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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 OSTI2025

Methane pyrolysis by Joule heating for graphitic carbon and hydrogen production

The global energy transition toward sustainability requires technologies that can decarbonize energy carriers and fuels while producing valuable materials. Methane, a primary component of natural gas, is both a high-energy-density fuel and a significant greenhouse gas. This study reports an approach for methane pyrolysis utilizing Joule heating within the deposition substrate to drive the endothermic reaction. With electric current passing through a resistive porous carbon cloth, heat is generated to break C-H bonds of methane molecules. Here, the decomposition of methane as it flows through the cloth results in hydrogen production and the formation of conformally layered graphite around the carbon fibers. The effects of input power, chamber pressure, feedstock flow rate, and process duration on hydrogen and graphite production are characterized via in situ mass spectrometry and laser absorption spectroscopy, resulting in methane conversion rates up to 88%, with hydrogen and carbon yields of 82% and 72%, respectively. Material characterization verifies uniform high-quality graphite deposition, with a Raman I D /I G ratio of 0.1 and 3.38 Å d-spacing. This Joule heating method for catalyst-free methane pyrolysis offers the potential for advancing hydrogen production technology by simultaneously producing valuable materials such as solid graphite, thus enhancing the economic viability of the fuel decarbonization process.

Energy Resources↗
DOE OSTI2025

Non-destructive evaluation and machine learning methods for inspection of spent nuclear fuel canisters: A state-of-the-art review

Nuclear energy is among the cleanest and most efficient energy sources currently available. The operation of nuclear power plants (NPPs) produces large amounts of high-level radioactive waste known as spent nuclear fuel (SNF). Currently, large amounts of SNF is stored in dry cask storage systems (DCSSs) for extended interim storage until a permanent disposal solution becomes available. During the extended interim storage, the DCSS, particularly the SNF canisters, may degrade and abnormal conditions may occur. Therefore, non-destructive evaluation (NDE) and machine learning (ML) approaches are necessary for inspection of SNF canisters. This paper presents a state-of-the-art review of literature by summarizing recent progress made on the applications of NDE and ML for inspection of SNF canisters. Sixteen NDE methods are examined and compared: visual inspection, ultrasonic guided waves (UGWs), laser-based approaches, acoustic emission (AE), eddy current testing (ECT), non-invasive acoustic sensing, dynamic modal testing, cosmic ray muons tomography, neutron imaging, gamma rays detection, fiber optical sensors, through-wall communications, X-ray computed tomography (CT), vibrothermography, monoenergetic photon sources, and surface acoustic wave (SAW) sensors. The technology readiness level (TRL) for each method is assessed and compared. Recent publications on ML-enhanced visual inspection, AE, non-invasive acoustic sensing, dynamic modal testing, and neutron imaging for SNF canisters are summarized and future research needs are identified. In conclusion, this review article provides a convenient reference on the state-of-the-art applications of NDE and ML methods for inspection of SNF canisters.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Mechanical Properties and Interfacial Bonding of Overmolded Polymer Composite Lattice Structures

This study investigates the mechanical properties and interfacial bonding of Polyamide 12 filled with Glass Fiber (PA12/GF) lattice structures overmolded with Nylon 66 (PA66) and Thermoplastic Polyurethane (TPU). The PA12/GF lattices, designed in Gyroid, Isotruss, and Octahedral geometries, were produced using the Selective Laser Sintering (SLS) technique. The thermal characteristics of both the lattice and overmolding materials were analyzed using Differential Scanning Calorimetry (DSC) and Thermogravimetric Analysis (TGA). The mechanical performance and interfacial bonding were evaluated through mechanical testing and microstructural analysis. The results indicate that overmolding improved flexural strength and impact resistance of the PA12/GF lattices. For instance, the plain PA12/GF Isotruss lattice exhibited a flexural strength of 15.5 MPa. By overmolding it with TPU the flexural strength increased by up to 137%, while PA66-overmolding resulted in an increase of 371%, achieving a flexural strength of 73 MPa. In terms of impact resistance, TPU-overmolding improved performance significantly, with an increase of 1800% (Gyroid) compared to the plain lattice. Microstructural analysis revealed good adhesion at the interface, especially when both the lattice and overmolding materials were thoroughly dried prior to the overmolding process to minimize interfacial porosity. This study highlights the potential of using overmolding to enhance lattice structures performance, offering lightweight and cost-efficient solutions for automotive applications.

Talabi, Isaac [ORNL] (ORCID:0000000340215594)↗
DOE OSTI2021

Collective optical Thomson scattering in pulsed-power driven high energy density physics experiments (invited)

Optical collective Thomson scattering is used to diagnose magnetized high energy density physics experiments at the Magpie pulsed-power generator at Imperial College London. The system uses an amplified pulse from the 2nd harmonic of a Nd:YAG laser (3 J, 8 ns, 532 nm) to probe a wide diversity of hightemperature plasma objects; with densities in the range of 10 17 -10 19 cm -3 and temperatures between 10 eV and a few keV. The scattered light is collected from 100 μm-scale volumes within the plasmas, which are imaged onto optical fiber arrays. Multiple collection systems observe these volumes from different directions, providing simultaneous probing with different scattering K-vectors (and different associated α-parameters, typically in the range 0.5 – 3) allowing independent measurements of separate velocity components of the bulk plasma flow. The fiber arrays are coupled to an imaging spectrometer with a gated ICCD. The spectrometer is configured to view the ion-acoustic waves (IAWs) of the collective Thomson scattered spectrum. Fits to the spectra with the theoretical spectral density function S(K,ω) yield measurements of the local plasma temperatures and velocities. Fitting is constrained by independent measurements of the electron density from laser interferometry, and the corresponding spectra for different scattering vectors. Furthermore, this TS diagnostic has been successfully implemented on a wide range of experiments, revealing temperature and flow velocity transitions across magnetized shocks, inside rotating plasma jets and imploding wire arrays, as well as providing direct measurements of drift velocities inside a magnetic reconnection current sheet.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

The SuperCam Instrument Suite on the NASA Mars 2020 Rover: Body Unit and Combined System Tests

The SuperCam instrument suite provides the Mars 2020 rover, Perseverance, with a number of versatile remote-sensing techniques that can be used at long distance as well as within the robotic-arm workspace. These include laser-induced breakdown spectroscopy (LIBS), remote time-resolved Raman and luminescence spectroscopies, and visible and infrared (VISIR; separately referred to as VIS and IR) reflectance spectroscopy. A remote micro-imager (RMI) provides high-resolution color context imaging, and a microphone can be used as a stand-alone tool for environmental studies or to determine physical properties of rocks and soils from shock waves of laser-produced plasmas. SuperCam is built in three parts: The mast unit (MU), consisting of the laser, telescope, RMI, IR spectrometer, and associated electronics, is described in a companion paper. The on-board calibration targets are described in another companion paper. Here we describe SuperCam’s body unit (BU) and testing of the integrated instrument. The BU, mounted inside the rover body, receives light from the MU via a 5.8 m optical fiber. The light is split into three wavelength bands by a demultiplexer, and is routed via fiber bundles to three optical spectrometers, two of which (UV and violet; 245–340 and 385–465 nm) are crossed Czerny-Turner reflection spectrometers, nearly identical to their counterparts on ChemCam. The third is a high-efficiency transmission spectrometer containing an optical intensifier capable of gating exposures to 100 ns or longer, with variable delay times relative to the laser pulse. This spectrometer covers 535–853 nm ( $105\text{--}7070~\text{cm}^{-1}$ Raman shift relative to the 532 nm green laser beam) with $12~\text{cm}^{-1}$ full-width at half-maximum peak resolution in the Raman fingerprint region. The BU electronics boards interface with the rover and control the instrument, returning data to the rover. Thermal systems maintain a warm temperature during cruise to Mars to avoid contamination on the optics, and cool the detectors during operations on Mars.Results obtained with the integrated instrument demonstrate its capabilities for LIBS, for which a library of 332 standards was developed. Examples of Raman and VISIR spectroscopy are shown, demonstrating clear mineral identification with both techniques. Luminescence spectra demonstrate the utility of having both spectral and temporal dimensions. Finally, RMI and microphone tests on the rover demonstrate the capabilities of these subsystems as well.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Multi-modality deep learning for pulse prediction in homogeneous nonlinear systems via parametric conversion

In this Letter, we introduce FusionNet, a multi-modality deep learning framework designed to predict and analyze output pulses in high-power rare-earth-doped laser systems driving parametric conversion in homogeneous guided nonlinear media. FusionNet integrates temporal, spectral, and physical experimental conditions to model ultrafast nonlinear phenomena, including parametric nonlinear frequency conversion, self-phase modulation, and cross-phase modulation in homogeneous guided systems such as gas-filled hollow-core fibers. These systems bridge physical models with experimental data, advancing our understanding of light-guiding principles and nonlinear interactions while expediting the design and optimization of on-demand high-power, high-brightness systems. Our results demonstrate a 73% reduction in prediction error and an 83% improvement in computational efficiency compared to conventional neural networks. This work establishes a new paradigm for accelerating parametric simulations and optimizing experimental designs in high-power laser systems, with further implications for high-precision spectroscopy, quantum information science, and distributed entangled interconnects.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Laser induced breakdown spectroscopy of liquid

Chemical composition of liquid phase samples is determined based on laser induced ablation spectroscopy of droplets. An aerosol jet comprising a carrier gas and liquid phase sample droplets, less than about 10 microns in diameter, is formed. An emissive plasma plume is generated from the sample droplets using a pulsed laser to deposit energy at a focal point in the aerosol jet. Light from the plasma plume is gathered with a concave mirror and focused into one end of a fiber optic lightguide. The lightguide can transmit spectral emissions from the plume to a spectrometer/detector which can send wavelength and intensity values to a computer. The computer is operable to determine a liquid sample composition based on the wavelength and intensity values.

Bol'shakov, Alexander A.↗
DOE OSTI2026

Texture development in magnetostrictive Fe-Ga alloys processed by laser powder bed fusion

Iron-gallium (Fe-Ga, Galfenol) alloys are promising magnetostrictive materials for actuators, sensors, and energy harvesting, but their performance is highly sensitive to microstructure and texture. Additive manufacturing by laser powder bed fusion (LPBF) offers a pathway to engineer texture and integrate functional materials into complex geometries. Here, we fabricate Fe-Ga alloys (Fe 82.2 Ga 17.8 ) by LPBF of gas-atomized powders and systematically optimize laser power and scan speed to maximize density and control texture. Nearly full-density parts (up to 99.6 %) are achieved within a narrow processing window. Electron backscatter diffraction (EBSD) reveals a strong <100> fiber texture aligned with the build direction and columnar grains up to 1 mm long. Magnetostriction measurements show saturation magnetostriction of 190 ppm in the build direction. Correlating texture data with macroscopic magnetostriction, we estimate intrinsic magnetostriction constants (λ 100 = 228 ppm, λ 111 = 12 ppm), closely matching single crystal-derived values. These results demonstrate the critical interplay between processing, texture, and functional performance in additively manufactured Fe-Ga alloys and establish LPBF as a viable route for high-performance magnetostrictive materials.

Additive manufacturing↗
DOE OSTI2020

Calibration of the CMS hadron calorimeters using proton-proton collision data at √ s = 13 TeV

Methods are presented for calibrating the hadron calorimeter system of the CMS detector at the LHC. The hadron calorimeters of the CMS experiment are sampling calorimeters of brass and scintillator, and are in the form of one central detector and two endcaps. These calorimeters cover pseudorapidities |η| < 3 and are positioned inside the solenoidal magnet. An outer calorimeter, outside the magnet coil, covers |η| < 1.26, and a steel and quartz-fiber Cherenkov forward calorimeter extends the coverage to |η| < 5.19. The initial calibration of the calorimeters was based on results from test beams, augmented with the use of radioactive sources and lasers. The calibration was improved substantially using proton-proton collision data collected at √ s = 7 , 8, and 13 TeV, as well as cosmic ray muon data collected during the periods when the LHC beams were not present. The present calibration is performed using the 13 TeV data collected during 2016 corresponding to an integrated luminosity of 35.9 fb -1 . The intercalibration of channels exploits the approximate uniformity of energy collection over the azimuthal angle. The absolute energy scale of the central and endcap calorimeters is set using isolated charged hadrons. The energy scale for the electromagnetic portion of the forward calorimeters is set using Z→ ee data. The energy scale of the outer calorimeters has been determined with test beam data and is confirmed through data with high transverse momentum jets. In this paper, we present the details of the calibration methods and accuracy.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

A Miniaturized, High-Bandwidth Optical Fiber Fabry–Perot Cavity Vibration Sensor Demonstrated up to 800 °C

A typical structural health monitoring technique involves measuring the vibrational characteristics of components or systems to detect signs of degradation or damage. Many industrial applications require engineered systems to safely operate under extreme, high-temperature environments that pose challenges not only to materials but also to sensors that would be used for structural health monitoring. Here, in this study, miniaturized optical Fabry-Perot cavities (FPCs) were developed and tested as a means of measuring the resonant frequencies of metal components that are most relevant to extreme-environment applications. Two of the three candidate FPC designs tested up to 800 ° C provided accurate measurements (validated by theoretical models and laser Doppler vibrometry) of the fundamental vibrational mode of the specimen to which each was bonded, although both sensors failed during thermal cycling. An analysis of the reflected optical spectrum from the FPC and X-ray computed tomography revealed two opportunities to improve the sensor reliability. First, the Cu optical fiber coating that was used could either be replaced with a more oxidation-resistant material or protected with commercially available films. Second, the adhesives used to bond the fibers to metal capillaries and establish the FPC could be replaced with a more robust solution, although the Resbond 907TS adhesive appeared to outperform Resbond 907.

Birri, Anthony [Oak Ridge National Laboratory (ORN↗
DOE OSTI2023

Embedded Fiber Bragg Grating (FBG) Sensors Fabricated by Ultrasonic Additive Manufacturing for High-Frequency Dynamic Strain Measurements

This article demonstrates high-frequency dynamic strain measurements using fiber Bragg grating (FBG) sensors embedded in metal parts. Using an ultrasonic additive manufacturing (UAM) process, FBGs inscribed in polyimide coated optical fibers were embedded in aluminum parts. An electromagnetic shaker was used to exert dynamic events on the embedded FBG sensors with frequencies from 1 to 10 kHz. The high-speed interrogation of FBG sensors was accomplished using a tunable vertical-cavity surface-emitting laser (VCSEL) and a high-speed interrogation system sampling at 120 kHz. The strain response measured by the FBG sensors was compared with real-time measurements using a laser velocimeter. A finite-element analysis (FEA) was performed to simulate responses to both static strain and high-frequency dynamic strain. In conclusion, results show that strains as small as 2.5$με$ can be resolved at frequencies up to 10 kHz.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A three-dimensional pore-scale model for redox flow battery electrode design analysis

A three-dimensional (3-D) pore-scale model has been developed to construct multiscale fibrous electrodes for redox flow batteries (RFB). New designs, such as biporous electrodes modify electrode structures by creating secondary pores on single carbon fiber to reduce internal battery resistance. Existing pore-scale models only resolve electrodes to the single carbon fiber scale and cannot incorporate recent multiscale electrode designs into numerical models. Our new model aims to bridge this gap and provide a tool to rapidly screen new electrode configurations. Two multiscale electrodes, laser-perforated and biporous electrodes, were investigated at varying operation conditions with the proposed 3-D pore-scale models. The laser-perforated electrode exhibits a reduced pressure drop, but follows the same permeability correlation compared to the corresponding pristine electrode. For the biporous electrode, the added specific surface area and faster reaction kinetics from the secondary pores are the most influential factors leading to improved battery efficiency. However, operating the biporous electrode in limiting current density conditions should be avoided due to the decreased mass transfer efficiency and a more significant voltage loss. Finally, we believe that our 3-D pore-scale model can accelerate the flow battery electrode design process and provide new insights into electrode geometry optimizations.

25 ENERGY STORAGE↗
DOE OSTI2022

Effect of Cooling Rate on Nano-Eutectic Formation in Laser Surface Remelted and Rare Earth Modified Hypereutectic Al-20Si Alloys

Laser Surface Remelting (LSR) was applied to arc-melted Al-20Si-0.2Sr, Al-20Si-0.2Ce, and Al-20Si hypereutectic alloys to refine microstructures. Experiments revealed that microstructures in the melt pool varied from fully eutectic to a mixture of Al dendrites and inter-dendritic eutectic. We calculated cooling rates using the Eagar-Tsai model and correlated cooling rates with characteristic microstructures, revealing that a cooling rate on the order of 104 K/s could lead to maximized fully eutectic microstructure morphology. Due to rapid solidification, the Si composition in the LSR eutectic was measured at 18.2 wt.%, higher than the equilibrium eutectic composition of 12.6 wt.%Si. Compared to Al-20Si, Ce addition had no significant effect on the volume fraction of the fully eutectic structure but refined Si fibers to approximately 30 nm in diameter. Sr addition did not further refine the diameter of eutectic Si fibers compared to Al-20Si but increased the volume fraction of the fully eutectic microstructure morphology. The refinement ratio (φ) of the Si fiber diameter from the bottom of the melt pool to the surface for the three alloys was similar, at around 28%. The established correlation between the cooling rate and the size and morphology of the microstructure within the melt pool will enable tailoring of the microstructure in laser-processed as well as deposited alloys for high strength and plasticity.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Flow Measurements in Pressurized Helium Gas Cooling Channels

Production of metastable Technetium-99 (Tc-99m) is vital to the medical imaging community. It is a radioactive tracer that emits gamma rays as it decays and it is these gamma rays that are then detected through imaging. Tc-99m is extracted from the decay of Molybdenum-99 (Mo-99) which has a half-life of about 2-3 days. One method of generating Mo-99 is using accelerator based technology, through the irradiation of Mo-100 using an electron beam. This is part of the NNSA’s mission to produce Mo-99 commercially, within the US, without the use of highly enriched uranium (HEU) in support of nonproliferation and global security. Los Alamos National Laboratory (LANL) is working with NorthStar medical Radioisotopes (NMR) on their efforts to produce Mo-99 from the irradiation of Mo-100 targets. The NMR target consists of an Inconel window that allows the electron beam to penetrate and irradiate a stack of Mo-100 discs. The irradiation process generates large amounts of heat and requires extensive cooling of the Mo-100 targets and target housing using pressurized helium gas. Before beam on target, the design of the target stack and target housing is tested at LANL using laser based diagnostics experiments. We quantify the velocity field of the helium gas around the target housing to estimate whether the cooling provided is sufficient for the design and to validate computational fluid dynamics (CFD) models. Fiber optic imaging is also developed for use during cold testing (without beam on target) as well as during irradiation, to obtain real time information on disc performance.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2021

Electron Beam Powder Bed Fusion Additive Manufacturing of Refractory Metals

The processing of refractory metals via additive manufacturing (AM) presents an opportunity to fabricatecomponents not possible through traditional powder metallurgy techniques. However, processing via AM isextremely challenging and there exist a host of technological limitations still unaddressed. Molybdenumand tungsten are two materials of particular interest for nuclear energy generation applications. Themajority of existing work on the processing of these materials is focused on laser powder bed fusion whereasa smaller body of work exists for electron beam melting AM. In general, material with acceptable densitycan be obtained via both routes however cracking is much more difficult to mitigate against. Strongcrystallographic fiber textures have been observed across a range of refractory systems. In this work wepresent our recent findings on electron beam melting AM of pure tungsten and molybdenum. Wedemonstrate that defect-free material can be obtained in both systems with appropriate processing. Strongbuild direction crystallographic texture fibers are observed in both systems. In molybdenum the fibertexture has direct impact on the resulting tensile behavior. These results demonstrate that electron beamAM is a suitable technology for processing these difficult to fabricate materials.

Fernandez-Zelaia, Patxi↗
DOE OSTI2023

Digital fabrication of a small diameter polymer optical waveguide

A novel polymer optical waveguide and method of manufacturing is presented herein. A digitally manufactured process is described which utilizes a micro-dispensed UV optical adhesive as the contour guiding cladding, a fused deposition modeling technology for creating a core, and a subtractive laser process to finish the two ends of the optical interconnect. The optical waveguide can be printed directly on a circuit board in some embodiments. Alternatively, using a slightly modified process including a step to bond the optical fiber to the substrate, the optical interconnect can be manufactured on a flexible substrate.

Bhethanabotla, Venkat Rama↗