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DOE OSTI2021

A Case for Electron-Astrophysics

Abstract The smallest characteristic scales, at which electron dynamics determines the plasma behaviour, are the next frontier in space and astrophysical plasma research. The analysis of astrophysical processes at these scales lies at the heart of the research theme of electron-astrophysics. Electron scales are the ultimate bottleneck for dissipation of plasma turbulence, which is a fundamental process not understood in the electron-kinetic regime. In addition, plasma electrons often play an important role for the spatial transfer of thermal energy due to the high heat flux associated with their velocity distribution. The regulation of this electron heat flux is likewise not understood. By focussing on these and other fundamental electron processes, the research theme of electron-astrophysics links outstanding science questions of great importance to the fields of space physics, astrophysics, and laboratory plasma physics. In this White Paper, submitted to ESA in response to the Voyage 2050 call, we review a selection of these outstanding questions, discuss their importance, and present a roadmap for answering them through novel space-mission concepts.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2026

Optimization of the FRIB beam dump: a hybrid genetic algorithm and reinforcement learning approach

The operational envelope of high-power-density systems, such as particle accelerators and advanced nuclear energy systems, is critically constrained by the need to manage extreme thermal loads. To address this, we present a novel hybrid optimization framework combining a genetic algorithm (GA) with a soft actor-critic (SAC) deep reinforcement learning agent. This framework was applied to a practical high-heat-flux problem: redesigning the beam dump at the Facility for Rare Isotope Beams (FRIB) for a power upgrade from 20 kW to 50 kW. The resulting design, validated by three-dimensional conjugate heat transfer simulations, suppresses hazardous hot spots and yields a markedly more uniform temperature distribution. This provides a robust operating margin, increasing the average power-handling capability by 72% relative to the current design, demonstrating the framework’s potential to solve complex thermal management challenges in both accelerator technology and advanced nuclear systems.

Accelerator↗

DOE OSTI2024

Heat transfer optimization of uo 2 -mo fuel using genetic algorithms

Two genetic algorithm (GA) methods were applied to thermal finite element models to optimize the heat transfer efficacy of a UO 2 -Mo composite fuel pellet with typical pressurized water reactor fuel geometry. Mo additions to UO 2 have been shown to increase the thermal conductivity, thus reducing centerline temperatures and temperature gradients. Previous studies evaluated uniformly dispersed Mo or continuous Mo internal geometries (e.g., fins, plates, discs) that were selected using engineering intuition. The current study uses two different implementations of the same GA to optimize Mo placement and minimize the fuel temperature with the only constraint being a maximum 10% Mo volume fraction. One approach superimposed Mo line elements onto the monolithic UO 2 pellet model, and the other converted entire UO 2 volume elements to Mo. The former method generated 1D heat transfer connections between nodes, whereas the latter method allowed for the formation of 3D structures. Features of the optimal fuel design produced by the GAs included dispersed Mo near the centerline that shifted the peak fuel temperature outward by 0.6 mm, Mo chains in the high-heat-flux region in the mid-to-outer radial zone, and a large continuous structure that spanned the full radius and height of the pellet and accounted for 87.7 % of the total Mo in the pellet. Analysis of this design indicates that the optimal Mo configuration is a balance between creating continuous heat transfer pathways and optimally dispersing Mo to minimize the heat transfer distance through UO 2 . This architecture ultimately produced an effective thermal conductivity of 11.3 W/m·K under the assumed boundary conditions. This result is higher than any previous values from the literature. In conclusion, potential fabrication methods and challenges are discussed in addition to the implications on fuel performance.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Overview of Liquid-Metal PFC R&D at the University of Illinois Urbana-Champaign

The design and implementation of future flowing liquid-lithium plasma-facing components (LLPFCs) will be dependent on several factors. Of course, one of the most important is the need to be able to deal with high heat fluxes incident on the surface of the LLPFCs, but there are also several other important liquid-metal behaviors that have been identified for their critical impact on the feasibility of a LLPFC. One of these is the ability to constantly wet 100% of the plasma-facing component area and the best way to achieve that. Another key point is knowing and understanding the erosion and corrosion of the surfaces subject to a flowing liquid-lithium system and the ability for hydrogen and helium uptake by the system. The Center for Plasma Material Interactions (CPMI) has been tasked with looking at these various issues. The Mock-up Entry module for EAST device was used to investigate wetting and erosion effects and to design a suitable distribution and collection system with a liquid-lithium loop. The vapor shielding effects of lithium on the surface were also modeled and studied. A model coupling CRANE, an open-source global reaction network solver, and Zapdos, a plasma transport solver, is being developed to better understand the dynamics of the vapor cloud. Experiments on the Magnum-PSI at the Dutch Institute for Fundamental Energy Research have been carried out to study the vapor shielding effect and obtain experimental benchmarks to verify the model. Also, initial experiments using the Hybrid Illinois Device for Research and Applications have been performed to understand the pumping effects of lithium on helium. Experiments with a drop of liquid lithium (~100 mg) into a helium plasma have shown the ability of lithium to take out the cold recycling helium gas as well as hydrogen and oxygen impurity gases. The improvement in plasma performance was significant, and further understanding of this effect will have impacts on how future LLPFCs will be designed. Further investigation into the exact mechanism for helium pumping by lithium needs to be performed in the future. Finally, this paper presents a summary of the results obtained at the CPMI.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Final Design of Vacuum Pumping Systems for the Material Plasma Exposure eXperiment

The Material Plasma Exposure eXperiment (MPEX) vacuum pumping system is responsible for creating prototypic conditions in the plasma material interaction chamber that mimic those in a fusion reactor divertor region. Additionally, the vacuum system needs to minimize the pressure in the plasma heating region to improve the coupling of the electron cyclotron heating and ion cyclotron heating to the plasma, minimizing waste heat exhausted to high heat flux components. Here, the final design of the system has been sized to comply with the vacuum pump operating environment and to reduce the number of unique pumps required while meeting performance requirements. Bounding cases with and without the plasma present have been developed in the pumping analysis, and an initial calculation has been performed based on the plasma pumping identified in Proto-MPEX operation though this result will remain unverified until MPEX operation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Thermohydraulic Design Analysis of the Target Assembly in the Material Plasma Exposure Experiment Facility

The Material Plasma Exposure eXperiment (MPEX) project seeks to design a steady-state linear plasma facility at Oak Ridge National Laboratory that will be used to study plasma-material interactions (PMIs) at fusion prototypic levels, supporting the evaluation and development of materials for the next generation of fusion devices. This study is focused on PMI exposure of small-size neutron-irradiated specimens, which are clamped onto an actively cooled component. A thermohydraulic evaluation of a new MPEX target assembly design to assess the appropriate operation during MPEX operation is presented. To further guide the design and assess the structural integrity of the components under expected loads, preliminary thermomechanical stress analyses were also conducted. To ensure good thermal contact between the components, thermal interface materials, such as silver flexible graphite, were used in the assembly. It was found that the maximum target temperatures of 1572, 1463, and 1315 K were obtained for Grafoil thicknesses of 0.61, 0.38, and 0.25 mm, respectively. The distribution of the axial deformation at high heat fluxes showed that there are no gaps between components, indicating good contact at material interfaces. Moreover, the contact pressure between the target and other components indicated that very good contact was established at these interfaces. Furthermore, the stress-strain conditions for the target will be further used to assess the appropriate operation during MPEX experiments and gain insight into materials science phenomena during PMI experiments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Simulation of Channel Flow with Square Ribs for Blanket First-Wall Cooling: Geometry-Specific Tuning of k-ω Model Using Adjoint Method

Cooling of the plasma-facing first wall is challenging in the design of blanket components because of the high heat flux (on the order of 𝑀𝑊/𝑚2) from the plasma, especially when a low thermal mass medium like helium is chosen as the coolant. Therefore, heat transfer enhancement in which the convective heat transfer rate is augmented by the addition of turbulence-promoting structures becomes a key initiative for providing sufficient cooling capability with helium. Previously, computational fluid dynamics simulations had been performed on pipe flows with different transverse and longitudinal ribbed geometries at Oak Ridge National Laboratory to compare the enhancement performance among different ribbed geometries. Rib shape morphing had been conducted to obtain an optimized rib profile. In the work presented here, the adjoint method is adopted in the ANSYS Fluent solver for turbulence model augmentation, and the Generalized k-ω (GEKO) turbulence model is employed because of its ability of tuning the turbulence model. The Nusselt number and pressure drop obtained from the channel flow with bottom ribbed wall experiments are used as the targets. Sensitivity analysis provides information as guidance to improve the turbulence model accuracy. The augmented GEKO model is tuned for the studied ribbed channel geometry and flow conditions, providing improved predictive accuracy within this context. Extension to other configurations offers potential but may require additional tuning and validation.

Xu, Tracy [ORNL] (ORCID:0009000193700887)↗

DOE OSTI2020

Improvement on the plasma performances via application of flowing lithium limiters in EAST tokamak

Three generation of flowing liquid lithium (FLiLi) limiters have been developed and successfully tested in EAST since 2014. It was confirmed that liquid Li could be driven by an innovative in-vessel DC electromagnetic J × B pump to form a recirculating loop. The FLiLi design was continuously upgraded, resulting in improvement of the liquid Li surface coverage (>80%), elimination of surface erosion, and the increase of heat exhaust capability. Promising results are obtained during FLiLi operations, including a reduction of impurities and recycling to improve plasma confinement, and a mitigation of ELM activity in H-mode plasmas. The FLiLi limiter program has shown basic compatibility with H-mode discharges with auxiliary heating power up to 8.3 MW. These efforts will expand to flowing liquid Li PFC in high heat flux zones, e.g. near the divertor strike point in reactors.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Overview of the first Wendelstein 7-X long pulse campaign with fully water-cooled plasma facing components

After a long device enhancement phase, scientific operation resumed in 2022. The main new device components are the water cooling of all plasma facing components and the new water-cooled high heat flux divertor units. Water cooling allowed for the first long-pulse operation campaign. A maximum discharge length of 8 min was achieved with a total heating energy of 1.3 GJ. Safe divertor operation was demonstrated in attached and detached mode. Stable detachment is readily achieved in some magnetic configurations but requires impurity seeding in configurations with small magnetic pitch angle within the edge islands. Progress was made in the characterization of transport mechanisms across edge magnetic islands: Measurement of the potential distribution and flow pattern reveals that the islands are associated with a strong poloidal drift, which leads to rapid convection of energy and particles from the last closed flux surface into the scrape-off layer. Using the upgraded plasma heating systems, advanced heating scenarios were developed, which provide improved energy confinement comparable to the scenario, in which the record triple product for stellarators was achieved in the previous operation campaign. However, a magnetic configuration-dependent critical heating power limit of the electron cyclotron resonance heating was observed. Exceeding the respective power limit leads to a degradation of the confinement.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

NSTX-U research advancing the physics of spherical tokamaks

Abstract The objectives of NSTX-U research are to reinforce the advantages of STs while addressing the challenges. To extend confinement physics of low- A , high beta plasmas to lower collisionality levels, understanding of the transport mechanisms that set confinement performance and pedestal profiles is being advanced through gyrokinetic simulations, reduced model development, and comparison to NSTX experiment, as well as improved simulation of RF heating. To develop stable non-inductive scenarios needed for steady-state operation, various performance-limiting modes of instability were studied, including MHD, tearing modes, and energetic particle instabilities. Predictive tools were developed, covering disruptions, runaway electrons, equilibrium reconstruction, and control tools. To develop power and particle handling techniques to optimize plasma exhaust in high performance scenarios, innovative lithium-based solutions are being developed to handle the very high heat flux levels that the increased heating power and compact geometry of NSTX-U will produce, and will be seen in future STs. Predictive capabilities accounting for plasma phenomena, like edge harmonic oscillations, ELMs, and blobs, are being tested and improved. In these ways, NSTX-U researchers are advancing the physics understanding of ST plasmas to maximize the benefit that will be gained from further NSTX-U experiments and to increase confidence in projections to future devices.

74 ATOMIC AND MOLECULAR PHYSICS↗

DOE OSTI2021

Dielectric Fluids for the Direct Forced Convection Cooling of Power Electronics

The future of electrification of vehicles and other systems will require the creation of high-power density power electronics with low junction-to-fluid thermal resistance cooling solutions. One way to create this solution is to move high-heat-flux liquid cooling (single- or two-phase) as close to the power electronics components as possible. One novel approach involves submersion in dielectric fluids as the cooling solution. We first provide the range of fluid properties and develop a figure of merit (FOM) to aid in dielectric fluid selection. Next, we perform computational fluid dynamics/heat transfer (CFD/HT) modeling using single-phase cooling (submerged jet impingement on an enhanced surface) to validate the dielectric fluid FOM. Results of the study show that the developed FOM is a good representation of the performance of the fluids when compared to the results of the CFD/HT analysis. Both FOM and the CFD/HT analysis show that based on pure thermohydraulic considerations, several commercially available fluids present higher performance, on the order of 5% of water. Finally, the FOM can be used to quickly assess the thermohydraulic performance of a dielectric fluid, as well as the secondary application-specific properties such as boiling point, saturation pressure, flash point, and global warming potential, thereby allowing for fluid candidates to be readily compared.

computational fluid dynamics↗

DOE OSTI2024

An Experimental Investigation of Sintered Particle Effect on Heat Transfer Performance in an “Annular Flow” Evaporation Tube

Wicking structures have been widely used within passive heat transfer devices with high heat fluxes, such as heat pipes, to enhance their thermal performance. While wicking structures promote capillary pumping of the working fluid and thin film evaporation, they can result in capillary evaporation and further enhance the evaporation heat transfer. In this study, a 0.5 mm thick layer of 105 µm sintered copper particles was added to the inner wall of a copper tube, aiming to form an “annular flow” and enhance the heat transfer characteristics by taking advantage of thin film and capillary evaporation. Acetone was chosen as the working fluid, and the performance of an evaporation tube was tested for power inputs of 10, 30, 50, and 70 W. For each power input, trials were run at inclination angles varying from -90 deg to 90 deg to investigate the capillary effects. The temperature measurements showed that the temperature distribution along the evaporation tube is always downward sloping, meaning the temperature at the fluid inlet is larger than the outlet. In conclusion, results show that an “annular flow” formed by a thin layer of sintered particles can promote thin film and capillary evaporation and, therefore, boost the evaporation heat transfer coefficient.

42 ENGINEERING↗

DOE OSTI2024

Flow and Heat Transfer Experimental Study for 3D-Printed Solar Receiving Tubes With Helical Fins at Internal Surface

3D-printing technology was applied to fabricate novel solar thermal collection tubes that have internal heat transfer enhancement fins and external surfaces with high solar absorptivity and low emissivity due to the ability to use different materials in one tube. Helical fins were selected to introduce circumferential flow and thus minimize the circumferential temperature difference of the tube that receives sunlight on one side. The structures of the helical fins were previously optimized from computational fluid dynamics (CFD) analysis with the objective of low entropy production rate by looking for high heat transfer coefficient and relatively lower pressure loss. High-temperature alloy, Inconel-718, was used to 3D print the tubes, which can resist corrosion for the potential application of molten chloride salts as heat transfer fluid. Experimental tests were carried out using water as the heat transfer fluid with the high heat flux provided by a tubular furnace heater. The tested Reynolds number ranges from 3.9 × 10 3 to 6.1 × 10 4 . Heat transfer coefficients of up to 2.8 times that of the smooth tube could be obtained with the expense of increased pressure loss compared to that of the smooth tube. The total system entropy generation can be significantly reduced due to the benefit of heat transfer enhancement that is greater than the expenses of the increased pressure loss. The experimental results of the 3D-printed heat transfer tubes confirmed the CFD-based results of fin optimization. Furthermore, the novel heat transfer tube is recommended for application in concentrating solar power systems.

14 SOLAR ENERGY↗

DOE OSTI2023

EB Vs PAM Vs VAR for Uranium Alloys

Questions were raised during the February ’97 PDP Meeting at LLNL as to the advisability of funding three separate melting development programs (Advanced Vacuum Arc Remelt (VAR), Plasma Arc Melting (PAM) and Electron Beam Melting (EB)) through PDP in this era of shrinking research funds. The main issues seemed to be: 1) Have we evaluated the potentials of the three processes sufficiently to eliminate any of them out of hand and 2) Have any of these processes to date produced results which show clear advantages over the other two. The feeling at the meeting toward the latter seemed to be that all three processes required further development before they would be accepted by the complex as the standard. As far as evaluating potential for process improvements, however, we at Livermore did go through somewhat of a trade study in 1993 when we proposed the EB route. It seemed to us that even with the elimination of the skull caster via a VIM/VAR/VAR route, the problem of recycle limitations in the VIM step due to excessive carbon pick-up limited the potential for a great improvement in material utilization using this method. A single-step, cold hearth route looked to be the preferable choice. Both EB and PAM are used commercially as cold hearth processes, and both have been used for the production of refractory and specialty metals; EB since the mid 1950’s and PAM since the mid 1980’s. Both seem to have found their individual niches with some applications being suited to EB and others to PAM. Both can be adapted to continuous casting techniques and both are capable of imparting the high heat fluxes necessary to melt refractory metals. The major differences appear to be that for most applications, the EB process is capable of producing a purer product, while PAM results in less loss of volatile components. There exists an abundance of information in the open literature on the results of processing via both routes on various materials. The attached 1984 paper gives a good explanation of electron beam melting and plasma melting, and, I believe, a fair assessment of the advantages and limitations of both processes.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Sierra Space Technology Collaboration-Advanced Manufacturing of Thermal Protection System Tiles for Space Plane Atmospheric Reentry

Thermal protection systems (TPS) constitute a major material, engineering, and manufacturing challenge for space access. Atmospheric re-entry generates very high heats and requires advanced materials to withstand such conditions. Combining the required materials and integrating them into the vehicle is a major engineering undertaking that often must use creative designs to accommodate the selected materials and systems. Likewise, the manufacture of TPS is costly and challenging; it requires a combination of materials in a range of complex and unique shapes with specialized process conditions. Compounding these challenges, for harsh re-entry profiles or on high heat flux regions of the vehicle, even state of the art TPS is effectively single use and thereby creating a strong economic incentive to improve the TPS materials, integration, and manufacture. This work focuses on the use of ceramic modifications to TPS materials thereby allowing multi flight capability.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Advanced Manufacturing of Thermal Protection System Tiles for Space Plane Atmospheric Reentry

36 MATERIALS SCIENCE↗

DOE OSTI2024

Design of a Meso-Scale Test of a Fracture Thermal Energy Storage (FTES) System

This paper will present the characterization, scaling, and design of an intermediate-scale field test of a fracture thermal energy storage system (FTES). Seasonal storage of thermal energy has the potential to both significantly reduce the total energy requirements for heating and cooling of buildings, but also allow for the flexibility to store thermal energy from intermittent sources. With approximately half of global energy consumption currently being used for heating and cooling, this represents an important path to reducing greenhouse gas (GHG) emissions. The concept of FTES is to drill two or more wells into a low permeability formation, generally at a depth of less than a few hundred meters, and then generate hydraulic fractures to create flow paths for water to circulate between the wells. Hot or cold thermal energy can then be stored in the surrounding rock mass by circulating hot or cold water through the fractures, which will heat or cool the rock mass. To recover the stored energy, ambient temperature water can be then circulated through the fractures, which will then be heated or cooled by the rock mass. Fractures inherently have a very large ratio of surface area to volume. This allows for very high heat fluxes to and from the rock mass to be achieved despite the relatively low thermal conductivity of most geologic formations. Because large fractures can be made with low-cost equipment and with only inexpensive and environmentally safe materials such as water and sand, the cost to construct even large FTES systems is expected to be quite low. This paper will present what the performance requirements, size, and operating conditions of a full-scale system to operate a commercial building. The paper will describe how these full-scale system characteristics will be used as a design basis for an intermediate-scale FTES test to be conducted at the Sanford Underground Research Facility (SURF) in Lead, SD.

Burghardt, Jeffrey A.↗

DOE OSTI2023

EXPERIMENTAL ANALYSIS OF SINGLE EVAPORATION TUBE UTILIZING SINTERED COPPER PARTICLE WICKING STRUCTURES

Wicking structures have been widely used within passive heat transfer devices with high heat fluxes, such as heat pipes, to enhance their thermal performance. While wicking structures promote capillary pumping of the working fluid as well as thin film evaporation, they can result in capillary evaporation and further enhances the evaporation heat transfer. In this study, a 0.5 mm thick layer of 105 microns sintered copper particles was added to the inner wall of a copper tube, aiming to enhance the heat transfer characteristics by taking advantage of capillary evaporation. Acetone was chosen as the working fluid, and the performance of an evaporation tube was tested for power inputs of 10, 30, 50, and 70 W. For each power input, trials were run at inclination angles varying from -90° and 90° to investigate the capillary effects. The temperature measurements showed that the temperature distribution along the evaporation tube is always downward sloping, meaning the temperature at the fluid inlet is larger than the outlet. Interestingly, the surface temperature at some locations is less than the outlet temperature, indicating the effect of capillary evaporation. In addition, a theoretical investigation was performed to investigate the effects of the particle size on the thermal performance of the evaporation tube and found that particle sizes affect capillary evaporation.

Wang, Pengtao↗