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DOE OSTI2020

Preload Characterization of Short Models of MQXF the Nb 3 Sn Low-β Quadrupole for the Hi-Lumi LHC

MQXF is the Nb3Sn Low-β Quadrupole magnet that the HL-LHC project is planning to install in the LHC interaction regions in 2026 as part of an upgrade to increase the LHC inte-grated luminosity by about a factor of ten. The magnet will be fab-ricated in two different lengths: 4.2 m for MQXFA, built in the US by the Accelerator Upgrade Project (AUP), and 7.15 m for MQXFB, fabricated by CERN. In order to qualify the magnet de-sign and characterize its performance with different conductors, cable geometries and pre-load configuration, five short model magnets, called MQXFS, were fabricated, assembled and tested. The latest model, MQXFS6, uses a new powder-in-tube (PIT) su-perconducting wire, featuring a bundle barrier surrounding the filaments. The coil and the support structure were equipped with strain gauges and optical fibres to monitor strain during assembly, cool-down and excitation. In this paper we further develop the conventional azimuthal preload analysis and introduce a new set of tools for MQXF coil pack characterization which we use to an-alyse the behaviour of MQXFS6 room temperature preload and to reanalyse all the short models tested at CERN. A comparison is made between all the studied magnets revealing new characteriz-ing preload parameters.

43 PARTICLE ACCELERATORS↗

DOE OSTI2019

Evidence of Room Temperature Ferromagnetism in Zn{sub 1−x}Sn{sub x}S Thin Films

Tin (Sn)-doped zinc sulfide (Zn{sub 1−x}Sn{sub x}S) thin films at different tin (Sn) concentrations (= 0.00, 0.02, 0.05, and 0.08) were coated onto Corning 7059 glass substrates using the electron beam evaporation technique. The films were subjected to different characterization techniques to study the physical properties of the thin films. The structural properties of the films were studied using a powder X-ray diffractometer (XRD), and it was found that the films were cubic in structure without any impurity phases. The crystallite size increased with an increase of Sn concentration, and the mean crystallite size was 21 nm. The chemical composition and surface morphology of the films were studied using scanning electron microscopy (FE-SEM) with energy-dispersive analysis of X-rays (EDAX). Optical properties such as transmittance and absorbance were recorded using a diffuse reflectance spectroscope (UV–vis–NIR). All the films exhibited high optical transmittance of 85% in the visible region of the solar spectrum. The band gap of the films was calculated using Tauc’s relation, and it was found that it increased from 3.53 to 3.57 eV with an increase in the Sn doping concentration from x = 0.02 to x = 0.08. The room temperature photoluminescence studies of the films were recorded using a fluorescence spectrophotometer, and it was found that the films exhibited a prominent emission peak at 420 nm. The magnetic properties of the films and glass substrates at room temperature were studied using a vibrating sample magnetometer. From this, it was found that the films were weakly ferromagnetic at room temperature and the strength of magnetization increased with an increase of doping concentration from x = 0.02 to x = 0.05 and decreased at higher doping concentrations (x = 0.08). The films showed high magnetization at x = 0.05. The films at x = 0.05 exhibited the magnetization (M{sub s}), retentivity (M{sub r}), and coercive fields (H{sub c}) 18 × 10{sup − 6} emu/cm{sup 3}, 1.6 × 10{sup − 6} emu/cm{sup 3}, and 91.80 Oe, respectively.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2025

Rheology improvement for silicon nitride and resin slurries for vat photopolymerization printing and sintering

This work presents the formulation, rheological characterization, and sintering of silicon nitride (Si₃N₄) slurries for vat photopolymerization (VPP) using digital light processing (DLP). Bimodal Si₃N₄ powder was dispersed into commercial photopolymer resin using two different dispersants with opposing effects on surface charge, resulting in varied slurry stability and flow behavior. Slurries were engineered to exhibit shear-thinning behavior suitable for VPP, and their flow properties were quantified using a power-law fluid model. The formulations achieved cure depths of approximately 40 µm and enabled printing of green bodies. Post-processing included thermal debinding and liquid-phase sintering, yielding primarily β-Si₃N₄ with a minor Y-Si-Al-O-N glass phase. The sintered parts reached ~85% of theoretical density and demonstrated a flexural strength of ~330 MPa. Microstructural analysis revealed closed porosity along with some defects related to powder agglomeration and interlayer adhesion. These findings provide insights into slurry formulation strategies for additive manufacturing of high-performance non-oxide ceramics.

Aerospace engineering↗

DOE OSTI2026

Quantum critical point followed by Kondo-like behavior due to Cu substitution in the itinerant antiferromagnet La 2 ⁢(Cu 𝑥 ⁢Ni 1−𝑥 ) 7

La 2 ⁢Ni 7 is an itinerant magnetic system with a small ordered moment of ∼ 0.1⁢µ 𝐵 /Ni and a series of antiferromagnetic (AFM) transitions at 𝑇 1 = 61.0K, 𝑇 2 = 56.5K, and 𝑇 3 = 42.2K. 𝑀 ⁡(𝐻), and 𝜌 ⁡(𝐻) isotherms as well as constant field 𝑀⁡ (𝑇) and 𝜌 ⁡(𝑇) measurements on single-crystalline samples manifest a complex, anisotropic 𝐻−𝑇 phase diagram with multiple phase lines. Here, in this study, we present the growth and characterization of single crystals of the La 2 ⁢(Cu 𝑥 ⁢Ni 1−𝑥 ) 7 series for 0 ≤ 𝑥 ≤ 0.181. We measured powder x-ray diffraction and composition, as well as anisotropic temperature- and field-dependent resistivity, temperature- and field-dependent magnetization, and temperature-dependent heat capacity on these single crystals. Using the measured data we infer a transition temperature-composition (𝑇−𝑥) phase diagram for this system to study the evolution of the AFM ordering upon Cu substitution. For 0 ≤ 𝑥 ≤ 0.097, the system remains magnetically ordered at base temperature with 𝑥 ≤ 0.012, showing signs of multiple AFM ordering temperatures. For the higher substitution levels 0.125 ≤ 𝑥 ≤ 0.181, there are no signatures of magnetic ordering, but anomalous features in resistance and heat capacity data are observed which are consistent with the Kondo effect in this system. The intermediate 𝑥 = 0.105 sample lies between the magnetic ordered and the Kondo regime and is in the vicinity of the AFM quantum critical point (QCP). Thus, La 2⁢ (Cu 𝑥 ⁢Ni 1−𝑥 ) 7 is an example of a small moment system that can be tuned through a QCP. Given these data combined with the fact that the La 2⁢ Ni 7 structure has kagomelike, Ni sublattices running perpendicular to the crystallographic 𝑐 axis, and a predicted 3⁢𝑑-electron flat band that contributes to the density of states near the Fermi energy, La 2 ⁢(Cu 𝑥 ⁢Ni 1−𝑥 ) 7 becomes a promising system to host and study exotic physics.

Das, Atreyee [Ames Laboratory, and Iowa State Univ↗

DOE OSTI2018

Towards Mixed Ionic and Electronic Conducting Li-Stuffed Garnets

Li-stuffed garnet-type Li 7 La 2.75 Ca 0.25 Zr 1.75 Nb 0.25 O 12 (LLCZNO) and Li 7+y La 2.75 Ca 0.25 Zr 1.75-y Nb 0.25 MyO 12 (M = Mn, Fe, Co, Ni; y = 0.1, 0.2, referred to as yM-LLCZNO) were synthesized in air by ceramic synthesis at different sintering temperatures. The resulting compositions were characterized for their phase formation and microstructure, and their ionic and electronic conductivities in air and 7% H 2 /N 2 . Powder X-ray diffraction showed that transition metal-doped LLCZNO garnets contain several impurity phases. The transition metal-substituted samples have lower conductivities than that of the parent LLCZNO. The electronic conductivities of selected transition metal-doped LLCZNO samples were found to be about 4 to 5 orders of magnitude lower than their corresponding ionic conductivity, highlighting the challenge to design single-phase mixed electronic and ionic conducting Li-stuffed garnets in both oxidizing and reducing atmospheres. The research area of single-phase mixed conducting Li-garnet is relatively unexplored at the moment, and a theoretical study will help to elucidate the underlying challenge in doping transition metal in Li-based garnets structure and its effect on transport properties.

25 ENERGY STORAGE↗

DOE OSTI2019

Controllable 3D Manufacturing System

Next generation Small Modular Reactor (SMR) requires new and improved techniques, instrumentations and strategies to deal with the anticipated high radiation and high temperature environment (esp. in reactors). Component manufacturing technologies will be required that take full advantage of the new 3-D printing methods employed by additive manufacturing technologies. These manufacturing methods must be capable of producing components or sub components on a limited production basis and with nuclear quality. Based on our success in developing a variety of award-winning high energy and high power ultrafast fiber lasers and our pioneered work in fs laser 3D manufacturing (US patents, 9643361 and 9770760), PolarOnyx proposes to use tunable fiber lasers to develop smart AM & SM system to make nuclear quality components for SMR. In Phase I, we have achieved critical milestones and experimentally demonstrated the most critical functions of the proposed controllable laser AM: • Developed and investigated a series of NDI sensing technologies. Combination of IR thermal image and high resolution visible camera provides a powerful tool to characterize thermal distribution and defects. • Built an in-line laser induced breakdown spectroscopy (LIBS) to real time detect compositions of powder and parts, and melting temperature of the melting pool. It proves the LIBS is a very powerful tool to precisely guide the process. • Filed a patent (Application number 16378485) for integrating IR and visible images and LIBS for intelligent AM system. • Developed control algorithm and proved it works well for overhang experiment. • Achieved high density (>99%) and excellent mechanical properties. • Succeeded in developing a working and reliable calibration method to extract true temperature distribution during AM process. • Demonstrated spatial and temporal pulse shaping methods, and impact on microstructures. • Filed one utility patent • Laid out a solid path for phase II to work on controllable 3D manufacturing system development and optimization and to make components with nuclear quality. Our proprietary fs fiber laser based AM processing offers an ultimate solution for manufacturing high temperature components with high strength for nuclear systems. The 3D AM system in conjunction with the intelligent sensing and control is energy efficient and cost effective for the growing nuclear industries. Successful development of the proposed AM technology will provide a vital tool to solve existing and potential issues. This technology will be directly applied in the 3D printing area with combined market share of $10(s) of billions. The achievement in this research will have significant and wide social, scientific, and economic impacts by providing affordable low cost intelligent AM/SM systems, laser micromachining systems, improving energy efficiency, and reducing fabrication and operational cost. Having demonstrated the proof of concept in Phase I, we will prototype the controllable AM/SM system and investigate the efficiency and qualification of fabricating various nuclear quality components in Phase II.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2019

3D Printing Catalytic Electrodes for Solar-Hydrogen Devices

Hydrogen production through water-splitting systems showed promising pathway to achieve <$2/kg cost target set by Department of Energy (DOE). As far, most efforts have been devoted to new electrocatalytical materials discovery. In contrast, the impact of architecture of the electrocatalysts as well as mass transport within the gas diffusion layers has not been well explored. In this project, we developed a new ink formulation with earth-abundant elements nickel and molybdenum (NiMo) for catalytical 3-dimentional (3D) electrodes in water-splitting devices. The NiMo electrodes fabricated via additive manufacturing have been characterized and tested. The architecture, morphology and compositions of the NiMo electrodes have been confirmed by Scanning Electric Microscopy (SEM) and Powder X-Ray Diffraction (XRD). We have demonstrated that the catalyst precursor survived the whole fabrication and post-treatment process. Furthermore, the NiMo 3D electrodes in this study exhibited state-of-art hydrogen evolution reaction (HER) performance, ~ 60 mV over potential for over 24 hours operation. The high performance of the 3D catalytical electrodes is attributed to large roughness factors (RF) of the electrodes and highly efficient mass transport. This study is in line with DOE initiative H2@Scale and national energy security missions at LLNL.

36 MATERIALS SCIENCE↗

NASA NTRS1980

Microstructure and mechanical properties of hip-consolidated Rene 95 powders

The effects of heat-treatments on the microstructure of P/M Rene 95 (a nickel-based powder metal), consolidated by the hot-isostatic pressing (HIP), were examined. The microstructure of as-HIP'd specimen was characterized by highly serrated grain boundaries. Mechanical tests and microstructural observations reveal that the serrated grain boundaries improved ductility at both room and elevated temperatures by retarding crack propagation along grain boundaries.

Shimanuki, Y.↗

NASA NTRS1997

Photorefractivity in a Titanium Doped ZnCdTe Crystal

Single crystals of Zn(.04)Cd(.96)Te was grown by horizontal physical vapor transport (PVT) method and doped by annealing with TiTe2 powder at 600 C for six days. Photorefractive two-beam coupling, along with photoluminescence and absorption spectroscopy, were used to characterize the ZnCdTe:Ti crystal. At 1.32 micrometers, the photorefractive gain has been measured as a function of the grating period. A gain of about 0.16/cm was obtained at an intensity of about 0.1 W/sq cm. The results of this titanium doped ZnCdTe crystal are compared to that of vanadium-doped CdTe crystals reported previously.

Davis, M.↗

NASA NTRS1997

Crystal Growth and Characterization of Bil3

Bismuth tri-iodide (BiI3) have been grown by physical vapor transport (PVT), and by the Bridgman (melt) method. These crystals along with pure and stoichiometric BiI3 powder have been investigated by differential scanning calorimetry (DSC). The DSC results show that pure BiI3 powder has no phase transition and melts around 408 C. While we found no evidence for the high temperature dissociation of BiI3, the DSC measurements show that crystals grown from melt method contain a significantly large amount of Bi-rich phases than crystals grown from PVT method, as indicated by phase transition detected at 270, 285, 298 and 336 C.

Hayes, Julia↗

NASA NTRS1985

Fourier transform-infrared spectroscopic methods for microbial ecology: analysis of bacteria, bacteria-polymer mixtures and biofilms

Fourier transform-infrared (FT-IR) spectroscopy has been used to rapidly and nondestructively analyze bacteria, bacteria-polymer mixtures, digester samples and microbial biofilms. Diffuse reflectance FT-IR (DRIFT) analysis of freeze-dried, powdered samples offered a means of obtaining structural information. The bacteria examined were divided into two groups. The first group was characterized by a dominant amide I band and the second group of organisms displayed an additional strong carbonyl stretch at approximately 1740 cm-1. The differences illustrated by the subtraction spectra obtained for microbes of the two groups suggest that FT-IR spectroscopy can be utilized to recognize differences in microbial community structure. Calculation of specific band ratios has enabled the composition of bacteria and extracellular or intracellular storage product polymer mixtures to be determined for bacteria-gum arabic (amide I/carbohydrate C-O approximately 1150 cm-1) and bacteria-poly-beta-hydroxybutyrate (amide I/carbonyl approximately 1740 cm-1). The key band ratios correlate with the compositions of the material and provide useful information for the application of FT-IR spectroscopy to environmental biofilm samples and for distinguishing bacteria grown under differing nutrient conditions. DRIFT spectra have been obtained for biofilms produced by Vibrio natriegens on stainless steel disks. Between 48 and 144 h, an increase in bands at approximately 1440 and 1090 cm-1 was seen in FT-IR spectra of the V. natriegens biofilm. DRIFT spectra of mixed culture effluents of anaerobic digesters show differences induced by shifts in input feedstocks. The use of flow-through attenuated total reflectance has permitted in situ real-time changes in biofilm formation to be monitored and provides a powerful tool for understanding the interactions within adherent microbial consortia.

NASA Discipline Number 61-10↗

NASA NTRS2018

Residual Stress Mapping of As-Built and Hot Isostatic Pressure Treated GRCop-84 as Fabricated by Selective Laser Melting

GRCop-84, a copper alloy developed by NASA Glenn Research Center (GRC) with the starting At% (atomic percent) Cu-8 Cr-4 Nb, has a copper matrix with a fine intermetallic dispersion of Cr2Nb (cubic Laves phase C15). The alloy is being developed for high-heat-flux applications and has excellent high temperature properties including retention of tensile strength at high temperatures, high thermal conductivity, and excellent creep resistance. GRCop-84 has shown higher survivability rates than other metal additive alloys, good surface finish, and requires less operator tweaking for builds, and this is not fully understood. Neutron diffraction provides an accurate, non-destructive method of measuring the thermal stresses accumulated during production; the primary source of failure before annealing. The unstressed lattice spacing (d (sub 0)), residual stress, and distribution have been characterized for simple shapes in HIP (Hot Isostatic Pressing,) and as-built conditions made with SLM (Selective Laser Melting), a powder bed fusion method, with the HIP samples showing significantly reduced stresses concentrations than the as-built.

Minnecci, Robert↗

NASA NTRSDate not supplied

Development and Testing of Pulse Guns for Combustion Instability Testing

Combustion stability requirements of a liquid propellant rocket engine are most commonly verified by evaluating the oscillatory pressure or vibration characteristics following an artificial disturbance of the combustion in the combustion chamber. Two types of devices are most commonly used for dynamic stability rating – nondirectional bombs and pulse guns. Bombs have historically been used most often, especially for the large engines developed around the Apollo era. However, bombs in recent years have become much more expensive and difficult to procure, and their transportation and handling requirements have become more demanding. Pulse guns, with inherently less expensive materials, and far less restrictive handling and shipping requirements, have become an attractive alternative. The NASA Marshall Space Flight Center has developed a pulse gun for use during future development programs at the center, and as a design reference for interested commercial users. The objective of this paper is to present the different variants of the pulse gun and characterize performance over a range of parameters. The parameters include the breech diameter and corresponding volume, barrel length, amount of gun powder used, the method of containing the gunpowder within the breech, and the pressure rating of the burst disk. In total, 44 tests were conducted with the pulse gun firing into a test chamber pressurized to 2300 psig with gaseous nitrogen. The best experimental results – including the highest and most consistent peak pressure amplitudes recorded by dynamic pressure sensors in the test chamber – were from a configuration consisting of a 0.40” inner-diameter breech, 15-16 grains of gunpowder wrapped in cigarette paper, and a 24,000 psid burst disk. With this configuration, the zero-to-peak overpressures recorded in the test chamber ranged from about 37% to 58% of the 2300 psig mean pressure, which is adequate for typical combustion stability rating. To complement the data analysis, the acoustics of the pressure waves as they propagated through the pulse gun and into the test chamber were modeled. A more comprehensive final report of this pulse gun development program is planned to be available in the near future.

Pulse Gun↗

NASA NTRS2024

Extreme Temperature Additively Manufactured GRX-810 Alloy Development and Hot-fire Testing for Liquid Rocket Engines

Additive manufacturing (AM) has revolutionized component design for liquid rocket engines by offering rapid manufacturing capabilities. This has led to significant opportunities for development and flight programs in the propulsion industry, resulting in cost and schedule savings, as well as performance improvements through new designs and alloy development. A noteworthy example is the GRX-810 oxide dispersion strengthened (ODS) alloy, which was specifically developed for extreme temperatures. This Ni-Co-Cr based alloy was created using integrated computational materials engineering (ICME) techniques to focus on a new class of materials with exceptional temperature and oxidation-resistant properties. The GRX-810 alloy utilizes AM processes to incorporate nano-scale yttria particles throughout its microstructure, resulting in remarkable enhancements. Compared to traditional Nickel-based superalloys, the GRX-810 alloy offers a two-fold increase in tensile strength, 1,000-fold better creep properties, and two-fold improvement in oxidation resistance. NASA successfully demonstrated the development and manufacturing of components using the GRX-810 alloy through laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Extensive efforts were made to model, evaluate metallurgical properties, develop heat treatment processes, characterize the microstructure, and determine mechanical properties. The GRX-810 alloy was specifically designed for aerospace applications, including liquid rocket engine injectors, preburners, turbines, and hot-section components, capable of withstanding temperatures up to 1,100 °C. The objective of this alloy development is to bridge the temperature gap between traditional Nickel-based superalloys and refractory alloys. This paper provides a comprehensive comparison of the GRX-810 alloy with other aerospace alloys, discussing its microstructure, mechanical properties, processing advancements, component development, and hot-fire testing results. The ultimate goal of this development was to elevate the Technology Readiness Level (TRL) of the GRX-810 alloy, enabling its integration into NASA and commercial aerospace applications.

GRX-810↗

NASA NTRS2024

Extreme Temperature Additively Manufactured GRX-810 Alloy Development and Hot-fire Testing for Liquid Rocket Engines

GRX-810↗

NASA NTRS1995

Preparation and Thermoelectric Properties of IR(sub x)Co(sub 1-x)Sb(sub 2) Alloys

The preparation and characterization of the binary arsenopyrite compounds CoSb2 and IrSb2 and IrxCo1-xSb2 alloys is reported. Single crystals of CoSb2 were grown by the vertical gradient freeze technique from solution rich in antimony. Polycrystalline samples of IrSb2 and IrxCo1-xSb2 alloys were prepared by hot-pressing of prereacted elemental powders. Samples were investigated by X-ray diffractometry, microprobe analysis and density measurements. It was found that a range of solid solution exist in the system IrxCo1-xSb2 for 0.1<x<0.8. Samples were also characterized by high temperature electrical resistivity, Seebeck coefficient and thermal conductivity measurements. All materials have p-type conductivity and are semiconductors. A band gap of about 0.98 eV was calculated for IrSb2. Preliminary measurements of the thermoelectric properties of these materials showed that their potential for thermoelectric applications is limited.

Thermoelectric Properties↗

DOE OSTI2022

Crystalline phase transitions and water-soluble complexes of copper(Ⅰ) 2-hydroxyethanethiolate

We report the coordination polymer copper(I) 2-hydroxyethanethiolate, (CuSCH 2 CH 2 OH) n , though insoluble in all common solvents, dissolved readily in basic aqueous solutions of the thiolate anion (HOCH 2 CH 2 S – ) of 2-mercaptoethanol to form a single species: the tetranuclear cluster [Cu 4 (μ-SCH 2 CH 2 OH) 6 ] 2– . From this solution were grown X-ray quality single crystals of copper(I) 2-hydroxyethanethiolate. This compound underwent a hitherto unknown crystal phase transition at ca. 6 °C, from point group P2 1 2 1 2 1 to Pna2 1 , with noticeable changes in the geometry of the Cu-S layer and in the orientation of the alkylthiolate side chains. When the bulky base tetrabutylammonium hydroxide was employed in the aqueous thiolate solution used to dissolve (CuSCH 2 CH 2 OH) n , the water-soluble polynuclear copper(I) complex bis(tetrabutylammonium) hexakis(μ-2-hydroxyethanethiolato) tetracuprate(I), [(C 4 H 9 ) 4 N] 2 [Cu 4 (μ-SCH 2 CH 2 OH) 6 ], could be isolated as X-ray quality crystals. Structural characterization of this complex revealed a tetrahedral arrangement of copper(I) centers with thiolates bridging the edges of the tetrahedra. On standing, this complex degraded to a larger polynuclear Cu(I) sulfide cluster.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Microstructure characterization of electric field assisted sintering (EFAS) sintered metallic and ceramic materials using local thermal diffusivity measurement

Electric Field Assisted Sintering (EFAS, also referred to as spark plasma sintering) is a powerful technology for the consolidation of powder materials. The high heating rate during the sintering process is critical for minimizing energy consumption, but it can also cause microstructure heterogeneities in sintered parts, such as spatially varied porosity. The examination of localized porosity usually requires the use of a scanning electron microscope with a carefully prepared surface. In this paper, photothermal radiometry is used to measure local thermal diffusivity and extract localized porosity of EFAS-sintered parts by using a percolation-threshold model. Applying this approach, we identified the radial position-dependent porosity variation in EFAS parts, which is likely formed due to the large temperature gradient during the sintering process. This approach has a unique advantage because it can measure samples with minimal or no surface preparation, enabling the possibility of in situ characterization in EFAS with proper system modification. Necessary modifications on the measurement approach for EFAS deployment and in situ characterization are also discussed.

36 MATERIALS SCIENCE↗