Final Report: Advanced Bond Coats for Thermal Barrier Coating Systems Based on High Entropy Alloys
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36 MATERIALS SCIENCE↗
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Mechanical Performance of Additively Manufactured ODS 316L and 316H Stainless Steels
This work package within the Advanced Materials and Manufacturing Technologies (AMMT) program focused on the mechanical and microstructural characterization of oxide dispersion strengthened (ODS) stainless steels produced using advanced manufacturing techniques. The research aimed to identify an accelerated development path for ODS alloys by integrating additive manufacturing (AM) technologies with recent advancements in ODS materials and traditional manufacturing methods. For FY 24, the research specifically targeted exploring an accelerated development path for ODS alloys by combining AM technologies with these advancements. Novel AM and post-build processing routes were developed for ODS austenitic alloys, including Fe-Cr-Ni alloys such as 316L and 316H. Electron microscopy and mechanical characterizations were conducted to evaluate the impact of process variables on microstructure and properties, with the goal of optimizing these properties economically. Traditionally, producing ODS alloys involves multi-day, high-energy mechanical milling of alloy powder with yttria powder, followed by milled-powder consolidation through extrusion or other methods, and additional thermomechanical processing (TMP) for property control. To overcome the challenges associated with this complex and costly approach, we propose exploring alternative, cost-effective processing routes that emphasize AM and traditional TMP methods. The new processing routes for ODS alloys have achieved significantly higher strengths—several times greater than those of wrought stainless steels—while maintaining substantial ductility and fracture toughness. This report outlines the novel and economical AM-based processing routes for ODS austenitic alloys, combined with post-build TMPs, and discusses the mechanical and microstructural characteristics of the developed materials.
36 MATERIALS SCIENCE↗
Integrated Magnetics for Multiport Inductive and Conductive Power Transfer Architecture for Electric Vehicles
This paper proposes a shared magnetic arrangement for an electric-vehicle charger that supports both conductive and inductive charging while preserving independent power control at the two ports. In the proposed implementation, the high-frequency transformer used for the conductive path and the resonant inductor required by the inductive path are realized in an integrated form. By combining the magnetic structure and primary-side converter hardware, the charger can deliver improved hardware utilization and higher power density without a corresponding increase in cost or implementation complexity. The paper describes the magnetic realization and presents finite-element and circuit-level simulation results to confirm minimal interaction between the two charging paths. The study demonstrates that the proposed charger is a viable option for flexible, high-power EV charging systems.
Mukherjee, Subho [ORNL] (ORCID:0009000672297925)↗
Nondestructive Modular Leak Detection in 3D Printed 316L Stainless Steel Pipes via Laser Powder Bed Fusion
This research investigates the leak detection features of 316L Stainless Steel pipe structures manufactured via Laser Powder Bed Fusion (LPBF). This work involves the design of a modular sensor system integrating nondestructive evaluation (NDE) methods, including thermal imaging and ultrasonic frequency detection to detect and characterize leaks in components. This aims to improve leak detection sensitivity within medium-pressure gas systems, during continuous operation without halting flow or introducing safety risks. The system could be adaptable for use on unmanned aerial vehicles (UAVs), enabling remote leak detection in active environments. A custom pneumatic system incorporating temperature and pressure sensors was assembled to detect leaks in LPBF-printed 316L SS tee pipes. Experimental results and simulations confirm the system’s effectiveness in leak detection and material evaluation. This research program also integrated a Python-based image recognition platform based on a metallography and optical microscopy to assess the porosity and complement the leak detection data on the printed structures. This allows a detailed analysis of pore distribution and internal leak paths, which could compromise structural integrity, critical for quality control during manufacturing. Findings suggest that the investigated approach holds potential for enhancing leak detection technologies and adapt them for advanced manufactured parts.
36 MATERIALS SCIENCE↗
Indistinguishable photons from an artificial atom in silicon photonics
Silicon is the ideal material for building electronic and photonic circuits at scale. Integrated photonic quantum technologies in silicon offer a promising path to scaling by leveraging advanced semiconductor manufacturing and integration capabilities. However, the lack of deterministic quantum light sources and strong photon-photon interactions in silicon poses a challenge to scalability. In this work, we demonstrate an indistinguishable photon source in silicon photonics based on an artificial atom. We show that a G center in a silicon waveguide can generate high-purity telecom-band single photons. We perform high-resolution spectroscopy and time-delayed two-photon interference to demonstrate the indistinguishability of single photons emitted from a G center in a silicon waveguide. Our results show that artificial atoms in silicon photonics can source single photons suitable for photonic quantum networks and processors.
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
Integrating Management of Spent Nuclear Fuel from Generation to Disposal
The current management system in the United States for commercial spent nuclear fuel does not emphasize integration among storage, transportation, and disposal. Unless a path can be implemented that addresses the long-term needs for integration, the United States could end up leaving substantial quantities of stranded commercial spent nuclear fuel stored at decommissioned reactor sites in an increasingly wide variety of containers. This lack of integration does not cause safety issues, but may delay transporting the spent fuel and complicate options for permanent disposal. The large containers now in use for dry storage remain at high temperatures for decades, thereby delaying transportation from decommissioned reactors. The large containers also have no easy path to disposal unless (1) disposal is further delayed (up to 150 years or more for some mined repository concepts); (2) the contents are repackaged into smaller, cooler packages; or (3) the high temperatures are used as de facto site-selection and design criteria for a repository. Implementing consolidated interim storage could address many issues that exist because of this lack of integration. A consolidated interim storage facility that includes appropriate capabilities can allow existing disparate parts to integrate as a system. Previous agencies and commissions have noted this theme before as a way to provide flexibility in the waste management system. This report uses the rationale for such an approach as a framework to discuss the complexities of reconfiguring the waste management system to include consolidated storage. However, concerns that increased storage capacity will reduce the national urgency for a repository are unavoidable, and continued effort will be necessary in public dialogues on the societal aspects of moving commercial spent nuclear fuel into consolidated interim storage. A single optimal solution for integrating current storage and planned transportation with disposal is unlikely. Rather, efforts to integrate various phases of spent fuel management should begin promptly and continue throughout the remaining life of the current fuel cycle. These efforts will need to adapt continuously to evolving circumstances.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Improved Geothermometry Through Multivariate Reaction-path Modeling and Evaluation of Geomicrobiological Influences on Geochemical Temperature Indicators: Final Report
The project was aimed at demonstrating that the geothermometric predictions can be improved through the application of multi-element reaction path modeling that accounts for lithologic and tectonic settings, while also accounting for biological influences on geochemical temperature indicators. The limited utilization of chemical signatures by individual traditional geothermometer in the development of reservoir temperature estimates may have been constraining their reliability for evaluation of potential geothermal resources. This project, however, was intended to build a geothermometry tool which can integrate multi-component reaction path modeling with process-optimization capability that can be applied to dilute, low-temperature water samples to consistently predict reservoir temperature within ±30 °C. The project was also intended to evaluate the extent to which microbiological processes can modulate the geochemical signals in some thermal waters and influence the geothermometric predictions.
15 GEOTHERMAL ENERGY↗
Substrate-integrated hollow waveguide sensors
Methods and apparatuses are provided that greatly expand the utility of conventional hollow waveguide-based sensors via either straight, substrate-integrated channels or via meandering (e.g., circuitous, curved or folded optical paths) waveguide sensor designs. Full- or hybrid-integration of the meandering hollow waveguide with light source, detector, and light-guiding optics facilitates compact yet high-performance gas/vapor and/or liquid sensors of the substrate-integrated hollow waveguide sensor.
Carter, Jerry Chance↗
Oxidation Dynamics of Supported Catalytic Cu Clusters: Coupling to Fluxionality
Copper oxide nanoclusters have a wide range of catalytic applications, such as the selective oxidation of hydrocarbons. O 2 binding to the catalyst, activation, and release upon reagent oxidation are key events in these catalytic chemistries. Furthermore, these events are expected to be accompanied by significant structural changes of the Cu clusters, because O atoms integrate into the cluster, rather than bind to its surface. Topping the complexity of the problem, partially oxidized Cu clusters are known to exhibit strong fluxionality and feature diverse and interconverting structures and oxygen contents in conditions of oxidative dehydrogenation (ODH). Hence, a significant dynamic coupling between the “hot” O 2 molecule impacting the cluster at reaction temperatures and the cluster fluxionality can be expected. In this work, we focus on the dynamics of dioxygen integration into a partially oxidized Cu cluster supported on hydroxylated amorphous alumina–a system recently reported to be an exceptionally selective catalyst for cyclohexane ODH with very little CO produced, whose mechanistic underpinnings are of utmost interest. The statistics over a swarm of adsorption and scattering trajectories where O 2 hits various sites on the cluster at reaction temperature shows that the O 2 binding does not only follow the minimal energy paths. O 2 also rarely integrates into the cluster in a single step and instead first binds to a single Cu atom via either an η 1 -O 2 or an η 2 -O 2 mode. Surprisingly, this step often has a higher barrier than the subsequent O 2 integration and dissociation, which in turn take multiple steps and complete the oxidation process. Dynamic trajectories starting from the key transition state of integration of the adsorbed O 2 can also lead to different intermediate structures during or right after the dissociation, due to the energy released from the transition state and the thermal intracluster effects. From these activated O 2 chemisorbed structures, O 2 dissociation occurs with moderate barriers (~0.5 eV), producing multiple final oxidized Cu 4 O 4 states. Hence, a diversity of reaction profiles for the attack of supported Cu cluster by O 2 emerges due to the dynamic effects, with implications for mechanisms, kinetic models, and catalyst design principles.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
The Ristra Project: FY20/21 Milestone Report
The ASC Advanced Technology Development and Mitigation (ATDM) sub-program was established in 2014 to develop new simulation tools operating on exascale-class computers to serve NNSA (see Appendix B). Over the course of ATDM, LANL management have set a strategy for exascale-class application codes that follows two supportive and mutually risk-mitigating paths: evolution for established production integrated design codes (IDCs) – with a strong pedigree within the user community – based upon existing programming paradigms(MPI+X); and a new start ATDM project, Ristra, a high-risk/high-reward push for a next-generation multi-physics, multi-scale simulation toolkit based on emerging advanced programming systems(with an initial focus on data-flow task-based models exemplified by Legion). The role of Ristra as the high-risk/high-reward path for LANL’s codes was fully consistent with the goals of ATDM as described in Appendix B, in particular its emphasis on evolving ASC capabilities through novel computing programming models and computing technologies.
97 MATHEMATICS AND COMPUTING↗
Errors in reconstruction of dichroic X-ray orientation tomography due to polarization rotation of the incident beam
Dichroic X-ray tomography is a technique in which the crystal orientation or magnetization of a sample is resolved in three dimensions. The best-known uses of this technique are for observation of magnetic moments via circular dichroism, using left- and right-handed circularly polarized X-ray beams. Another variant uses linear dichroism to resolve the crystal orientation. In both these techniques, it is assumed that the absorption of X-rays along a path inside a material can be computed as a line integral of a local absorption coefficient along the ray path. For linear dichroism, this assumption is inaccurate because the polarization of the beam changes along the propagation direction when the optic axis of the material is not aligned along the polarization. In this work, a finite-element Maxwell solver is used to simulate tomography and reconstructions. The propagation effect can lead to significant errors in the reconstructed orientations. These errors may be mitigated by taking data at additional angles or by operating at energies at which the dichroism is weak. An iterative approach is proposed which may allow accurate reconstruction with fewer data than would otherwise be required.
X-ray linear dichroism↗
Systems biology approaches towards predictive microbial ecology
Through complex interspecies interactions, microbial processes drive nutrient cycling and biogeochemistry. However, we still struggle to predict specifically which organisms, communities and biotic and abiotic processes are determining ecosystem function and how environmental changes will alter their roles and stability. While the tools to create such a predictive microbial ecology capability exist, cross-disciplinary integration of high-resolution field measurements, detailed laboratory studies and computation is essential. In this perspective, we emphasize the importance of pursuing a multiscale, systems approach to iteratively link ecological processes measured in the field to testable hypotheses that drive high-throughput laboratory experimentation. Mechanistic understanding of microbial processes gained in controlled lab systems will lead to the development of theory that can be tested back in the field. Using N 2 O production as an example, we review the current status of field and laboratory research and layout a plausible path to the kind of integration that is needed to enable prediction of how N-cycling microbial communities will respond to environmental changes. We advocate for the development of realistic and predictive gene regulatory network models for environmental responses that extend from single-cell resolution to ecosystems, which is essential to understand how microbial communities involved in N 2 O production and consumption will respond to future environmental conditions.
59 BASIC BIOLOGICAL SCIENCES↗
U.S. Department of Energy Basic Research Opportunities in Genomic Science to Advance the Production of Biofuels and Bioproducts from Plant Biomass: White Paper
The Genomic Science program of the Office of Biological and Environmental Research (BER) within the U.S. Department of Energy (DOE) Office of Science focuses on understanding microbes, microbial communities, and plants as integrated systems of relevance to DOE’s energy and environmental missions. One aspect of the program seeks to develop the fundamental science, research technologies, and knowledgebase necessary to enable the cost-effective, sustainable production of biofuels and bioproducts from plant biomass. This initial potential of biomass was outlined in the Billion-Ton Study (U.S. DOE 2005; update, U.S. DOE 2011a). Achieving multiple societal benefits underlies DOE’s research efforts to support a viable and sustainable domestic lignocellulosic advanced biofuels and bioproducts industry. These benefits include ensuring future energy security, lowering greenhouse gas production to mitigate climate impacts, diversifying the range of available biobased products, producing less toxic chemicals and byproducts, creating jobs in rural areas, and improving the U.S. trade balance. An earlier DOE workshop sought ways to realize these benefits by accelerating the emergence of a robust, new cellulosic ethanol industry. The resulting report, Breaking the Biological Barriers to Cellulosic Ethanol (U.S. DOE 2006), outlined a path toward this future, emphasizing integrated research opportunities, from feedstock development to conversion technologies.
09 BIOMASS FUELS↗
Path optimization by a variational reaction coordinate method. I. Development of formalism and algorithms
The development of algorithms to optimize reaction pathways between reactants and products is an active area of study. Existing algorithms typically describe the path as a discrete series of images (chain of states) which are moved downhill toward the path, using various reparameterization schemes, constraints, or fictitious forces to maintain a uniform description of the reaction path. The Variational Reaction Coordinate (VRC) method is a novel approach that finds the reaction path by minimizing the variational reaction energy (VRE) of Quapp and Bofill. The VRE is the line integral of the gradient norm along a path between reactants and products and minimization of VRE has been shown to yield the steepest descent reaction path. In the VRC method, we represent the reaction path by a linear expansion in a set of continuous basis functions and find the optimized path by minimizing the VRE with respect to the linear expansion coefficients. Improved convergence is obtained by applying constraints to the spacing of the basis functions and coupling the minimization of the VRE to the minimization of one or more points along the path that correspond to intermediates and transition states. The VRC method is demonstrated by optimizing the reaction path for the Müller-Brown surface and by finding a reaction path passing through 5 transition states and 4 intermediates for a 10 atom Lennard-Jones cluster.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Updates to the Regional Seismic Travel Time (RSTT) Model: 2. Path-dependent Travel-time Uncertainty
Abstract The regional seismic travel time (RSTT) model and software were developed to improve travel-time prediction accuracy by accounting for three-dimensional crust and upper mantle structure. Travel-time uncertainty estimates are used in the process of associating seismic phases to events and to accurately calculate location uncertainty bounds (i.e. event location error ellipses). We improve on the current distance-dependent uncertainty parameterization for RSTT using a random effects model to estimate slowness (inverse velocity) uncertainty as a mean squared error for each model parameter. The random effects model separates the error between observed slowness and model predicted slowness into bias and random components. The path-specific travel-time uncertainty is calculated by integrating these mean squared errors along a seismic-phase ray path. We demonstrate that event location error ellipses computed for a 90% coverage ellipse metric (used by the Comprehensive Nuclear-Test-Ban Treaty Organization International Data Centre (IDC)), and using the path-specific travel-time uncertainty approach, are more representative (median 82.5% ellipse percentage) of true location error than error ellipses computed using distance-dependent travel-time uncertainties (median 70.1%). We also demonstrate measurable improvement in location uncertainties using the RSTT method compared to the current station correction approach used at the IDC (median 74.3% coverage ellipse).
58 GEOSCIENCES↗
A Novel Charge Sensitive Pre-Amplifier Structure for Biological Temperature Readout Applications
Charge sensitive pre-amplifier architectures have been studied for decades for various applications, most of which adopt a gain stage with capacitor feedback to integrate the signal and a reset path to provide DC bias. For the biological temperature readout front-end, we propose a novel structure without the gain stage, which implies a strong potential for fully integrated high frequency applications. The proposed design provides 0.94 mV/pC with high conversion linearity while consuming only 1.4 micro watts of power with buffer under a 1.2-V supply rail. The prototype occupying a chip area of 0.038 square millimeter is fabricated in 130 nm standard CMOS process.
Wang, Hangfeng↗
Scatter Signal Elimination by Localized Primary Modulation in Industrial Computed Radiography
In industrial computed radiography, same as the other projection imaging systems, quantitative integrated information of total beam path including the object is carried by primary part of the beam. It is well known that the accuracy of the image useful data carried by the primary part degrades by scattered part of the beam. In order to have the beam path quantitative information accurately, it is essential to obtain the primary part of the total signal purely. In current study, a practical approach using localized primary modulation has been proposed to extract the primary signal. A semi-transparent beam attenuation grid was used as the beam intensity modulator. Efficiency and accuracy of the approach was practically validated through thickness measurement of metallic planar steps as an illustrative example. Simplified practical implementation and availability of the required accessories are some of advantages of the proposed approach. The results are indicative of the fact that this approach can also be applied as a new technique in thickness measurement, yielding a noticeable accuracy improvement in the most radiography methods. A procedure is included to explain the approach implementation for thickness measurement in computed radiography systems. The procedure overcomes some practical limitations and difficulties of the approach adaptation for computed radiography.
42 ENGINEERING↗
Plant-based engineering for production of high-valued natural products
Plants are a unique source of complex specialized metabolites, many of which play significant roles in human society. In many cases, however, the availability of these metabolites from naturally occurring sources fails to meet current demands. Thus, there is much interest in expanding the production capacity of target plant molecules. Traditionally, plant breeding, chemical synthesis, and microbial fermentation are considered the primary routes towards large scale production of natural products. Here, in this paper, we explore the advances, challenges, and future of plant engineering as a complementary path. Although plants are an integral part of our food and agricultural systems and sustain an extensive array of chemical constituents, their complex genetics and physiology have prevented the optimal exploitation of plants as a production chassis. We highlight emerging engineering tools and scientific advances developed in recent years that have improved the prospects of using plants as a sustainable and scalable production platform. We also discuss technological limitations and overall economic outlook of plant-based production of natural products.
59 BASIC BIOLOGICAL SCIENCES↗