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NASA NTRS1990

Development of Low Conductivity and Ultra High Temperature Ceramic Coatings Using A High-Heat-Flux Testing Approach

The development of low conductivity, robust thermal and environmental barrier coatings requires advanced testing techniques that can accurately and effectively evaluate coating thermal conductivity and cyclic resistance at very high surface temperatures (up to 17OOOC) under large thermal gradients. In this study, a laser high-heat-flux test approach is established for evaluating advanced low conductivity, ultra-high temperature ceramic thermal and environmental barrier coatings under the NASA Ultra Efficient Engine Technology (UEET) program. The test approach emphasizes the real-time monitoring and assessment of the coating thermal conductivity: the initial conductivity rise under a steady-state high temperature thermal gradient test due to coating sintering, and the later coating conductivity reduction under a subsequent cyclic thermal gradient test due to coating cracking/delamination. The coating system is then evaluated based on the damage accumulations and failure after the combined steady-state and cyclic thermal gradient tests. The lattice and radiation thermal conductivity of advanced ceramic coatings can also be evaluated using laser heat-flux techniques. The coating external radiation resistance is assessed based on the measured specimen temperature response under a laser heated intense radiation flux source. The coating internal radiation contribution is investigated based on the measured apparent coating conductivity increases with the coating surface test temperature under large thermal gradient test conditions. Since an increased radiation contribution is observed at these very high surface test temperatures, by varying the laser heat-flux and coating average test temperature, the complex relation between the lattice and radiation conductivity as a function of surface and interface test temperature is derived.

Zhu, Dongming↗

DOE OSTI2021

Ultrafast visualization of phase transitions in nonequilibrium warm dense matter

Intense ultrafast laser excitation brings materials into highly nonequilibrium states with complex solid–liquid phase transitions. These ultrafast processes yield warm dense matter (WDM) conditions characterized by comparable thermal and Fermi energies, and strong ion–ion coupling. Here, we review recent studies employing mega-electron-volt ultrafast electron diffraction to resolve the structural dynamics of nonequilibrium WDM created by femtosecond laser heating of solids. Furthermore, for the study of warm dense gold, the results showed homogeneous melting that occurs within tens of picoseconds at absorbed energy densities of 0.4–1.4 MJ/kg. These results constrained the electron–ion coupling rate and revealed the melting sensitivity to nucleation seeds. For the study of radiation-damaged tungsten, the results showed a melting transition below the melting temperature. Molecular dynamics simulations suggested that this melting behavior is driven by vacancy defect clusters from radiation damage. These studies provided atomic-level insights into the melting behavior of materials under extreme conditions.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Orientation-selected micro-pillar compression of additively manufactured 316L stainless steels: Comparison of as-manufactured, annealed, and proton-irradiated variants

In this work, irradiation response and deformation mechanisms of additively manufactured (AM) 316L stainless steel were studied by atomic scale characterization and micro-pillar compression. The AM 316L stainless steels were fabricated by direct energy deposition, a laser-based additive manufacturing process. Irradiation with 2 MeV protons at 360°C was performed to create ~1.8 displacements-per-atom (dpa) damage in AM 316L. Deformation behaviors of the as-manufactured, annealed, and proton-irradiated variants were studied, focusing on the effects of manufacturing-induced pores, residual stress, and irradiation-introduced defects (dislocation loops and voids). Micro-pillars were prepared from grains of pre-selected orientation, avoiding contributions of grain boundaries and allowing determination of resolved shear stress on {111} glide planes. Transmission electron microscopy was used to characterize the pre- and post-deformation microstructure. It was found that in the as-manufactured alloy variant, moving dislocations were the major deformation carrier, with noticeable blocking by fabrication-induced pores, In the annealed variant, hardness was reduced, and deformation was also accomplished by dislocation gliding. In the proton-irradiated variant, significant twinning was observed. Comparing measured resolved shear stress and predicted critical stress for dislocation dissociation, we conclude that irradiation hardening became high enough to activate twinning. Therefore, the deformation mechanism changes from dislocation gliding to twinning. The study is important for both processing optimization and performance evaluation of AM alloys for reactor applications.

36 MATERIALS SCIENCE↗

NASA NTRS1994

Optically Addressable, Ferroelectric Memory With NDRO

For readout, memory cells addressed via on-chip semiconductor lasers. Proposed thin-film ferroelectric memory device features nonvolatile storage, optically addressable, nondestructive readout (NDRO) with fast access, and low vulnerability to damage by ionizing radiation. Polarization switched during recording and erasure, but not during readout. As result, readout would not destroy contents of memory, and operating life in specific "read-intensive" applications increased up to estimated 10 to the 16th power cycles.

Thakoor, Sarita↗

NASA NTRS2011

Microwave Tissue Soldering for Immediate Wound Closure

A novel approach for the immediate sealing of traumatic wounds is under development. A portable microwave generator and handheld antenna are used to seal wounds, binding the edges of the wound together using a biodegradable protein sealant or solder. This method could be used for repairing wounds in emergency settings, by restoring the wound surface to its original strength within minutes. This technique could also be utilized for surgical purposes involving solid visceral organs (i.e., liver, spleen, and kidney) that currently do not respond well to ordinary surgical procedures. A miniaturized microwave generator and a handheld antenna are used to deliver microwave energy to the protein solder, which is applied to the wound. The antenna can be of several alternative designs optimized for placement either in contact with or proximity to the protein solder covering the wound. In either case, optimization of the design includes the matching of impedances to maximize the energy delivered to the protein solder and wound at a chosen frequency. For certain applications, an antenna could be designed that would emit power only when it is in direct contact with the wound. The optimum frequency or frequencies for a specific application would depend on the required depth of penetration of the microwave energy. In fact, a computational simulation for each specific application could be performed, which would then match the characteristics of the antenna with the protein solder and tissue to best effect wound closure. An additional area of interest with potential benefit that remains to be validated is whether microwave energy can effectively kill bacteria in and around the wound. Thus, this may be an efficient method for simultaneously sterilizing and closing wounds. Using microwave energy to seal wounds has a number of advantages over lasers, which are currently in experimental use in some hospitals. Laser tissue welding is unsuitable for emergency use because its large, bulky equipment cannot be easily moved between operating rooms, let alone relocated to field sites where emergencies often occur. In addition, this approach is highly dependent on the uniformity and thickness of the protein solder as well as the surgeon s skills. In contrast, the use of microwave energy is highly tolerant of the thickness of the protein solder, level of fluids in and around the wound, and other parameters that can adversely affect the outcome of laser welding. However, controlling the depth of penetration of the microwave energy into the wound is critical for achieving effective wound sealing without damaging the adjacent tissue. In addition, microspheres that encapsulate metallic cores could also be incorporated into the protein solder to further control the depth of penetration of the microwave energy.

Arndt, G. Dickey↗

DOE OSTI2026

Integrated Neutronics Modeling for Inertial Fusion Energy Systems: Development and Application to LD-FIRST

Lawrence Livermore National Laboratory (LLNL) is proposing a new Laser Driven Fusion Integration Research and Science Test Facility (LD-FIRST) with the goal of providing an experimental testbed for future Inertial Fusion Energy (IFE) systems. However, IFE systems require detailed and accurate multiphysics modeling to quantify material damage, thermal loading, and tritium breeding within complex chamber environments. This article presents the first step in an integrated multiphysics framework that couples meshed CAD-based geometry within Monte Carlo neutronic simulations to enable high-fidelity analysis of IFE chamber concepts, with future coupling to external codes. The neutronics workflow utilizes OpenMC and its third-party capability to use CAD-based geometries through DAGMC and tally on unstructured meshes with Libmesh to evaluate neutron transport behavior, geometric fidelity, and material performance under reactor-relevant conditions. The use of tailored tallies on unstructured meshes in this framework allows direct transfer without interpolating to CFD simulation tools. Two IFE chambers were evaluated, both conceived by LLNL: HYLIFE-II and Laser IFE (LIFE). This work produced high-fidelity conformal surface and volumetric meshes of the HYLIFE-II and LIFE chambers with mapped spatial insight into material damage, thermal loading, and tritium breeding. The HYLIFE-II model was built utilizing available resources and used as a test case to verify that the neutronics framework can handle complex geometries. The LIFE chamber CAD was provided by LLNL and was the main focus of this work. This work analyzes multiple ternary alloy breeding materials for the LIFE chamber, across different 6 Li enrichments to produce data relevant to the LD-FIRST project. This work also investigates the level of model fidelity for the LIFE chamber, and results show that inclusion of detailed first wall and coolant structures increased the predicted tritium breeding ratio (TBR) by ~30%, highlighting the sensitivity of tritium breeding and the need for a high-fidelity simulation framework for IFE chambers. These developments provide a scalable toolset for the design and optimization of next-generation IFE chambers, forming a solid foundation for future coupled multiphysics analysis.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Depolarization self-compensation in high-power lasers enabled by a mid-cavity quartz rotator

Depolarization from thermal stress remains a major limitation in high-average-power laser amplifiers, often addressed by complex, costly active methods or by using magneto-optical effects to restore the polarization. We demonstrate a passive polarization self-compensation technique using a quartz rotator in a relay-imaged, multi-pass amplifier geometry. A detailed theoretical framework is presented and validated experimentally, showing a 47 × reduction in depolarized light in a relay-imaged 4-pass cavity. This approach employs a high-damage-threshold, reciprocal material and avoids the use of polarizers or active controls, thereby simplifying system design and reducing costs. Scalability is discussed for realistic inertial fusion energy driver designs, including effectiveness for broadband lasers and thick gain media.

Batysta, František [Lawrence Livermore National La↗

NASA NTRS2012

Laser Remediation of Threats Posed by Small Orbital Debris

The continually increasing amount of orbital debris in near Earth space poses an increasing challenge to space situational awareness. Recent collisions of spacecraft caused abrupt increases in the density of both large and small debris in near Earth space. An especially challenging class of threats is that due to the increasing density of small (1 mm to 10 cm dimension) orbital debris. This small debris poses a serious threat since: (1) The high velocity enables even millimeter dimension debris to cause serious damage to vulnerable areas of space assets, e.g., detector windows; (2) The small size and large number of debris elements prevent adequate detection and cataloguing. We have identified solutions to this threat in the form of novel laser systems and novel ways of using these laser systems. While implementation of the solutions we identify is challenging we find approaches offering threat mitigation within time frames and at costs of practical interest. We base our analysis on the unique combination of coherent light specifically structured in both space and time and applied in novel ways entirely within the vacuum of space to deorbiting small debris. We compare and contrast laser based small debris removal strategies using ground based laser systems with strategies using space based laser systems. We find laser systems located and used entirely within space offer essential and decisive advantages over groundbased laser systems.

Fork, Richard L.↗

DOE OSTI2021

Converting existing optical detectors into fast x-ray detectors

Here, the very short burn time and small size of burning plasmas created at advanced laser-fusion facilities will require high-spatial-resolution imaging diagnostics with fast time resolution. These instruments will need to function in an environment of extremely large neutron fluxes that will cause conventional diagnostics to fail because of radiation damage and induced background levels. One solution to this challenge is to perform an ultrafast conversion of the x-ray signals into the optical regime before the neutrons are able to reach the detector and then to relay image the signal out of the chamber and into a shielded bunker, protected from the effects of these neutrons. With this goal in mind, the OMEGA laser was used to demonstrate high-temporal-resolution x-ray imaging by using an x-ray snout to image an imploding backlighter capsule onto a semiconductor. The semiconductor was simultaneously probed with the existing velocity interferometry system for any surface reflector (VISAR) diagnostic, which uses an optical streak camera and provided a one-dimensional image of the phase in the semiconductor as a function of time. The phase induced in the semiconductor was linearly proportional to the x-ray emission from the backlighter capsule. This approach would then allow a sacrificial semiconductor to be attached at the end of an optical train with the VISAR and optical streak camera placed in a shielded bunker to operate in a high neutron environment and obtain time-dependent one-dimensional x-ray images or time-dependent x-ray spectra from a burning plasma.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Defect And Damage Characterization Of Additively Manufactured Titanium Alloy Ti-5553 Using Traditional Computed Tomography Volume Segmentation And Machine Learning Algorithms

The mechanical response of a component is affected by defects, such as porosity, arising from the laser powder bed fusion (LPBF) fabrication process. Thus, it is important to develop accurate and efficient inspection methods for identifying porosity. In this work, porosity identified in an X-ray computed tomography (XCT) volume of a Ti-5553 coupon was compared to pores identified in a serial sectioned volume that represented the ground truth. The porosity of the XCT scan was identified using contrast-based, ISO-based, and machine learning (ML) methods for segmentation. Large inherent porosity was easy to identify, but the ISO thresholding still struggled due to the intensity gradient resulting from both the beam hardening in XCT and the uneven lighting of the serial sectioning panels. Further, the results show that ML-based methods were better suited for identifying small pores and reducing the amount of false positives. Additionally, high strain-rate impact testing was done on some of the XCT samples as well as post-mortem XCT inspection, and the same suite of segmentation and quantification tools were used to identify the large spallation cavities. The comparison of porosity pre- and post-mortem provides insight on the influence of the LPBF porosity on the formation of spall cavities.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Photon-In/Photon-Out X-ray Free-Electron Laser Studies of Radiolysis

Understanding the origin of reactive species following ionization in aqueous systems is an important aspect of radiation–matter interactions as the initial reactive species lead to production of radicals and subsequent long-term radiation damage. Tunable ultrafast X-ray free-electron pulses provide a new window to probe events occurring on the sub-picosecond timescale, supplementing other methodologies, such as pulse radiolysis, scavenger studies, and stop flow that capture longer timescale chemical phenomena. We review initial work capturing the fastest chemical processes in liquid water radiolysis using optical pump/X-ray probe spectroscopy in the water window and discuss how ultrafast X-ray pump/X-ray probe spectroscopies can examine ionization-induced processes more generally and with better time resolution. Ultimately, these methods will be applied to understanding radiation effects in complex aqueous solutions present in high-level nuclear waste.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Ultra-rapid, physics-based development pathway for reactor-relevant RF antenna materials

This paper presents a rapid, atomistically-informed, experimental development pathway for fusion reactor-relevant radio frequency (RF) antenna materials in the Cu-Cr-(Nb,Al,Zr) composition system, with the goal of improving upon GRCop-84. RF antennas in a tokamak fusion reactor will face a unique set of challenges as both structural and functional materials. The desired material must simultaneously achieve and maintain high electrical conductivity, high strength, high thermal conductivity, resist high temperatures, possess low nuclear activation, and incur low damage due to neutron bombardment. The GRCop-84 alloy serves as a starting point for iterative improvement, with the desire to reduce or eliminate Nb from the material to minimize nuclear activation. The rapid development pathway makes use of a multi-target combinatorial thick film sputtering process to produce full ternary phase diagrams on a Si wafer substrate. Transient grating spectroscopy (TGS), a laser-ultrasonic method, will determine spatially-varying thermo-elastic properties, while four terminal electrical conductivity measurements will map out the best per- forming regions of the sample for in-depth study at larger length scales. High energy proton and self-ion irradiation emulates the effects of neutron damage on the thermal/electric properties. With rapid turnaround time (∼days) in terms of mapping radiation damage-induced material property changes in the full ternary system, these techniques allow rapid iteration towards an optimal material, testing hundreds of nearby compositions in the time it took to test one. Focused testing of larger, single composition samples (produced in an arc furnace or by laser sintering) provides data on structural and high power RF properties, and validates our thick-film based workflow.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRSDate not supplied

NDE Methods and Capabilities Handbook – Resources for the Composites NDE Community

Composite structures are often difficult to inspect due to the anisotropic nature of the material systems and the range of flaws and defects that can arise in the manufacturing process. NASA’s Advanced Composites Project, a public-private partnership between government, universities and industry, sought to address improved methods, tools, and protocols to reduce the development and certification timeline for composite materials and structures. The rapid inspection of composites was one of the three focused research areas of the project. One deliverable of the project was to develop an NDE Methods and Capabilities Handbook. This Handbook provides a publicly available guidance document that facilitates the selection of appropriate NDE techniques and provides recommended protocols for detecting and characterizing common flaw types in solid laminate carbon fiber reinforced polymer composite (CFRP) structures. The Handbook seeks to reduce the time required to develop qualified inspection processes for composite aircraft structures during the development, certification, and manufacturing phases by providing a reference that helps minimize trial and error and provides guidance on best practices, techniques, and settings, for specific flaw types and geometries. NDE techniques include, but are not limited to ultrasound, laser based ultrasound, infrared thermography, and x-ray CT. Flaw types include, but are not limited to porosity, delamination, voids, AFP defects and impact damage. The Handbook contains details such as inspection parameters, data analysis techniques, inspection efficiency (speed & cost), and limitations. This presentation will describe key Handbook activities with examples of the techniques and flaw types examined by the Advanced Composite Consortium members. Availability of the fabricated NDE standards as well as the raw data collected on the standards by the Consortium members to the NDE community is discussed.

Patricia A Howell↗

DOE OSTI2023

Building the next high voltage dc photogun polarized source for the ILC at JLab

During the ILC Global Design Effort (2007) two 200 kV high voltage photoguns based on an inverted insulator geometry were developed in 2010 and successfully tested at Jefferson Lab (JLab). One of the photoguns has been operated at 130 kV in the CEBAF accelerator for the JLab nuclear physics program. The inverted insulator replaces the electrode support structure, consequently significantly less metal prone to field emission is biased and surfaces contributing to the vacuum load are significantly reduced. Implementing a biased anode, and using a larger laser spot size has made this the state of the art polarized beam source with ~200 C charge lifetime from SSL GaAs photocathodes. However, operating at the design 200 kV voltage has been hindered by field emission at ~190 kV. To reliably operate without field emission requires lengthy conditioning applying 50-100 kV beyond the voltage needed for beam operations, without breakdown or damage to the insulator. Over the past decade, JLab has developed two photoguns with a larger version of the commercial inverted insulators used in the ILC design. One photogun operated at 300 kV for magnetized beam studies, and the concept has been implemented in the BNL polarized photogun. The second photogun has recently been installed in CEBAF to operate at 200 kV field emission free. Higher voltage photoguns help the ILC and CLIC achieve higher bunch charge (2013 TDR), and additionally provide margin for operating with shorter laser pulse length and/or smaller laser spot size (better emittance at higher peak current). Such photogun designs need to reach ~400 kV without breakdown or insulator damage to operate field emission free at > 300 kV. This also allows for direct injection into a SRF booster. JLab submitted a proposal to HEP for developing in partnership with industry an inverted geometry insulator to fit commercial 400 kV cables. This contribution describes JLab experience developing and testing high voltage photoguns, and what is needed to sufficiently condition for voltage levels higher than beam operational voltage.

Hernandez-Garcia, Carlos↗

NASA NTRS2001

The Effects of Shot and Laser Peening on Fatigue Life and Crack Growth in 2024 Aluminum Alloy and 4340 Steel

Fatigue and crack growth tests have been conducted on 4340 steel and 2024-T3 aluminum alloy, respectively, to assess the effects of shot peening on fatigue life and the effects of shot and laser peening on crack growth. Two current programs involving fixed and rotary-wing aircraft will not be using shot peened structures. Since the shot peening compressive residual stress depth is usually less than the 0.05-inch initial damage tolerance crack size, it is believed by some that shot peening should have no beneficial effects toward retarding crack growth. In this study cracks were initiated from an electronic-discharged machining flaw which was cycled to produce a fatigue crack of approximately 0.05-inches in length and then the specimens were peened. Test results showed that after peening the crack growth rates were noticeably slower when the cracks were fairly short for both the shot and laser peened specimens resulting in a crack growth life that was a factor of 2 to 4 times greater than the results of the average unpeened test. Once the cracks reached a length of approximately 0.1-inches the growth rates were about the same for the peened and unpeened specimens. Fatigue tests on 4340 steel showed that the endurance limit of a test specimen with a 0.002-inch-deep machining-like scratch was reduced by approximately 40 percent. However, if the "scratched" specimen was shot peened after inserting the scratch, the fatigue life returned to almost 100 percent of the unflawed specimens original fatigue life.

Everett, R. A., Jr.↗

DOE OSTI2025

Postirradiation Examination of HFIR-Irradiated Yttrium Hydrides

The US Department of Energy Microreactor Program is developing compact, high-temperature microreactors that require robust neutron moderators. Known for its high hydrogen retention and structural stability, YH x is a leading candidate for this purpose. As part of an ongoing evaluation, Oak Ridge National Laboratory conducted post-irradiation examinations on YH x specimens irradiated in the High Flux Isotope Reactor under the legacy Transformational Challenge Reactor program, focusing on their structural integrity, hydrogen retention, and thermal properties. The post-irradiation examination campaign primarily examined specimens from two irradiation campaigns, covering a range of hydrogen-to-yttrium atomic ratios (H/Y), neutron damage levels (0.1–2 displacements per atom), and targeted irradiation temperature of 600°C. The investigations included electron microscopy, high-energy x-ray diffraction, laser flash analysis, differential scanning calorimetry, and SiC thermometry analysis.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRSDate not supplied

TPSAS-NF1676L-32030-DND

Composite structures are often difficult to inspect due to the anisotropic nature of the material systems and the range of flaws and defects that can arise in the manufacturing process. NASA?s Advanced Composites Project, a public-private partnership between government, universities and industry, seeks to address improved methods, tools, and protocols to reduce the development and certification timeline for composite materials and structures. The rapid inspection of composites is one of the three focused research areas of the project. One deliverable of the project is to develop an NDE Methods and Capabilities Handbook. This Handbook provides a publically available guidance document that facilitates the selection of appropriate NDE techniques and provides recommended protocols for detecting and characterizing common flaw types in solid laminate polymer matrix composite (PMC) structures. The Handbook will reduce the time required to develop qualified inspection processes for composite aircraft structures during the development, certification, and manufacturing phases by providing a reference that helps minimize trial and error and provides guidance on best practices, techniques, and settings, for specific flaw types and geometries. The Handbook will include an NDE Guidance Matrix that provides an applicability rating for NDE techniques as they apply to given flaw types. NDE techniques will include, but is not limited to ultrasound, laser based ultrasound, infrared thermography, and x-ray CT. Flaw types will include, but are not limited to porosity, delamination, voids, AFP defects and impact damage. The Handbook will contain details that support the applicability rating including, but not limited to, specimen details, inspection parameters, data analysis techniques, inspection efficiency (speed & cost), and limitations. This presentation will describe key Handbook activities with examples of the techniques and flaw types examined by the Advanced Composite Consortium members.

Patricia A Howell↗

DOE OSTI2021

Effects of Build Orientation and Heat Treatment on Neutron Irradiation Hardening in Inconel 625 Fabricated via Laser Powder Bed Fusion

Various Inconel 625 coupons fabricated via Laser Powder Bed Fusion (L-PBF) were neutron irradiated using the inside reflector of the reactor at the University of Missouri Research Reactor (MURR). Effects of build orientation and heat treatment on neutron-induced hardening were investigated by inspecting L-PBF samples built vertically or at a 45º angle in the following heat-treated conditions: as-built (no heat treatment), 700 ºC for 1 hour, 900 ºC for 1 hour, and 1050 ºC for 1 hour. The microhardness results of L-PBF samples before and after neutron irradiation were compared with traditional wrought Inconel 625. All samples underwent an irradiation flux of 6.61 x 1013 neutrons/cm²/s for 310 hours for an estimated damage of 0.012 dpa. Results indicate that as-built L-PBF specimens are less prone to radiation hardening relative to their wrought counterparts. As-printed diagonal specimens were shown to harden by 8% as compared to 1.2% hardening in as-printed vertical specimens.

36 MATERIALS SCIENCE↗