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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 289 records · Page 16

Designing ITER motional Stark effect line shift (MSE-LS) spectrometers

As a part of ITER beam aided diagnostics, the design of Motional Stark Effect (MSE) diagnostic observing the emission from the Balmer-α line is underway. The physics of Stark splitting shows that the Stark manifold is polarization dependent, and the energy splitting results in a line shift proportional to the electric field. Due to the challenges of maintaining the calibration of the plasma facing mirrors in ITER, the conventional MSE polarimetry measurement technique is replaced with a spectral approach that is deemed more favorable in the ITER environment. The MSE line shift (LS) diagnostic is designed to quantify the Lorentz electric field magnitude by measuring the Stark manifold using visible spectroscopy. In the presence of large magnetic fields and high energy heating beams of 1 MeV, the expected Stark splitting is much larger than in typical devices. The MSE-LS design has unique challenges requiring careful consideration and modeling of its viewing geometry and photon budget. The MSE-LS approach on ITER is promising but has stringent demands on the allowable errors for the statistical and systematic fitting uncertainties. In this study, a full system model and numerical simulations of data for each sightline are completed. For a range of optical transmission fractions, photon noise analysis is conducted to determine the statistical uncertainties. This provides guidance on the spectrometer throughput, dispersion at the detector, optics, and other design choices. A conceptual design of a high throughput spectrometer with a volume phase transmission grating is presented.

Instruments & Instrumentation↗

Outer shell symmetry for double shell capsules with aluminum ablators

Double shell targets are a promising potential avenue to obtain robust neutron yield at current laser facilities. Similar to single shell designs, double shells require the symmetric implosion of an ablator in order to uniformly compress and heat a fuel volume, with the goal of achieving thermonuclear burn. Significant differences between double and single shells include the usage of an aluminum ablator as well as a reverse ramp laser pulse. In addition, double shells require a different convergence than single shells for fuel ignition. Numerical implosion studies at various energies with comparisons to experimental outcomes are required to gain confidence that simulations can capture the ablator shape from subscale to full scale. The current work builds on previous implosion experiments conducted at 1-MJ laser energy to confirm achieved ablator symmetry at 1.25 and 1.5 MJ. Average ablator P2 and P4 shapes measured in these experiments are within 5% of the simulated shape, which merits the platforms for further experimental studies.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Atomic layer deposition of nanofilms on porous polymer substrates: Strategies for success

Atomic layer deposition (ALD) is a versatile technique for engineering the surfaces of porous polymers, imbuing the flexible, high-surface-area substrates with inorganic and hybrid material properties. Previously reported enhancements include fouling resistance, electrical conductance, thermal stability, photocatalytic activity, hydrophilicity, and oleophilicity. However, there are many poorly understood phenomena that introduce challenges in applying ALD to porous polymers. In this paper, we address five common challenges and ways to overcome them: (1) entrapped precursor, (2) embrittlement, (3) film fracture, (4) deformation, and (5) pore collapse. These challenges are often interrelated and can exacerbate one another. To investigate these phenomena, we applied various ALD chemistries to porous polymers including polyethersulfone, polysulfone, polyvinylidene fluoride, and polycarbonate track-etched membranes. Reaction-diffusion modeling revealed why certain precursors and processing conditions result in embrittling subsurface material growth, entrapment of unreacted precursors, and nongrowth. We quantify the limits of ALD processing temperatures that are dictated by thermal expansion mismatch and can lead to fractured ALD films. The results herein allow us to make recommendations to avoid, mitigate, or overcome the difficulties encountered when performing ALD and plasma-enhanced ALD on porous polymers. We intend this article to serve as a “lessons learned” guide informed by previous experience to provide a better understanding of the difficulties and limitations of ALD on porous polymers and knowledge-based guidelines for successful depositions. This knowledge can accelerate future research and help experimentalists navigate and troubleshoot as they expose porous polymers to reactive precursor vapors.

36 MATERIALS SCIENCE↗

Charm and bottom hadrons in hot hadronic matter

Heavy quarks, and the hadrons containing them, are excellent probes of the QCD medium formed in high-energy heavy-ion collisions, as they provide essential information on the transport properties of the medium and how quarks color-neutralize into hadrons. Large theoretical and phenomenological efforts have been dedicated thus far to assess the diffusion of charm and bottom quarks in the quark–gluon plasma and their subsequent hadronization into heavy-flavor (HF) hadrons. However, the fireball formed in heavy-ion collisions also features an extended hadronic phase, and therefore any quantitative analysis of experimental observables needs to account for the rescattering of charm and bottom hadrons. This is further reinforced by the presence of a QCD cross-over transition and the notion that the interaction strength is maximal in the vicinity of the pseudo-critical temperature. We review existing approaches for evaluating the interactions of open HF hadrons in a hadronic heat bath and the pertinent results for scattering amplitudes, spectral functions and transport coefficients. While most of the work to date has focused on D -mesons, we also discuss excited states as well as HF baryons and the bottom sector. Both the HF hadro-chemistry and bottom observables will play a key role in future experimental measurements. We also conduct a survey of transport calculations in heavy-ion collisions that have included effects of hadronic HF diffusion and assess its impact on various observables.

effective field theories↗

Getting to the bottom of it: do laser-driven coils really work? (Final Technical Report)

Since claims of ultra-high (up to ~ 1.5 kiloTesla) magnetic fields appeared in the scientific literature, it became necessary to conduct controlled experiments to determine the validity of these claims and assess the real capability of laser-driven coils (LDCs) to produce high B-field to be used in HEDP (high energy density physics) experiments. This project assessed the viability of generating magnetic fields using LDCs. This was accomplished with a thorough analysis of several focused experiments on the OMEGA EP laser at LLE designed to measure the magnetic field inside LDCs. We demonstrated how problems with prior diagnostic analyses have led to overestimations of the magnetic fields generated from LDCs.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

ICRF near-field effects sensitivity to magnetic tilt-angle

This paper complements the study reported in G. Urbanczyk et al 2025 Nucl. Fusion 65 046018 by investigating how near-field effects from Ion Cyclotron Range of Frequency (ICRF) antennas depend on the magnetic geometry, particularly focusing on the sensitivity of rectified sheath potentials and associated impurity production to variations in magnetic field tilt-angle. Simulations were conducted using Petra-M, employing a flat model of the ASDEX Upgrade (AUG) three-strap antenna, and COMSOL, utilizing a curved model of the WEST antenna. Results demonstrate indications of sensitivity of the rectified sheath potentials and impurity sputtering to the alignment of Faraday screen bars with the magnetic field lines, emphasizing the necessity for careful consideration of geometric alignment in antenna design for fusion devices. This trend is consistent with experimental data measured with various diagnostics.

Urbanczyk, Guillaume [Universite de Lorraine, Nanc↗

Synthesis, Characterization, and Testing of High-Lithium-Density Composite Breeders

Solid tritium breeder materials must first and foremost have sufficiently high concentrations of lithium to enable a plant-scale tritium breeding ratio greater than 1:1. However, in addition to lithium content, such breeder materials must also meet other performance metrics including high tritium release rates, thermal conductivities, and irradiation damage tolerance. Perhaps most importantly, tritium breeders must maintain their mechanical integrity during reactor operation so as to avoid degradation which can jeopardize the functionality of the tritium breeder blanket module, which in most designs takes the form of a pebble bed geometry. Unfortunately, the mechanical robustness of most lithium-bearing ceramics under investigation for fusion applications is often inversely related to the lithium atom density. For example, a material such as lithium oxide (Li2O), which has one of the highest lithium atom densities, has a much lower mechanical splitting strength than lithium metatitanate (Li2TiO3), though Li2TiO3 has less than half the lithium atom density of Li2O. This work seeks to provide an alternative to monolithic ceramic tritium breeders, in the form of metal-reinforced composite tritium breeders. Specifically, composite tritium breeders have been synthesized combining Li2O with various ferrous metal reinforcements via electric field assisted sintering (EFAS), also known as spark plasma sintering (SPS). As the metal reinforcement content is increased, metallic networks are observed, via electron microscopy and X-ray computed tomography, to form throughout the composite material. Through destructive mechanical testing, even dilute metal reinforcement loading enables drastic mechanical strength improvements over pure Li2O while higher loadings give rise to quasi-ductile behavior and higher ultimate strengths than Li2TiO3 – while still maintaining a higher density of lithium atoms than Li2TiO3 and many other breeder candidates. In addition to microstructural characterization and mechanical testing, thermal property measurements and hydrogen permeability testing are underway to further assess the suitability of such composites for fusion reactor applications.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Height-resolved emission spectroscopy and high-speed imaging of the TiAl6V4 vapor plume under laser powder bed fusion conditions

Optical emission spectroscopy is increasingly used as an in situ monitoring technique during laser powder bed fusion (LPBF) because plume emission holds elemental information not found in other in situ sensing techniques. This work explores the shape, stability, and temperature of the emission plume above the melt pool of Ti6Al4 V undergoing laser scans under LPBF-like processing conditions, using high-speed video and height-resolved spectroscopy to study the details of plume dynamics. Optical emission spectroscopy is conducted in the 480 nm to 525 nm region, where Ti emission is strong, with 0.3 mm vertical resolution above the baseplate. The Boltzmann plot method is used to determine temperature at each probed elevation, which indicates that the hottest location of the plume is occasionally elevated 0.3 mm to 0.6 mm above the scanning surface. The results show that the plume shape, stability, temperature, and spectra are highly dependent on the processing conditions. We highlight some of the complexities of optical emission spectroscopy and discuss potential challenges for implementing optical emission spectroscopy across an entire build.

36 MATERIALS SCIENCE↗

Laser-driven ion and electron acceleration from near-critical density gas targets: Towards high-repetition rate operation in the 1 PW, sub-100 fs laser interaction regime

Ion acceleration from gaseous targets driven by relativistic-intensity lasers was demonstrated as early as the late 1990s, yet most of the experiments conducted to date have involved picosecond-duration, Nd:glass lasers operating at low repetition rate. Here, we present measurements on the interaction of ultraintense ( ≈ 10 20 W cm − 2 , 1 PW ) , ultrashort ( ≈ 70 fs ) Ti:Sa laser pulses with near-critical ( ≈ 10 20 cm − 3 ) helium gas jets, a debris-free targetry with the potential for future compatibility with high ( ≈ 1 Hz ) repetition rate operation. We provide evidence of α particles being forward accelerated up to ≈ 2.7 − MeV energy with a total flux of ≈ 10 11 sr − 1 as integrated over > 0.1 − MeV energies and detected within a 0.5 − mrad solid angle. We also report on on-axis emission of relativistic electrons with an exponentially decaying spectrum characterized by a ≈ 10 − MeV slope, i.e., five times larger than the standard ponderomotive scaling. The total charge of these electrons with energy above 2 MeV is estimated to be of ≈ 1 nC , corresponding to ≈ 0.1 % of the laser drive energy. In addition, we observe the formation of a plasma channel, extending longitudinally across the gas density maximum and expanding radially with time. These results are well captured by large-scale particle-in-cell simulations, which reveal that the detected fast ions most likely originate from reflection off the rapidly expanding channel walls. The latter process is predicted to yield ion energies in the MeV range, which compare well with the measurements. Finally, direct laser acceleration is shown to be the dominant mechanism behind the observed electron energization. Published by the American Physical Society 2024

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Multiphysics and Multiscale Simulation Methods for Electromagnetic Energy Assisted Fossil Fuel to Hydrogen Conversion (Final Scientific/Technical Report)

This report summarizes the technical accomplishments of the four-year research project “Multiphysics and Multiscale Simulation Methods for Electromagnetic Energy Assisted Fossil Fuel to Hydrogen Conversion” (Award No. DE-FE0032092), conducted at Howard University and the University of Houston (subawardee) from September 2021 to August 2025. The project successfully achieved all four major objectives: 1. 3D Structural Characterization – Developed 3D optical imaging and mechanical sectioning methods to characterize catalyst distribution and support morphology in nickel foam substrates. Successfully reconstructed 3D geometries and imported them into COMSOL Multiphysics for electromagnetic simulations. 2. EM Hotspot Simulation – Created all-frequency stable electromagnetic formulations and 3D nodal discontinuous Galerkin (NDG) methods for coupled electromagnetic-thermal-fluid problems in multiscale catalytic media. Demonstrated stable solutions from DC to microwave frequencies. 3. Multiphysics Coupling – Developed multiscale simulation methods coupling FEM electromagnetic solvers with thermal transport equations. Reactive molecular dynamics (ReaxFF MD) simulations were performed to investigate catalytic reaction mechanisms at the atomistic level. Demonstrated electromagnetic-thermal co-simulation capabilities for porous catalyst structures. 4. System Optimization – Designed and optimized EM-assisted catalytic systems using nickel foam and carbon foam structures, demonstrating significant temperature increases due to microwave heating. Observed and characterized plasma generation in carbon fiber catalysts. Investigated multiple reaction chamber geometries for improved microwave energy deposition. The project produced significant scientific contributions including 15+ peer-reviewed publications, trained multiple Ph.D. students and undergraduate researchers, and advanced the understanding of microwave-assisted hydrogen production from fossil fuels.

08 HYDROGEN↗

Broadband multiwavelength properties of the archetypal blazar 3C 279 during the 2017 Event Horizon Telescope campaign

The archetypal blazar 3C 279 hosts a prominent relativistic jet and exhibits strong broadband variability across the electromagnetic spectrum. In April 2017, the Event Horizon Telescope (EHT) observed 3C 279, alongside one of the most extensive quasi-simultaneous multiwavelength (MWL) campaigns ever conducted. With the aim of investigating the physical processes governing 3C 279, we analyzed individual observations and multiband light curves, and constructed a new quasi-simultaneous MWL spectrum. We also performed phenomenological modeling using the turbulent extreme multi-zone (TEMZ) model to constrain the fundamental physical properties of the source. The EHT observations reveal a clear flux increase in the innermost core between April 5 and 11, 2017. Over a broader timescale, radio measurements at longer wavelengths show concurrent enhancements in core flux and polarization around mid-April, coinciding with the ejection of a superluminal knot. Record UV-optical flares with strong polarization variability occurred in late March, followed by gamma-ray activity that declined before the end of the EHT observing period. During this interval, the source remained in a low X-ray state and showed no detectable VHE emission. The TEMZ modeling suggests that the broadband spectrum and variability of 3C 279 can be explained within a jet scenario in which turbulent plasma cells are compressed by a stationary conical shock. However, alternative interpretations, such as magnetic reconnection or a moving shock-in-jet event, remain plausible. This coordinated MWL campaign advances our understanding of the origin of jet and gamma-ray emission in 3C 279, while also providing a comprehensive publicly available dataset that will serve as a valuable reference for future studies.

Principe, G. [Trieste U.; INFN, Trieste; Bologna, ↗

Detection of Br and I as atomic anions using liquid sampling – atmospheric pressure glow discharge/Orbitrap mass spectrometry

The quantification and determination of halogen isotope composition is essential in many fields including geochemistry and nuclear forensics. Detection of the halogen elements is commonly attempted with inductively coupled plasma mass spectrometry (ICP-MS) however, there are multiple challenges faced. Most significantly this includes very poor ionization efficiency and the potential for isobaric interferences from either matrix or plasma species. Thus, sensitivity and accuracy are often limiting issues. Here a liquid sampling-atmospheric pressure glow discharge (LS-APGD) ionization source is coupled with an ultrahigh resolution Orbitrap MS to perform halogen detection of bromine and iodine as initial analytes. This facilitates simple and sensitive detection of these elements as atomic anions from simple aqueous salt solutions. Collision-induced dissociation (CID) and higher-energy collisional dissociation (HCD) energies were optimized to produce the maximum response of Br − and I − . The LS-APGD conditions were optimized using a design of experiments (DOE) approach for Br − and I − concurrently. Response curves for Br − and I − solutions determined limit of detection (LOD) values of 50 pg and 5 pg, respectively, in 20 μL aliquots. The curves indicated response factors of 0.67 for 79 Br − and 0.90 for 127 I − . Br isotope ratios were determined with precision between 0.7 and 7.3% RSD, with the isotope ratios determined with precision 0.8% RSD at concentrations above the limit of quantification. Preliminary tests were conducted to evaluate the effect of different cations (Na + , K + , and Mg 2+ ) on Br − responses, with no discernible impacts observed on the halogen signal responses. This study demonstrates the potential use of the LS-APGD-Orbitrap-MS for the detection of multiple halogens while avoiding interferences, minimizing sample preparation, and overcoming ionization barriers.

Lang, Dehlia A. [Clemson University, SC (United St↗

Eliminating Signal Bias Caused by Vacuum System Backstreaming in the Diagnostic Residual Gas Analyzer of ITER

In fusion neutral gas analysis, such as with the Diagnostic Residual Gas Analyzer (DRGA) for ITER, the primary measurement range of interest comprises the low-amu species (1 to 6), especially deuterium and helium. The challenge in successfully obtaining accurate measurements is two-fold. First, the sensitivity of the method must be sufficient to resolve trace amounts accurately; typically, one percent or less. Second, the gas signal from the fusion processes must be free of bias caused by the latent presence (from system outgassing and/or vacuum backstreaming) of these gases to enable accurate interpretation of the measured signal. This latter criterion can be problematic for the lightest gases since there is a propensity for some fraction of the pumped gas load to undergo a phenomenon known as backstreaming. This behavior is manifested in pumping systems for gas properties related to relative atomic weight (lightest) and size (smallest). Backstreaming results in a significant amount of the pumped gas undertaking a reverse flow and re-entering the measurement region; thus, contaminating the forward, real-time measurement. To fully eliminate this adverse effect, a conductance-limiting device – or orifice – has been installed in the high-vacuum pumping system of the present ITER DRGA prototype. The system was already equipped with a secondary turbomolecular pump (TMP), but with limited effectiveness against backstreaming in the inter-pump volume (IPV). This orifice is placed within the suction inlet coupling of the secondary TMP, which is downstream of the IPV. Its objective is to eliminate the backstreaming phenomenon by increasing the back pressure in the IPV. However, the orifice sizing must take into consideration other factors, such as the diagnostic measurement objectives. For example, in the ITER DRGA, one of the measurement requirements is a dynamic response time of ~1s. Fortunately, an added benefit of the pumping restriction created by the orifice is that the upstream pressure increase is beneficial for the DRGA’s optical gas analysis (OGA) sensors. These sensors are attached to the IPV in the present design. The glow discharges, when used as an OGA light source, will typically have a brighter light emission with increasing plasma cell pressure. In addition to the fusion machine research sector, there are other potential applications of this pumping technique where the monitoring of lighter gas concentrations is essential, such as the photolithography process for the semiconductor fabrication of integrated circuits. This presentation will describe the vacuum system used to demonstrate a process to eliminate backstreaming as well as show test results to verify the accomplishment of this critical objective.

Marcus, Chris↗

Amplification of laser imprint in the presence of strong, externally imposed, target-normal magnetic fields

Here, an experiment was performed on the OMEGA EP Laser System to investigate the effects of magnetic fields on laser imprint. A 30 µ⁢m thick CH target was driven by a single beam delivering 3.0 kJ of UV energy in a 5 ns square pulse without smoothing by spectral dispersion. The Rayleigh-Taylor amplification of this beam's imprint on the target surface was monitored using face-on gated x-ray radiography from a Gd backlighter. Magnetic fields of up to 45 T were applied normal to the target surface. Analysis of the resulting radiographs shows a 60 ± 13% increase in the spectrally resolved surface perturbation amplitudes, consistent at all times and for all unsaturated frequencies. This consistency indicates that the increase in perturbation amplitudes was due to a change in the initial amplitudes rather than Rayleigh-Taylor growth. This is supported by the trajectory of individual modes and the inferred time-averaged perturbation growth rates. Laser imprint is therefore inferred to have increased due to strong magnetic fields that remain in the conduction zone of the target, suppressing off-axis electron motion and limiting the effects of thermal smoothing.

direct drive↗

Machine-Learned Force Field for Molecular Dynamics Simulations of Nonequilibrium Ammonia Synthesis on Iron Catalysts

Ammonia (NH 3 ) is one of the most important industrial chemicals. The conventional NH 3 synthesis method-the Haber–Bosch process-converts atmospheric nitrogen (N 2 ) into NH 3 using H 2 with an iron (Fe) catalyst. However, this process requires high pressures (100–200 atm) and temperatures (700–800 K) near thermal equilibrium. Recently, Fe-based nanocatalysts have been reported to produce promising NH 3 yields under atmospheric pressures and temperature-modulated nonequilibrium conditions. Understanding the mechanism of nonequilibrium catalysis with programmed temperature variation could help to optimize this fully electrified and less energy-intensive process. Although reactive molecular dynamics (RMD) simulations can be a useful tool to model nonequilibrium catalytic processes, they require the development of accurate force fields (i.e., interatomic potentials). Here, we present a machine-learned (ML) force field within the Deep Potential MD (DPMD) framework, trained using periodic density functional theory (DFT) calculations, to model NH 3 synthesis on Fe catalysts with various surface adsorbates such as *N, *H, *N 2 , *H 2 , *NH, *NH 2 , and *NH 3 . Here, we generated the DFT data from static models of elementary reactions on the most stable (110) surface of body-centered cubic Fe, which then were augmented by data from constant number of particles–volume–temperature (NVT) DFT-MD trajectories at various temperatures. Finally, we utilized the fully optimized ML force field to investigate reaction dynamics at an Fe(110) surface at linearly increasing temperatures using NVT-DPMD simulations. Our simulations indicate that pulsed temperature ramping could prove favorable for NH3 synthesis. For example, we conducted ramping under multiple sets of conditions: (i) from 900 to 1200 K over periods of 0.1–0.3 ns for Fe surfaces precovered with N or NH along with H; and (ii) from 300 to 600 K over 0.1–0.3 ns for Fe surfaces precovered with NH 3 . While our simulations so far are limited to short time scales (very rapid heating), these observations shed light on the mechanism of the high NH 3 synthesis rate achieved in a novel temperature-modulated nonequilibrium catalytic reactor using pulsed heating and cooling.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Building a new multiphysics workflow in MOOSE: application to tritium migration, trapping and advection in TMAP8

Fusion devices are anticipated to produce and consume several kilograms of tritium per year. This rare fuel resource is both highly mobile and radioactive, making tracking inventories a priority for operation and safety. The fusion safety program at the Idaho National Laboratory has been developing the Tritium Migration and Analysis Program (TMAP), of which the latest version is a MOOSE-based application. TMAP8 is verified against its predecessors and possesses additional multi-dimensional tritium migration modeling capabilities. As we extend its capabilities towards both whole device (in multiple dimensions) and whole plant (with multiple components) simulations, the syntax of inputs must become compact, descriptive, compatible with quality assurance processes, and as error-proof as achievable. The new Physics system developed MOOSE can set up equations and instantiating them on plant components. The system permits the automatic definition of complex discretization with a consistency between object parameters achieved programmatically. The Physics system can currently instantiate the equations for heat conduction and Navier Stokes weakly compressible flow. In MOOSE-terms, it automates the definition of kernels, boundary conditions, and several core and helper materials and fields. As part of this effort, Physics classes were developed for tritium migration, trapping and advection within either a multi-dimensional Navier Stokes fluid dynamics simulation, or a 1D thermal hydraulics piping system. In this presentation, we will showcase the new syntax, its application to several verification and validation cases which were already studied using the classical TMAP8 syntax, and a demonstration of the new coupling capabilities for the migration of tritium into blanket coolant channels and the subsequent advection into the coolant loop.

70 - PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Propagation of EMIC Waves From Shabansky Orbits in the Dayside Magnetosphere

We explore the characteristics of EMIC waves generated in a non-dipole, compressed magnetic field at the minimum of the magnetic field. We conducted 2D full-wave simulations using the Petra-M code, focusing on a compressed magnetic field in the outer dayside magnetosphere for a range of L values (L = 8 - 10). By comparing the simulation results with MMS observations, we aim to understand how the observed wave characteristics are affected by a shifting source region across different L-shells. Our findings indicate that the direction of the Poynting vector systematically changes depending on the local source location of the wave, which is consistent with the observations. EMIC waves propagate along the magnetic field line and reach both the northern and southern hemispheres; however, there is a notable difference in the power of EMIC waves between the two hemispheres, indicating seasonal asymmetries in their occurrence.

58 GEOSCIENCES↗

Robust Solar Receivers Using MAX Phase Materials

This work was supported by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy under the Solar Energy Technologies Office Award Number 35928. The objective of the proposed effort was to develop and optimize additive manufacturing technologies for low-cost fabrication of high-temperature receivers using MAX phase-based materials (Ti 3 SiC 2 and Ti 3 AlC 2 ). MAX phase materials are a group of ternary metal carbides and nitrides where M stands for an early transition metal element, A is a group 13–16 element, and X is C and/or N. In Phase 1, the binder jetting additive manufacturing process was used to synthesize and characterize the Ti 3 SiC 2 MAX phase material. The typical process involved first producing a TiC preform using binder jetting followed by infiltration of the preform with silicon melt to form Ti 3 SiC 2 in situ. The reaction-infiltrated samples showed formation of MAX phase in the sample core; however, the surface showed cracking. Various process conditions—cooling rates, hold times, Si proportion, etc.—were varied to minimize the surface cracking. The fabricated MAX phase core was characterized by microstructure analysis and evaluations of mechanical properties such as hardness and thermal shock. In Phase 2, the focus included fabrication of Ti 3 SiC 2 MAX phase materials by spark plasma sintering (SPS) and synthesis of Ti 3 AlC 2 MAX phase materials by the Al melt infiltration process. It is expected that Al infiltration will not cause sample cracking, since Al does not expand during solidification. In addition, other processing approaches were investigated to fabricate the MAX phase materials, such as SPS with a graphite bedding approach for producing short-length Ti 3 AlC 2 MAX phase tubes for demonstration of prototypical Concentrating Solar Power receiver tubes. Fabricated samples underwent thermo-mechanical testing to validate the materials for the solar receiver application at temperatures >1000°C. In Phase 3, the effort focused on the development and optimization of the Ti-Al-C MAX phase composite material using the Al melt infiltration approach. We started with optimization of precursor powders and making preform structures by either pressing them in a die or using the binder jetting additive manufacturing process followed by Al melt infiltration. In addition, we investigated the formation of preform structures by cold isostatic pressing followed by Al melt infiltration for making Ti-Al-C MAX phase composite. Thermo-mechanical characterizations, such as creep, strength, and thermal shock, were conducted to establish the structures’ performance.

36 MATERIALS SCIENCE↗