These combined efforts aim to predict the performance of additively manufactured materials under various reactor conditions, supporting their qualification for nuclear reactor applications by interpreting ion irradiation data. This report underscores the potential of integrated multiscale modeling to analyze ion irradiation data in the effort to accelerate the qualification of additively manufactured materials for nuclear reactor components.

316 stainless steel↗
NASA NTRS2000

Magnetic Flux Compression Concept for Nuclear Pulse Propulsion and Power

The desire for fast, efficient interplanetary transport requires propulsion systems having short acceleration times and very high specific impulse attributes. Unfortunately, most highly efficient propulsion systems which are within the capabilities of present day technologies are either very heavy or yield very low impulse such that the acceleration time to final velocity is too long to be of lasting interest, One exception, the nuclear thermal thruster, could achieve the desired acceleration but it would require inordinately large mass ratios to reach the range of desired final velocities. An alternative approach, among several competing concepts that are beyond our modern technical capabilities, is a pulsed thermonuclear device utilizing microfusion detonations. In this paper, we examine the feasibility of an innovative magnetic flux compression concept for utilizing microfusion detonations, assuming that such low yield nuclear bursts can be realized in practice. In this concept, a magnetic field is compressed between an expanding detonation driven diamagnetic plasma and a stationary structure formed from a high temperature superconductor (HTSC). In general, we are interested in accomplishing two important functions: (1) collimation of a hot diamagnetic plasma for direct thrust production; and (2) pulse power generation for dense plasma ignition. For the purposes of this research, it is assumed that rnicrofusion detonation technology may become available within a few decades, and that this approach could capitalize on recent advances in inertial confinement fusion ICF) technologies including magnetized target concepts and antimatter initiated nuclear detonations. The charged particle expansion velocity in these detonations can be on the order of 10 (exp 6)- 10 (exp 7) meters per second, and, if effectively collimated by a magnetic nozzle, can yield the Isp and the acceleration levels needed for practical interplanetary spaceflight. The ability to ignite pure fusion micro-bursts with reasonable levels of input energy is an equally challenging scientific problem. It remains to be seen, however, whether an effective ignition driver can be developed which meets the requirements for practical spaceflight application (namely high power density, compactness, low weight, and low cost). In this paper, system level performance and design issues are examined including generator performance, magnetic flux compression processes, magnetic diffusion processes, high temperature superconductor (HTSC) material properties, plasmadynamic processes, detonation plasma expansion processes, magnetohydrodynamic instabilities, magnetic nozzle performance, and thrust production performance. Representative generator performance calculations based on a simplified skin layer formulation are presented as well as the results of exploratory small-scale laboratory experiments on magnetic flux diffusion in HTSC materials. In addition, planned follow-on scientific feasibility experiments are described which utilize high explosive detonations and high energy gas discharges to simulate the plasma conditions associated with thermonuclear micro-detonations.

Litchford, Ronald J.↗
NASA NTRS1997

Real Time Quantitative 3-D Imaging of Diffusion Flame Species

A low-gravity environment, in space or ground-based facilities such as drop towers, provides a unique setting for study of combustion mechanisms. Understanding the physical phenomena controlling the ignition and spread of flames in microgravity has importance for space safety as well as better characterization of dynamical and chemical combustion processes which are normally masked by buoyancy and other gravity-related effects. Even the use of so-called 'limiting cases' or the construction of 1-D or 2-D models and experiments fail to make the analysis of combustion simultaneously simple and accurate. Ideally, to bridge the gap between chemistry and fluid mechanics in microgravity combustion, species concentrations and temperature profiles are needed throughout the flame. However, restrictions associated with performing measurements in reduced gravity, especially size and weight considerations, have generally limited microgravity combustion studies to the capture of flame emissions on film or video laser Schlieren imaging and (intrusive) temperature measurements using thermocouples. Given the development of detailed theoretical models, more sophisticated studies are needed to provide the kind of quantitative data necessary to characterize the properties of microgravity combustion processes as well as provide accurate feedback to improve the predictive capabilities of the computational models. While there have been a myriad of fluid mechanical visualization studies in microgravity combustion, little experimental work has been completed to obtain reactant and product concentrations within a microgravity flame. This is largely due to the fact that traditional sampling methods (quenching microprobes using GC and/or mass spec analysis) are too heavy, slow, and cumbersome for microgravity experiments. Non-intrusive optical spectroscopic techniques have - up until now - also required excessively bulky, power hungry equipment. However, with the advent of near-IR diode lasers, the possibility now exists to obtain reactant and product concentrations and temperatures non-intrusively in microgravity combustion studies. Over the past ten years, Southwest Sciences has focused its research on the high sensitivity, quantitative detection of gas phase species using diode lasers. Our research approach combines three innovations in an experimental system resulting in a new capability for nonintrusive measurement of major combustion species. FM spectroscopy or high frequency Wavelength Modulation Spectroscopy (WMS) have recently been applied to sensitive absorption measurements at Southwest Sciences and in other laboratories using GaAlAs or InGaAsP diode lasers in the visible or near-infrared as well as lead-salt lasers in the mid-infrared spectral region. Because these lasers exhibit essentially no source noise at the high detection frequencies employed with this technique, the achievement of sensitivity approaching the detector shot noise limit is possible.

Kane, Daniel J.↗
DOE OSTI2016

Injection molding of high precision optics for LED applications made of liquid silicone rubber

Light Emitting Diodes (LED) conquer the growing global market of lighting technologies. Due to their advantages, they are increasingly used in consumer products, in lighting applications in the home and in the mobility sector as well as in industrial applications. Particularly, with regard to the increasing use of high-power LED (HP-LED) the materials in the surrounding area of the light emitting semiconductor chip are of utmost importance. While the materials behind the semiconductor chip are optimized for maximum heat dissipation, the materials currently used for the encapsulation of the semiconductor chip (primary optics) and the secondary optics encounter their limits due to the high temperatures. In addition certain amounts of blue UV radiation degrade the currently used materials such as epoxy resins or polyurethanes for primary optics. In the context of an ongoing joint research project with various partners from the industry, an innovative manufacturing method for high precision optics for LED applications made of liquid silicone rubber (LSR) is analyzed at the Institut of Plastics Processing (IKV), Aachen. The aim of this project is to utilize the material-specific advantages of high transparent LSR, especially the excellent high temperature resistance and the great freedom in design. Therefore, a high integrated injection molding process is developed. For the production of combined LED primary and secondary optics a LED board is placed in an injection mold and overmolded with LSR. Due to the integrated process and the reduction of subcomponents like the secondary optics the economics of the production process can be improved significantly. Furthermore combined LED optics offer an improved effectiveness, because there are no losses of the light power at the transition of the primary and secondary optics.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS2006

Carbon-Nanotube-Carpet Heat-Transfer Pads

Microscopic thermal-contact pads that include carpet-like arrays of carbon nanotubes have been invented for dissipating heat generated in integrated circuits and similarly sized single electronic components. The need for these or other innovative thermal-contact pads arises because the requisite high thermal conductances cannot be realized by scaling conventional macroscopic thermal-contact pads down to microscopic sizes. Overcoming limitations of conventional thermal-contact materials and components, the carbon-nanotube thermal-contact pads offer the high thermal conductivities needed to accommodate the high local thermal power densities of modern electronic circuits, without need for large clamping pressures, extreme smoothness of surfaces in contact, or gap-filling materials (e.g., thermally conductive greases) to ensure adequate thermal contact. Moreover, unlike some conventional thermal-contact components, these pads are reusable. The figure depicts a typical pad according to the invention, in contact with a rough surface on an electronic component that is to be cooled. Through reversible bending and buckling of carbon nanotubes at asperities on the rough surface, the pad yields sufficiently, under relatively low contact pressure, that thermal contact is distributed to many locations on the surface to be cooled, including valleys where contact would not ordinarily occur in conventional clamping of rigid surfaces. Hence, the effective thermal-contact area is greater than that achievable through scaling down of a macroscopic thermal-contact pad. The extremely high longitudinal thermal conductivities of the carbon nanotubes are utilized to conduct heat away from potential hot spots on the surface to be cooled. The fibers protrude from a layer of a filler material (Cu, Ag, Au, or metal-particle- filled gels), which provides both mechanical support to maintain the carbon nanotubes in alignment and thermal conductivity to enhance the diffusion of concentrated heat from the nanotubes into the larger adjacent volume of a heat sink. The array of carbon nanotubes, the filler material, and the heat sink are parts of a unitary composite structure that is fabricated as follows: 1. Using techniques that have been reported previously, the array of substantially perpendicularly oriented carbon nanotubes is grown on a metal, silicon, or other suitable thermally conductive substrate that is intended to become the heat sink. 2. By means of chemical vapor deposition, physical vapor deposition, plasma deposition, ion sputtering, electrochemical deposition, or casting from a liquid phase, some or all of the interstitial volume between carbon nanotubes is filled with the aforementioned layer of mechanically supporting, thermally conductive material. 3. To cause the carbon nanotubes to protrude the desired length from the filler material, an outer layer of filler is removed by mechanical polishing, chemical mechanical polishing, wet chemical etching, electrochemical etching, or dry plasma etching.

Li, Jun↗
DOE OSTI2025

Final report on assessment of molten salt corrosion testing of unirradiated and ion irradiated advanced manufactured high entropy alloys

Generation IV reactors and future fusion reactor designs have led to more demanding materials performance requirements due to their increased operating temperatures, corrosive coolants, and increased radiation doses compared to the current light-water reactor fleet. Among the innovative nuclear technologies under development, molten salt reactors stand out for their potential to offer superior fuel utilization, intrinsic safety characteristics, and economic viability. Of the proposed Generation IV designs, the gas fast reactor operates at 450 to 850°C and the molten salt reactor operates at 565 to 850°C, with the molten salt reactor design needing molten salt corrosion resistant materials [1, 2]. These increased temperatures and more extreme corrosion environments necessitate higher material performance, such as creep strength, radiation-tolerant microstructures, corrosion resistance, and high-temperature tensile properties. Hastelloy-N, a nickel-based alloy with additions of molybdenum and chromium, has been successfully employed to contain molten fluoride salt at temperatures up to 705°C. However, Hastelloy-N becomes embrittled upon neutron irradiation, primarily due to the accumulation of helium produced by (n,a) transmutation reactions. Furthermore, the corrosive nature of molten fluoride and chloride salts presents a formidable challenge, as these salts can react with and dissolve alloying elements such as Cr, Mo, and Fe, leading to selective leaching, loss of protective oxide layers, and accelerated degradation. High entropy alloys (HEAs) and refractory high entropy alloys (RHEAs) have emerged as a prominent area of interest, due to their ability to achieve tailored chemical compositions for specific applications. Unlike conventional alloys, HEAs are characterized by having multiple principal elements in equimolar or near equimolar ratios, leading to an unconventional alloying strategy [3]. This alloying strategy is believed to promote unique properties, such as single-phase stabilization of chemically compatible elements, lattice distortion effects due to atomic radius differences, and proposed sluggish diffusion effects. For extreme-environment applications, RHEAs have garnered much research interest because of the possibility of creating relatively ductile materials that can operate in extremely high-temperature environments, beyond the operating temperatures where other Ni-based superalloys begin to lose strength [4-6]. Idaho National Laboratory (INL) initiated a joint international effort with the Czech Republic to explore the feasibility of manufacturing HEAs for high-temperature nuclear applications using advanced manufacturing. This effort was funded at INL by the United States Department of Energy's Office of Nuclear Energy under the Advanced Reactor Technologies and Advanced Materials and Manufacturing Technologies (AMMT) Program. The HEAs were specifically designed for the corrosive and irradiation environments experienced in gas-cooled fast reactors, molten salt reactors, and fusion power. These alloys have been manufactured by multiple processes to determine the impact of manufacturing processes on the performance of the alloys in corrosive and irradiation environments. Preliminary molten salt corrosion testing showed that equimolar MoNbTiV and MoNbTi alloys exhibit exceptional performance, with arc-melted variants demonstrating only minimal degradation after 1000 hours of exposure to molten chloride salt at 700°C. Conversely, Nb2TiVZr2 showed significant molten salt corrosion susceptibility and microstructural instability during high-temperature molten salt exposures, and was, therefore deemed unfit for molten salt reactor applications. The MoNbTiV, MoNbTi, and Nb2TiVZr2 alloys were further evaluated through ion irradiation experiments conducted at the Michigan Ion Beam Laboratory at the University of Michigan. The microstructural stability and the evolution of irradiation-induced defects were characterized to assess the irradiation resistance of each of these alloys.

36 - MATERIALS SCIENCE↗
DOE OSTI2020

Rapid Patterning and Advanced Device Structures for Low Cost Manufacturable Crystalline Si IBC Cells

Recent record efficiency Si cells have had an interdigitated back contact (IBC) design where both positive and negative contacts are fabricated on the back side of the Si wafer. Many industry groups have investigated IBC cells but used photolithography to pattern the rear contacts although it is considered impractical for low cost, high volume manufacturing. Alternative patterning methods using lasers and mechanical masking have been utilized in fabrication of patterned regions in IBC Si solar cells to replace photolithography. Another exciting advance in Si solar cell technology has been replacing the high temperature diffusion of doped regions inside the crystalline Si wafer with low temperature deposition of very thin layers of doped amorphous hydrogenated Si (a-Si:H) on the Si wafer. This is called a Si heterojunction (HJ) device. The a-Si:H provides excellent passivation of surface defects and has produced the highest open circuit voltages (VOC) of any Si solar cell device structure. The Institute of Energy Conversion (IEC) demonstrated the first IBC-HJ solar cell combining these two strategies in 2007 and has fabricated IBC-HJ cells with 20% efficiency using three photolithography steps. Despite the demonstrated efficiency potential of this device by industry groups (>26%) there is no commercial production because of the challenges of patterning and processing the structure in an industrial environment. Our work sought to address that challenge. The objective of this 3 year project was to develop the processing for the IBC-HJ Si solar cell using lasers for patterning and contact formation instead of photolithography. Laser patterning enables rapid, contactless manufacturing of patterned regions. We intensively studied laser fired contacts, laser patterning of the a-Si multi-layer stacks and metal layers and the use of plasma shadow masks. After an exhaustive focus in the first year on the laser fired emitter (LFE) and contact (LFC), we were unable to achieve VOC greater than 660 mV, compared to the 720 mV required to meet our milestones. We discovered that an additional issue with our original IBC structure was the presence of an inversion layer at the back surface connecting the p and n regions which reduced the VOC and fill factor (FF). We developed innovative methods for characterizing the inversion layer. These two limitations in the original design lead to development of a new IBC-HJ process sequence and device structure which we called Plasma Masked Laser Processed (PMLP). It retained the original high efficiency features including manufacturability. The LFC was replaced with a standard n-type a-Si HJ contact. The inversion layer was eliminated by replacing the previous p-type stack in the gap with an n-type or SiN stack. The PMLP used laser ablation of a multi-layer a-Si stack followed by chemical etching to open the n-contact. It required deposition of a patterned stack through a mask in the plasma deposition chamber. This turned out to be a source of significant problems due to inevitable unwanted deposition ‘leakage’ under the mask. This formed a blocking contact on the emitter which significantly reduced Voc and FF. Several iterations in PMLP device structure and chemical etching steps resulted in a large improvements, e.g. the efficiency increasing from 3 to 15% and Voc from 450 to 660 mV but they were unable to completely eliminate it. The best IBC-HJ device we fabricated had only 15% efficiency. For perspective, our standard FHJ devices had 20% efficiency.

14 SOLAR ENERGY↗