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Enhancement of γ/γ’ Microstructured Cobalt Superalloys Produced from Atomized Powder by Creating a Harmonic Structure
A material’s properties must be continuously improved to meet the demands of extreme conditions in high-temperature applications. It is demonstrated that γ-γ’ Co-based superalloys could surpass the yield stress of Ni-based superalloys at high temperature due to the γ-γ’ structure. The powders were subjected to a harmonic modification in order to refine the grain structure on the surface and to activate the sintering process. This study examines how harmonic structure affects microstructure and mechanical properties at high temperatures. Spark Plasma Sintering (SPS) was used for consolidation to maintain the ultrafine grain size microstructure of the powder. Compression tests were conducted from room temperature (RT) to 750 °C to assess the mechanical properties of the material. Yield stress values obtained from harmonic structures are four times higher than those obtained from cast alloys.
Self-consistent integrated modeling of combined hybrid discharge-laser produced plasma devices for extreme ultraviolet metrology
Discharge- and laser-produced plasma (DLPP) devices are being used as light sources for extreme ultraviolet (EUV) generation. A key challenge for both, DPP and LPP, is achieving sufficient brightness to support the throughput requirements of nanometrology tools. To simulate the environment of a hybrid DLPP device and optimize the EUV output, we have developed an integrated HEIGHTS-DLPP computer simulation package. The package integrates simulation of two evolving plasmas (DPP and LPP) and includes modeling of a set of integrated self-consistent processes: external power source and plasma energy balance, plasma resistive magnetohydrodynamics, plasma heat conduction, detailed radiation transport (RT), and laser absorption and refraction. We simulated and optimized DLPP devices using Xe gas as a target material. We synchronized the external circuit parameters, chamber gas parameters, and laser beam temporal and spatial profiles to achieve maximum EUV output. The full 3D Monte Carlo scheme was integrated for detailed RT and EUV output calculations in Xe using more than 3600 spectral groups. The modeling results are in good agreement with Julich Forschungszentrum experimental data. Theoretical models, developed and integrated into the HEIGHTS package, showed wide capabilities and flexibility. In conclusion, the models and package can be used for optimization of the experimental parameters and settings, investigation of DLPP devices with complex design, analyzing the impact of integrated spatial effects and working timeline arrangement on the final EUV output, and EUV source size, shape, and angular distribution.
Heavy ions in Jupiter's environment
The extended atmosphere of the Jupiter system consists of heavy-element atoms and ions. This material originates on the satellite Io. Energy is lost from the thermal plasma in collisionally-excited optical and ultraviolet emission. The juxtaposition of earth and spacecraft measurements provide insight concerning the underlying processes of particle transport and energy supply.
The eruption of a quiescent prominence as observed in UV lines
Observations of an eruptive and a quiescent prominence are compared in order to understand better the energetic processes in an eruptive prominence. Several differences are pointed out which suggest that the activation consists not only of a mechanical movement of material, but also changes in the temperature of the prominence plasma. Some prominence material that does not seem to participate in the large-scale prominence motion is heated during the eruptive event. Most of this material is heated to transition zone temperatures with almost no cool 'core'. The behavior indicates that there are structures that are first cool and then heat up to transition zone temperatures, apparently remaining stable for some time at these temperatures.
The magnetosphere of Neptune - Hot plasmas and energetic particles
An overview is presented of the hot plasmas and energetic (not less than 20 keV) particles observed in the vicinity of Neptune by the Low Energy Charged Particle (LECP) experiment aboard the Voyager 2 spacecraft. The LECP findings are presented on the shock, the magnetosheath, the magnetopause, and the cusp of the Neptune's magnetosphere; the middle magnetosphere; the inner magnetosphere and material interactions; the magnetotail and the substorms; and the characteristics of Triton's plasma. It is shown that, in sharp contrast to the Uranian magnetotail, the Neptunian magnetotail shows no evidence of substorm processes.
Fabrication and Testing of Low Cost 2D Carbon-Carbon Nozzle Extensions at NASA/MSFC
Subscale liquid engine tests were conducted at NASA/MSFC using a 1.2 Klbf engine with liquid oxygen (LOX) and gaseous hydrogen. Testing was performed for main-stage durations ranging from 10 to 160 seconds at a chamber pressure of 550 psia and a mixture ratio of 5.7. Operating the engine in this manner demonstrated a new and affordable test capability for evaluating subscale nozzles by exposing them to long duration tests. A series of 2D C-C nozzle extensions were manufactured, oxidation protection applied and then tested on a liquid engine test facility at NASA/MSFC. The C-C nozzle extensions had oxidation protection applied using three very distinct methods with a wide range of costs and process times: SiC via Polymer Impregnation & Pyrolysis (PIP), Air Plasma Spray (APS) and Melt Infiltration. The tested extensions were about 6" long with an exit plane ID of about 6.6". The test results, material properties and performance of the 2D C-C extensions and attachment features will be discussed.
Laser Ablation Plasmas and Spectroscopy for Nuclear Applications
The development of measurement methodologies to detect and monitor nuclear-relevant materials remains a consistent and significant interest across the nuclear energy, nonproliferation, safeguards, and forensics communities. Optical spectroscopy of laser-produced plasmas is becoming an increasingly popular diagnostic technique to measure radiological and nuclear materials in the field without sample preparation, where current capabilities encompass the standoff, isotopically resolved and phase-identifiable (e.g., UO and UO[Formula: see text]) detection of elements across the periodic table. These methods rely on the process of laser ablation (LA), where a high-powered pulsed laser is used to excite a sample (solid, liquid, or gas) into a luminous microplasma that rapidly undergoes de-excitation through the emission of electromagnetic radiation, which serves as a spectroscopic fingerprint for that sample. This review focuses on LA plasmas and spectroscopy for nuclear applications, covering topics from the wide-area environmental sampling and atmospheric sensing of radionuclides to recent implementations of multivariate machine learning methods that work to enable the real-time analysis of spectrochemical measurements with an emphasis on fundamental research and development activities over the past two decades. Background on the physical breakdown mechanisms and interactions of matter with nanosecond and ultrafast laser pulses that lead to the generation of laser-produced microplasmas is provided, followed by a description of the transient spatiotemporal plasma conditions that control the behavior of spectroscopic signatures recorded by analytical methods in atomic and molecular spectroscopy. High-temperature chemical and thermodynamic processes governing reactive LA plasmas are also examined alongside investigations into the condensation pathways of the plasma, which are believed to serve as chemical surrogates for fallout particles formed in nuclear fireballs. Laser-supported absorption waves and laser-induced shockwaves that accompany LA plasmas are also discussed, which could provide insights into atmospheric ionization phenomena from strong shocks following nuclear detonations. Furthermore, the standoff detection of trace radioactive aerosols and fission gases is reviewed in the context of monitoring atmospheric radiation plumes and off-gas streams of molten salt reactors. Finally, concluding remarks will present future outlooks on the role of LA plasma spectroscopy in the nuclear community.
Microstructure Optimization and Novel Processing Development of ODS Steels for Fusion Environments (Final ARPA-E Report)
This project aimed to develop scalable, cost-effective fabrication of high-performance, oxide- dispersion-strengthened (ODS) steel using advanced manufacturing methods (AMMs) for fusion blanket-breeding applications. Gas atomization reaction synthesis (GARS) enables the synthesis of precursor ODS steel powders without prolonged mechanical alloying. This process creates a chromium (Cr)-enriched surface oxide with yttrium/titanium (Y/Ti)-enriched intermetallics in powder interiors. GARS powders were consolidated to >99% of the theoretical density using a first-of-a-kind shear assisted processing and extrusion (ShAPE) and laser-based powder bed fusion (L-PBF) AM processes. These processes led to ODS steels containing a high-density of nano-oxide dispersoids that enhance high-temperature mechanical properties. Such scalable, cost-effective fabrication of ODS steels can enable efficient power conversion cycles (=40%) at operating temperatures beyond 900 K in future fusion power plants.
Increased accuracy and signal-to-noise ratio through recent improvements in infra-red video bolometer fabrication and calibration
The infra-red video bolometer (IRVB) is a diagnostic equipped with an infra-red camera that measures the total radiated power in thousands of lines of sight within a large field of view. Recently validated in MAST-U [Fderici et al., Rev. Sci. Instrum. 94, 033502 (2023)], it offers a high spatial resolution map of the radiated power in the divertor region, where large gradients are expected. The IRVB’s sensing element comprises a thin layer of high Z absorbing material, typically platinum, usually coated with carbon to reduce reflections [Peterson et al., Rev. Sci. Instrum. 79, 10E301 (2008)].Here, the possibility of using a relatively inert material such as titanium, is explored that can be produced in layers up to 1 μm compared to 2.5 μm for Pt and then coat it with Pt of the desired thickness (0.3 μm per side here) and carbon. This leads to a higher temperature signal (about 3 times) and better spatial resolution (about 4 times), resulting in higher accuracy in the measured power [Peterson et al., Rev. Sci. Instrum. 79, 10E301 (2008)]. This assembly is also expected to improve foil uniformity, as the Pt layer is obtained via deposition rather than mechanical processes [Mukai et al., Rev. Sci. Instrum. 87, 2014 (2016)].Given its multi-material composition, measuring the thermal properties of the foil assembly is vital. Various methods using a calibrated laser as a heat source have been developed, analyzing the temperature profile shape [Sano et al., Plasma and Fusion Res. 7, 2405039 (2012)] and [Mukai et al., Rev. Sci. Instrum. 89, 10E114 (2018)] or fitting the calculated laser power for different intensities and frequencies [Fderici et al., Rev. Sci. Instrum. 94, 033502 (2023)]. Here, a simpler approach is presented, which relies on analyzing the separate components of the foil heat equation for a single laser exposure in a given area. This can then be iterated over the entire foil to capture local deviations.
Formation of Organic Compounds Through Meteoritic Atmospheric Shock
This document is a Final Technical Report for DoE award DE-SC0023375 “Formation of Organic Compounds Through Meteoritic Atmospheric Shock”. The document includes a summary of topics studied, specific tasks completed, challenges, and results from the project. The main goal of this project was to investigate the production of organic molecules and/or complex inorganic precursor molecules in a plasma environment reminiscent of the environment surrounding meteoroids during atmospheric entries. The specific hypothesis tested in this project was that meteoroid ablation during the entry and the chemical reactions in the meteoroid plasma tail could have produced significant amounts of organics or precursor inorganics in the Early Earth’s atmosphere. Investigation of these processes is essential in understanding the origins of life on Earth and the search for life beyond our planet. This project was focused on a set of experiments conducted at the Utilizing the DIII-D tokamak in San Diego, CA. The experiments aimed to study the interaction of carbonaceous and silica materials (typically found in meteoroids) with mixtures of hot plasma gases (mimicking atmospheric entry conditions. The material samples and gas mixtures were selected to investigate the synthesis of the organic compound urea – a key ingredient in the origin of life – or one of its precursor, the complex inorganic compound ammonia.
Large radiation back-flux from Monte Carlo simulations of fusion neutron–material interactions
Abstract Fusion power reactors will generate intense neutron fluxes into plasma-facing and structural materials (SMs). Radiation back-fluxes, generated from neutron–material interactions under these fluxes, can dramatically impact the plasma dynamics, e.g. by seeding runaway electrons during disruptions via Compton scattering of background electrons by wall-emitted gamma radiation. Here, we quantify these back-fluxes, including neutrons, gamma rays, and electrons, using Monte Carlo calculations for a range of SM candidates and first wall (FW) thicknesses. The radiation back-flux magnitudes are remarkably large, with neutron and gamma radiation back-fluxes on the same order of magnitude as the incident fusion neutron flux. Electron back-fluxes are two orders of magnitudes lower, but are emitted at sufficiently high energies to impact the sheath and boundary plasma dynamics. Material configuration plays a key role in determining back-flux magnitudes. The SM chiefly determines the neutron back-flux magnitude, while the FW thickness principally attenuates the gamma ray and electron back-fluxes. In addition to prompt back-fluxes, which are emitted immediately after fusion neutrons impact the surface, significant delayed gamma ray and electron back-fluxes arise from nuclear decay processes in the activated materials. These delayed back-flux magnitudes range from 2% to 7% of the prompt back-fluxes, and remain present during transients when fusion no longer occurs. During disruptions, build-up of delayed gamma radiation back-flux represents potential runaway electron seeding mechanisms, posing additional challenges for disruption mitigation in a power reactor compared with non-nuclear plasma operations. This work highlights the impact of these radiation back-fluxes plasma performance and demonstrates the importance of considering back-flux generation in materials selection for fusion power reactors.
Synthesis of Nano-Crystalline Gamma-TiAl Materials
One of the principal problems with nano-crystalline materials is producing them in quantities and sizes large enough for valid mechanical property evaluation. The purpose of this study was to explore an innovative method for producing nano-crystalline gamma-TiAl bulk materials using high energy ball milling and brief secondary processes. Nano-crystalline powder feedstock was produced using a Fritsch P4(TM) vario-planetary ball mill recently installed at NASA-LaRC. The high energy ball milling process employed tungsten carbide tooling (vials and balls) and no process control agents to minimize contamination. In a collaborative effort, two approaches were investigated, namely mechanical alloying of elemental powders and attrition milling of pre-alloyed powders. The objective was to subsequently use RF plasma spray deposition and short cycle vacuum hot pressing in order to effect consolidation while retaining nano-crystalline structure in bulk material. Results and discussion of the work performed to date are presented.
Fabrication of 4H-SiC Low Gain Avalanche Detectors (LGADs)
Low gain avalanche detectors (LGADs) offer high temporal resolution for high energy particle detection, which is critical for next generation experiments in hadron colliders. While silicon LGADs (Si-LGADs) have rapidly matured in the last decade, research into silicon carbide (SiC) LGADs has only recently begun. By accounting for fundamental differences in material properties and fabrication processes, we present a prototype device design and process flow for 4H-SiC LGADs with etch-based isolation. Critical steps of the process flow and their results are discussed, including plasma etching, passivation, and the formation of low resistivity contacts. Electrical characterization (I-V, C-V) shows sufficient depletion of the device structure to demonstrate low-gain charge carrier multiplication.
Anodic arc discharge: Why pulsed?
Pulsed anodic arc discharge is a novel synthesis method of nanomaterials by means of low-temperature atmospheric plasma. The technique consists in periodically supplying DC power to two vertically aligned electrodes in the form of short unipolar pulses with peak currents of a few hundred Amperes in helium atmosphere. The pulsed arc plasmas are sustained at frequencies of the order of 1 Hz with around 10% of duty cycle. It constitutes a versatile technique thanks to a series of advantages compared to continuous DC arc processes, in particular: flexibility in the experimental conditions, process stability and repeatability, better utilization of ablating anode material, lower production of macroparticles, and lower thermal loads. Such features are discussed in this article. A brief overview concerning the recent accomplishments of pulsed arc discharge on deposition of carbon nanostructures (graphene and carbon nanotubes) and few-layer flakes of molybdenum disulphide (MoS 2 ) is provided, as well as an outlook on future applications of this method for the discovery of new materials with tailored functional properties.
The influence of cooling rate on condensation of iron, aluminum, and uranium oxide nanoparticles
Fundamental observations of particle size distributions are needed to develop models that predict the fate and transport of radioactive materials in the atmosphere following a nuclear incident. The extent of material transport is influenced by the time scales of particle formation processes (e.g., condensation, coagulation). In this study, we investigated the influence of cooling time scales on size distributions of uranium, aluminum, and iron oxide particles that are synthesized separately under identical run conditions inside the controlled environment of an argon plasma flow reactor. Two distinct temperature distributions are imposed along the flow reactor by varying the argon flow rate downstream of the plasma torch. The vaporized reactants of uranium, aluminum, and iron are cooled from about 5000K to 1000K before they are collected on silicon wafers for ex situ scanning electron microscope analysis. The microscope images show that the sizes of the largest aluminum and iron oxide particles heavily depend on the cooling time scales, whereas significant size variation with cooling rate is not observed for uranium oxide particles. In addition, the size distribution of aluminum oxide particles exhibits the broadest range among all three metal oxides studied. We performed simulations of particle size distributions using a kinetic model that couples gas phase oxidation chemistry with particle formation processes, including nucleation, condensation, and coagulation. The model results demonstrate the strong sensitivity of particle size distribution to different cooling histories (i.e., temperature vs residence time) along the flow reactor. In conclusion, the kinetic model also helps identify directions for future research to improve the predictions.
Oxide Dispersion Strengthened Ferritic Steel Wire Feedstock Development for Larger Format Additive Manufacturing (CRADA Final Report)
This CRADA project funded through DOE’s INFUSE program sought to demonstrate the viability of fabricating large, complex parts from oxide dispersion strengthened (ODS) steel with advanced manufacturing. Exhibiting excellent radiation tolerance and high mechanical performance at elevated temperatures, ODS steel is a promising structural material candidate for near-plasma components in fusion energy systems. Its use, however, has been limited by a lack of manufacturability. This project sought to produce ODS steel wire through a solid-state shear assisted extrusion process and then demonstrate that the wire can undergo controlled local melting while being welded with the final part sufficiently retaining the beneficial properties of ODS steel. This would allow the use of wire-arc additive manufacturing (WAAM) to manufacture large-scale ODS parts, even though ODS is currently only available as a powder. WAAM is a promising technique for producing components like the replaceable ARC vacuum vessel in CFS’ fusion reactor design. Meanwhile, this project will also expand PNNL’s capability in producing custom wire feedstock with friction extrusion, enabling downstream large-scale manufacturing with WAAM and solid-state based additive manufacturing. The project achieved its goals of developing tooling and fixturing to produce ODS wire at smaller diameters than previous projects. Several small lengths of wire of 1.5 mm and 2.5 mm diameter in the range of 2.5-30 mm long were produced at tool temperatures that are known to cause ODS particle coarsening (~1200 °C). Fixtures and tooling for longer (>1 m) wires were developed but further process development is needed reduce tool temperature during extrusions and to increase wire length needed for WAAM testing and development.
Space Environment Factors Affecting the Performance of International Space Station Materials: The First Two Years of Flight Operations
In this paper, the natural and induced space environment factors affecting materials performance on ISS are described in some detail. The emphasis will be on ISS flight experience and the more significant design and development issues of the last two years. The intent is to identify and document the set of space environment factors, affecting materials, that are producing the largest impacts on the ISS flight hardware verification and acceptance process and on ISS flight operations. Orbital inclination (S1.6 ) and altitude (nominal3S0 km to 400 km altitude) determine the set of natural environment factors affecting the functional life of materials and subsystems on ISS. ISS operates in the F2 region of Earth's ionosphere in well-defined fluxes of atomic oxygen, other ionospheric plasma species, and solar UV, VUV, and x-ray radiation, as well as galactic cosmic rays, trapped radiation, and solar cosmic rays (1,2). The high latitude orbital environment also exposes external surfaces to significantly less well-defined or predictable fluxes of higher energy trapped electrons and auroral electrons (3 ,4). The micrometeoroid and orbital debris environment is an important determinant of spacecraft design and operations in any orbital inclination. Environment factors induced by ISS flight operations include ram-wake effects, magnetic induction voltages arising from flight through Earth's magnetic field, hypergolic thruster plume impingement from proximity operations of visiting vehicles, materials outgassing, venting and dumping of fluids, ISS thruster operations, as well as specific electrical power system interactions with the ionospheric plasma (S-7). ISS must fly in a very limited number of approved flight attitudes leading to location specific environmental exposures and extreme local thermal environments (8). ISS is a large vehicle and produces a deep wake structure from which both ionospheric plasma and neutrals (atomic oxygen) are largely excluded (9-11). At high latitude, the ISS wake may produce a spacecraft charging environment similar to that experienced by the DMSP and Freja satellites (800 to 100 km altitude polar orbits), especially during geo-magnetic disturbances (12-14). ISS is also subject to magnetic induction voltages (VxB L) on conducting structure, a result of high velocity flight through Earth's magnetic field. The magnitude of the magnetic induction voltage varies with location on ISS, as well as the relative orientation of the vehicle velocity vector and planetary magnetic field vector, leading to maximum induction voltages at high latitude (15). The space environment factors, natural and induced, that have had the largest impact on pre-launch ISS flight hardware verification and flight operations during the first two years of ISS flight operations are listed below and grouped according to the physical and chemical processes driving their interaction with ISS materials.