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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Wetted-foam target stability for laser-direct-drive inertial confinement fusion

Using highly resolved three-dimensional radiation-hydrodynamic simulations, the effects of wetted-foam (WF) ablators in direct-drive inertial confinement fusion cryogenic implosions on the OMEGA laser were investigated. The performance of these implosions was compared with that of implosions using targets with solid-plastic ablators. Simulations considering WF ablators as a homogeneous material show no mitigation of the effects of laser imprint, where the absence of this mitigation can be attributed to the use of picket pulses. Heterogeneous random-structure WF ablators introduce large short-wavelength perturbations, which are seeded by WF inhomogeneities. These perturbations exceed the perturbations seeded by the imprint and cause an additional reduction in implosion performance when the average pore size in the WF exceeds ~0.2 μm. Foam-seeded perturbations are expected to be less damaging in more stable high-adiabat (⁠ ≳ 5⁠) implosions. Here, the perturbations introduced by the WF ablators can be substantially reduced by using a foam matrix with a layered structure instead of a random one. Further study of the effects of WFs in ignition designs of the MJ laser energy scale is required in the perspective of future inertial fusion energy mass production.

Igumenshchev, I. V. [University of Rochester, NY (↗
DOE OSTI2026

Numerical investigation of liquid wall ablation in inertial fusion energy chambers

This paper presents a novel approach for modeling liquid wall ablation in liquid wall-protected inertial fusion energy (IFE) chambers. These systems are promising candidates for the implementation of fusion technology, yet significant gaps remain in understanding the underlying physical processes and their implications for design. Following target ignition, a portion of the fusion energy is released as x-rays, which deposit their energy into an array of liquid jets, leading to partial vaporization. Accurately modeling this heat deposition and vaporization process remains challenging due to the complex geometries typical of (pre-conceptual) IFE chamber designs. Furthermore, the subsequent expansion of vaporized material into the chamber’s vacuum environment poses difficulties for conventional CFD methods based on continuum assumptions, which can lead to significant inaccuracies. To address some aspects of these challenges, this work introduces a ray-tracing-based methodology to map the spatial distribution of ablated material in liquid wall-protected systems. In addition, a vacuum-tracking scheme is developed to extend the applicability of an OpenFOAM-based solver to gas dynamics in rarefied environments. The proposed approach has been verified through numerical benchmarks and applied to a practical case involving the HYLIFE-II (High Yield Lithium Injection Fusion Energy) chamber. The methodology advances the modeling capabilities for liquid wall-protected IFE systems and provides valuable tools to support their design and optimization.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Femto-second Laser’s Enabling New Length Scale Fabrications for Rapid Post Irradiation Examination of Materials: Concluding LDRD Project Poster

Mechanical testing campaigns are required to qualify materials for advanced reactor conditions, yet economical and safety limitations restrict the number of standardized mechanical tests that can be performed. Reducing the size of the sample is one approach to addressing these challenges and to accelerating testing. Previous research has shown that smaller mechanical test samples produce higher yield and ultimate stress values compared to values measured from standard sample sizes: the “smaller is stronger” effect. Specimens used in accelerated material testing campaigns must reflect bulk material performance to enable engineering scale material property measurement. The objective of this research project was to determine if engineering scale mechanical behavior—the yield stress—could be measured with micro-tensile test samples smaller than traditional standard testing geometries. The relationship between yield stress and sample size was explored with two different nuclear-relevant structural materials: Zircaloy-4 and tungsten. Mechanical testing of both metals demonstrated decreasing yield stress values with increasing sample gauge size across three different sizes. Yield stress values from the largest gauge size, fabricated with a femto-second laser ablation system, approach bulk material yield stress values reported in published literature. Preliminary analysis of the tungsten samples indicates the yield stress value depends on the grain characteristics within the gauge section, in addition to the gauge size. Accompanying modeling efforts, including response surface generation and crystal plasticity approaches, further demonstrated that the size of the sample gauge section alone cannot explain the change in yield stress values.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Lithography-Free Mesa Isolation of III–V Solar Cells Through Laser Ablation

Eliminating photolithography from solar cell processing is a significant opportunity for cost reduction for III-V solar cells. Here, in this work, we explore femtosecond laser ablation as an alternative to contact photolithography and wet chemical etching for mesa isolation. We demonstrate both GaAs and GaInP solar cells mesa-isolated by femtosecond laser ablation with minimal to no loss in solar cell performance. We show the best results with a 400 fs UV pulsed laser and a short clean-up etch that also serves as a contact layer removal etch.

14 SOLAR ENERGY↗
DOE OSTI2026

Lithography-Free Mesa Isolation by Laser Ablation for Multijunction III-V Photovoltaic Space Power Generation

Eliminating photolithography from photovoltaic device processing is a significant opportunity for cost reduction and increased manufacturing throughput. In this work, we test femtosecond laser ablation and scribing as an alternative to contact photolithography and wet chemical etching for mesa isolation of multijunction devices. We demonstrate that upright multijunction devices isolated by using the laser as a scribe to cleave through the substrate had virtually no performance loss when compared to a baseline device processed with photolithography. By contrast, devices isolated by laser ablating through the active layers have performance losses that cannot be fully eliminated with postprocess etching. This demonstration of photolithography-free mesa isolation with no performance losses is promising as a pathway to less expensive and higher throughput III-V device manufacturing.

14 SOLAR ENERGY↗
DOE OSTI2025

X-ray diffraction strains in laser-ablated aluminum, nickel, sodium, and invar: Pressures to 475 GPa

Dynamically compressed materials in longitudinal waves are described by two physical models: hydrostatic pressure, with equal, normal, principal stresses or material uniaxially strained in the wave propagation direction. These models are disparate, so experimental comparisons and evaluations are important. Polycrystalline material in a state of hydrostatic pressure will have no eccentricity of x-ray-diffracted Debye–Scherrer rings. A general three-dimensional solution of Bragg diffracted x rays based on principal crystallographic strains in the compression wave was found. The distortion of x-ray diffraction beams has been used for strain measurements; the analysis developed incorporates a strained reciprocal lattice and the incident x-ray beam. Strain-distorted Polanyi surfaces form an annulus of compression with an ellipsoid of revolution in reciprocal space, which is intersected by Ewald's sphere for Bragg diffraction. The in situ measurements for strain describe nanosecond diffraction evaluated using two planes, (hkl) and (h′k′l′), both in the same crystallographic phase. Diffraction from Al, Ni, Na, and Invar quantifies the compression axial strains in these materials: The compression axial ratios are 0.65, 1.05, 0.88, and 1.58 at pressures of 291, 402, 409, and 367 GPa for the respective materials. Crystal structure transformations with homogeneous pressurized stresses, mandating equal normal strains, should not be anticipated to agree with heterogeneous, uniaxially strained, and sheared crystalline phases. Measurements support in-plane strains increasing with pressure, p , in fcc and hcp aluminum as ε 22 = −0.21 p /TPa.

Alloys↗
DOE OSTI2026

A Relief Zone Architecture for Enhanced Durability of Ultrathin Membranes in Electrochemical Conversion Devices

Premature cell failures in electrochemical conversion systems often result when membrane electrode assemblies (MEAs) are prepared with ultra-thin (= 15 micrometer-thick) polymer electrolyte membranes (PEMs). These high-performance PEMs are susceptible to mechanical degradation from stress concentrations arising from component and device-level integration. Herein, a relief zone was developed to mitigate mechanical degradation by alleviating excess and non-uniform compression across the active area. Relief zones, created through the ablation of carbonaceous diffusion material achieves a seamless adaptation across a range of MEA dimensions and electrochemical applications without need for costly hardware modifications. This concept was demonstrated using fuel cells as a case study. Accelerated stress test (AST) validations yielded a 6-fold improvement for MEAs prepared with relief zones (i.e., lifetime approximately 1500 h) compared to those fabricated using conventional edge-protection techniques, showcasing the utility of this technique in decoupling integration and device-level engineering effects from intrinsic material limitations for durable electrochemical devices.

14 SOLAR ENERGY↗
DOE OSTI2025

Carbon Fiber Oxidation in 4D

The oxidation of carbon fibers at high temperatures is the primary degradation process in the thermal protection system of many hypersonic flight vehicles. Predicting the rate and the extent of oxidation is critical to ensure a safe and effective design. An oversized thermal protection system adds unnecessary mass, while an under-designed one risks system failure and mission loss. Resolving high-temperature material degradation due to oxidation has been a long-standing challenge in designing for re-entry flight environments. Using time-resolved in situ X-ray microtomography, the oxidation of carbon fibers at high temperatures is directly imaged, resolving the two limiting degradation regimes: diffusion- and reaction-limited. The ability to resolve material degradation in time at the sub-micron scale sheds light on the ablation phenomenon and enables predictions of material constitutive properties evolving in time, with profound implications on the ability to model the aerothermal response of heat shield materials in hostile environments.

ablation↗
DOE OSTI2026

Automation of Laser Plasma Focused Ion Beam Microscopy for Next-Gen Energy Materials

Automation can revolutionize the use of ultrafast laser ablation and plasma-focused ion beam (PFIB) techniques for high-throughput, reproducible cross-sectioning and various sample preparation in materials characterization. As these methods become essential for analyzing complex energy materials and next-generation devices, efficient, standardized workflows are needed to minimize variability and enhance precision. This work highlights our advancements in developing automated processes for sample preparation that integrates machine learning, workflow optimization, and large-scale data acquisition to improve efficiency and scalability in applications such as electrolyzers, photovoltaic cells, and microelectronics. To streamline cross-sectioning and lamella fabrication, we have implemented fully automated workflows that standardize laser ablation and PFIB milling sequences. These workflows incorporate pre-programmed protocols for material removal, alignment, and thinning, reducing user intervention and ensuring consistency across different sample types. Machine learning algorithms further enhance automation by predicting optimal milling strategies and adapting parameters based on material properties and sectioning requirements. This approach significantly improves throughput while maintaining the structural integrity of prepared samples for high-resolution imaging and analysis, including transmission electron microscopy. Beyond sample preparation, our automation platform enables the acquisition of large, high-resolution datasets through serial sectioning, image alignment, and 3D reconstruction. These automated routines facilitate multi-scale characterization, capturing structural and compositional details from the nanoscale to the device level. By reducing variability and increasing efficiency, our automated approach enhances defect analysis, failure diagnostics, and process optimization, accelerating advancements in materials research and device engineering.

36 MATERIALS SCIENCE↗
DOE OSTI2026

A MINi Powder INjector (MINPIN) for the SMART tokamak

Here, this article presents the design and performance characterization of a MINi Powder INjector (MINPIN) developed for boron wall conditioning (boronization) in the SMall Aspect Ratio Tokamak (SMART) at the University of Seville, Spain. SMART studies positive and negative triangularity plasmas within the low aspect ratio range of 1.4 < R/a < 3, with a major radius (R) of 0.40–0.60 m and a minor radius (a) of 0.20–0.33 m. MINPIN, in design, will gravitationally deliver boron (B) powder into the plasma, which ablates and transports the injected material. Mounted on the top of the vessel, the MINPIN will drop controlled amounts of powder using a piezoelectric blade driven by a signal generator that vibrates at a set frequency. The B will then be deposited in a layer on SMART’s stainless steel vacuum vessel walls, and this boronization process reduces the influx of intrinsic wall impurities, such as oxygen, carbon, nitrogen, and iron, which radiate power and cool the plasma. In the laboratory, we calibrated the drop rate for 1–10 mg/s, which will enable controlled boronization coating while achieving efficient powder ablation. We propose MINPIN’s operational scenarios based on the calibrated drop rate and estimated drop duration, assuming the distance from MINPIN to SMART’s plasmas.

Boron powder↗
DOE OSTI2025

Comparison of atomized mass and crater volume in laser ablation

The extent and dynamics of laser ablation are typically studied using crater imaging or by invoking the relationship between atomic emission and the mass removed. The former is a static view of a dynamic process and requires the accumulation of multiple shots in one location. The latter is complex and not absolute without calibration of the optical system with a standard of spectral radiance. We measure the mass of the atomized plume by laser atomic-absorption spectroscopy at 2 µs without external mass calibration; mass uncertainty in laser-ablation atomic absorption spectroscopy (LA-AAS) results from uncertainties in line area fitting, tabulated oscillator strengths, and partition functions as well as a <10% underrepresentation of the mass due to treating the plasma as a single thermodynamic equilibrium. The LA-AAS-measured mass pertains to the atoms in the probed charge states and does not include condensed or molecular species. The ablation efficiency at 300 mbar of helium varies significantly between the two focusing conditions used. A comparison of crater-derived masses and LA-AAS masses suggests that more defocused ablation may result in significant redeposition of material in the crater, distorting the conclusions from drilling studies and crater imaging. More focused ablation conditions result in crater-derived masses that exceed those measured with LA-AAS and suggest melt expulsion or phase explosion.

Merten, Jonathan [Arkansas State University, Jones↗
DOE OSTI2025

Optimizing ablator thickness for laser shock experiments

In laser shock experiments, a well-defined, flat-top shock wave at the ablator/sample interface is important for accurately probing material response under uniaxial strain compression. However, the relationship between the ablator thickness and the resulting shock wave characteristics is insufficiently understood, limiting the ability to design optimal experiments. To address this need, we conducted a systematic experimental study using a 100 J laser to shock-compress polyimide ablators to peak stresses ranging from 20.4 to 111.6 GPa. Laser interferometry diagnostics measured the transmitted wave profiles at the ablator/sample interface, consistently showing a single jump followed by a constant peak state before the arrival of release waves. Here, by analyzing shock transit time, flat-top duration, and stress, our results establish a framework for selecting ablator thickness to maximize the flat-top duration, improving the precision and reproducibility of laser shock experiments.

design of experiments↗
DOE OSTI2024

Supersonic hot jet ablative testing and analysis of boron nitride nanotube hybrid composites

Boron nitride nanotubes (BNNTs) are high-strength, high-modulus nanotubes with high thermal and oxidative stabilities. Two hybrid composites were prepared with satin weave carbon fiber (CF) and resole-type phenolic resin: one with surface layers of BNNTs and one with alternating interlayers of BNNTs. The samples were subjected to hot jet tests that simulate realistic high-pressure-temperature conditions to understand the behavior of BNNTs under high-pressure erosion. Adding BNNTs to CF/phenolic laminates enhanced the ablation resistance by reinforcing the char material and mitigated localized thermal damage. Hybrid laminates exhibited up to 14% lower weight loss, 55% increase in flexural modulus, higher thermal diffusivity, and improved char yield and microstructure compared to CF/phenolic samples. The surface layer hybrid had many surviving nanotubes reinforcing the char and crystalline oxide structures that could mitigate further oxygen diffusion. Further, various characterization methods were used to deduce possible mechanisms and their products, indicating that BNNTs could serve as growth templates for direct crystalline boron oxide formation. Overall, hybrid BNNT/CF/phenolic laminates displayed better ablation resistance and favorable microstructure evolution under high-pressure conditions.

42 ENGINEERING↗
DOE OSTI2025

Experimental and numerical evaluation of laser shinethrough in polystyrene at 3 ω and 4 ω laser frequencies

In laser-direct-drive inertial confinement fusion (ICF), laser shinethrough is the process associated with laser propagation through the target plastic ablator, polystyrene is often used in ICF experiments, and leads to energy deposition in the target until the critical density is established at the ablator front surface. This process causes material modifications that may change the shock propagation and lead to density and pressure perturbations at the interface between the polystyrene and cryogenic deuterium-tritium (DT) layer. This work reports on experimental observations and numerical investigations of laser shinethrough at the third and the fourth harmonic of ICF class laser systems (1 ω corresponds to a wavelength of ∼1.06 μm ). The experiments evidence that, at 4 ω , the laser is absorbed over a distance of about a few microns and laser shinethrough is completely eliminated in contrast with the behavior at 3 ω . These experimental observations are reproduced by numerical simulations. The laser fluence required to reach the critical density at the ablator front surface is also found to be more than one order of magnitude higher at the third harmonic. Finally, modeling suggests that the back surface of the ablator exhibits ion temperatures greater than the melting temperature of cryogenic DT and electron pressure larger than the bulk and shear moduli of cryogenic DT for the case of using a 3 ω laser.

Pineau, A. [Univ. of Rochester, NY (United States)↗
DOE OSTI2025

Detailed simulations of the first deuterium-tritium-filled double shell implosions on the National Ignition Facility

The first indirectly driven, liquid DT-filled double shell inertial confinement fusion (ICF) implosions have recently been successfully performed on the National Ignition Facility (NIF). Double shells are a class of alternative designs that use a low-Z outer shell to compress a foam cushion that accelerates a high-Z inner shell to efficiently compress a liquid DT core. Double shells are challenging to fabricate, field, and model. Important engineering features enabling double shell fabrication include a fill-tube penetrating all shells and a carefully designed and very narrow (few μm) step-joint in the ablator. Due to the higher density materials involved, high Atwood number instabilities are also important at many material interfaces. In this paper, numerical simulations of double shell implosions using the Los Alamos National Laboratory multi-physics radiation-hydrodynamics code xRAGE will be discussed. An extensive effort has been under way for several years to develop the code capabilities for ICF simulations in a common modeling framework to allow ease of simulation setup and standardization of the computational methodology. This paper will present a wide range of simulation results capturing, quantifying, and comparing the impact of all these degradation mechanisms on implosion performance. Brief comparisons with recent experimental results and suggestions for future improvements will also be discussed. Our results suggest that capsule surface roughness and the step-joint gap have the largest impact on implosion performance. Initial experimental data may suggest that the sensitivity to the step-joint gap could provide the dominant explanation for DT-filled double shell experiments that have been fielded on NIF thus far.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Laser pulse-length dependent ablation and shock generation in silicon at 5 × 10 14 W/ cm 2 intensities

The effect of laser pulse duration on energy coupling into a planar silicon target is investigated in experiments at the OMEGA-EP facility by varying the laser pulse length τ —spanning 3 orders of magnitude from 100 ps to 10 ns—while maintaining a constant peak laser intensity, I 0 = 5 × 10 14 W/ cm 2 . In theoretical models, the ablation pressure primarily scales for a given material with laser intensity and wavelength, which are all fixed variables here, allowing us to explore the specific role of laser pulse duration. Two-dimensional radiation-hydrodynamics simulations benchmarked with optical probing of the expanding plasma show that the pulse duration is critical for the ablation pressure to reach a steady state. Moreover, the pulse duration impacts shock decay and multiple wave effects, which strongly dictate the evolving shock profile that propagates within the laser-shocked target as ultimately measured by rear-surface diagnostics. The shock velocities inferred from the theoretical model, after considering shock decay, impedance matching, and shock Hugoniot, are found to be in good agreement with velocimetry measurements. However, discrepancies are observed with simulations for the shorter (0.1 ns) and longer (10 ns) pulse durations, which are respectively attributed to unaccounted contributions of kinetic absorption mechanisms and instabilities in simulations. Published by the American Physical Society 2024

Bailly-Grandvaux, M. (ORCID:0000000175294013)↗
DOE OSTI2026

Core plasma fueling by fast inward particle transport after hydrogen pellet injection in Wendelstein 7-X

A large database of more than 1000 individual cryogenic hydrogen pellets injected into Wendelstein 7-X for plasma fueling was analyzed to improve the understanding of the three phases of the process: the ablation, deposition and transport of the pellet material. Kilohertz-sampled electron density and temperature measurements revealed a more complex drift behavior than predicted by numerical code simulation. It could be explained by the poloidal plasma E r x B- drift rotation, which plays a significant role in stellarators, but was not previously considered in pellet injection codes like HPI2. The drift results in a fast poloidal rotation of the pellet material around the plasma core, leading to an almost homogeneous deposition over the involved flux surfaces regardless of magnetic high and low field side injection geometry. Additionally, a novel fast inward directed transport mechanism (‘FIT-effect’) was observed. The effect occurs on timescales of tens of milliseconds and cannot be explained by neoclassical transport or diffusion. It might be linked to the turbulence pinch recently found in Wendelstein 7-X. When the FIT-effect occurs, the pellet particles are rapidly transferred from the deposition flux surfaces to the plasma core, causing the plasma density profile to peak, which is beneficial for confinement in Wendelstein 7-X. The large pellet injection database was statistical analyzed with regard to pellet and plasma parameters, which delivered some starting points towards developing an understanding of the physics behind the FIT-effect. The results indicate, that plasma core fueling via pellet injection is largely independent of the injection geometry in stellarators under certain conditions, reducing the technical complexity of the injection system.

Wendelstein 7-X↗
DOE OSTI2024

Light–Material Interactions Using Laser and Flash Sources for Energy Conversion and Storage Applications

Abstract This review provides a comprehensive overview of the progress in light–material interactions (LMIs), focusing on lasers and flash lights for energy conversion and storage applications. We discuss intricate LMI parameters such as light sources, interaction time, and fluence to elucidate their importance in material processing. In addition, this study covers various light-induced photothermal and photochemical processes ranging from melting, crystallization, and ablation to doping and synthesis, which are essential for developing energy materials and devices. Finally, we present extensive energy conversion and storage applications demonstrated by LMI technologies, including energy harvesters, sensors, capacitors, and batteries. Despite the several challenges associated with LMIs, such as complex mechanisms, and high-degrees of freedom, we believe that substantial contributions and potential for the commercialization of future energy systems can be achieved by advancing optical technologies through comprehensive academic research and multidisciplinary collaborations.

Materials Science↗