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DOE OSTI2026

Custom surface reflectance, shade mask, and equivalent water thickness maps for the Colorado Headwaters Ecological Spectroscopy Study (2025)

This dataset contains land surface reflectance estimates and additional derived products generated from NEON Imaging Spectrometer (NIS) data collected in the Upper Gunnison river basin during June and July of 2025. Data was collected over three domains: the Upper East River (CRBU), Almont Triangle (ALMO), and the Upper Taylor Basin (UPTA). These products were derived from radiance and LiDAR data collected by the NEON Airborne Observation Platform (AOP) campaign funded by the Colorado Headwaters Ecological Spectroscopy Study (CHESS) (doi:10.15485/3017965). Products include per-pixel surface reflectance (rfl) and reflectance uncertainty (rfl_unc), observational data (obs), canopy equivalent water thickness (ewt), and shade masks. Atmospheric correction was performed per flightline using the ISOFIT (Imaging Spectrometer Optimal FITting) optimal estimation framework to estimate surface reflectance and the associated per-band reflectance uncertainty. Reflectance retrievals achieved a mean absolute error of 1.5% across diverse validation surfaces (see validation report.pdf). Equivalent water thickness was calculated from surface reflectance using the Beer–Lambert absorption of liquid water. Shade masks were generated based on the geometry between the sun angle, ground surface, and sensor at the time of flight. Data products are provided per-flightline and as mosaics for each domain. Flightline data products are provided as ENVI-formatted binary files (rfl, rfl_unc, ewt) and GeoTIFFs (shade). Reflectance and uncertainty mosaics are provided as tiled NetCDFs, while all other mosaicked products are provided as cloud-optimized GeoTIFFs. These formats are supported by common geospatial software (e.g., QGIS, ArcGIS, ENVI) and programmatic libraries in Python (e.g., rasterio, xarray, spectral, netCDF4) and R (e.g., terra, ncdf4). Processing workflows were designed to be equivalent to those used to generate the 2018 CHESS campaign airborne imaging spectroscopy data products (doi:10.15485/3013527). All outputs were co-registered to a common spatial grid to support time series analyses. CHESS Project Description: The Colorado Headwaters Ecological Spectroscopy Study (CHESS) comprised a multi-week airborne remote sensing and field observation campaign in the Upper Gunnison Basin, Colorado, conducted in June and July of 2025. Airborne remote sensing was conducted by the National Ecological Observatory Network Airborne Observation Platform (NEON AOP), concurrent with a field campaign run by the Rocky Mountain Biological Laboratory (RMBL), the Lawrence Berkeley National Laboratory (LBNL) and SLAC National Accelerator Laboratory Watershed Function Science Focus Area (SFA), and NASA-JPL (Jet Propulsion Laboratory) Earth Surface Mineral Dust Source Investigation (EMIT) program. Between June 10 and July 18, 2025, the NEON AOP flight team collected high-resolution aerial imaging spectroscopy and Light Detection and Ranging (LiDAR) data over three domains: the Upper East River (CRBU), Almont Triangle (ALMO), and the Upper Taylor Basin (UPTA). In coordination with the flights, a field campaign acquired ground-truth observations, including observations of vegetation composition, foliar traits, forest demography, and subsurface properties in 18 core sampling areas within the domains. Additional surface water observations were taken at over 380 point locations. All CHESS campaign datasets can be found within the CHESS ESS-DIVE data portal: https://data.ess-dive.lbl.gov/portals/chess. Funding Acknowledgment: Data acquisition was performed under a grant from the National Aeronautics and Space Administration (80NSSC24K1005). Computational research was carried out at the Jet Propulsion Laboratory, California Institute of Technology, under a contract with the National Aeronautics and Space Administration (80NM0018D0004) and was funded by EMIT Extended Mission Phase E Science.

2018 NEON and 2025 CHESS Campaigns↗

NASA NTRS2011

A Modular, Reusable Latch and Decking System for Securing Payloads During Launch and Planetary Surface Transport

Efficient handling of payloads destined for a planetary surface, such as the moon or mars, requires robust systems to secure the payloads during transport on the ground, in space and on the planetary surface. In addition, mechanisms to release the payloads need to be reliable to ensure successful transfer from one vehicle to another. An efficient payload handling strategy must also consider the devices available to support payload handling. Cranes used for overhead lifting are common to all phases of payload handling on Earth. Similarly, both recent and past studies have demonstrated that devices with comparable functionality will be needed to support lunar outpost operations. A first generation test-bed of a new high performance device that provides the capabilities of both a crane and a robotic manipulator, the Lunar Surface Manipulation System (LSMS), has been designed, built and field tested and is available for use in evaluating a system to secure payloads to transportation vehicles. A payload handling approach must address all phases of payload management including: ground transportation, launch, planetary transfer and installation in the final system. In addition, storage may be required during any phase of operations. Each of these phases requires the payload to be lifted and secured to a vehicle, transported, released and lifted in preparation for the next transportation or storage phase. A critical component of a successful payload handling approach is a latch and associated carrier system. The latch and carrier system should minimize requirements on the: payload, carrier support structure and payload handling devices as well as be able to accommodate a wide range of payload sizes. In addition, the latch should; be small and lightweight, support a method to apply preload, be reusable, integrate into a minimal set of hard-points and have manual interfaces to actuate the latch should a problem occur. A latching system which meets these requirements has been designed and fabricated and will be described in detail. This latching system works in conjunction with a payload handling device such as the LSMS, and the LSMS has been used to test first generation latch and carrier hardware. All tests have been successful during the first phase of operational evaluations. Plans for future tests of first generation latch and carrier hardware with the LSMS are also described.

Doggett, William R.↗

NASA NTRS2012

Arctic PBL Cloud Height and Motion Retrievals from MISR and MINX

How Arctic clouds respond and feedback to sea ice loss is key to understanding of the rapid climate change seen in the polar region. As more open water becomes available in the Arctic Ocean, cold air outbreaks (aka. off-ice flow from polar lows) produce a vast sheet of roll clouds in the planetary boundary layer (PBl). The cold air temperature and wind velocity are the critical parameters to determine and understand the PBl structure formed under these roll clouds. It has been challenging for nadir visible/IR sensors to detect Arctic clouds due to lack of contrast between clouds and snowy/icy surfaces. In addition) PBl temperature inversion creates a further problem for IR sensors to relate cloud top temperature to cloud top height. Here we explore a new method with the Multiangle Imaging Spectro-Radiometer (MISR) instrument to measure cloud height and motion over the Arctic Ocean. Employing a stereoscopic-technique, MISR is able to measure cloud top height accurately and distinguish between clouds and snowy/icy surfaces with the measured height. We will use the MISR INteractive eXplorer (MINX) to quantify roll cloud dynamics during cold-air outbreak events and characterize PBl structures over water and over sea ice.

Wu, Dong L.↗

NASA NTRS2011

Dust Removal on Mars Using Laser-Induced Breakdown Spectroscopy

Dust coatings on the surface of Mars complicate and, if sufficiently thick, mask the spectral characteristics and compositional determination of underlying material from in situ and remote sensing instrumentation. The Laser-Induced Breakdown Spectroscopy (LIBS) portion of the Chemistry & Camera (ChemCam) instrument, aboard the Mars Science Laboratory (MSL) rover, will be the first active remote sensing technique deployed on Mars able to remove dust. ChemCam utilizes a 5 ns pulsed 1067 nm high-powered laser focused to less than 400 m diameter on targets at distances up to 7 m [1,2]. With multiple laser pulses, dust and weathering coatings can be remotely analyzed and potentially removed using this technique [2,3]. A typical LIBS measurement during MSL surface operations is planned to consist of 50 laser pulses at ~14 mJ, with the first 5 to 10 pulses used to analyze as well as remove any surface coating. Additionally, ChemCam's Remote Micro-Imager (RMI) is capable of resolving 200 m details at a distance of 2 m, or 1 mm at 10 m [1,4]. In this study, we report on initial laboratory experiments conducted to characterize the removal of dust coatings using similar LIBS parameters as ChemCam under Mars-like conditions. These experiments serve to better understand the removal of surface dust using LIBS and to facilitate the analysis of ChemCam LIBS spectral data and RMI images.

Graff, T. G.↗

NASA NTRS2017

Monte Carlo Computational Modeling of Atomic Oxygen Interactions

Computational modeling of the erosion of polymers caused by atomic oxygen in low Earth orbit (LEO) is useful for determining areas of concern for spacecraft environment durability. Successful modeling requires that the characteristics of the environment such as atomic oxygen energy distribution, flux, and angular distribution be properly represented in the model. Thus whether the atomic oxygen is arriving normal to or inclined to a surface and whether it arrives in a consistent direction or is sweeping across the surface such as in the case of polymeric solar array blankets is important to determine durability. When atomic oxygen impacts a polymer surface it can react removing a certain volume per incident atom (called the erosion yield), recombine, or be ejected as an active oxygen atom to potentially either react with other polymer atoms or exit into space. Scattered atoms can also have a lower energy as a result of partial or total thermal accommodation. Many solutions to polymer durability in LEO involve protective thin films of metal oxides such as SiO2 to prevent atomic oxygen erosion. Such protective films also have their own interaction characteristics. A Monte Carlo computational model has been developed which takes into account the various types of atomic oxygen arrival and how it reacts with a representative polymer (polyimide Kapton H) and how it reacts at defect sites in an oxide protective coating, such as SiO2 on that polymer. Although this model was initially intended to determine atomic oxygen erosion behavior at defect sites for the International Space Station solar arrays, it has been used to predict atomic oxygen erosion or oxidation behavior on many other spacecraft components including erosion of polymeric joints, durability of solar array blanket box covers, and scattering of atomic oxygen into telescopes and microwave cavities where oxidation of critical component surfaces can take place. The computational model is a two dimensional model which has the capability to tune the interactions of how the atomic oxygen reacts, scatters, or recombines on polymer or nonreactive surfaces. In addition to the specification of atomic oxygen arrival details, a total of 15 atomic oxygen interaction parameters have been identified as necessary to properly simulate observed interactions and resulting polymer erosion that have been observed in LEO. The tuning of the Monte Carlo model has been accomplished by adjusting interaction parameters so the erosion patterns produced by the model match those from several actual LEO space experiments. Surface texturing in LEO can also be predicted by the model. Such comparison of space tests with ground laboratory experiments have enabled confidence in ground laboratory lifetime prediction of protected polymers. Results of Monte Carlo tuning, examples of surface texturing and undercutting erosion prediction, and several examples of how the model can be used to predict other LEO and Mars orbital space results are presented.

Monte Carlo Modeling↗

NASA NTRS2017

Monte Carlo Computational Modeling of Atomic Oxygen Interactions

Atomic Oxygen↗

NASA NTRS2010

A Modular, Reusable Latch and Decking System for Securing Payloads During Launch and Planetary Surface Transport

Efficient handling of payloads destined for a planetary surface, such as the moon or Mars, requires robust systems to secure the payloads during transport on the ground, in-space and on the planetary surface. In addition, mechanisms to release the payloads need to be reliable to ensure successful transfer from one vehicle to another. An efficient payload handling strategy must also consider the devices available to support payload handling. Cranes used for overhead lifting are common to all phases of payload handling on Earth. Similarly, both recent and past studies have demonstrated that devices with comparable functionality will be needed to support lunar outpost operations. A first generation test-bed of a new high performance device that provides the capabilities of both a crane and a robotic manipulator, the Lunar Surface Manipulation System (LSMS), has been designed, built and field tested and is available for use in evaluating a system to secure payloads to transportation vehicles. National Institute of Aerospace, Hampton Va 23662 A payload handling approach must address all phases of payload management including: ground transportation, launch, planetary transfer and installation in the final system. In addition, storage may be required during any phase of operations. Each of these phases requires the payload to be lifted and secured to a vehicle, transported, released and lifted in preparation for the next transportation or storage phase. A critical component of a successful payload handling approach is a latch and associated carrier system. The latch and carrier system should minimize requirements on the: payload, carrier support structure and payload handling devices as well as be able to accommodate a wide range of payload sizes. In addition, the latch should; be small and lightweight, support a method to apply preload, be reusable, integrate into a minimal set of hard-points and have manual interfaces to actuate the latch should a problem occur. A latching system which meets these requirements has been designed and fabricated and will be described in detail. This latching system works in conjunction with a payload handling device such as the LSMS, and the LSMS has been used to test first generation latch and carrier hardware. All tests have been successful during the first phase of operational evaluations. Plans for future tests of first generation latch and carrier hardware with the LSMS are also described.

Doggett, William R.↗

NASA NTRS2011

The 2010 Desert Rats Science Operations Test: Outcomes and Lessons Learned

The Desert RATS 2010 Team tested a variety of science operations management techniques, applying experience gained during the manned Apollo missions and the robotic Mars missions. This test assessed integrated science operations management of human planetary exploration using real-time, tactical science operations to oversee daily crew science activities, and a night shift strategic science operations team to conduct strategic level assessment of science data and daily traverse results. In addition, an attempt was made to collect numerical metric data on the outcome of the science operations to assist test evaluation. The two most important outcomes were 1) the production of significant (almost overwhelming) volume of data produced during daily traverse operations with two rovers, advanced imaging systems and well trained, scientifically proficient crew-members, and 2) the degree to which the tactical team s interaction with the surface crew enhanced science return. This interaction depended on continuous real-time voice and data communications, and the quality of science return from any human planetary exploration mission will be based strongly on the aggregate interaction between a well trained surface crew and a dedicated science operations support team using voice and imaging data from a planet s surface. In addition, the scientific insight developed by both the science operations team and the crews could not be measurable by simple numerical quantities, and its value will be missed by a purely metric-based evaluation of test outcome. In particular, failure to recognize the critical importance of this qualitative type interaction may result in mission architecture choices that will reduce science return.

Eppler, D. B.↗

NASA NTRS2011

Passive Microwave Remote Sensing of Falling Snow and Associated GPM Field Campaigns

Retrievals of falling snow from space represent one of the next important challenges for the atmospheric, hydrological, and energy budget scientific communities. Historically, retrievals of falling snow have been difficult due to the relative insensitivity of satellite rain-based channels as used in the past. We emphasize the use of high frequency passive microwave channels (85-200 GHz) since these are more sensitive to the ice in clouds and have been used to estimate falling snow from space. While satellite-based remote sensing provides global coverage of falling snow events and the science is relatively new, retrievals are still undergoing development with challenges remaining. There are several current satellite sensors, though not specifically designed for estimating falling snow, are capable of measuring snow from space. These include NOAA's AMSU-B, the MHS sensors, and CloudSat radar. They use high frequency (greater than 85 GHz) passive and active microwave and millimeter-wave channels that are sensitive to the scattering from ice and snow particles in the atmosphere. Sensors with water vapor channels near 183 GHz center line provide opaqueness to the Earth's surface features that can contaminate the falling snow signatures, especially over snow covered surface. In addition, the Global Precipitation Measurement (GPM) mission scheduled for launch in 2013 is specifically designed to measure both liquid rain and frozen snow precipitation. Since falling snow from space is the next precipitation measurement challenge from space, information must be determined in order to guide retrieval algorithm development for these current and future missions. This information includes thresholds of detection for various sensor channel configurations, snow event system characteristics, and surface types. For example, can a lake effect snow system with low cloud tops having an ice water content (IWC) at the surface of 1.0 gram per cubic meter be detected? If this information is known, we can focus retrieval efforts on detectable storms and concentrate advances on achievable results. In this work, the focus is to determine thresholds of detection for falling snow for various snow conditions over land and lake surfaces. The results rely on simulated Weather Research Forecasting (WRF) simulations of falling snow cases [9] since simulations provide all the information to determine the measurements from space and the ground truth. This analysis relies on data from the Canadian CloudSat/CALIPSO Validation Program (C3VP) field campaign held from October 31, 2006 through March 1, 2007. In January 2012 GPM will return to the C3VP area for the GPM Cold Precipitation Experiment (GCPEx). This presentation will describe the thresholds-of-detection procedure and results, as well as the field campaign details.

Skofronick-Jackson, Gail↗

DOE OSTI2022

Exsolution-Driven Surface Transformation in the Host Oxide

Exsolution synthesizes self-assembled metal nanoparticle catalysts via phase precipitation. An overlooked aspect in this method thus far is how exsolution affects the host oxide surface chemistry and structure. Such information is critical as the oxide itself can also contribute to the overall catalytic activity. Here, combining X-ray and electron probes, we investigated the surface transformation of thin-film SrTi 0.65 Fe 0.35 O 3 during Fe 0 exsolution. We found that exsolution generates a highly Fe-deficient near-surface layer of about 2 nm thick. Moreover, the originally single-crystalline oxide near-surface region became partially polycrystalline after exsolution. Such drastic transformations at the surface of the oxide are important because the exsolution-induced nonstoichiometry and grain boundaries can alter the oxide ion transport and oxygen exchange kinetics and, hence, the catalytic activity toward water splitting or hydrogen oxidation reactions. These findings highlight the need to consider the exsolved oxide surface, in addition to the metal nanoparticles, in designing the exsolved nanocatalysts.

36 MATERIALS SCIENCE↗

NASA NTRS2020

Alaska Transportation & Infrastructure Identifying Permafrost Subsidence Using NASA Earth Observations to Pinpoint Road and Infrastructure Vulnerability in Fairbanks, Alaska

A rapidly warming Arctic has compromised the structural integrity of critical infrastructure through accelerated permafrost thaw and thermokarst development underlying these areas. Infrastructure, including roads, bridges, and airports across the state of Alaska are particularly at risk, as permafrost underlies ~85% of the state. However, monitoring the impacts of permafrost thaw on infrastructure is largely limited to in situ observations and frequently identified after the damage is evident. In order to assist transportation and infrastructure decision-makers in Alaska, this project identified and quantified areas of surface subsidence near critical infrastructure. Seasonal interferograms were created using Sentinel-1 C-band Synthetic Aperture Radar (SAR) and L-band Uninhabited Aerial Vehicle SAR (UAVSAR) data to identify areas experiencing surface deformation. Additionally, Light Detection and Ranging (LiDAR) datasets were used to validate select interferograms created between 2017 and 2019. Validation of subsidence detection across platforms was performed over a 7x8 sq. kilometer field site for 2017. The strongest relationship in spatial deformation is observed between Sentinel-1 and UAVSAR with a residual root mean square error of 20 mm. These results suggest that both UAVSAR and Sentinel-1 platforms are capable of detecting surface subsidence. The higher resolution of UAVSAR is better able to resolve localized subsidence features of less than 80 meters, but is limited by temporal resolution. In conjunction, UAVSAR and Sentinel-1 can provide complementary spatial and temporal resolutions for subsidence analysis in the absence of in situ data.

DEVELOP Tech Paper↗

NASA NTRS1983

Jet array impingement heat transfer characteristics

Two dimensional arrays of circular air jets impinging on a heat transfer surface parallel to the jet orifice plate are considered. The jet flow, after impingement, is constrained to exit in a single direction along the channel formed by the jet orifice plate and the heat transfer surface. In addition to the crossflow which originates from the jets following impingement, an initial crossflow is present which approaches the array through an upstream extension of the channel. The configurations considered are intended to model the impingement cooled midchord region of gas turbine airfoils in cases where an initial crossflow is also present. A major objective is determination of the effect of initial crossflow air temperature relative to jet array air temperature on impingement surface heat fluxes.

Florschuetz, L. W.↗

NASA NTRS2017

The Effects of Normal Metal Stripes on TES Performance

Exploring the effects of size and geometry of normal metal features on the transition shapes and performance of transition-edge sensor microcalorimeters. The spectral resolution of transition-edge sensor (TES) microcalorimeters is very sensitive to the specific dependencies of the resistance R in the superconducting transition on the current I, magnetic field B, and temperature T. In particular, it has been shown that transitions that are very steep in (R,T) space lead to a significant noise term, in excess of conventional expectations. This so-called unexplained noise is known to be reduced by the addition of normal metal stripes across the TES perpendicular to the direction of current flow. These normal metal stripes have been shown to drastically alter the oscillatory patterns seen in measurements of the critical current as a function of magnetic field. However, there are many remaining questions about the exact impact of the stripes on current distributions within the TES, the Fraunhofer pattern and, therefore, the shape of the R(I, B, T) surface. Through measurements of the resistance under DC bias of TES devices of various sizes, with different stripe patterns and dimensions, we will discuss how these stripes can affect the R(I, B, T) surface. In addition, using measurements and analysis of the noise spectra of various devices we will present how these changes to the stripe pattern may affect the performance of the TES. In particular, we will discuss strategies to reduce the presence of localized discontinuities in the derivative of R, associated with increased noise, while maintaining the globally low levels of unexplained noise currently achieved with conventional metal stripe patterns. Implementing these strategies is a path towards producing large arrays with highly uniform transitions and high spectral resolution. These large uniform arrays will be required for future x-ray astronomy applications, such as the X-IFU on ATHENA.

TES↗

NASA NTRS2020

Alaska Transportation & Infrastructure - Identifying Permafrost Subsidence Using NASA Earth Observations to Pinpoint Road & Infrastructure Vulnerability in Fairbanks, Alaska

A rapidly warming Arctic has compromised the structural integrity of critical infrastructure through accelerated permafrost thaw and thermokarst development underlying these areas. Infrastructure, including roads, bridges, and airports across the state of Alaska are particularly at risk, as permafrost underlies ~85% of the state. However, monitoring the impacts of permafrost thaw on infrastructure is largely limited to in situ observations and frequently identified after the damage is evident. In order to assist transportation and infrastructure decision-makers in Alaska, this project identified and quantified areas of surface subsidence near critical infrastructure. Seasonal interferograms were created using Sentinel-1 C-band Synthetic Aperture Radar (SAR) and L-band Uninhabited Aerial Vehicle SAR (UAVSAR) data to identify areas experiencing surface deformation. Additionally, Light Detection and Ranging (LiDAR) datasets were used to validate select interferograms created between 2017 and 2019. Validation of subsidence detection across platforms was performed over a 7x8 sq. kilometer field site for 2017. UAVSAR and Sentinel-1 seasonal deformation returns produced consistent spatial deformation patterns with residual root mean squared errors of 13 and 21 millimeters, respectively. These results suggest that both UAVSAR and Sentinel-1 platforms are capable of detecting surface subsidence. The higher resolution of UAVSAR is better able to resolve localized subsidence features of less than 80 meters, but is limited by temporal resolution.In conjunction, UAVSAR and Sentinel-1 can provide complementary spatial and temporal resolutions for subsidence analysis in the absence of in situ data.

Patrick Saylor↗

DOE OSTI2025

Stability evaluation and mitigation strategies in advanced tokamaks using 3D MHD spectroscopy

Multi-modal, active 3D MHD spectroscopy is applied in high-performance advanced tokamak scenarios to study their stability time evolution, revealing an intriguing dependence on both and . A tailored applied 3D field provides a 3D plasma response to extract the growth rate of the least stable mode. The estimated growth rate finds a decrease in stability when the minimum in the safety factor (q) passes through 2.0 and reveals inherent risks of crossing an additional rational surface at integer q min , even above the usual q = 1 sawtooth condition. Based on this result, the potential scenario in which q min ~ 2 can be safely crossed during a more stable lower β N phase was investigated, and the improved stability of this scenario is confirmed by the estimated growth rate. This shows that 3D MHD spectroscopy can offer insights into strategies for improving stability by identifying the vulnerable aspects of such scenarios. In addition, the method highlights its potential for instability avoidance by enabling early detection of multiple modes, even before magnetic coils can measure them. The measured growth rate by the 3D MHD spectroscopy shows its reliability by exhibiting a correlation with the programmed rises in plasma beta across various high β N and high q min discharges. In addition, this method is successfully applied during rapidly evolving I p ramp-up phases, a key part of the scenario development. By achieving reasonable growth rate measurements at high-performance scenario developments, this technique contributes to the development of advanced diagnostic tools for tokamak scenario stability, which will help identify an effective pathway to stable, high-performance scenarios.

Yang, S. M. [Princeton Plasma Physics Laboratory (↗

DOE OSTI2020

On the hydrogenation of Poly-Si passivating contacts by Al 2 O 3 and SiN x thin films

Doped polycrystalline silicon (poly-Si), when coupled with a thin SiO 2 interlayer, is of large interest for crystalline silicon ( c -Si) solar cells due to its outstanding passivating contact properties. To reach high levels of surface passivation, it is pivotal to hydrogenate the poly-Si and the underlying c -Si/SiO 2 interface. This can be done by capping the poly-Si with a hydrogen-containing dielectric layer such as Al 2 O 3 or SiN x , followed by a thermal anneal. On the basis of recent research, this work addresses several aspects of such hydrogenation by dielectric materials, including the effect of the annealing ambient, the thermal stability and reversibility of hydrogenation, the poly-Si doping level and c -Si surface texture. Additionally, the implementation of hydrogenation of poly-Si by dielectric materials in solar cells is discussed.

14 SOLAR ENERGY↗

DOE OSTI2022

In situ synchrotron tensile investigations on ultrasonic additive manufactured (UAM) zirconium

The microstructure evolution during room temperature uniaxial tensile straining of ultrasonic additive manufactured (UAM) zirconium was evaluated using the Advanced Photon Source (APS) facility. Miniature dog-bone tensile specimens of two orientations were cut from a UAM-fabricated zirconium bar for in situ synchrotron tensile tests. Wide-angle X-ray scattering (WAXS) scanning was used to unveil the changes in microstructure of the entire gauge regions throughout the straining. A series of WAXS data analysis methods were utilized to quantify both elastic and plastic deformation mechanisms within the strained specimens. Stress concentrations were identified during early stages of plastic deformation, which become candidate necking positions and eventually lead to failure. Additionally, fracture surface analysis implied that these stress concentration locations may be correlated to the fabrication defects, providing insightful guidance for future improvements of the UAM zirconium fabrication process.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Tribological Behavior of Structural Materials in High Temperature Helium Gas-Cooled Reactor Environments

The High-Temperature Gas-cooled Reactor (HTGR) is a Generation IV concept designed to produce electricity and hydrogen at high efficiencies via high operating temperatures (700 °C or higher). Helium, the primary coolant for HTGRs, contains impurities (e.g., CO, H2O and CH4) that can induce corrosion reactions at high temperatures such as oxidation and (de)carburization, which in turn can affect the tribological behavior of components. Incoloy® 800HT (Ni-Fe-Cr austenitic solid-solution alloy) and Inconel® 617 (Ni-Cr-Co-Mo solid-solution alloy) are two high-temperature superalloys currently selected as candidate structural materials for the HTGR. The objective of this study is to evaluate the high-temperature tribological performance of these two candidate alloys after conditioning them in HTGR environments. Four regimes of corrosion were considered: a non-conditioned regime (Regime I), an oxidizing regime (Regime II), a carburizing and oxidizing regime (Regime III), and a carburizing regime (Regime IV). To simulate oxidation in HTGR, samples were conditioned for 22 days at elevated temperatures in a once-through helium loop with 4 ppmv H2O. Carburization of the samples was achieved by the commercial process, Kolsterising®. In addition, two surface treatments – shot peening and aluminization – were considered as potential routes of improving the alloys’ wear resistance. Surface-treated samples were tested both before and after conditioning in Regime II. Tribological testing of the samples was performed via a pin-on-disk tribometer at elevated temperatures in ambient environment – 650 and 750°C for 800HT; 850 and 900°C for 617 – with applied loads of 1N, 2N and 5N. The wear behavior of the alloys was assessed via wear volume and friction coefficient measurements, supported by morphological, structural and compositional analyses of the wear tracks. Conditioning the samples in Regime II led to the formation of a chromium oxide on both alloys. This protective scale increased the wear resistance compared to that of as-received samples (Regime I) due to the formation of a compacted ‘glaze’ oxide layer during sliding, rendering the wear track nearly undistinguishable from the unworn background and resulting in wear volumes below the detection limits of the measurement technique. The variability of the friction coefficients of the conditioned samples was also considerably reduced compared to that of the as-received samples due to the glaze layer. Additionally, the initial friction coefficients of the samples conditioned in Regime II were reduced by 45% and 54% compared to those of as-received samples for alloys 800HT and 617, respectively. Carburizing the samples (Regime IV) hardened the surfaces of both alloys and promoted the formation of an iron oxide on 800HT during tribological testing, thereby increasing the wear resistance and decreasing the initial friction coefficient by a factor of two compared to those of as-received 800HT. Alloy 617 exhibited an enhanced wear resistance but similar initial friction coefficient compared to those of as-received samples due to the increased surface hardness. The Mn-Cr oxide developed during Regime III conditioning of 800HT did not develop a glaze layer during tribotesting, even at lower loads. Thus, it was not as protective as the oxide produced during conditioning of Regime II samples, leading to lower wear resistance of 800HT in Regime III compared to that measured in the Regime II condition. 800HT benefited from the aluminization surface treatment, particularly before conditioning in Regime II, due to the promotion of a wear-resistant aluminum oxide layer during testing and the increase in surface hardness due to the presence of a FeAl intermetallic phase. The presence of this phase caused an order-of-magnitude reduction in wear volumes compared to those of as-received 800HT. Aluminization of 617 decreased its wear resistance, particularly after conditioning in Regime II, due to significant wear of the aluminum oxide via a ceramic wear mechanism. This aluminum oxide was removed during sliding, causing the wear volumes to increase by a factor of five compared to those of 617 conditioned in Regime II. Shot-peened 800HT exhibited a tribological behavior similar to that of as-received 800HT, despite an enhancement in the rate of chromium oxide formation. Shot-peened 800HT conditioned in Regime II showed lower wear resistance compared to that of 800HT conditioned in Regime II due to the poor adhesion between the oxide and the underlying metal, preventing the formation of the glaze layer during sliding. Shot peening of 617 increased its wear resistance at higher load, reducing worn volumes by 60% compared to that measured with as-received 617. Tribotesting of shot-peened 617 in Regime II revealed that the glaze-oxide layer was formed at every load, resulting in negligible wear, similar to what was observed from testing 617 after conditioning in Regime II. Overall, alloy 617 exhibited tribologically superior behavior compared to that of alloy 800HT, as demonstrated by its lower friction coefficients and its order-of-magnitude lower wear volumes when measurable.

36 MATERIALS SCIENCE↗