Atomic precision advanced manufacturing (APAM) of ultra-doped nanostructures for advanced CMOS devices and interconnects.
Abstract not provided.
Scrymgeour, David↗
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Survey of Modeling and Simulation Techniques for Advanced Manufacturing Technologies Volume I – Predicting Initial Microstructures
This report summarizes the current state of modeling and simulation methods for predicting the initial structure and properties of material in components assembled using advanced manufacturing technologies (AMTs). The report is the first volume in a two-volume series. This first volume focuses on predicting initial microstructures of AM material. The second volume discusses predicting material properties given the initial microstructure. The focus is on technologies of particular relevance to the design and manufacture of nuclear reactor components. The purpose of the report is to help develop the technical knowledge base to support regulatory decisions that will be needed to assess nuclear components manufactured with AMTs as these components are installed at nuclear power plants (NPPs). The report develops a list of AMTs of particular interest to the NRC and summarizes the key microstructural features and corresponding processing parameters relevant to each technology. Further sections describe available physically-based and data-driven prediction methods and survey widely available software tools. The report concludes with a summary of gaps that may be of particular interest to the NRC when evaluating modeling and simulation methods for AMTs.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE Advanced Manufacturing Office 2020 Peer Review
The U.S. Department of Energy (DOE) Office of Energy Efficiency and Renewable Energy (EERE) requires each of its programs to conduct periodic peer reviews to enhance EERE program planning. The EERE Advanced Manufacturing Office (AMO) held a virtual peer review of its program activities online on June 2–3, 2020. An independent panel of experts provided AMO with feedback on how well the program’s portfolio aligns with its overarching goals, identified possible course correction and new direction, and shared information.
42 ENGINEERING↗
NNSA Minority Serving Institute Partnership Program (MSIPP)-- Partnership for Advanced Manufacturing Education and Research (PAMER) (Q1 FY2022 Progress Report)
The following report summarizes the status update during this quarter for the National Nuclear Security Agency (NNSA) initiated Minority Serving Institution Partnership Plan's (MSIPP) project titled, Partnership for Advanced Manufacturing Education and Research (PAMER). In 2016, the National Nuclear Security Agency (NNSA) initiated the Minority Serving Institution Partnership Plan (MSIPP) targeting Tribal Colleges and Universities (TCUs) to offer programs that will prepare students for technical careers in NNSA’s laboratories and production plants. The MSIPP consortium’s approach is as follows: 1) align investments at the college and university level to develop a curriculum and workforce needed to support NNSA’s nuclear weapon enterprise mission, and 2) to enhance research and education at under-represented colleges and universities.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
Assessment of Benefits of Solid-State Advanced Manufacturing Processes for Nuclear Energy Products
The Advanced Materials and Manufacturing Technology (AMMT) program develops cross cutting technologies in support of a broad range of nuclear reactor technologies and maintains U.S. leadership in materials and manufacturing technologies for nuclear energy applications. This overall project provides the U.S. Department of Energy a critical feasibility study comparison of three solid-state processes to other AM processes, thereby providing the feasibility of the solid-state processes examined to manufacture 316H SS and ODS steel components: • Fused-filament fabrication (FFF): This work provides an initial evaluation of the impact of powder morphology and sizes on the FFF process, and the feasibility and adaptability for different material systems, to use FFF for ODS steels and 316 SS. • Shear-assisted processing and extrusion (ShAPE): Specifically for this portion of the project on ShAPE tube forming, the objectives will be to determine the feasibility to direct tube forming of high tensile strength steel tubing, specifically for ODS steel to determine the effect of the patented extrusion process on the dispersoids of the ODS material. Additionally, as often ODS powders are mechanically alloyed and therefore more platelike or angular, this feasibility was to explore the impact on the optimization process and initial feasibility of direct tube forming. • Cold spray and friction stir additive manufacturing as a stretch goal: Bulk and near net shape manufacturing processes for high-temperature, high-strength alloys are needed. Additionally, cold spray techniques can be applied in-situ at the operational level for repair and can provide multiple benefits to the nuclear industry. These tasks aim to provide information to show benefits of cold spray during the full life cycle, namely research and development, product manufacturing, and repair to mention a few key points.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Photothermal alternative to device fabrication using atomic precision advanced manufacturing techniques
The attachment of dopant precursor molecules to depassivated areas of hydrogen-terminated silicon templated with a scanning tunneling microscope (STM) has been used to create electronic devices with subnanometer precision, typically for quantum physics experiments. This process, which we call atomic precision advanced manufacturing (APAM), dopes silicon beyond the solid-solubility limit and produces electrical and optical characteristics that may also be useful for microelectronic and plasmonic applications. However, scanned probe lithography lacks the throughput required to develop more sophisticated applications. In this work, we demonstrate and characterize an APAM device workflow where scanned probe lithography of the atomic layer resist has been replaced by photolithography. An ultraviolet laser is shown to locally and controllably heat silicon above the temperature required for hydrogen depassivation on a nanosecond timescale, a process resistant to under- and overexposure. STM images indicate a narrow range of energy density where the surface is both depassivated and undamaged. Modeling that accounts for photothermal heating and the subsequent hydrogen desorption kinetics suggests that the silicon surface temperatures reached in our patterning process exceed those required for hydrogen removal in temperature-programmed desorption experiments. A phosphorus-doped van der Pauw structure made by sequentially photodepassivating a predefined area and then exposing it to phosphine is found to have a similar mobility and higher carrier density compared with devices patterned by STM. Lastly, it is also demonstrated that photodepassivation and precursor exposure steps may be performed concomitantly, a potential route to enabling APAM outside of ultrahigh vacuum.
nanoscale devices↗
Unsupervised multimodal fusion of in-process sensor data for advanced manufacturing process monitoring
Effective monitoring of manufacturing processes is crucial for maintaining product quality and operational efficiency. Modern manufacturing environments often generate vast amounts of complementary multimodal data, including visual imagery from various perspectives and resolutions, hyperspectral data, and machine health monitoring information such as actuator positions, accelerometer readings, and temperature measurements. However, fusing and interpreting this complex, high-dimensional data presents significant challenges, particularly when labeled datasets are unavailable or impractical to obtain. This paper presents a novel approach to multimodal sensor data fusion in manufacturing processes, inspired by the Contrastive Language-Image Pre-training (CLIP) model. We leverage contrastive learning techniques to correlate different data modalities without the need for labeled data, overcoming limitations of traditional supervised machine learning methods in manufacturing contexts. Our proposed method demonstrates the ability to handle and learn encoders for five distinct modalities: visual imagery, audio signals, laser position (x and y coordinates), and laser power measurements. By compressing these high-dimensional datasets into low-dimensional representational spaces, our approach facilitates downstream tasks such as process control, anomaly detection, and quality assurance. The unsupervised nature of our method makes it broadly applicable across various manufacturing domains, where large volumes of unlabeled sensor data are common. We evaluate the effectiveness of our approach through a series of experiments, demonstrating its potential to enhance process monitoring capabilities in advanced manufacturing systems. This research contributes to the field of smart manufacturing by providing a flexible, scalable framework for multimodal data fusion that can adapt to diverse manufacturing environments and sensor configurations. The proposed method paves the way for more robust, data-driven decision-making in complex manufacturing processes.
Contrastive Learning↗
Prefabricated Zero Ascend Omnispecies (ZAO) Modular Fish Passage Modules Using Advanced Manufacturing Techniques
The Zero Ascend Omnispecies (ZAO) fish passage attraction module “ZAO Attractor” is a novel system designed to facilitate upstream passage for a broad spectrum of fish species, with a particular focus on American shad and river herring (alewife and/or blueback herring). Combining the use of prefabricated, modular components with advanced manufacturing, the ZAO aims to provide a cost-effective and scalable solution for fish passage attractions across various hydropower sites. The system features a surface level entry, so fish do not need to climb. In addition, it is designed to be adjusted and repositioned to create the most effective attraction flows by managing the outflows from hydropower turbines. Budget Period 1 (BP1) focused on the design and modeling of the ZAO Attractor and demonstrated the engineering feasibility of a modular, prefabricated, hydrodynamically efficient structure with surface level entry and passage. It was discovered that there were limited published studies on the direct correlation between quantified flow patterns and fish attraction, emphasizing the need for controlled studies to observe and measure these effects. In Budget Period 2 (BP2), controlled studies with live fish were prioritized to address these complexities. In conclusion, the ZAO fish passage attraction module presents a promising approach to fish passage at hydropower stations, with the potential to balance environmental concerns with renewable energy development. However, further field validation and optimization are necessary to ensure its effectiveness and practicality in real-world applications.
13 HYDRO ENERGY↗
Nanostructured Alumina Forming Austenitic Alloy (NAFA) Production using Advanced Manufacturing
Alumina-forming austenitic (AFA) alloys are well known for their exceptional corrosion-resistant properties due to the formation of a dense oxide scale beneficial in their application as a nuclear material. However, use of the alloys in core material applications is limited due to the high nickel-transmutation and helium generation rate in service, leading to swelling and reduced lifetimes. Enhancing the sink strength to pin gas bubbles and increasing gas management of the material may mitigate many of the degradation phenomena expected during alloy deployment (such as high-temperature helium embrittlement and cavity swelling for lead-cooled fast-reactor applications). Nanostructured materials are usually produced using a time-consuming and expensive batch process like mechanical alloying to achieve the fine homogenous distribution of nanoprecipitates throughout the matrix material. Integrating the nanoprecipitates in modern additive manufacturing processes has proven difficult, as the required nano-sizes or number densities cannot be achieved simultaneously. Efforts to increase the number density of precipitates by adding more precipitate-forming rare-earth elements led to agglomeration of such elements, while the nano-sized precipitates did not form in sufficient quantity when not enough rare-earth element was use. In this work a novel approach to advanced manufacturing and the fabrication of Nanostructured AFA (NAFA) materials was chosen. A dual precipitate-forming NAFA steel with a chemistry more suitable for advanced reactor applications was produced to create an environmentally resistant, high-sink-strength austenitic alloy for advanced reactor cladding applications.
36 MATERIALS SCIENCE↗
Nanostructured Alumina-Forming Austenitic Alloy (NAFA) Production Using Advanced Manufacturing
Alumina-forming austenitic (AFA) alloys are well known for their exceptional corrosion-resistant properties due to the formation of a dense oxide scale beneficial in their application as a nuclear material. However, use of the alloys in core material applications is limited due to the high nickel-transmutation and helium generation rate in service, leading to swelling and reduced lifetimes. Enhancing the sink strength to pin gas bubbles and increasing gas management of the material may mitigate many of the degradation phenomena expected during alloy deployment (such as high-temperature helium embrittlement and cavity swelling for lead-cooled fast-reactor applications). Nanostructured materials are usually produced using a time-consuming and expensive batch process like mechanical alloying to achieve the fine homogenous distribution of nanoprecipitates throughout the matrix material. Integrating the nanoprecipitates in modern additive manufacturing processes has proven difficult, as the required nano-sizes or number densities cannot be achieved simultaneously. Efforts to increase the number density of precipitates by adding more precipitate-forming rare-earth elements led to agglomeration of such elements, while the nano-sized precipitates did not form in sufficient quantity when not enough rare-earth element was use. In this work a novel approach to advanced manufacturing and the fabrication of Nanostructured AFA (NAFA) materials was chosen. A dual precipitate-forming NAFA steel with a chemistry more suitable for advanced reactor applications was produced to create an environmentally resistant, high-sink-strength austenitic alloy for advanced reactor cladding applications.
36 MATERIALS SCIENCE↗
A Novel Laser 3D Printing Method for the Advanced Manufacturing of Protonic Ceramics
Protonic ceramics (PCs) with high proton conductivity at intermediate temperatures (300–600 °C) have attracted many applications in energy conversion and storage devices such as PC fuel/electrolysis cells, PC membrane reactors, hydrogen pump, hydrogen or water-permeable membranes, and gas sensors. One of the essential steps for fulfilling the practical utilization of these intermediate-temperature PC energy devices is the successful development of advanced manufacturing methods for cost-effectively and rapidly fabricating them with high energy density and efficiency in a customized demand. In this work, we developed a new laser 3D printing (L3DP) technique by integrating digital microextrusion-based 3D printing and precise and rapid laser processing (sintering, drying, cutting, and polishing), which showed the capability of manufacturing PCs with desired complex geometries, crystal structures, and microstructures. The L3DP method allowed the fabrication of PC parts such as pellets, cylinders, cones, films, straight/lobed tubes with sealed endings, microchannel membranes, and half cells for assembling PC energy devices. The preliminary measurement of the L3DP electrolyte film showed a high proton conductivity of ≈7 × 10−3 S/cm. This L3DP technique not only demonstrated the potential to bring the PCs into practical use but also made it possible for the rapid direct digital manufacturing of ceramic-based devices.
08 HYDROGEN↗
Advanced Manufactured Strain Sensors for Extreme Environments
Experimentation at irradiation test facilities are essential for reducing the innovation time of developmental fuels, fuel cladding, and structural materials employed in next-generation nuclear reactors. However, due to the harsh conditions generated in such reactors and limited instrumentation space, the evaluation of a material’s mechanical properties is often limited to characterization after the materials have been removed from reactor conditions, or post-irradiation examination. These experiments are costly, time-consuming, and fail to capture the critical time-evolving phenomena that occur during the irradiation experiments. Advanced manufactured digital image correlation patterns and strain sensor devices serve as two promising technologies that can be deployed in the confined and challenging orientations of these irradiation experiments while also providing key insight on salient materials phenomena (i.e., mechanical properties). To guide the development of the printed strain sensors prior to their deployment in critical experiments, the adhesion strength between the substrate and printed film interface is measured via tensile testing and a non-contact laser-induced spallation technique. The establishment of these process control steps helped guide the successful fabrication and testing of direct-write strain sensing devices discussed in this work. The fabrication process controls are necessary for enabling the sustained operation of these strain sensing device through experimentation and minimize the potential for premature failure.
36 - MATERIALS SCIENCE↗
Advanced Manufactured Strain Sensors for Extreme Environments
Experimentation at irradiation test facilities are essential for reducing the innovation time of developmental fuels, fuel cladding, and structural materials employed in next-generation nuclear reactors. However, due to the harsh conditions generated in such reactors and limited instrumentation space, the evaluation of a material’s mechanical properties is often limited to characterization after the materials have been removed from reactor conditions, or post-irradiation examination. These experiments are costly, time-consuming, and fail to capture the critical time-evolving phenomena that occur during the irradiation experiments. Advanced manufactured digital image correlation patterns and strain sensor devices serve as two promising technologies that can be deployed in the confined and challenging orientations of these irradiation experiments while also providing key insight on salient materials phenomena (i.e., mechanical properties).To guide the development of the printed strain sensors prior to their deployment in critical experiments, the adhesion strength between the substrate and printed film interface is measured via tensile testing and a non-contact laser-induced spallation technique. The establishment of these process control steps helped guide the successful fabrication and testing of direct-write strain sensing devices discussed in this work. The fabrication process controls are necessary for enabling the sustained operation of these strain sensing device through experimentation and minimize the potential for premature failure.
36 - MATERIALS SCIENCE↗
FWP FEW0223: "Advanced Manufactured Carbonate Materials for Algal Biomass Production: Joint LLNL SNL Program" (Final Report)
The ability to easily and cheaply transport carbon dioxide (CO 2 ) from coal-fired power plants equipped with capture facilities to multiple, potentially distant utilization sites of widely varying scales will enable wider use of CO 2 captured from flue gas. In the case of algal biomass cultivation, delivery of CO 2 in the form of carbonate-based materials may provide a more efficient and economical method of inorganic carbon delivery than CO 2 sparging, reducing the cost of algae cultivation and increasing the value of carbon capture. Lawrence Livermore National Laboratory (LLNL) has developed advanced manufactured materials that are well-suited for carbon capture, storage, transport, and delivery. These materials consist of aqueous sodium carbonate, which captures CO 2 as sodium bicarbonate, extruded or 3D printed in a CO 2 permeable polymer to increase the surface area and improve capture kinetics. By encapsulating carbonate solutions, LLNL has demonstrated order-of-magnitude enhancements in carbon capture rates compared with liquid carbonates, enabling the use of these (otherwise kinetically-limited) inexpensive, environmentally-benign solvents for carbon capture.
20 FOSSIL-FUELED POWER PLANTS↗
Solid State Ionics: Materials Development by Multiscale Modeling and Advanced Manufacturing Techniques
Solid-state ionic materials are an important enabling technology for energy conversion and storage. Solid-state batteries would be a safer and higher energy density alternative to commercially available lithium ion batteries (LIB), however their implementation requires ion conduction in solids at room temperature to occur on the same level as the current generation of liquid electrolytes. Microstructural modifications have been demonstrated to play a major role on ion transport through the control of grain boundary interfaces, which traditionally serve as “blocking” layers. Ultimately, these materials will be fabricated in thin films form as electrolytes in order to minimize ohmic losses in electrochemical devices. This work uses advanced manufacturing techniques in combination with theoretical modeling to implement a science-based approach in the deposition of thin films ion conductors with controlled microstructures used in ceramic energy conversion and storage devices.
25 ENERGY STORAGE↗
Adsorption and Surface Diffusion of Metals on α-Al2O3 for Advanced Manufacturing Applications
Abstract The adsorption and diffusion of Mo and Nb adatoms on the $$\alpha$$ α -Al 2 O 3 (0001) surface were explored using density functional theory-based methods. Adsorption energies of Mo and Nb adatoms at minima sites on the surface were determined. Mo and Nb adatoms prefer to adsorb to the same locations on the surface, and larger adsorption energies calculated for Nb compared to Mo indicate that Nb adatom-surface interactions are stronger than Mo. Using minima adsorption sites as initial and final locations for surface diffusion, energy barriers for diffusion were calculated using the nudged elastic band method. Overall, Mo and Nb follow roughly the same diffusion paths. The diffusion pre-factors for Mo and Nb are similar; however, Mo diffusion has a lower energy barrier and thus a larger diffusion coefficient compared with Nb. These results provide insight into the role of surface diffusion of Mo and Nb adatoms during advanced manufacturing processes.
Biaggne, Austin (ORCID:0000000328074960)↗
Advanced multimaterial shape optimization methods as applied to advanced manufacturing of wind turbine generators
Abstract Currently, many utility‐scale wind turbine generator original equipment manufacturers are dependent on imported rare earth permanent magnets, which are susceptible to market risks from cost instability. To lower the production costs of these generators and stay competitive in the market, several small wind manufacturers are pursuing continuous improvements to both generator design and manufacturing. However, traditional design and manufacturing methods have yielded marginal improvements in wind power performance. This work presents novel methods to redesign a baseline 15‐kW wind turbine generator with reduced rare‐earth permanent magnets by leveraging cutting‐edge three‐dimensional (3D) printed polymer‐bonded permanent magnets and steel. Symmetric, asymmetric, and multimaterial‐magnet parametrization methods are introduced for shape optimization. We extend the symmetric and asymmetric methods to the back iron in the stator to further investigate the impact and opportunities for performance improvements with lesser active materials. We employ a design‐of‐experiments approach with parametric computer‐aided design for shape generation and evaluate different designs by magneto‐thermal modeling and finite‐element analysis. We use adaptive sampling technique to identify better performing designs with lesser magnet mass, higher efficiency, and lower cogging torque when compared with the baseline generator. Asymmetric pole designs resulted in a magnet mass in the range of 4.77–5.37 kg, which was 27%–35% lighter than the baseline generator, suggesting that a new design freedom exists that can be enabled by advanced manufacturing, such as 3D printing. Shaping the back iron in the stator resulted in material savings in electrical steel of up to 14.62 kg, which was 20% lighter than the baseline stator. We conducted a structural analysis to evaluate an optimized asymmetric rotor design from the point of view of mechanical integrity and air‐gap stiffness. The magnetically optimal shape profile was shown as having a positive impact on the radial stiffness, and an optimal solution was discovered to reduce the structural mass by nearly 30 kg, which was 29% lighter than the baseline.
17 WIND ENERGY↗
Advancing Manufacturing Water Resilience: Addressing Risks through New Approaches and Technologies
Water is indispensable in manufacturing operations, and many manufacturers operate on the assumption that water of sufficient quality and quantity will be available whenever and wherever needed. As such, the importance of water to this sector has been overlooked, despite its critical importance for operations and meeting production demands, due to perceived sufficient availability and low cost of water to manufacturers. However, the situation is changing as water-related risks are markedly increasing due to aging infrastructure, changing climate, and resource extraction, which alter global and regional water cycles and characteristics. These changes are occurring against a backdrop of intensifying competition from other sectors for scarce and/or unevenly distributed water resources and changing trends in water needs. Section 1 of this report explores those risks in the U.S. context, while the remaining sections detail the work needed to advance the resilience of manufacturing water supplies to these changing risks by filling critical data gaps, re-evaluating the value of water to manufacturers, and advancing opportunities for novel technologies and analyses. The intended audience for this report is broad, including manufacturers, decision makers, researchers, and policymakers.
36 MATERIALS SCIENCE↗