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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Process-driven roadmap for depositing super duplex stainless steel via wire Arc additive manufacturing

Here, this study systematically investigates the effects of shielding gas, bead spacing, weld mode, and travel speed on the phase balance, porosity, and hardness of wire arc additively manufactured (WAAM) super duplex stainless steel (ER2594). Robotic WAAM was employed to fabricate multilayer walls under systematically varied process conditions, followed by phase transformation simulations, X-ray computed tomography (XCT), electron backscatter diffraction (EBSD), and microhardness evaluation. Thermodynamic simulations predicted rapid cooling of AM process can suppress the potential formation of deleterious precipitates which was later validated via cross-sectional microstructure analyses of printed samples. XCT revealed porosity levels below 0.2% for all deposits, with reduced travel speed significantly lowering defect volume. Microstructural analyses revealed the evolution of various austenite precipitates, including grain boundary austenite (GBA), Widmanstätten austenite (WA), and intergranular austenite (IGA), sequentially upon cooling of the ferrite phase. Among all process parameters, weld transfer mode exhibited the strongest influence on phase balance; pulsed mode promoted higher ferrite retention (~ 36%) compared to RapidX mode. No consistent relationship between stabilized phase fraction and captured microhardness was observed. This work provides critical insights for optimizing WAAM parameters to control phase balance and mechanical performance, which is essential for producing high-integrity super duplex stainless-steel components for nuclear and marine applications.

Grain orientation↗
DOE OSTI2026

Validation Data for Benchmarking Wire Arc Additive Manufacturing Process Simulations

Residual stresses cause geometric distortion and affect mechanical performance of additively manufactured structures, yet they are notoriously difficult to assess and predict. Distortion (warpage) can drive parts outside dimensional tolerance limits, leading to part rejection or rework. For parts that meet tolerance, locked-in residual stress fields can affect structural integrity during operation, particularly subcritical cracking by fatigue, creep, or corrosion. This work develops benchmark data for a common additive manufacturing process (Wire Arc Additive Manufacturing) that can be applied for calibration and validation of physical process models that predict residual stress fields. The work includes design of two different samples of differing geometry, detailed manufacturing records for a set of physical samples, and an extensive set of residual stress measurement data developed using two diverse techniques (the contour method and neutron diffraction). An initial application of the work is also reported, where a modeling challenge was issued to secure residual stress model predictions from two independent laboratories that were blind to residual stress measurement data. These initial blind residual stress predictions show significant discrepancies relative to the measurement data, illustrating the potential value of the underlying validation data. An open repository for this work, including the sample designs, manufacturing process records, and the residual stress data, is also provided for future application in non-blind validation efforts.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Tetragonal structure and uniaxial magnetic anisotropy in the arc-melted (Ce,Zr) 2 (Fe,M) 17 (M = Mo, W, Co) alloys

The tetragonal ThMn 12 -type structure is stabilized in (Ce 1-x Zr x ) 2 T 16 M (x = 0.2 – 0.3; T = Fe or Fe/Co, M = Mo or W) arc-melted alloys. Approximately 5 at% of Mo or W admixture is sufficient to transform the hexagonal Th 2 Ni 17 -type structure of (Ce 1-x Zr x ) 2 Fe 17 into the tetragonal ThMn 12 -type structure of nearly single-phase (Ce 1-x Zr x ) 2 Fe 16 M and/or (Ce 1-x Zr x ) 2 Fe 15 CoM bulk alloys. X-ray Rietveld refinements reveal that Zr and Mo (W) substitute different sites in the tetragonal crystal structure. Zirconium preferentially replaces Ce, whereas Mo (W) substitutes Fe. At room temperature, the tetragonal phases exhibit strong ferromagnetism and a uniaxial magneto-crystalline anisotropy with anisotropy fields of 15 – 17 kOe. These materials possess room-temperature saturation magnetizations of 95 – 105 emu/g and Curie temperature of 420 – 505 K. At some concentrations, concurrent Zr and Mo (W) site occupancy facilitates 1:12 structure formation in bulk alloys with minimal presence of non-magnetic element in the Fe sublattice, thus securing the highest known magnetic moment per Fe atom (∼ 1.37 µ B ) in this type of materials. The intrinsic magnetic characteristics, as well as the absence of critical rare earths (RE), make these compounds interesting for development as low-cost permanent magnets. In conclusion, small Co additions improve the Curie temperature, especially if combined with W.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Gas tungsten arc welding and post weld heat treatment effects on microstructure and mechanical property of castable nanostructured alloy steel

Here, this paper details the first study of castable nanostructured alloy (CNA) steel gas tungsten arc weldability and the post-weld heat treatment (PWHT) effects. Effects of welding heat input, thermal cycles, and PWHT on microstructures, microhardness distributions, room temperature tensile properties, and fracture characteristics are discussed. Results show that CNA steel exhibits excellent weldability (i.e., no indication of welding defects and reasonable tensile properties). The welded joint exhibited heterogeneous microstructures with δ-ferrite as well as large microhardness variation and fluctuation. The welded joint yield and ultimate tensile strengths were similar to those of the base metal, but the elongations decreased by 30 %. However, with normalization and tempering PWHT, the δ-ferrite was eliminated, microstructure was modified, hardness was unified, and joint ductility was restored. The study indicated that the CNA reduced-activation ferritic-martensitic steel owns excellent weldability, and PWHT is needed for the industrial application of welded structures.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Simulations of grain growth in tungsten armor materials under ARC plasma edge operation conditions using an integrated plasma-edge/materials model

An integrated model of grain growth deuterium-exposed tungsten polycrystals, consisting of a two-dimensional vertex dynamics model fitted to atomistic data, has been developed to assess the grain growth kinetics of deuterium-exposed polycrystalline tungsten (W). The model tracks the motion of grain boundaries under the effect of driving forces stemming from grain boundary curvature and differential deuterium concentration accumulation. Here, we apply the model to experimentally synthesized tungsten polycrystals under deuterium-saturated conditions relevant to the ARC concept design. The results indicate rapid grain growth kinetics in the near-surface region adjacent to the plasma, where the temperature reaches 1400 K, whereas the microstructure remains stable deeper in the material with the lower temperature of 1000 K. The combined modeling and analysis further reveal that monolithic tungsten produced via conventional fabrication routes is highly susceptible to grain coarsening at temperatures exceeding 1000 K, largely independent of the magnitude of the applied driving force. Moreover, the accumulation of deuterium near grain boundaries has a pronounced inhibitory effect on grain boundary migration. High-angle grain boundaries ( > 50°) contribute more significantly to the overall grain growth process.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Oxidized Sulfur Species in Slab Fluids as a Source of Enriched Sulfur Isotope Signatures in Arcs

Recycling of oxidized sulfur from subducting slabs to the mantle wedge provides simultaneous explanations for the elevated oxygen fugacity (fO 2 ) in subduction zones, their high hydrothermal and magmatic sulfur outputs, and the enriched sulfur isotopic signatures (i.e., δ 34 S > 0‰) of these outputs. However, a quantitative understanding of the abundance and speciation of sulfur in slab fluids consistent with high pressure experiments is lacking. Here we analyze published experimental data for anhydrite solubility in H 2 O-NaCl solutions to calibrate a high-pressure aqueous speciation model of sulfur within the framework of the deep earth water model. We characterize aqueous complexes, required to account for the high experimental anhydrite solubilities. We then use this framework to predict the speciation and solubility of sulfur in chemically complex fluids in equilibrium with model subducting mafic and ultramafic lithologies, from 2 to 3 GPa and 400 to 800°C at log fO 2 from FMQ-2 to FMQ+4. We show that sulfate complexes of calcium and sodium markedly enhance the stability of sulfate in moderately oxidized fluids in equilibrium with pyrite at fO 2 conditions of FMQ+1 to +2, causing large sulfur isotope fractionations up to 10‰ in the fluid relative to the slab. Such fluids could impart oxidized, sulfur-rich and high δ 34 S signatures to the mantle wedge that are ultimately transferred to arc magmas, without the need to invoke 34 S-rich subducted lithologies.

58 GEOSCIENCES↗
DOE OSTI2025

A co-registered in-situ and ex-situ dataset from wire arc additive manufacturing process

Recent progress in sensing techniques and data analytics tools have significantly accelerated the development of Wire Arc Additive Manufacturing (WAAM) systems. This data-centric approach emphasizes leveraging sensor data available throughout the production process to optimize performance. Integration of extensive data analysis provides opportunities for improving precision, reducing waste, and enhancing the quality of produced parts. This method relies on AI/ML models and optimization techniques, which are developed using the data collected from various sources, including in-situ sensors, ex-situ imaging, and manufacturing process parameters. The quality and diversity of this data, along with the alignment between different data streams (achieved through spatiotemporal registration) are critical for the successful development of AI/ML and optimization models. In this work, we present a spatiotemporally registered dataset generated during the WAAM process of deposition of a rectangular block. The dataset includes a comprehensive description of the deposition process, process parameters, welding characteristics and acoustic data collected in-situ, and X-Ray Computed Tomography data of the build.

42 ENGINEERING↗
DOE OSTI2025

Rapid data acquisition and machine learning-assisted composition design of functionally graded alloys via wire arc additive manufacturing

Abstract The lack of high-quality datasets in materials science hinders artificial intelligence (AI)-driven alloy design. To address this challenge, wire arc additive manufacturing (WAAM) was employed to fabricate graded alloys, generating extensive data for machine learning (ML)-assisted property prediction. ML models were developed using high-throughput experiments, computational models, and genetic algorithm to optimize feature selection, successfully predicting hardness and porosity. The ML model demonstrated its efficacy by designing a gradient alloy with enhanced properties. However, scaling up revealed uncertainties in tensile property and porosity due to differences in size and thermal conditions between the designed alloy build and the gradient print used to construct the ML model. This underscores the need for uncertainty quantification and process optimization in WAAM-driven alloy design. Our work advances AI-integrated additive manufacturing, offering a rapid approach to exploring process–structure–property relationships and accelerating materials development.

Wang, Xin↗
DOE OSTI2025

Development and scaling of MeV x-ray radiography at NIF-ARC

We investigate the generation of MeV x-rays using the Advanced Radiography Capability laser system at the National Ignition Facility using 1, 10, and 38 ps pulse durations, with laser energies reaching up to 4 kJ and using compound parabolic concentrators. Hydrodynamic simulations using up-to-date measurements of the contrast of the ARC laser are conducted, allowing us to employ an electron scaling model that incorporates scale length and pulse duration, which aligns closely with the observed temperature distributions. Comparable x-ray sources, in terms of dose, are generated when using a 10 ps pulse duration with 2.4 kJ at ∼1.9 ± 0.4 × 10 18 W/cm 2 and when using a 38 ps pulse duration with 4 kJ at 9.9 ± 0.4 × 10 17 W/cm 2 , both achieving ∼16 rad in air at 1 m for x-ray energies > 0.5 MeV. Radiographs performed on the laser “line-of-sight” show significant improvements in image quality than radiographs performed at 65 degrees to the laser axis. We verify the radiography performance using Monte Carlo Simulations.

Physics - Plasma physics↗
DOE OSTI2024

A large net carbon loss attributed to anthropogenic and natural disturbances in the Amazon Arc of Deforestation

The Amazon forest contains globally important carbon stocks, but in recent years, atmospheric measurements suggest that it has been releasing more carbon than it has absorbed because of deforestation and forest degradation. Accurately attributing the sources of carbon loss to forest degradation and natural disturbances remains a challenge because of the difficulty of classifying disturbances and simultaneously estimating carbon changes. We used a unique, randomized, repeated, very high-resolution airborne laser scanning survey to provide a direct, detailed, and high-resolution partitioning of aboveground carbon gains and losses in the Brazilian Arc of Deforestation. Our analysis revealed that disturbances directly attributed to human activity impacted 4.2% of the survey area while windthrows and other disturbances affected 2.7% and 14.7%, respectively. Extrapolating the lidar-based statistics to the study area (544,300 km 2 ), we found that 24.1, 24.2, and 14.5 Tg C y −1 were lost through clearing, fires, and logging, respectively. The losses due to large windthrows (21.5 Tg C y −1 ) and other disturbances (50.3 Tg C y −1 ) were partially counterbalanced by forest growth (44.1 Tg C y −1 ). Our high-resolution estimates demonstrated a greater loss of carbon through forest degradation than through deforestation and a net loss of carbon of 90.5 ± 16.6 Tg C y −1 for the study region attributable to both anthropogenic and natural processes. This study highlights the role of forest degradation in the carbon balance for this critical region in the Earth system.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Volcanic arc rigidity variations illuminated by coseismic deformation of the 2011 Tohoku-oki M9

Rock strength has long been linked to lithospheric deformation and seismicity. However, independent constraints on the related elastic heterogeneity are missing, yet could provide key information for solid Earth dynamics. Using coseismic Global Navigation Satellite Systems (GNSS) data for the 2011 M9 Tohoku-oki earthquake in Japan, we apply an inverse method to infer elastic structure and fault slip simultaneously. We find compliant material beneath the volcanic arc and in the mantle wedge within the partial melt generation zone inferred to lie above ~100 km slab depth. We also identify low-rigidity material closer to the trench matching seismicity patterns, likely associated with accretionary wedge structure. Along with traditional seismic and electromagnetic methods, our approach opens up avenues for multiphysics inversions. Those have the potential to advance earthquake and volcano science, and in particular once expanded to InSAR type constraints, may lead to a better understanding of transient lithospheric deformation across scales.

58 GEOSCIENCES↗
DOE OSTI2025

Pseudogap and Fermi arc induced by Fermi surface nesting in a centrosymmetric skyrmion magnet

Skyrmions in noncentrosymmetric materials are believed to occur due to the Dzyaloshinskii-Moriya interaction. By contrast, the skyrmion formation mechanism in centrosymmetric materials remains elusive. Here, in this work, we reveal the intrinsic electronic structure of the centrosymmetric GdRu 2 Si 2 by selectively measuring magnetic domains using angle-resolved photoemission spectroscopy (ARPES). We found robust Fermi surface (FS) nesting, consistent with the magnetic modulation q -vector detected by the previous resonant x-ray scattering measurements. The pseudogap opens at the nested FS portions, which vary for different magnetic domains. The anomalous pseudogap disconnects the FS to generate Fermi arcs with twofold symmetry. These results indicate that the Ruderman-Kittel-Kasuya-Yosida (RKKY) interaction plays a decisive role in generating the screw spin modulation responsible for the skyrmion formation in GdRu 2 Si 2 . Furthermore, we demonstrate the flexible nature of magnetism in GdRu 2 Si 2 by manipulating magnetic domains with magnetic field and temperature cyclings, providing potential future applications for data storage and processing devices.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

ZrH2 as measured on ARCS for NXS2021

This data is for ZrH2 in an Al can it is measured at room temperature. This data was used for the Neutron and Xray scattering school in 2021. It was measured on the ARCS direct geometry spectrometer at the spallation neutron source. The .nxs files are event files that can be read and processed with Mantid. The nxspe files are auto reduced files that can be read with Mantid, Dave, or Mslice. Both types of files are hdf5 and can be read with any tool that reads hdf5.

MATERIALS SCIENCE↗
DOE OSTI2025

Electric field effect on lattice dynamics of a relaxor ferroelectric PMN-30PT measured on ARCS.

The combined inelastic neutron scattering data from ARCS for poled PMN-30PT single crystal is at 300K and for unpoled crystal the data were collected at 300K and at 488K. The incident neutron energy for both poled and unpoled crystals was 25 meV . To obtain a significant four-dimensional Q-E volume, the crystal was rotated with steps of 0.5 degree in the beam. All individual angles were combined using HORACE software package (https://pace-neutrons.github.io/Horace/unstable/user_guide/Getting_started.html) to generate these sqw files. The file labeled PMN_PT_poled_new.sqw is for poled crystal and files labeled PMN_PT_300K.sqw and PMN_PT_488K.sqw are for unpoled crystal at 300K and 488K respectively.

MATERIALS SCIENCE↗