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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 523 records · Page 29
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

The next-generation particle x-ray temporal diagnostic for simultaneous time-resolved measurements of nuclear-burn and x-ray emission histories in support of basic-science and inertial confinement fusion experiments at OMEGA

The next-generation Particle X-ray Temporal Diagnostic (PXTD) has been implemented for simultaneous measurements of x-ray, charged particle, and neutron emission histories from a wide range of inertial confinement fusion and high energy density plasma experiments, demonstrating excellent timing accuracy and greatly improved experimental flexibility. The key changes to the previously fielded system are a redesigned set of thin foil filters in front of the scintillators and individual neutral density filters for each region of the detector. The fully implemented PXTD system can provide unique information about the evolution of ion and electron temperatures in multi-ion and kinetic-physics experiments, proton radiography experiments, and DT experiments executed at the OMEGA facility. The system has 35 ps time resolution and negligible relative timing uncertainty between measured emission history signals. The first use of the upgraded four-channel PXTD system during a set of D 3 He-filled silica-glass implosions on OMEGA captured electron temperatures with a minimum uncertainty of 0.5 keV and resolved both the relative timings and widths of neutron, proton, and x-ray peaks within a single recorded image.

Evans, T. E. [Massachusetts Inst. of Technology (M↗
DOE OSTI2025

Predicting High‐Resolution Spatial and Spectral Features in Mass Spectrometry Imaging with Machine Learning and Multimodal Data Fusion

Recent advancements in molecular Mass Spectrometry Imaging have sparked interest in integrating high spatial resolution methods with molecular mass-spectrometry-based chemical imaging. Fusion-based algorithms have proven effective in generating high spatial-resolution molecular mass spectra. However, a significant challenge stems from the differing physical mechanisms underlying image generation and data upsampling techniques, potentially leading to discrepancies in integrated information channels. Integrating physical constraints into data processing workflows is essential to tackle this issue. In this study, we propose an innovative approach that merges data from Fourier transform ion cyclotron resonance (FTICR), time-of-flight matrix-assisted laser desorption/ionization, and time-of-flight secondary ion mass spectrometry imaging techniques. By leveraging FT-ICR's unparalleled spectral resolution and ToF-SIMS's exceptional spatial resolution, we achieve submicron spatial resolution, enabling the observation of intact molecular species with remarkable spectral precision. Canonical correlation analysis is employed to incorporate physical constraints. Through sophisticated image processing and machine learning techniques, the results of this fusion hold significant promise for advancing our comprehension of complex systems and unveiling concealed molecular intricacies.

canonical correlation analysis↗
DOE OSTI2024

Structural studies of intrinsically disordered MLL -fusion protein AF9 in complex with peptidomimetic inhibitors

AF9 (MLLT3) and its paralog ENL(MLLT1) are members of the YEATS family of proteins with important role in transcriptional and epigenetic regulatory complexes. These proteins are two common MLL fusion partners in MLL -rearranged leukemias. The oncofusion proteins MLL-AF9/ENL recruit multiple binding partners, including the histone methyltransferase DOT1L, leading to aberrant transcriptional activation and enhancing the expression of a characteristic set of genes that drive leukemogenesis. The interaction between AF9 and DOT1L is mediated by an intrinsically disordered C-terminal ANC1 homology domain (AHD) in AF9, which undergoes folding upon binding of DOT1L and other partner proteins. We have recently reported peptidomimetics that disrupt the recruitment of DOT1L by AF9 and ENL, providing a proof-of-concept for targeting AHD and assessing its druggability. Intrinsically disordered proteins, such as AF9 AHD, are difficult to study and characterize experimentally on a structural level. In this study, we present a successful protein engineering strategy to facilitate structural investigation of the intrinsically disordered AF9 AHD domain in complex with peptidomimetic inhibitors by using maltose binding protein (MBP) as a crystallization chaperone connected with linkers of varying flexibility and length. The strategic incorporation of disulfide bonds provided diffraction-quality crystals of the two disulfide-bridged MBP–AF9 AHD fusion proteins in complex with the peptidomimetics. These successfully determined first series of 2.1–2.6 Å crystal complex structures provide high-resolution insights into the interactions between AHD and its inhibitors, shedding light on the role of AHD in recruiting various binding partner proteins. We show that the overall complex structures closely resemble the reported NMR structure of AF9 AHD/DOT1L with notable difference in the conformation of the β-hairpin region, stabilized through conserved hydrogen bonds network. These first series of AF9 AHD/peptidomimetics complex structures are providing insights of the protein–inhibitor interactions and will facilitate further development of novel inhibitors targeting the AF9/ENL AHD domain.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Free-Surface Liquid Lithium Flow Modeling and Stability Analysis for Fusion Applications

Liquid metal plasma facing components are considered an attractive design choice for fusion devices including pilot plants. Virtual prototyping of such devices includes modeling of free-surface flow of the electrically conductive liquid, which requires computational fluid dynamics (CFD) and magnetohydrodynamics (MHD) simulations. Numerical tools capable of simulating flows and heat transfer in the free-surface MHD flow were developed at PPPL based on the customized ANSYS CFX. Here, MHD is introduced using a magnetic vector potential approach. Free-surface flow capabilities are available in the code and were tested. Special stabilization procedures were derived and applied to improve convergence of the momentum equations with the source terms due to the Lorentz force and surface tension. Important characteristics of the fusion-relevant liquid metal flow is free surface smoothness and stability. Heat flux from the plasma impacts the liquid surface at a very acute angle, so any change of the free surface from axisymmetry can dramatically increase the local heat flux density and thus create excessive evaporation of liquid lithium into the plasma, which is detrimental to operations. Stability analysis of the liquid metal film flow was performed to determine applicable flow regimes. Thin film flow along horizontal wall is considered. Effects of gravity, magnetic field, and surface tension are included in the analysis.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Fusion Innovation and the Valley of Death—Lessons from Fission

Over the past several decades, the United States (U.S.) and other countries have done important research and development in advanced nuclear energy technologies, both fission and fusion. The urgency of our current climate, energy, and security needs have prompted a concerted effort by innovators, investors, and the public sector to transition from research and development (R&D) to demonstration and commercialization—to cross the proverbial “valley of death.” The stakes are high: humanity needs clean energy options, and the failure of any promising alternative will lower our odds of success. The process of moving an innovation into use has often been described in phases that begin with early research and end with deployment at scale. Between those two phases lies an area often referred to as the “valley of death” because it can require a long period of time, large investments, and often includes significant challenges related to regulation, standardization, and entering markets already structured around incumbent technologies. What can we learn from recent experience with fission to inform our path forward with fusion? At least five key lessons rise to the top: 1) Set bold targets; 2) Empower the private sector; 3) Engage with regulators and the public; 4) Address costs and markets; and 5) Deliver results. Here, this editorial will consider each of these in turn.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Valuing Maintenance Strategies for Fusion Plants as Part of a Future Electricity Grid

Scheduled maintenance is likely to be lengthy and therefore consequential for the economics of fusion power plants. The maintenance strategy that maximizes the economic value of a plant depends on internal factors such as the cost and durability of the replaceable components, the frequency and duration of the maintenance blocks, and the external factors of the electricity system in which the plant operates. Here, this paper examines the value of fusion power plants with various maintenance properties in a decarbonized United States Eastern Interconnection circa 2050. Seasonal variations in electricity supply and demand mean that certain times of year, particularly spring to early summer, are best for scheduled maintenance. Seasonality has two important consequences. First, the value of a plant can be 15% higher than what one would naively expect if value were directly proportional to its availability. Second, in some cases, replacing fractions of a component in shorter maintenance blocks spread over multiple years is better than replacing it all at once during a longer outage, even through the overall availability of the plant is lower in the former scenario.

power plant, maintenance, seasonality, electricity↗
DOE OSTI2020

Revealing transient powder-gas interaction in laser powder bed fusion process through multi-physics modeling and high-speed synchrotron x-ray imaging

Laser powder bed fusion (LPBF) is an emerging metal additive manufacturing process. The gas-driven powder motions in laser powder bed fusion have significant influence on the build quality. However, the transient powder-gas interaction has not been well understood due to the challenges in quantitative experiment measurements. In this work, the powder-gas interaction for a single pulse laser illuminating on the powder bed is studied. We establish a multi-physics model to simulate the complex liquid/gas flow as well as the gas-driven powder motions, which is substantiated by high-speed synchrotron x-ray imaging. We identify and quantify four characteristic modes of powder-gas interaction in LPBF. The motion of a powder is controlled by one or multiple interaction modes collectively. As revealed by simulations and confirmed by experiments, powders can merge into the molten pool from its rim, be ejected at different divergence angles (powder spattering), or dive into the molten pool to cause significant molten pool fluctuation. Overall, our results provide insights toward the driving forces controlling the dynamic powder behavior, which pave the way for reducing structure defects during the build process.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Laser powder bed fusion of Inconel 718 on 316 stainless steel

The joining of Inconel 718 and 316 stainless steel has notable industrial importance. However, traditional arc-welding has many issues. In particular, the formation of the detrimental Nb-rich Laves phase in the heat affected zone can promote crack initiation and propagation, which leads to poor mechanical properties. The small heat input and the rapid solidification of laser powder bed fusion (PBF) has the potential to suppress this problem. Despite the infancy of the multi-material PBF, it is of interest to investigate the relationship among the process parameter, the microstructure at the materials joining point, and the mechanical performance. In this study, we used high-speed x-ray imaging to in-situ monitor the printing of Inconel 718 tracks on a 316H SS substrate via laser powder bed fusion, followed by post-build characterization and testing with SEM, XRD and nanoindentation. We observed that a higher linear energy density resulted in a more diffused interface and a smaller compositional gradient, but as a trade-off, generated more keyhole pores and thermal cracks. Furthermore, we also showed that the built layer exhibited chemical inhomogeneity at two length scales: a tens-of-mu m-scale compositional vortex due to the melt flow, and a sub-mu m-scale Nb-rich dendritic structure due to the non-equilibrium solidification that led to the formation of the Laves phase. It was inferred that the chemical inhomogeneity may benefit the mechanical properties at the interface by providing more interlocking between the two materials and also by limiting the effect of the brittle Laves phase to potentially short range.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Deformation and fracture behavior of a laser powder bed fusion processed stainless steel: In situ synchrotron x-ray computed microtomography study

Tensile plastic deformation and fracture behavior of a laser powder bed fusion processed 316L stainless steel alloy was investigated in situ using high-resolution synchrotron x-ray computed microtomography (sXCT). Three different cases were studied: (1) specimen A1, near full-density with initial porosity of 0.04%, (2) specimen B1, initial lack-of-fusion (LOF) porosity of about 3% with the major axis of defects aligned nearly perpendicular to the tensile loading direction (LD), and (3) specimen B, similar to B1 but with the major axis of LOF defects aligned nearly parallel to LD. The effects of type, density, and orientation of defects in as-printed samples on plastic deformation and failure modes were studied by analyzing sXCT image sequences and quantitative defect properties. Specifically, the evolutions of porosity, size, aspect ratio, and angle of gas pores and LOF defects were characterized as a function of applied strain. Moreover, interactions between as-printed defects and deformation-induced crack propagation were investigated. The tensile behavior of specimen A1 was comparable to that of a commercial wrought plate. Furthermore, the quantitative in-situ sXCT results showed a void-growth phenomenon in A1 but without noticeable coalescence, resulting in a ductile cup-cone failure. Specimen B1 showed damage-driven brittle failure with limited plasticity due to early and rapid propagation of open voids. On the other hand, specimen B, with a similar amount of LOF defects as B1, showed deceivingly strong and ductile tensile behavior similar to A1 without any major crack propagations due to the favorable orientation relationship between LOF defects and the LD.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Photodiode-based machine learning for optimization of laser powder bed fusion parameters in complex geometries

We report the quality of parts produced through laser powder bed fusion additive manufacturing can be irregular, with complex geometries sometimes exhibiting dimensional inaccuracies and defects. For optimal part quality, laser process parameters should be selected carefully prior to printing and adjusted during the print if necessary. This is challenging since approaches to control and optimize the build parameters need to take into account the part geometry, the material, and the complex physics of laser powder bed fusion. This work describes a data-driven approach using experimental diagnostics for the optimization of laser process parameters prior to printing. A training dataset is generated by collecting high speed photodiode signal data while printing simple parts containing key geometry features with various process parameter strategies. Supervised learning approaches are employed to train both a forward model and an inverse model. The forward model takes as inputs track-wise geometry features and laser parameters and outputs the photodiode signal along the scan path. The inverse model takes as inputs the geometry features and photodiode signal and predicts the laser parameters. Given the part geometry and a desired photodiode signal, the inverse model can thus determine the required laser parameters. Two test parts which contain defect-prone features are used to assess the validity of the inverse model. The use of the model leads to improved part quality (higher dimensional accuracy, reduced dross, reduced distortion) for both test geometries.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Electrostatic powder spreading for metal powder bed fusion applications

Typical powder bed fusion processes spread each layer of powder by pushing it across the build area with a spreader bar or roller. While simple, these methods require good flowing powder and do not have the ability to place more than one powder type per layer. This naturally limits the ability to incorporate more than one material onto each powder layer in powder bed additive manufacturing processes. Here we demonstrate electrostatic powder spreading, a method to deposit a powder layer without mechanical contact with the previous layers. Electrostatic powder spreading (ESPS) uses an electric field formed between a powder container and a counter electrode to move powder particles from the container to the powder bed. We show that the rate at which powder is deposited can be controlled by adjusting the strength of the electric field. Correspondingly, the deposited layer thickness is controlled by the strength of the electric field and the recoating speed. To demonstrate the feasibility of ESPS for laser powder bed fusion powder spreading, nearly fully dense (> 99.8%) coupons were built in a commercial L-PBF machine using the ESPS setup. Finally, we achieve 2D patterning of a single layer by using an array of electrodes and switching the applied electric field on and off. ESPS represents a method to produce an arbitrary patterned multi-material powder bed without complicated powder removal steps and easy implementation into existing L-PBF machines. Furthermore, ESPS presents an opportunity to build parts with 3D gradients in material properties.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Remarkable enhancement in thermal conductivity of stainless-steel leveraging metal composite via laser powder bed fusion: 316L-Cu composite

This work aimed to significantly enhance the thermal conductivity of the SS matrix by fabricating a metal composite SS-Cu system utilizing a laser powder bed fusion process. The impact of process parameters on the microstructure of SS-Cu samples is investigated. Here, the processing and post-processing factors that influence the effective thermal conductivity of the metal composite SS-Cu system are discussed. Then, the effective thermal conductivity and mechanical properties of the SS-Cu composite are measured at room temperature and operating temperature of 300 °C. The optimized laser powder bed fusion parameters led to low Marangoni convection, high cooling rate, greater macro-segregation, and higher thermal conductivity values albeit at the cost of ductility in SS-Cu metal composite likely due to the presence of the unmelted powder particles. As-printed SS-60 vol % Cu and annealed SS-60 vol % Cu had 2.5X and 6.6X thermal conductivity enhancement, respectively. During annealing, phase separation, partial melting of Cu, and formation of a continuous network of Cu surrounding SS play a key role in enhancing the thermal conductivity of the SS-Cu metal composite structure.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Multimodal sensor fusion for real-time standoff estimation in directed energy deposition

In Laser Powder-based Direct Energy Deposition (LP-DED) systems, achieving consistency, precision and quality of produced parts requires tight control over printing parameters. One of the critical parameters is the standoff distance. Maintaining an optimal standoff height is crucial for achieving correct laser power density and powder catchment efficiency, as both laser and powder streams are focused at this distance. Here, this study introduces a novel approach using multimodal sensor fusion to predict standoff height in real-time. The proposed system integrates two low-profile, cost-effective sensors: an RGB coaxial camera and a high frequency and high dynamic range microphone. By utilizing a simple fully connected neural network, trained on a limited dataset, data fusion of these sensors allowed for the real-time prediction of the standoff height. The results demonstrate high resolution and accuracy of the predictions across multiple geometries and a wide range of standoff heights. This approach offers a simple, and cost-effective solution for real-time standoff height monitoring and lays the groundwork for future integration into commercial LP-DED systems.

42 ENGINEERING↗
DOE OSTI2026

Establishing an acoustic-property relationship in laser powder bed fusion with machine learning

Quality control of Laser Powder Bed Fusion (PBF-LB) additively manufactured parts is an important hurdle inhibiting the technology’s use structural applications. Acoustic monitoring of the laser powder bed fusion process can detect defects in-situ that are known to degrade mechanical properties. However, processing-structure-property (PSP) relationships are required to extrapolate from detected defects to part performance. Here, this study explores how acoustics may be a suitable signature linking processing conditions to properties, thus effectively substituting for structure in the PSP relationship. Establishing such a relationship would enable a part’s mechanical performance to be directly predicted from its acoustic signature, reducing the need for destructive testing or microstructural analysis to ensure a part will meet performance requirements. One hundred CoCrFeMnNi high entropy alloy tensile bars were printed across 13 process conditions in a series of 6 prints. The acoustic signatures of these tensile bars were used to train machine learning models to predict each part’s mechanical properties. By using both process information and acoustic information to predict mechanical properties, yield strength was predicted 18% more accurately and ductility to failure was predicted 10% more accurately than is achieved when using duplicate parts to predict part performance. Finally, individual acoustic frequencies were investigated to determine why acoustic signatures improve mechanical property predictions and the potential physical origins of these signatures. This work demonstrates how blending acoustics, process information, and machine learning can provide in-situ diagnostics of mechanical properties and improve the reliability of the PBF-LB process.

Acoustic emission↗
DOE OSTI2021

SIMS and HR-XPS characterization of lithiated graphite from the magnetic fusion device RFX-mod

Lithium wall conditioning has improved the performance of many magnetic fusion devices. Li conditioning in the RFX-mod device was performed by: (1) a single Li pellet injector and (2) a multi-Li pellet injector during He plasma discharges; (3) a Li evaporator after He glow discharge cleaning and He plasma discharge exposure. This report compares the spatial and depth distributions of Li deposited on polycrystalline graphite witness samples at different locations in RFX-mod and the elemental and chemical compositions of the resulting surfaces. The sample surfaces were analyzed ex situ using secondary ion mass spectrometry (SIMS) and high-resolution X-ray photoelectron spectroscopy (HR-XPS). The results showed that Li pellet injection provided a relatively uniform toroidal coverage while Li evaporation produced highly localized Li deposition. A Li 1s HR-XPS peak at 56.5 eV binding energy (BE) characteristic of lithium-intercalated graphite was only observed with the sample exposed to Li evaporation. All of the samples exhibited a HR-XPS C 1s peak at 285.1–285.2 eV BE that is largely attributed to hydrogenated graphite. This finding suggests that hydrogenation of fresh graphite occurs during He plasma discharge exposures. Finally, our results have implications for density control and the selection of Li conditioning techniques in magnetic fusion devices.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Predictive process mapping for laser powder bed fusion: A review of existing analytical solutions

One of the main challenges in the laser powder bed fusion (LPBF) process is making dense and defect-free components. These porosity defects are dependent upon the melt pool geometry and the processing conditions. Power-velocity (PV) processing maps can aid in visualizing the effects of LPBF processing variables and mapping different defect regimes such as lack-of-fusion, under-melting, balling, and keyholing. This work presents an assessment of existing analytical equations and models that provide an estimate of the melt pool geometry as a function of material properties. The melt pool equations are then combined with defect criteria to provide a quick approximation of the PV processing maps for a variety of materials. Finally, the predictions of these processing maps are compared with experimental data from the literature. Here, the predictive processing maps can be computed quickly and can be coupled with dimensionless numbers and high-throughput (HT) experiments for validation. The present work provides a boundary framework for designing the optimal processing parameters for new metals and alloys based on existing analytical solutions.

36 MATERIALS SCIENCE↗
DOE OSTI2025

OpenEdge: A collaborative, open-source, multi-purpose direct simulation Monte Carlo for plasma simulation in magnetic fusion environments

OpenEdge is a collaborative, open-source, object-oriented Direct Simulation Monte Carlo (DSMC) code, designed specifically for plasma simulations in magnetic fusion environments. Here, the code features include advanced structures, robust capabilities, and an effective parallelization strategy, all of which significantly enhance performance. It includes specialized modules for managing complex particle interactions, including collisions, ionization/recombination, and reflection/sputtering. Benchmarks and performance analyses have confirmed its efficiency and scalability. Versatile and adaptable, OpenEdge is applied across a broad spectrum of plasma-material interaction studies and charged particle transport in various fusion research settings.

Boundary plasma↗
DOE OSTI2020

An Evaluation of the Global Effects of Tritium Emissions from Nuclear Fusion Power

We report that tritium, like all hydrogen isotopes, is difficult to confine and easily diffuses through most materials. As currently planned, fusion power plants will process and handle large quantities of deuterium and tritium as fuel, and therefore, will become sources of tritium input into the environment. Tritium releases from a worldwide distribution of tritium sources (fusion or fission) will lead to higher tritium levels overall and have global impact. This report investigates the hydrologic partitioning of yearly tritium releases assuming 1 g/yr loss per 500 MW of nuclear power generation for varying scales of power generation. On large scales, it is found that the worldwide average levels of tritium could exceed some public health goals and regulatory guidelines. Tritium concentrations at such levels may also have other impacts on the environment through increased ion-pair generation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗