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DOE OSTI2025

Automated Segmentation of Twin Boundaries in TRISO Silicon Carbide Using Deep Neural Networks

Coated particle fuels, such as the tristructural isotropic (TRISO) fuel particle, are essential for high-temperature gas reactor (HTGR) applications due to their efficiency and stability under normal and off-normal conditions. However, widespread commercialization and deployment of this technology for next-generation nuclear applications require robust quality assurance and quality control (QA/QC) methods linking fabrication, properties, and performance. Of the many important metrics for TRISO QA/QC, quantification of the silicon carbide (SiC) microstructure is critical because it correlates with fission product retention during irradiation. Previous work has shown extensive twinning of the SiC microstructure, which strongly affects microstructural metrics; however, twin grain boundaries are not expected play a significant role in fission product diffusion. This report summarizes the initial development, training, and testing of a machine learning image processing algorithm to detect twin grain boundaries in a backscattered electron image, which can be removed so that microstructural metrics can be recalculated for legacy data. Further development and deployment of this model will provide automated, scalable improvement of potential QA/QC methods for the SiC layer of TRISO particles.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2003

Developing A Contoured Deposition Head for In-Situ Tape Laying and Fiber Placement

A conformable compaction system employing three individual compactors has been designed for integration into fiber placement and tape laying deposition heads for out-of-autoclave fabrication of thermoplastic contoured parts. The compactors are intended to perform against two geometry specifications: (1) a general minimum radius of curvature limit of 180cm (71-in), and (2) a pad-up specification with a maximum height of 2.5mm (0.1-in) and a minimum ramp of 2.5mm (1-in). The mirrored specification is applicable to a pan-down. The three designs include a hot line compactor capable of a 1000N (400-lb) force at 450C over a 114mm (4.5-in) width, a hot area compactor capable of a 400N (100-lb) force at 450C over a 114mm width by 76mm length (4.5-in by 3-in), and a cold compactor that combines the features of a line and an area compactor. The cold compactor s line segments act with a 2800N (700-lb) force across a 127mm (5-in) width, while the cold compactor's area segments act with a 1000N (250-lb) force over a 127mm by 102mm (5-in by 4-in) area. Two of the designs, the hot line and hot area compactors, have been constructed, developed, and proven out in hot mode to compact actual thermoplastic composite plies over undulating geometry. IM-7PEEK [0/90/0/90]s pan-down and IM-7PEEK [0/-45/90/45]2s pad-up laminates have been fabricated and photomicrographs show good microstructure.

Lamontia, Mark A.↗

NASA NTRSDate not supplied

In-situ Imaging of Pyrolyzing Aerospace Materials

Tracking morphological changes of materials during heating is crucial to understand its response in fire protection, biofuel production, thermal protection systems (TPS) for hypersonic flight. As materials are heated, they undergo physical and chemical changes due to water loss, stretching or shrinking, pyrolysis and chemical reactions in the ambient environment. The effects of these changes can have a profound impact on the material’s performance, indicated by changes in on the porosity and volume. While materials such as wood shrink as they pyrolyze and lose mass, others swell due to their inherent characteristics when exposed to heat [1]. This study focuses on experiments conducted at the Advanced Light Source (ALS) beamline 8.3.2, where in situ micro-computed tomography (µ-CT) is performed on materials as they are being pyrolyzed. Through in situ µ-CT, the change in total volume and porosity can be obtained in real-time, allowing for better understanding of the underlying thermophysical and chemical processes as a function of temperature. This study also focuses on the implementation of the Porous Microstructure Analysis software (PuMA) [2] to obtain thermal conductivity, permeability, and other properties of the material from the 3D tomographies. The information gained from these tomographies will supplement microscale model development of material morphological change and will aid macroscale modeling for high-temperature applications. For this study, Room Temperature Vulcanizing silicone (RTV) [3-5] is heated from room temperature to 1000°C using an infrared lamp heating system, and tomographies are continuously collected as the sample is heated. The tomographies are then segmented to obtain solid and void phases, from which estimates of pore size, porosity and total volume are extracted as a function of temperature. PuMA is deployed on the segmented tomographies to obtain thermal conductivity, permeability, and other properties as a function of temperature. Preliminary results show that RTV first intumesces (swells) as pyrolysis begins, due to build-up of pyrolysis gases in closed pores, and then shrinks significantly as more open pores are formed and the pyrolysis gases outgas. Pore network visualization of the tomographies using OpenPNM [6] showed the increase in pore connectivity with increase in temperature. Future work will focus on using PuMA to obtain macroscopic properties of RTV as a function of temperature.

Tomography↗

DOE OSTI2025

Damage progression and failure of SiC/SiC composite tubes under hard-contact radial expansion

The response of silicon carbide (SiC) fiber-reinforced SiC matrix (SiC/SiC) composite cladding to mechanical interaction with fissile fuel is a knowledge gap that must be overcome to design and assess SiC-based cladding systems for advanced nuclear applications. This study developed the relevant mechanical testing capability and identified the failure behavior and the critical microstructural features and processing defects. Sections of SiC composite tube were subjected to a modified expansion-due-to-compression (EDC) test in an X-ray computed tomography microscope: a polyurethane plug pressed surrogate Al 2 O 3 into the inner walls of the SiC/SiC composite tubes to achieve hard contact. A pure EDC test with just a polyurethane plug was also performed as a reference. Through the use of displacement fields, digital volume correlation revealed inhomogeneous deformation fields in the tubes, even for pure EDC, which was related to the inherent defects in the structure. Deep learning–aided segmentation and systematic data analysis revealed that the presence of inhomogeneous deformation applied by the hard contact was exaggerated by the presence of inner surface imperfections left behind from the matrix densification process. In conclusion, the findings provide insights into the applications, highlighting the necessity for improvements in inner surface roughness and the incorporation of localized contacts in pellet–cladding mechanical interaction computational models.

Composites↗

DOE OSTI2025

Stochastic parametric skeletal dosimetry model for humans: Pediatric and adult computational skeleton phantoms for internal bone marrow dosimetry

Currently, computational phantoms that simulate skeletal tissues are used in active red bone marrow (AM) internal dosimetry. Up-to-date reference computational phantoms recommended by the ICRP are based on the analysis of CT-images of cadavers. Such phantoms have significant disadvantages. One disadvantage is that the assessment of uncertainty due to the population variability of skeleton dimensions and microstructure results from the limited availability of autopsy material. Another disadvantage is the simplified modelling of cortical layer and bone microarchitecture. A method of stochastic parametric skeletal dosimetry modelling of the bone structures – SPSD modelling – has been developed as an alternative to the ICRP reference phantoms. In the framework of this approach, skeletal phantom parameters are evaluated based on extensively reviewed results of published measurements of real bones. The SPSD approach allows for the assessment of both population-average values and their variability. SPSD-phantoms of the skeleton are modelled in voxel representation. They consist of smaller phantoms of the bone sites – segments – described by simple geometric shapes with uniform microarchitecture parameters. Such segmentation makes it possible to account for non-homogeneous skeletal microarchitecture and to model the bone structure with the required voxel resolution to elaborate suitable skeletal phantoms. The current study presents the parameters of the SPSD skeletal phantoms for the following age-groups: newborn, 1-year-old, 5-year-old, 10-year-old, 15-year-old (male and female), and adult (male and female). This skeletal phantom can be used for dosimetry as an alternative to available reference phantoms for bone-seeking radionuclides. The above-mentioned age- and sex-specific skeletal phantoms are comprised of 289 unique segments. The characteristics of the SPSD phantoms do not contradict published data and are in good agreement with the measurement results of real bones.

Science & Technology - Other Topics↗

NASA NTRS1999

Interacting Surfaces and Atmospheres in the Outer Solar System

The work reported here is an extension of ongoing efforts in data reduction and modeling of the spectral reflectances of several objects in the outer Solar System. In general terms, this requires an evaluation of the data obtained at the telescope, conversion of those data into geometric albedo units, and the combination of individual spectrum segments into a complete spectrum over the wavelength interval of interest. The modeling effort to produce a synthetic spectrum of a given Solar System object requires the complex refractive indices (the optical constants) of candidate surface materials, including ices, minerals, and organic solids. Those indices are primarily available only through contacts with other researchers, including colleagues at NASA Ames and at other institutions. Once obtained, the indices must be convolved with the telescopic data and then used in a computational model to produce the required synthetic spectrum for comparison with the data obtained at the telescope. In this way, we reach a convergence on the chemical composition and microstructural properties of the surfaces of objects in the outer Solar System.

DalleOre, Cristina↗

DOE OSTI2025

Tracking Dendritic Growth in Hydrogen-Based Hematite Reduction via Computer Vision

The reduction of hematite to metallic iron using hydrogen (H2) as a reducing agent presents a promising pathway for decarbonizing steel production. In this study, we employ a combination of in situ confocal scanning laser microscopy (CSLM) and advanced computer vision techniques to quantitatively analyze dendritic growth of ferrite during H2-based reduction of iron oxide at high temperatures. A workflow integrating Watershed Image Segmentation (WIS) and Lucas-Kanade Optical Flow (LKOF) is developed to extract both global and local kinetic information from time-resolved micrograph sequences. H2 reduction experiments conducted at 1400 degrees C and 1500 degrees C demonstrate a clear correlation between temperature and reduction rate, as evidenced by accuracy of fitted Johnson-Mehl-Avrami-Kolmogorov (JMAK) parameters. Optical flow analysis further elucidates the anisotropic and branched nature of dendritic growth, providing spatially resolved velocity fields that correlate well with global transformation kinetics. The proposed methodology demonstrates strong agreement with experimental measurements and literature values, offering a robust framework for automated image-based analysis to study kinetics through microstructural evolution in the reduction of iron ore, and likely other reaction-diffusion phenomena.

08 HYDROGEN↗

NASA NTRS2011

Metallographic Preparation of Space Shuttle Reaction Control System Thruster Electron Beam Welds for Electron Backscatter Diffraction

A Space Shuttle Reaction Control System (RCS) thruster failed during a firing test at the NASA White Sands Test Facility (WSTF), Las Cruces, New Mexico. The firing test was being conducted to investigate a previous electrical malfunction. A number of cracks were found associated with the fuel closure plate/injector assembly (Fig 1). The firing test failure generated a flight constraint to the launch of STS-133. A team comprised of several NASA centers and other research institutes was assembled to investigate and determine the root cause of the failure. The JSC Materials Evaluation Laboratory was asked to compare and characterize the outboard circumferential electron beam (EB) weld between the fuel closure plate (Titanium 6Al-4V) and the injector (Niobium C-103 alloy) of four different RCS thrusters, including the failed RCS thruster. Several metallographic challenges in grinding/polishing, and particularly in etching were encountered because of the differences in hardness, ductility, and chemical resistance between the two alloys and the bimetallic weld. Segments from each thruster were sectioned from the outboard weld. The segments were hot-compression mounted using a conductive, carbon-filled epoxy. A grinding/polishing procedure for titanium alloys was used [1]. This procedure worked well on the titanium; but a thin, disturbed layer was visible on the niobium surface by means of polarized light. Once polished, each sample was micrographed using bright field, differential interference contrast optical microscopy, and scanning electron microscopy (SEM) using a backscatter electron (BSE) detector. No typical weld anomalies were observed in any of the cross sections. However, areas of large atomic contrast were clearly visible in the weld nugget, particularly along fusion line interfaces between the titanium and the niobium. This prompted the need to better understand the chemistry and microstructure of the weld (Fig 2). Energy Dispersive X-Ray Spectroscopy (EDS) was used to confirm the chemical composition of the variations in contrast in these areas. Niobium alloys generally require exposure to more aggressive chemical reagents than titanium alloys for etching because of niobium s chemical resistance; therefore, the titanium portion of the sample was etched first. A five second immersion in Kroll s reagent revealed a general microstructure on the titanium portion of the sample; however, the titanium heat affected zone closest to the weld, was over-etched due to higher concentrations of refined grains and an increase in eta-phase. The Kroll s etchant also revealed some microstructure in the weld nugget itself; the niobium portion of the sample remained unetched.

Martinez, James↗

DOE OSTI2025

Effects of Internal and External Heat Sources on Cladding Microstructure and Rupture Performance

In the event of a Loss of Coolant Accident (LOCA), the primary supply of cooling water for a nuclear reactor is lost, leading to a significant pressure differential across the cladding wall. Without adequate cooling, the fuel rods continue to heat as a result of fission reactions. Research at Oak Ridge National Laboratory’s (ORNL’s) Severe Accident Test Station (SATS) is currently focused on evaluating fuel cladding performance using an external infrared lamp as a heat source, whereas legacy testing primarily utilized an internal heating approach. While external heating may better simulate the effect of neighboring fuel rods heating a central rod, it may not accurately represent the internal heat absorption from the fuel during accident transients. The heating dynamics depend greatly on the fuel rod's position within the bundle and the reactor. To fully understand the implications of a LOCA event and assess the influence of internal heating on cladding performance, combined internal heating and pressurization capability was developed at ORNL. Tests were conducted to compare cladding segments heated internally (representing heat from the fuel within the rod) and externally (representing heat from adjacent fuel rods). The findings indicate that both internal and external heating result in comparable rupture temperatures during 5°C/s laboratory LOCA tests and also agree with legacy test data. Axial temperature gradients and internal heat source dispersal were found to significantly impact cladding deformation and rupture geometry. Clear modifications were outlined to further improve the capability with heating rates above 5°C/s.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Effects of Internal and External Heat Sources on Cladding Microstructure and Rupture Performance

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Temperature and dose effects on dislocation loops in self-ion irradiated high-purity iron

Body-centered cubic (BCC) Fe-based alloys are promising candidate materials for advanced nuclear reactors. However, a detailed understanding of irradiation induced dislocation loop microstructure development remains unresolved. It is a widespread belief that 〈001〉 loops become increasingly favorable over ½〈111〉 loops as irradiation temperature rises above ∼300 C. Unfortunately, the temperature effects on 〈001〉 loop have been primarily examined in in-situ irradiation on TEM thin foils but poorly explored on bulk Fe due to exceedingly limited experimental studies on bulk specimens, raising concerns about the potential influence of TEM thin foil artifacts on observed results. Here, in this study, we conducted experiments on ultra-high purity BCC Fe specimens irradiated with 6.7–8 MeV Fe ions over a wide temperature range on bulk samples. We investigated the effects of temperature (T irr = 250–500 °C), dose rate (10⁻⁵ to 10⁻³ dpa/s), and dose (0.35 to 3.5 dpa) on the formation and evolution of 〈001〉 and ½〈111〉 loops as well as cavity (void) formation. Post-irradiation Burgers vector analysis via g•b method on dislocation segments and loops revealed that 〈001〉 loop fraction does not show a monotonic positive correlation with irradiation temperature. Combined with previous and current theoretical as well as experimental findings, we explore the temperature effects on all existing models of 〈001〉 loop formation. We conclude that the prevailing reports regarding the dominance of 〈001〉 loops in Fe at elevated temperatures are mainly attributable to the loss of glissile ½〈111〉 clusters in TEM thin foil experiments.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Computer vision models and advanced TEM imaging for microstructures of irradiated AM316 stainless steels

Advancements were made in automating microscopy-based material characterization, particularly in studying irradiation effects on additively manufactured (AM) materials using machine learning (ML) and computer vision (CV). These automation efforts address the challenges of analyzing complex microstructures, accelerating the detection of irradiation-induced defects. Two CV models were developed at Argonne National Laboratory (ANL) to enhance transmission electron microscopy (TEM) analysis of irradiated AM 316 stainless steel. The first model focused on the detection of irradiation-induced dislocation loops, which contribute to material hardening and embrittlement. These loops, categorized as faulted or perfect, were automatically detected and classified using a Mask R-CNN model trained on TEM images from both in-situ and ex-situ ion irradiation experiments. The model achieved high accuracy, with precision, recall, and F1 scores of 0.839, 0.734, and 0.776, respectively, demonstrating its effectiveness in analyzing dislocation loops in irradiated AM materials. The second CV model was developed to analyze the size and wall thickness of dislocation cells in laser powder bed fusion (LPBF) 316 stainless steel. Using a U-Net++ architecture with EfficientNet as the encoder, the model was trained on TEM images to segment and measure cell size and wall thickness.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Electric field enhanced diffusion welding of alloy 617: Microstructural characteristics and mechanical properties

This study investigated the microstructural characteristics and mechanical behavior of diffusion welded nickel-based Alloy 617 obtained by electric field-assisted sintering (EFAS) using various parameters. The interfacial microstructure exhibited different characteristics including good grain boundary (GB) migration across the interface in the samples diffusion-welded at 1100 °C and a flat interface in the samples joined at 1000 °C and 1050 °C. The interface consisted of fine Al 2 O 3 oxides, while precipitation of interfacial M 23 C 6 carbides was not observed. Grain boundaries migrated across the Al 2 O 3 oxides, leaving these oxides within the grains. Graded grain size was observed, with grain coarsening being more significant near the sample surface due to the temperature gradient induced by EFAS. Tensile testing revealed that the specimens fractured in the matrix away from the interface, indicting strong diffusion-welded joints. Further, the peak tensile strength of 807 MPa was obtained in the samples welded at 1000 °C due to minimal grain growth. The materials obtained at 1100 °C exhibited reduced tensile strength but improved ductility. Strain maps revealed by digital image correlation showed alternating high and low strain segments in the samples produced at 1000 °C and 1050 °C, indicating that the flat interfaces with no GB migration were less ductile compared to the matrix. A greater strain uniformity was observed along the bond interfaces with improved GB migration. The hardness reduced near the sample surfaces due to enlarged grains induced by temperature gradient. This study demonstrates that GB migration and enhanced mechanical strength can be achieved in diffusion-welded Alloy 617.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Correlative X-ray micro-nanotomography with scanning electron microscopy at the Advanced Light Source

Geological samples are inherently multi-scale. Understanding their bulk physical and chemical properties requires characterization down to the nano-scale. A powerful technique to study the three-dimensional microstructure is X-ray tomography, but it lacks information about the chemistry of samples. To develop a methodology for measuring the multi-scale 3D microstructure of geological samples, correlative X-ray micro- and nanotomography were performed on two rocks followed by scanning electron microscopy with energy-dispersive spectroscopy (SEM-EDS) analysis. The study was performed in five steps: (i) micro X-ray tomography was performed on rock sample cores, (ii) samples for nanotomography were prepared using laser milling, (iii) nanotomography was performed on the milled sub-samples, (iv) samples were mounted and polished for SEM analysis and (v) SEM imaging and compositional mapping was performed on micro and nanotomography samples for complimentary information. Correlative study performed on samples of serpentine and basalt revealed multiscale 3D structures involving both solid mineral phases and pore networks. Significant differences in the volume fraction of pores and mineral phases were also observed dependent on the imaging spatial resolution employed. This highlights the necessity for the application of such a multiscale approach for the characterization of complex aggregates such as rocks. Information acquired from the chemical mapping of different phases was also helpful in segmentation of phases that did not exhibit significant contrast in X-ray imaging. Adoption of the protocol used in this study can be broadly applied to 3D imaging studies being performed at the Advanced Light Source and other user facilities.

58 GEOSCIENCES↗

NASA NTRS2014

Spindle-shaped Microstructures: Potential Models for Planktonic Life Forms on Other Worlds

Spindle-shaped, organic microstructures ("spindles") are now known from Archean cherts in three localities (Figs. 1-4): The ~3 Ga Farrel Quartzite from the Pilbara of Australia [1]; the older, ~3.3-3.4 Ga Strelley Pool Formation, also from the Pilbara of Australia [2]; and the ~3.4 Ga Kromberg Formation of the Barberton Mountain Land of South Africa [3]. Though the spindles were previously speculated to be pseudofossils or epigenetic organic contaminants, a growing body of data suggests that these structures are bona fide microfossils and further, that they are syngenetic with the Archean cherts in which they occur [1-2, 4-10]. As such, the spindles are among some of the oldest-known organically preserved microfossils on Earth. Moreover, recent delta C-13 study of individual spindles from the Farrel Quartzite (using Secondary Ion Mass Spectrometry [SIMS]) suggests that the spindles may have been planktonic (living in open water), as opposed to benthic (living as bottom dwellers in contact with muds or sediments) [9]. Since most Precambrian microbiotas have been described from benthic, matforming communities, a planktonic lifestyle for the spindles suggests that these structures could represent a segment of the Archean biosphere that is poorly known. Here we synthesize the recent work on the spindles, and we add new observations regarding their geographic distribution, robustness, planktonic habit, and long-lived success. We then discuss their potential evolutionary and astrobiological significance.

Oehler, Dorothy Z.↗

DOE OSTI2025

Scaling deep learning for material imaging with a pseudo 3D model for domain transfer

The recent introduction of deep learning methods for image processing has greatly advanced the characterization of materials using three-dimensional (3D) X-ray imaging techniques. However, deep learning models often have difficulty performing consistently across images owing to unavoidable variations in imaging conditions, which create inconsistencies even for the same material. As a result, networks must frequently be retrained for new datasets, limiting their applicability and generalization. Thus, it is critical to reduce the variations between images to enable a single model to process multiple datasets. Herein, we introduce P3T-Net, a pseudo-3D domain transfer network that transfers diverse 3D images into a uniform domain before processing using deep learning models. Remarkably, P3T-Net enables the reuse of previously trained networks for processing new images and considerably reduces the computational cost of transferring 3D images across domains. These unique capabilities were demonstrated in the following scenarios: (i) image enhancement of fast scans for geological rock and hydrogen fuel cells, (ii) enhancement of images to match the quality of multi-source imaging for lithium-ion batteries, (iii) accurate segmentation of images captured under different conditions, and (iv) tera-scale 3D transfer (10 11 voxels) on a single GPU. Overall, the proposed approach addresses cross-domain inconsistencies across various materials and conditions, thereby enabling more robust and generalizable deep learning solutions for a wide range of material imaging tasks.

25 ENERGY STORAGE↗