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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Accurate hydrodynamic force and torque correlations for prolate spheroids from Stokes regime to high Reynolds numbers

Detailed simulations of flow around various prolate spheroids are performed using multi-relaxation time lattice Boltzmann method (LBM). The simulations are performed in the Reynolds numbers range 0.1 ≤ Re ≤ 2000 at different incident angles 0°≤ φ ≤ 90° for various prolate spheroids of aspect ratios 1 ≤ λ ≤ 8. The Re is based on the volume equivalent sphere diameter. From the simulations, accurate correlations for average drag, lift and torque coefficients (C D , C L , and C T respectively) are proposed. The mean deviations between the correlations and the simulation data for C D , C L , and C T are 2%, 6.5%, and 4.7% respectively. Furthermore, the correlations are fitted with the physics in mind such that they can be extrapolated beyond the regimes simulated. The fits are designed such that correlations reduce to analytical (C D and C L ) solutions available for prolate spheroids in the limit Re ≈ 0. At high Re, the correlations mimic the asymptotic flattening of C D as for spheres and therefore, we expect the correlations to be valid until the critical Re (≈ 10 5 ). Furthermore, extensive comparison of our correlations with other high-fidelity simulations from literature demonstrate the accuracy of our work compared to other correlations from literature. This work enables researchers to perform accurate unresolved Euler-Lagrangian simulations for a wide range of elongated particles.

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

GrainGNN: A dynamic graph neural network for predicting 3D grain microstructure

We propose GrainGNN, a surrogate model for the evolution of polycrystalline grain structure under rapid solidification conditions in metal additive manufacturing. High fidelity simulations of solidification microstructures are typically performed using multicomponent partial differential equations (PDEs) with moving interfaces. The inherent randomness of the PDE initial conditions (grain seeds) necessitates ensemble simulations to predict microstructure statistics, e.g., grain size, aspect ratio, and crystallographic orientation. Here, currently such ensemble simulations are prohibitively expensive and surrogates are necessary.In GrainGNN, we use a dynamic graph to represent interface motion and topological changes due to grain coarsening. We use a reduced representation of the microstructure using hand-crafted features; we combine pattern finding and altering graph algorithms with two neural networks, a classifier (for topological changes) and a regressor (for interface motion). Both networks have an encoder-decoder architecture; the encoder has a multi-layer transformer long-short-term-memory architecture; the decoder is a single layer perceptron.We evaluate GrainGNN by comparing it to high-fidelity phase field simulations for in-distribution and out-of-distribution grain configurations for solidification under laser power bed fusion conditions. GrainGNN results in 80%–90% pointwise accuracy; and nearly identical distributions of scalar quantities of interest (QoI) between phase field and GrainGNN simulations compared using Kolmogorov-Smirnov test. GrainGNN's inference speedup (PyTorch on single x86 CPU) over a high-fidelity phase field simulation (CUDA on a single NVIDIA A100 GPU) is 150×–2000× for 100-initial grain problem. Further, using GrainGNN, we model the formation of 11,600 grains in 220 seconds on a single CPU core.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Heat Transfer Coefficients of Additively Manufactured Tubes with Internal Pin Fins for Supercritical Carbon Dioxide Cycle Recuperators

This paper describes the measurement of convective heat transfer coefficients and friction factors for sCO 2 flowing in additively manufactured tubes with internal pin fins at the US DOE’s National Energy Technology Laboratory in Morgantown, WV. The measurement procedures were validated by conducting benchmark tests with smooth stainless-steel tube and comparing the results with published correlations for Nusselt number (Nu) and friction factor. Over Reynolds numbers (ReD) ranging from 5 × 10 4 to 2.5 × 10 5 , measured Nu was within 5% of the Dittus-Boelter correlation and measured friction factors were within 5% of the McAdams correlation for smooth tube flow. The candidate pin fin patterned pipes were additively manufactured (AM) at the Oak Ridge National Laboratory. The pins were circular or elliptical in cross-section and were printed at a 30⁰ angle relative to the inner wall (to meet AM constraints). The pin arrangement was helical to promote enhanced heat transfer due to swirl flow. Pin length to diameter aspect ratio was 1.33, 2, and 8, while the pin diameter to tube diameter ratio was 0.188, 0.125, and 0.063. Tests were performed for ReD varying from 6.9 × 10 4 to 2.2 × 10 5 and at conditions equivalent to the low pressure (LP) outlet (8.69 MPa, 361 K) and the high pressure (HP) inlet (20.7 MPa, 350 K) of the low temperature recuperator (LTR) in an indirect sCO 2 cycle. The Wilson plot technique was utilized to measure the bulk heat transfer coefficients. For the best performing design (tube A, pin length to tube diameter ratio: 1.33, pin diameter to tube diameter ratio: 0.19), the local heat transfer coefficient increased by 136% relative to the Dittus-Boelter correlation at the LTR low pressure outlet and 194% at the LTR high pressure inlet. These correspond to a 282% and a 271% increase in the product of the heat transfer coefficient and surface area (adjusted for fin efficiency) product, respectively. Large pressure drops across the test articles were observed. For Tube Design A, the average friction factor, across the range of ReD considered, was significantly larger than the McAdams correlation at both the LTR LP outlet and the LTR HP inlet. A thermal performance factor was utilized to express the ratio of material required to build a finned heat exchanger relative to a finless heat exchanger with the same heat duty and pumping power. Tube Design A was estimated to decrease the required heat exchanger material by 13%.

Searle, Matthew↗
DOE OSTI2024

Simulations of radiatively cooled magnetic reconnection driven by pulsed power

Magnetic reconnection is an important process in astrophysical environments, as it reconfigures magnetic field topology and converts magnetic energy into thermal and kinetic energy. In extreme astrophysical systems, such as black hole coronae and pulsar magnetospheres, radiative cooling modifies the energy partition by radiating away internal energy, which can lead to the radiative collapse of the reconnection layer. In this paper, we perform two- and three-dimensional simulations to model the MARZ (Magnetic Reconnection on Z) experiments, which are designed to access cooling rates in the laboratory necessary to investigate reconnection in a previously unexplored radiatively cooled regime. These simulations are performed in GORGON, an Eulerian two-temperature resistive magnetohydrodynamic code, which models the experimental geometry comprising two exploding wire arrays driven by 20 MA of current on the Z machine (Sandia National Laboratories). Radiative losses are implemented using non-local thermodynamic equilibrium tables computed using the atomic code Spk, and we probe the effects of radiation transport by implementing both a local radiation loss model and P 1/3 multi-group radiation transport. The load produces highly collisional, super-Alfvénic (Alfvén Mach number M A ≈ 1.5), supersonic (Sonic Mach number M S ≈ 4–5) strongly driven plasma flows which generate an elongated reconnection layer (Aspect Ratio L/δ≈100 , Lundquist number S L ≈ 400). The reconnection layer undergoes radiative collapse when the radiative losses exceed the rates of ohmic and compressional heating (cooling rate/hydrodynamic transit rate = τ$^{–1}_{cool}$/τ$^{–1}_{H}$ ≈100); this generates a cold strongly compressed current sheet, leading to an accelerated reconnection rate, consistent with theoretical predictions. Lastly, the current sheet is also unstable to the plasmoid instability, but the magnetic islands are extinguished by strong radiative cooling before ejection from the layer.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

High temperature air oxidation behavior of Hastelloy X processed by Electron Beam Melting (EBM) and Selective Laser Melting (SLM)

The microstructure and oxidation behavior of Laser Beam Melted, Electron Beam Melted and wrought Hastelloy X were studied at 950 °C in dry air, 50 h cycles, up to 1000 h. The variability of processing parameters and powder compositions strongly impacted the oxidation and spallation behavior. Finally, the alloys with high Mn and Si were associated with higher oxidation rates, finer Cr 2 O 3 grain microstructure and increased spallation was observed for the alloys with large elongated grain microstructures (aspect ratio of 10 ± 3).

36 MATERIALS SCIENCE↗
DOE OSTI2021

Thermal confinement and transport in spherical tokamaks: a review

Here, we review the thermal plasma confinement and transport properties observed and predicted in low aspect ratio tokamaks, or spherical tokamaks (STs), which can depart significantly from those observed at higher aspect ratio. In particular, thermal energy confinement scalings show a strong, near linear dependence of energy confinement time on toroidal magnetic field, while the dependence on plasma current is more modest, the opposite of what is seen at higher aspect ratio. STs have revealed a very strong improvement in normalized confinement with decreasing collisionality, much stronger than at higher aspect ratio, which bodes well for an ST-based fusion pilot plant should this trend continue at an even lower collisionality than has already been accessed. These differences arise because of fundamental differences in transport in STs due to the more extreme toroidicity (i.e. reduced region of bad curvature), and to the relatively larger $E_r \times B$ shearing rates, both of which can suppress electrostatic drift wave instabilities at both ion and electron gyroradius scales. In addition, electromagnetic effects are much stronger in STs because they operate at high β T . Gyrokinetic (GK) studies, coupled with low- and high-k turbulence measurements, have shed light on the underlying physics controlling transport. At lower β T , both ion- and electron-scale electrostatic drift turbulence may be responsible for transport. At higher β T , microtearing, kinetic ballooning, and hybrid trapped electron/kinetic ballooning modes increasingly play a role, and they have a much stronger impact in the core of ST plasmas than at higher aspect ratio. Flow shear affects the balance between ion- and electron-scale modes. Non-linear GK simulations find regimes where the electron heat flux decreases with decreasing collisionality, consistent with the experimental global normalized confinement scaling. The ST is unique in that the relatively low toroidal magnetic field allows for localized measurements of electron-scale turbulence, and this coupled with turbulence measurements at ion-scales has facilitated detailed comparisons with GK simulations. These data have provided compelling evidence for the presence of ion temperature gradient and electron temperature gradient turbulence in some plasmas, and direct experimental support for the impact of experimental actuators like rotation shear, density gradient and magnetic shear on turbulence and transport.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Temporal dynamics of large-scale structures for turbulent Rayleigh–Bénard convection in a moderate aspect-ratio cylinder

We investigate the spatial organization and temporal dynamics of large-scale, coherent structures in turbulent Rayleigh–Bénard convection via direct numerical simulation of a 6.3 aspect-ratio cylinder with Rayleigh and Prandtl numbers of 9.6×10 7 and 6.7, respectively. Fourier modal decomposition is performed to investigate the structural organization of the coherent turbulent motions by analysing the length scales, time scales and the underlying dynamical processes that are ultimately responsible for the large-scale structure formation and evolution. We observe a high level of rotational symmetry in the large-scale structure in this study and that the structure is well described by the first four azimuthal Fourier modes. Two different large-scale organizations are observed during the duration of the simulation and these patterns are dominated spatially and energetically by azimuthal Fourier modes with frequencies of 2 and 3. Studies of the transition between these two large-scale patterns, radial and vertical variations in the azimuthal energy spectra, as well as the spatial and modal variations in the system's correlation time are conducted. Rotational dynamics are observed for individual Fourier modes and the global structure with strong similarities to the dynamics that have been reported for unit aspect-ratio domains in prior works. It is shown that the large-scale structures have very long correlation time scales, on the order of hundreds to thousands of free-fall time units, and that they are the primary source for a horizontal inhomogeneity within the system that can be observed during a finite, but a very long-time simulation or experiment.

42 ENGINEERING↗
DOE OSTI2023

Mallat Scattering Transformation based surrogate for Magnetohydrodynamics

Abstract A Machine and Deep Learning (MLDL) methodology is developed and applied to give a high fidelity, fast surrogate for 2D resistive MagnetoHydroDynamic (MHD) simulations of Magnetic Liner Inertial Fusion (MagLIF) implosions. The resistive MHD code is used to generate an ensemble of implosions with different liner aspect ratios, initial gas preheat temperatures (that is, different adiabats), and different liner perturbations. The liner density and magnetic field as functions of x , y , and z were generated. The Mallat Scattering Transformation (MST) is taken of the logarithm of both fields and a Principal Components Analysis (PCA) is done on the logarithm of the MST of both fields. The fields are projected onto the PCA vectors and a small number of these PCA vector components are kept. Singular Value Decompositions of the cross correlation of the input parameters to the output logarithm of the MST of the fields, and of the cross correlation of the SVD vector components to the PCA vector components are done. This allows the identification of the PCA vectors vis-a-vis the input parameters. Finally, a Multi Layer Perceptron (MLP) neural network with ReLU activation and a simple three layer encoder/decoder architecture is trained on this dataset to predict the PCA vector components of the fields as a function of time. Details of the implosion, stagnation, and the disassembly are well captured. Examination of the PCA vectors and a permutation importance analysis of the MLP show definitive evidence of an inverse turbulent cascade into a dipole emergent behavior. The orientation of the dipole is set by the initial liner perturbation. The analysis is repeated with a version of the MST which includes phase, called Wavelet Phase Harmonics (WPH). While WPH do not give the physical insight of the MST, they can and are inverted to give field configurations as a function of time, including field-to-field correlations.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Role of Three-Dimensional Swirl in Forced Convection Heat Transfer Enhancement in Wavy-Plate-Fin Channels

The influence of wall-corrugation-induced swirl flow on enhanced forced convection in wavy-plate-fin cores has been investigated. Three-dimensional computational simulations were carried out for steady-state periodically developed air flow (Pr ~ 0.71; 50 ≤ Re ≤ 4000) with channel walls subject to constant-uniform temperature conditions. The recirculation that develops in the wall troughs and grows to have an axially helical character is scaled by the Swirl number Sw. As Sw increases with higher flowrate and/or corrugation severity, tornado-shaped vortices appear in the wave trough region midway of the interfin channel height, then extend longitudinally to encompass majority of the flow channel. The local wall-shear and heat transfer coefficient variations indicate that boundary-layer thinning upstream of the wave peak aids in intensifying momentum and heat transfer. However, the flow recirculation in wall trough impedes heat transfer at low Sw due to flow stagnation but promotes it at high Sw because of the vortices-induced augmented fluid mixing. The effects of this secondary flow are quantified by Φf(or j), which is seen to increase log-linearly as fin corrugation aspect ratio γ and/or fin spacing ratio ζ increases; the influence of cross section aspect ratio α is marginal. Moreover, the pressure drag penalty due to swirl critically affects overall pressure loss, and its proportion remains nearly constant when α varies, but grows as Sw, γ, and/or ζ increases and can be as much as 80% of the total pressure drop.

Engineering↗
DOE OSTI2021

hr-Adaptivity for nonconforming high-order meshes with the target matrix optimization paradigm

In this study, we present an \(hr\) -adaptivity framework for optimization of high-order meshes. This work extends the r -adaptivity method by Dobrev et al. (Comput Fluids, 2020), where we utilized the Target-Matrix Optimization Paradigm (TMOP) to minimize a functional that depends on each element’s current and target geometric parameters: element aspect-ratio , size , skew , and rotation . Since fixed mesh topology limits the ability to achieve the target size and aspect-ratio at each position, in this paper, we augment the r -adaptivity framework with nonconforming adaptive mesh refinement to further reduce the error with respect to the target geometric parameters. The proposed formulation, referred to as \(hr\) -adaptivity, introduces TMOP-based quality estimators to satisfy the aspect-ratio target via anisotropic refinements and size target via isotropic refinements in each element of the mesh. The methodology presented is purely algebraic, extends to both simplices and hexahedra/quadrilaterals of any order, and supports nonconforming isotropic and anisotropic refinements in 2D and 3D. Using a problem with a known exact solution, we demonstrate the effectiveness of \(hr\) -adaptivity over both r - and \(h\) -adaptivity in obtaining similar accuracy in the solution with significantly fewer mesh nodes. We also present several examples that show that \(hr\) -adaptivity can help satisfy geometric targets even when \(r\) -adaptivity fails to do so, due to the topology of the initial mesh.

42 ENGINEERING↗
DOE OSTI2023

Activity model for 36 elements in Fe-Ni-Si-S-C liquids with application to terrestrial planet accretion and mantle geochemistry: New data for Ru, Re, Pt, Os, Ti, Nb, and Ta

Understanding siderophile element partitioning between metal and silicate melts under diverse conditions can be used to place important constraints on the materials and conditions of planetary accretion and core formation, as well as post core formation processes. However, the effects of Si on the partitioning and activity coefficients for these elements are not well known, despite Si likely being one of the dominant light elements in Earth’s core. To address this gap in understanding, we have undertaken a systematic study of the highly siderophile elements Re, Pt, Os, and Ru, and the refractory lithophile elements Nb, Ta and Ti at 1600 °C and 1 GPa, to derive epsilon interaction parameters for these elements in FeSi metallic liquids. Positive epsilon interaction parameters were measured for Nb, Ta, Ti, Ru, Re, Pt, and Os, indicating that dissolved Si in Fe liquids causes a decrease in their metal/silicate partition coefficients (or ‘silicophobic’ behavior). Furthermore, ε$_{Re, Os, or Ru}^{Si}$ > ε$_{Re, Os, or Ru}^{S}$ which means Si causes a larger decrease in D(metal/silicate) than S, and the chalcophile behavior expected from some elements will be completely masked by the presence of Si in a metallic liquid. The new parameters are used to update an activity model that now includes 36 siderophile elements in Fe-Ni-Si-S-C liquids (27 trace elements considered here). Systematic assessment of these 27 elements shows which have the strongest affinity for Si, C, and S, and also how activity coefficients for these elements would vary during accretion and core formation in Earth, Mars, and Mercury of widely differing fO 2 and core compositional conditions. The activity model is combined with new partitioning expressions for Mo, W, Cr, Re Ru, Pt, and Os and applied to aspects of post core formation mantle geochemistry of Earth, Mars, and Mercury. Our updated expressions show that the BSE Mo/W ratio can easily be achieved with metal/silicate partitioning during growth of the Earth, whereas Re, Os and Ru become lower than and highly fractionated compared with BSE values during core formation and accretion, and thus nearly 99% of their BSE abundances are likely contributed by late accretion. Ru isotopes should be a very good indicator of the source material for the late accretion. The high Pt/Os and Re/Os developed in a deepening magma ocean during the growth of the Earth, indicates 186 Os and 187 Os isotopes could be coupled if this ancient material remained isolated and subsequently became entrained in mantle plumes and measured in surficial lavas. The extent to which this occurred will be limited by the low Os content of this ancient material, thus requiring mixing as a major component in plume sources. Martian mantle Hf/W ratio stays low during accretion and core formation modelling, suggesting that W isotope anomalies are more likely due to solid/liquid silicate fractionation than to core formation. Finally, Ti contents measured by MESSENGER at Mercury’s surface can be explained by segregation of either a metallic core (IW-6 to -8) or metallic core + sulfide (IW-4 to -7.5) followed by mantle melting.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2021

Observations of Stably Stratified Flow through a Microscale Gap

This paper reports the findings of a comprehensive field investigation on flow through a mountain gap subject to a range of stably stratified environmental conditions. This study was embedded within the Perdigão field campaign, which was conducted in a region of parallel double-ridge topography with ridge-normal wind climatology. One of the ridges has a well-defined gap (col) at the top, and an array of in situ and remote sensors, including a novel triple Doppler lidar system, was deployed around it. The experimental design was mostly guided by previous numerical and theoretical studies conducted with an idealized configuration where a flow (with characteristic velocity U 0 and buoyancy frequency N ) approaches normal to a mountain of height h with a gap at its crest, for which the governing parameters are the dimensionless mountain height G= (Nh)/U 0 and various gap aspect ratios. Modified forms of G were proposed to account for real-world atmospheric variability, and the results are presented in terms of a gap-averaged value G c . The nature of gap flow was highly dependent on G c , wherein a nearly neutral flow regime (G c <1), a transitional mountain wave regime (G c ~O(1)), and a gap-jetting regime ( G c >O(1)) were identified. The measurements were in broad agreement with previous numerical and theoretical studies on a single ridge with a gap or double ridge topography, although details vary. This is the first ever detailed field study reported on microscale (O(100 m)) gap flows, and provides useful data and insights for future theoretical and numerical studies.

Microscale, Gap, environmental fluid dynamics, win↗
DOE OSTI2020

Simulating Buildings While the Design is Still in the Architect's Imagination

Very early in the design process, prior to drawing a single line, architects get information from their client or prospective client trying to understand the nature and requirements of the building that needs to be designed. The design of the building is completely fluid, as the architect considers many options in their imagination. The overall massing of the building, the general shape and form, are being considered during this early step. Even for a simple box-shaped building, the aspect ratio between the east-west and the north-south dimensions of the building can greatly impact energy consumption due to daylighting availability. The prevailing winds and building orientation can impact natural ventilation. The locations of high and low population density spaces can also impact energy use. Deciding the floor area per office workstation or the size of the auditorium will impact energy use. Does making a building two stories instead of one reduce energy impacts by reducing roof area or does the additional volume for stairs and elevators result in more energy use. Since certain types of spaces require more windows for occupants than others, the locations of those spaces will determine how much glazing each building orientation has impacting daylighting as well as heating and cooling energy. The project was an attempted first step toward creating a system tailored toward architects for this very early stage in the design process to help them understand the energy impacts of design options. The approach was not to be based on drawing the building, and instead, the main inputs would have been the size of each type of space in the building. This report describes information gathered during the development that might be of use to others developing similar software as well as some of the software that was developed during the project. Phase II funding to continue this work was not pursued due to intellectual property issues discovered during the development of the commercialization plan.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Hydrokinetic energy harvesting from slow currents using flow-induced oscillations

To harness marine hydrokinetic energy from slow flows, which constitute the majority of currents, tides, and rivers, new Passive Turbulence Control (PTC), consisting of large turbulence stimulators, is tested experimentally on circular cylinders on springs. Here, this study experimentally investigates the effect of PTC on the onset of Flow-Induced Oscillations (FIO) and particularly the relative onset of Vortex-Induced Vibrations (VIV) and galloping. Experiments are conducted in the Low Turbulence Free Surface Water Channel, University of Michigan. Fixed are: mass ratio m* = 1.48, aspect ratio l/D = 10.29, and total damping ratio ζ = 0.04. Parameters are: cylinder diameter D, spring stiffness K, PTC location and height, and flow speed U$\in$[0.36 m/s-1.45 m/s]. Placing the leading edge of PTC at 40–60° induces high amplitude FIO while placement at 10–20° suppresses FIO. As PTC height increases, VIV and galloping initiate earlier and exhibit higher amplitude with a steeper slope. Lower spring stiffness initiates VIV earlier by reducing the oscillator natural frequency in water. Even though large PTC maintained its effectiveness in initiating galloping early, it has no effect on the earlier initiation of VIV, which starts at a nearly fixed reduced velocity. Lower spring stiffness and large PTC enable power generation at low current speed (0.2 m/s).

16 TIDAL AND WAVE POWER↗
DOE OSTI2023

Mechanical properties of heterogeneous metallic glasses: Insights from brick-and-mortar designs

The brick-and-mortar architectural paradigm is commonly applied in structural design to achieve an exceptional combination of strength and plasticity due to its highly tunable mechanical attributes. This study applies molecular dynamics simulations of tensile loading to investigate the mechanical properties and failure mechanisms of brick-and-mortar metallic glasses (BMMGs). The focus is primarily on the implications of the aspect ratio of the bricks and interlayer thickness on the strength, plasticity, and deformation mechanisms. Results indicate that the failure mode is typified by multiple shear bands localized within the softer mortar regions, creating a staggered network under smaller aspect ratios that significantly enhances plastic deformation. However, a transition to a single dominant SB occurs when the aspect ratio exceeds 4.1. In addition, results indicate that a concurrent improvement in strength and plasticity can be achieved by modulating the distance between brick layers in BMMGs. This enhancement originates from the extensive generation and interaction of shear transformation zones. Furthermore, this study highlights that a desirable balance between strength and plasticity can be obtained in BMMGs with appropriate brick aspect ratios and interlayer thicknesses, providing a potential design strategy for the advancement of novel metallic glasses with superior properties.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Air-transfer production method for large-area picosecond photodetectors

We have designed and prototyped the process steps for the batch production of large-area micro-channel-plate photomultipliers (MCPPMT) using the “air-transfer” assembly process developed with single LAPPD TM modules. Results are presented addressing the challenges of designing a robust package that can transmit large numbers of electrical signals for pad or strip readout from inside the vacuum tube and of hermetically sealing the large-perimeter window–body interface. We have also synthesized a photocathode in a large-area low-aspect-ratio volume and have shown that the micro-channel plates recover their functionality after cathode synthesis. These steps inform a design for a multi-module batch facility employing dual nested low-vacuum and ultra-high-vacuum systems in a small-footprint. The facility design provides full access to multiple MCP-PMT modules prior to hermetic pinch-off for leak-checking and real-time photocathode optimization.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Tensor-to-scalar ratio forecasts for extended LiteBIRD frequency configurations

LiteBIRD is a planned JAXA-led cosmic microwave background (CMB) B-mode satellite experiment aiming for launch in the late 2020s, with a primary goal of detecting the imprint of primordial inflationary gravitational waves. Its current baseline focal-plane configuration includes 15 frequency bands between 40 and 402 GHz, fulfilling the mission requirements to detect the amplitude of gravitational waves with the total uncertainty on the tensor-to-scalar ratio, δr, down to δr < 0.001. A key aspect of this performance is accurate astrophysical component separation, and the ability to remove polarized thermal dust emission is particularly important. In this paper we note that the CMB frequency spectrum falls off nearly exponentially above 300 GHz relative to the thermal dust spectral energy distribution, and a relatively minor high frequency extension can therefore result in even lower uncertainties and better model reconstructions. Specifically, we compared the baseline design with five extended configurations, while varying the underlying dust modeling, in each of which the High-Frequency Telescope (HFT) frequency range was shifted logarithmically toward higher frequencies, with an upper cutoff ranging between 400 and 600 GHz. In each case, we measured the tensor-to-scalar ratio r uncertainty and bias using both parametric and minimum-variance component-separation algorithms. When the thermal dust sky model includes a spatially varying spectral index and temperature, we find that the statistical uncertainty on r after foreground cleaning may be reduced by as much as 30–50% by extending the upper limit of the frequency range from 400 to 600 GHz, with most of the improvement already gained at 500 GHz. We also note that a broader frequency range leads to higher residuals when fitting an incorrect dust model, but also it is easier to discriminate between models through higher χ 2 sensitivity. Even in the case in which the fitting procedure does not correspond to the underlying dust model in the sky, and when the highest frequency data cannot be modeled with sufficient fidelity and must be excluded from the analysis, the uncertainty on r increases by only about 5% for a 500 GHz configuration compared to the baseline.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2022

Microstructure-refinement–driven enhanced tensile properties of high-pressure die-cast A380 alloy through friction stir processing

This work employs friction stir processing (FSP), a well-known severe plastic deformation technique, to selectively modify the microstructure of thin-walled, high-pressure die-cast (HPDC) aluminum alloy A380, a major HPDC alloy fabricated in the die casting sector. FSP effectively breaks down Al dendrites and acicular Si particles, creating a homogenized distribution of equiaxed Si particles in the aluminum matrix. After FSP, the refined Si particles (~1.5 µm) are smaller than the eutectic Si particles (3–8 µm) in HPDC condition. In addition, interparticle distance has decreased almost 50% compared to dendritic arm spacing, and FSP has reduced the aspect ratio of Si particles to ~2. Furthermore, FSP eliminates porosity, and breaks down needle-like second-phase Fe-Mn and Cu-rich particles, yielding a refined, homogeneous distribution. The FSP-induced microstructural refinement and porosity reduction improve bulk yield strength and ductility by 23% and 66%. Tensile properties are enhanced beyond those of the die skin of the HPDC plate, and the alloy possesses lower defect density and a highly refined microstructure. This study establishes the viability of FSP as a tool for microstructure modification and mechanical property improvement for HPDC Al alloys for the light-weighting goal of the automotive industries.

36 MATERIALS SCIENCE↗