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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

ICARUS at the Short-Baseline Neutrino Program: First Results

The ICARUS collaboration employed the 760-ton T600 detector in a successful three-year physics run at the underground LNGS laboratory. In 2021, ICARUS started its new operation at Fermilab, collecting a substantial amount of neutrino events from the Booster Neutrino Beam (BNB) and the neutrinos at the Main Injector (NuMI) beam off-axis. These were used to test the ICARUS event selection, reconstruction, and analysis algorithms. ICARUS successfully completed its commissioning phase in June 2022, moving then to data taking for neutrino oscillation physics, aiming at first to either confirm or refute the claim by the Neutrino-4 short-baseline reactor experiment. ICARUS will also perform measurements of neutrino cross sections in LAr with the NuMI beam and several Beyond Standard Model studies. After the first year of operations, ICARUS will search for evidence of sterile neutrinos jointly with the Short-Baseline Near Detector, within the Short-Baseline Neutrino program. In this work, preliminary results from the ICARUS data with the BNB and NuMI beams are presented, both in terms of the performance of all ICARUS subsystems and the capability to select and reconstruct neutrino events.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Characterization of Inlet Guide Vane Performance for Discharge Compressor Operation near the Dome of an sCO 2 Pumped Heat Energy Storage

Southwest Research Institute® (SwRI®) developed and tested a Variable Inlet Guide Vane (IGV herein) assembly on an integrally-geared sCO 2 compressor (IGC) to demonstrate compressor operation at both the compressor design point and near the dome and to define the operating limits of the compressor by monitoring for two-phase flow, flow turbulence from the IGVs, and compressor choke and surge as the CO 2 inlet temperature is varied. Performance testing was conducted on an existing integrally-geared, two-stage main compressor designed for near-critical-point operation with CO 2 . This testing campaign validated the IGV design and operation, as well as improved the understanding and confidence in operating compressors and predicting performance characteristics near the critical point where fluid properties change rapidly with temperature. In addition to improving the robust operating limits of an sCO 2 compressor, the development of an IGV for the IGC system improved off-design compressor efficiency by 12%.

25 ENERGY STORAGE↗
DOE OSTI2025

Microstructural, Oxidation, and Mechanical Behavior of NbTi-Based Refractory Alloys with 5 to 10 Pct Co, Cr, and Ni Additions

NbTi-based refractory alloys with additions of Co, Cr, and Ni represent an interesting medium-entropy alloy system with potential for protective oxide film formation, high strength, and ductility. This study investigates the microstructural evolution, oxidation behavior, and mechanical properties of NbTi-based alloys containing 5 to 10 at. pct Co, Cr, and Ni. CALPHAD predictions suggest that this composition range can be heat treated to obtain a predominantly body-centered cubic matrix phase. Mechanical properties, including microhardness, yield strength, maximum strength, and specific strength are evaluated through isothermal compression tests conducted between room temperature and 800 °C. The oxidation kinetics of these alloys are assessed through discontinuous oxidation tests. Parabolic oxidation kinetics were observed for NbTi–10Ni and NbTi–5Co, while linear oxidation kinetics were found for NbTi–10Cr and NbTi–10(CoCrNi). Microstructures and oxide layers are characterized using X-ray diffraction, electron backscatter diffraction, energy-dispersive X-ray spectroscopy, and scanning electron microscopy. All alloys exhibit significant mechanical softening between room temperature and 800 °C, with elastic-perfectly plastic flow observed at 800 °C. The addition of 10 pct Cr to NbTi resulted in two BCC phases up to 1050 °C, conflicting with CALPHAD predictions of a single-phase solid solution at this temperature, and resulting in higher flow stress at 800 °C. NbTi–10(CoCrNi) exhibited the lowest flow stress at 800 °C despite having more ‘cocktail effect’ potential and insufficient molar fractions of Co, Cr, or Ni to form a desirable protective oxide film.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Irradiation of UC1+x kernels using the MiniFuel vehicle: Microstructure, phase analysis, and initial post-irradiation examination

Uranium carbide is a candidate fuel form for a wide range of advanced reactors, including larger Generation IV reactors as well as small modular reactors and microreactors. However, its commercial deployment timeline faces challenges via traditional qualification approaches. To address this issue, an accelerated fission rate irradiation test was performed to collect basic fuel performance data to inform fuel performance models and potential future integral tests. Hyperstoichiometric UC (UC1+x) kernels were irradiated in the High Flux Isotope Reactor using the MiniFuel irradiation vehicle. The test matrix spanned two temperature regimes (700 °C and 800 °C) and burnup levels (1.8 % FIMA and 2.8 % FIMA). Between 21 and 63 kernels were tested at each unique temperature and burnup condition. As-fabricated microstructural analysis revealed a multiphase composition with UC, UC2, UC2−y, and U-C-O bearing phases for the irradiated kernels. Following irradiation, fission gas release, swelling, and microstructures were analyzed. Measured fission gas release was below 5 % for all irradiation conditions, reaching a maximum at the highest temperature and burnup condition. A binary swelling response was observed; the lower burnup and temperature conditions resulted in negligible swelling, but the higher burnup and temperature conditions produced significant anisotropic swelling and densification in a subset of kernels. The basic microstructural exams of kernels following irradiation were not capable of showing a correlation between kernels that exhibited excessive swelling and those that did not. Characterization of a subset of samples using the Advanced Photon Source and more detailed microstructural examination of unirradiated kernels revealed that a subset of kernels contained very high UC2 phase fractions. The anomalous swelling response is hypothesized to have been driven by this chemical variation. The results of this irradiation highlight the potential of accelerated fission rate irradiation testing to explore such behaviors and inform the development of fuel specifications.

Adorno Lopes, Denise [ORNL] (ORCID:000900023705987↗
DOE OSTI2024

Hybrid Quantum Mechanical, Molecular Mechanical, and Machine Learning Potential for Computing Aqueous-Phase Adsorption Free Energies on Metal Surfaces

Performing reliable computer simulations of elementary processes occurring at metal–water interfaces is pivotal for novel catalyst design in sustainable energy applications. Computational catalyst design hinges on the ability to reliably and efficiently compute the potential energy surface (PES) of the system. Here, due to the large system sizes needed for studying processes at liquid water–metal interfaces, these systems can currently not be described using density functional theory (DFT). In this work, we used a hybrid quantum mechanical, molecular mechanical, and machine learning potential for studying the adsorption behavior of phenol, atomic hydrogen, 2-butanol, and 2-butanone on the (0001) facet of Ru under reducing conditions when Ru is not oxidized. Specifically, we describe the adsorbate and the surrounding metal atoms at the DFT level of theory. Here, we also considered the electrostatic field effect of the water molecules on adsorbate–metal interactions. Next, for the water–water and water–adsorbate interactions, we used established classical force fields. Finally, for the water–Ru surface interaction, for which no reliable force fields have been published, we used Behler–Parrinello high-dimensional neural network potentials (HDNNPs). Employing this setup, we used our explicit solvation for metal surface (eSMS) approach to compute the aqueous-phase effect on the low-coverage adsorption of selected molecules and atoms on the (0001) facet of Ru. In agreement with previous experimental and computational studies of oxygenated molecules over transition metal facets, we found that liquid water destabilizes the tested adsorbates on Ru(0001). Interestingly, our findings indicate that adsorbates on Ru are less affected by the presence of an aqueous phase than on other transition metals (e.g., Pt), highlighting the necessity of experimental investigations of Ru-based catalytic systems in liquid water.

Adsorption↗
DOE OSTI2026

Development of a Test-Bed for Testing and Refining EarthEn’s Supercritical CO 2 Based Energy Storage System

EarthEn’s energy storage concept leverages supercritical carbon dioxide (sCO 2 ) as a working fluid and relies on compact, high-performance components operating at elevated pressures and temperatures. To accelerate component development and reduce technical risk prior to larger-scale demonstrations, Oak Ridge National Laboratory (ORNL) developed a 100 kW-scale sCO 2 test-bed under a Cooperative Research and Development Agreement with EarthEn (CRADA NO. NFE-24-10050). The objective of the work was to design and construct a flexible experimental facility capable of reproducing key thermodynamic state points and heat-transfer conditions relevant to EarthEn’s thermal energy storage (TES) cycle, with particular emphasis on enabling development and evaluation of next-generation heat exchangers and TES concepts. The test-bed consists of a closed-loop sCO 2 circulation system housed within an open-topped enclosure. In its as-installed configuration, dense-phase sCO 2 is recirculated through a printed circuit recuperator, an electrically heated section, a throttling device used to simulate turbine expansion, and a water-cooled printed circuit heat exchanger that rejects heat to the building chilled-water system before returning to the pump. The pump is driven by a variable frequency drive, enabling controlled adjustment of flow and operating point. A comprehensive instrumentation suite was integrated to support both safe operation and high-quality data collection. Installed sensors include Coriolis flow meters for sCO 2 flow rate and density, resistance temperature detectors and thermocouples distributed throughout the loop (including the heated section and key heat exchanger ports), and pressure transducers for absolute and differential pressure measurements. The facility was designed to support high-pressure (19 MPa nominal) and high-temperature (575°C nominal) operation with credited overpressure protection provided by a rupture disk. Nominal operating conditions were selected to support 100 kW-class testing while maintaining flexibility for non-heated and heated shakedown, control development, and future integration of advanced TES test sections. In parallel with facility development, a system-level thermal-hydraulic model was created using Modelica-based tools to support component sizing, anticipate performance over targeted test conditions, and establish a framework for future model calibration against experimental data. At the conclusion of the project performance period, the facility was in final assembly, and the pressure boundary was nearly completed. However, several practical challenges associated with high-pressure/high-temperature systems and specialized component procurement impacted schedule and prevented initial pump-driven operation and full commissioning within the available resources. This report documents the as-built design, operating capabilities, and instrumentation, and it summarizes key lessons learned related to heater fabrication and testing, first-of-a-kind assembly factors, specialty flange supply constraints, and fill pump corrective actions. Finally, it outlines a phased plan for future commissioning and experimental campaigns, including control and instrumentation shakedown, heater characterization, model calibration, and testing at state points representative of EarthEn’s TES cycle.

25 ENERGY STORAGE↗
DOE OSTI2026

SULI Report - Development of a Molten Salt Circulation Loop for in-situ Spectroscopy

This project supports the development of real time optical monitoring capabilities for molten salt reactor (MSR) environments by designing, testing, and refining a molten salt circulation loop suitable for combined laser induced breakdown spectroscopy (LIBS) and ultraviolet visible (UV Vis) absorption measurements. Online spectroscopic monitoring is increasingly important for nuclear safeguards, corrosion tracking, and material accountancy, yet MSR process fluids present substantial challenges due to their chemical complexity and hazards such as high temperatures and radiation. To address these needs, this work focuses on Phase I, the development of a room temperature aqueous circulation loop that serves as a surrogate platform for evaluating flow behavior, optical access, and component performance prior to high temperature salt operation. Initial testing identified several practical issues—including leaks, obstructions, and two-phase flow through the absorption cell—that were systematically resolved through hardware replacement, flow path redesign, and venturi pressure optimization. Relocating the flow cell upstream of the primary venturi enabled periods of stable single-phase flow, demonstrating the feasibility of integrating optical diagnostics into a circulation system. The results of Phase I provide essential design insight for Phase II, which will incorporate furnace compatible materials and LiCl KCl eutectic salt. Completion of the molten salt system will deliver a reusable testbed for evaluating multimodal spectroscopic techniques, advancing nondestructive, real time monitoring tools for future MSR and nuclear fuel cycle applications.

98 - NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL↗
DOE OSTI2024

Characterization of the Triassic Newark Basin of New York and New Jersey for Geologic Storage of Carbon Dioxide

The project Characterization of the Triassic Newark Basin of New York and New Jersey for Geologic Storage of Carbon Dioxide is one of 9 site characterization projects that were implemented as part of ARRA (American Recovery and Reinvestment Act). Data from this project was used to improve resolution of data in NATCARB in the area of study. Data related to this study has already been incorporated in NATCARB Atlas. Sandia Technologies, LLC, and co-investigator Conrad Geoscience Corporation, examined the potential for large-scale, permanent CO2 storage in sedimentary strata within the Newark Rift Basin. The Newark Rift Basin underlies an industrialized, developed region comprising parts of New York, New Jersey, and Pennsylvania. The project characterized and investigated the suitability of Triassic age sedimentary formations for potential geologic CO2 storage. The project team drilled and cored two test wells to define the sedimentary geologic formations underlying the basin and to document or reach basement rock. With this geologic characterization phase, an integration of seismic, geologic, borehole, and formation core results provided a higher resolution assessment of CO2 storage potential. The Stockton Formation is known to be a potentially favorable geologic storage formation in the basin. In 2011, the 1-NYSTA Tandem Lot stratigraphic test well was drilled to a depth of 6,855 feet in the northern portion of the Newark Basin in southern New York State. Approximately 9 miles south-southeast on the Lamont Doherty Campus, TW-4 was drilled and cored in 2013 to a depth of 1,802 feet and contacted apparent igneous basement at a depth of 1,712 feet. Both wells penetrated the Palisades Sill ranging from 800 feet thick in the eastern well to approximately 1,800 feet in thickness at the 1-NYSTA Tandem Lot deep drill site. A diabase sill can provide an excellent seal and dense confining layer for potential CO2 storage reservoirs and flow layers that are situated beneath it within the Stockton Sandstone. The Stockton Sandstone was encountered beneath the sill in the TW-4 well on the Lamont campus, and data integration suggests that it was likely observed near total depth in the deep 1-NYSTA Tandem Lot well. The test wells confirm and define reservoirs are present beneath the sill and offer CO2 storage potential. The integration of geologic and reservoir characterization of well logs, formation cores, and formation fluids indicated Triassic age lacustrine playa lake and mudbank shales of the Upper Passaic Group can provide an effective seal for the porous and permeable underlying sandstone reservoir layers. This project acquired seismic data, drilled borehole well logs, acquired core samples, and integrated these findings to provide a better understanding of the subsurface geologic formations in the Newark Rift Basin. These findings have contributed to a higher degree of accuracy in predicting potential geologic storage opportunities, while refining geologic storage capacity estimates for the indicated reservoirs and flow units.

.las↗
DOE OSTI2026

Advanced blade-shaped thermal energy storage device: Development and application

Thermal energy storage (TES) using phase change materials (PCMs) is a promising approach for capturing and reusing excess thermal energy, yet widespread adoption is limited by low thermal conductivity, bulky configurations, and inadequate scalability. Here, this study presents a modular, blade-shaped TES prototype designed to address these challenges. The device integrates a lightweight aluminum shell, an embedded serpentine coil for active or passive heat exchange, and a cost-effective corrugated metal mesh for enhanced PCM thermal conductivity. With thickness-to-length and thickness-to-width ratios of 0.03 and 0.08, respectively, the blade-shaped TES achieves a compact, modular form factor suitable for space-constrained applications. Experimental testing demonstrated the efficient charge and discharge behavior of blade-shaped TES, capturing PCM superheating, phase-change transitions, and subcooling dynamics, with charging and discharging efficiencies of 94.9% and 94.6%, respectively. Also, the system can potentially achieve higher energy density than that of conventional TES designs. When integrated into a household refrigerator during the study, three blade-shaped TES modules successfully shifted 100% of peak-time compressor operation to off-peak hours, reducing energy consumption while maintaining more stable compartment temperatures. The blade-shaped TES's thin geometry, modularity, and enhanced thermal performance support scalable deployment across residential, commercial, and industrial applications, providing a versatile, cost-effective solution for high-efficiency, demand-flexible thermal energy management.

Blade-shaped↗
DOE OSTI2024

CalWave's xWave Design for PacWave (Final Technical Report)

CalWave Inc. (CalWave) is developing a wave energy converter (WEC) technology that can generate electricity from ocean waves. CalWave’s design offers a unique approach to wave energy conversion that operates fully submerged and can actively adjust the wave excitation. This capability gives the architecture enhanced survivability in ocean storms without adding significant costs. Prior to this project, CalWave had completed a demonstration of a fully functional WEC system in an open ocean demonstration at nominal 1:5 scale under FOA 1663. The goal of this project was the detailed design, following relevant standards and industry best-practices, of a variant of the xWave WEC technology that can safely and efficiently operate at the DOE’s PacWave South test site for a targeted deployment of up two years. The WEC design and associated review processes proceeded in two distinct project phases: a ‘Preliminary’ and a ‘Final’ design phase. The first phase of the project consisted of the systematic design of the WEC’s key features with regards to appropriate IEC standards. The work resulted in a preliminary design of the xWave hull including structural and Power Take-Off (PTO) load estimates, as well as performance estimates for all ocean conditions the WEC would operate in at PacWave South. Following the first open-water demonstration of CalWave’s small-scale “x1” device under FOA 1663, lessons learned were fed directly into a comprehensive review of the xWave design in the second design phase of this FOA project. CalWave’s work was supported by Sandia National Lab (SNL) and the National Renewable Energy Lab (NREL) on the holistic WEC design, and detailed feedback from specialized partners on hull design, mooring and anchoring specification, and electrical grid interconnection. Optimization of the WEC system was performed using a novel numerical optimization tool developed by Sandia and optimization trends were confirmed via an experimental model scale tank test campaign. Performance estimates for PacWave and a detailed xWave design including integration of all relevant system components were concluded. The mooring design was also concluded in the Final design phase using the most up to date sea floor characterization (CPT) data.

16 TIDAL AND WAVE POWER↗
DOE OSTI2024

WEST full tungsten operation with an ITER grade divertor

The mission of WEST (tungsten-W Environment in Steady-state Tokamak) is to explore long pulse operation in a full tungsten (W) environment for preparing next-step fusion devices (ITER and DEMO) with a focus on testing the ITER actively cooled W divertor in tokamak conditions. Following the successful completion of phase 1 (2016-2021), phase 2 started in December 2022 with the lower divertor made entirely of actively cooled ITER-grade tungsten mono-blocks. A boronization prior the first plasma attempt allowed for a smooth startup with the new divertor. Despite the reduced operating window due to tungsten, rapid progress has been made in long pulse operation, resulting in discharges with a pulse length of 100 s and an injected energy of around 300 MJ per discharge. Plasma startup studies were carried out with equatorial boron nitride limiters to compare them with tungsten limiters, while Ion Cyclotron Resonance Heating assisted startup was attempted. High fluence operation in attached regime, which was the main thrust of the first campaigns, already showed the progressive build up of deposits and appearance of dust, impacting the plasma operation as the plasma fluence increased. In total, the cumulated injected energy during the first campaigns reached 43 GJ and the cumulated plasma time exceeded 5 h. Demonstration of controlled X-Point Radiator regime is also reported, opening a promising route for investigating plasma exhaust and plasma-wall interaction issues in more detached regime. This paper summarises the lessons learned from the manufacturing and the first operation of the ITER-grade divertor, describing the progress achieved in optimising operation in a full W environment with a focus on long pulse operation and plasma wall interaction.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Experimental verification of integrability in a Danilov-Nagaitsev lattice using machine learning

In non-linear optics, achieving integrability can enhance the dynamic aperture in storage rings. We analyze turn-by-turn phase-space data from our Danilov-Nagaitsev lattice implementation at Fermilab's Integrable Optics Test Accelerator using machine learning. AI Poincaré estimates conserved quantities from experimental data without prior knowledge of the invariant structure, showing qualitative agreement with theoretical predictions. Additionally, one of the two learned invariants exhibits comparable or better conservation compared to known theoretical expressions.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Experimental Verification of Integrability in a Danilov-Nagaitsev Lattice using Machine Learning

In non-linear optics, achieving integrability can enhance the dynamic aperture in storage rings. We analyze turn-by-turn phase-space data from our Danilov-Nagaitsev lattice implementation at Fermilab's Integrable Optics Test Accelerator using machine learning. \textit{AI Poincar\'e} estimates conserved quantities from experimental data without prior knowledge of the invariant structure, showing qualitative agreement with theoretical predictions. Additionally, one of the two learned invariants exhibits comparable or better conservation compared to known theoretical expressions.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Material Characterization Report of FFTF MFF 5 Fuel Element

This report was written as part of the TerraPower Cooperative Research and Development Agreement No. 11-CR-19 with Idaho National Laboratory. TerraPower provided the funding. An as-fabricated fuel element from the Fast Flux Test Facility MFF-5 experiment was sectioned and analyzed for material properties. Results reported include phase characterization, microstructural analysis, density, microhardness, and chemical composition.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Impact of window temperature variations on ITER toroidal interferometer and polarimeter (TIP) measurements

Abstract The toroidal interferometer and polarimeter (TIP) is one of the primary electron density diagnostics on ITER. To meet measurement requirements over several thousand seconds, environmental factors such as changes in the window temperature, air temperature, and humidity, which can cause uncompensated phase drifts, must be minimized. This paper reports measurements of the phase shift induced by ZnSe and BaF₂ windows as their temperature is varied utilizing the TIP prototype. To accomplish these measurements, test pieces of BaF₂ and ZnSe are placed in a small oven that is located in one leg of the 10.59/5.22 micron two-color interferometer TIP prototype. The oven temperature was varied from room temperature to ∼90 °C, which is slightly higher than the expected window temperatures on ITER. The vibration compensated phase shifts measured for these two materials are dϕᵥ꜀ /dT/L = 0.0121 and −0.275 deg. /°C/cm −1 for BaF₂ and ZnSe, respectively. From these measurements, it was concluded that temperature variations of the environmental/secondary confinement barrier window and primary vacuum window have to be suppressed within approximately 1°C and 2°C, respectively, in order to passively meet the electron density measurement requirements in ITER.

Akiyama, T (ORCID:0000000198469795)↗
DOE OSTI2024

Phase-space entropy cascade and irreversibility of stochastic heating in nearly collisionless plasma turbulence

We consider a nearly collisionless plasma consisting of a species of “test particles” in one spatial and one velocity dimension, stirred by an externally imposed stochastic electric field—a kinetic analog of the Kraichnan model of passive advection. The mean effect on the particle distribution function is turbulent diffusion in velocity space—known as stochastic heating. Accompanying this heating is the generation of fine-scale structure in the distribution function, which we characterize with the collisionless (Casimir) invariant C 2 ∝ ∫ ∫ d x d v 〈 f 2 〉 —a quantity that here plays the role of (negative) entropy of the distribution function. We find that C 2 is transferred from large scales to small scales in both position and velocity space via a phase-space cascade enabled by both particle streaming and nonlinear interactions between particles and the stochastic electric field. We compute the steady-state fluxes and spectrum of C 2 in Fourier space, with k and s denoting spatial and velocity wave numbers, respectively. In our model, the nonlinearity in the evolution equation for the spectrum turns into a fractional Laplacian operator in k space, leading to anomalous diffusion. Whereas even the linear phase mixing alone would lead to a constant flux of C 2 to high s (towards the collisional dissipation range) at every k , the nonlinearity accelerates this cascade by intertwining velocity and position space so that the flux of C 2 is to both high k and high s simultaneously. Integrating over velocity (spatial) wave numbers, the k -space ( s -space) flux of C 2 is constant down to a dissipation length (velocity) scale that tends to zero as the collision frequency does, even though the rate of collisional dissipation remains finite. The resulting spectrum in the inertial range is a self-similar function in the ( k , s ) plane, with power-law asymptotics at large k and s . Our model is fully analytically solvable, but the asymptotic scalings of the spectrum can also be found via a simple phenomenological theory whose key assumption is that the cascade is governed by a “critical balance” in phase space between the linear and nonlinear timescales. We argue that stochastic heating is made irreversible by this entropy cascade and that, while collisional dissipation accessed via phase mixing occurs only at small spatial scales rather than at every scale as it would in a linear system, the cascade makes phase mixing even more effective overall in the nonlinear regime than in the linear one. Published by the American Physical Society 2024

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Mesoscale Modeling of the Effects of Accelerated Burnup on UO2 Microstructural Evolution

Accelerating the nuclear fuel qualification process will rely on some combination of advanced modeling and simulation techniques with accelerated irradiation testing and separate effects experiments to enable the development of new fuel concepts in a shorter time frame. One of the key challenges to successfully leveraging accelerated irradiation tests will be understanding the artifacts that may be introduced with accelerated accumulation of dose and/or burnup. This work presents phase field (MARMOT) simulations of the evolution of representative 2D UO2 microstructures up to 40 MWd/kgU. Simulations were performed under both commercial light water reactor fuel conditions as well as those that would be expected for highly accelerated (~10x) burnup conditions similar to those used in the MiniFuel irradiations in Oak Ridge National Laboratory’s High Flux Isotope Reactor. The phase field model was coupled with a discrete nucleation algorithm to model re- structuring at high burnup. The effect of the different fission rates in both microstructures was investigated at two temperatures: 650?C and 800?C. The lower temperature simulations both showed an onset of restructuring at nearly 60 MWd/kgU. More extensive restructuring was obtained in the MiniFuel microstructure compared with that of the PWR fuel. At 800?C, no restructuring was obtained as a result of the thermally activated diffusion of Xe atoms and U vacancies to fission gas bubbles, which reduces the nucleation driving force. These results highlight the importance of using modeling and simulation tools to inform the environmental conditions during targeted accelerated irradiation tests to extract the most useful fuel performance data.

accelerated fuel qualification, Phase Field, Restr↗
DOE OSTI2024

Part-scale microstructure prediction for laser powder bed fusion Ti-6Al-4V using a hybrid mechanistic and machine learning model

Laser powder bed fusion (LPBF) Ti-6Al-4V is widely studied for use in structural applications in aerospace and medical industries, but mechanical anisotropy and microstructural inhomogeneity prohibits its wider adoption. Although successful microstructure prediction models have been developed, a remaining challenge is their limited integration across length/time scales and validation by experimental studies. Here, this work proposes a physics-augmented machine learning surrogate model to unite predictions of LPBF temperature, β phase morphology and texture, and α/α’ formation into a single framework that is calibrated and validated with experiments. First, a phase field (PF) model of the martensitic β→α’ transformation is developed and calibrated using data from in-situ synchrotron cyclic heating/cooling studies quantifying the variation of α phase fraction with time. In parallel, an established finite difference-Monte Carlo (FDMC) model predicts the part-scale temperature profile and β grain formation during solidification. A dataset is developed using LPBF cyclic temperature descriptors from the FDMC model as inputs and corresponding α/α’ phase fraction and width from the PF model as outputs. Five machine learning (ML) regression models are tested and optimized, having mean absolute error in testing ≤ 4 %, and the k-nearest neighbors (KNN) model is selected as the best performing. The KNN model is called at the nodal level during post-processing of the FDMC model to replace and downscale the response of the PF model. The combined agility and accuracy of the hybrid FDMC-ML model enables part-scale microstructure predictions that can be further used for property predictions to accelerate AM process optimization.

36 MATERIALS SCIENCE↗