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DOE OSTI2025

Understanding Oxide–Metal Interactions During Hot Isostatic Pressing to Diffusion Bond Aluminum Alloy 6061 Plates

The interaction between Mg, Si, and Al 2 O 3 during hot isostatic pressing diffusion bonding of aluminum alloy 6061 (AA6061) plates was investigated through thermodynamic calculations and experimental microstructural characterization. Thermodynamic calculations as functions of temperature, pressure, and composition revealed that the interaction among Mg, Si, and Al 2 O 3 yields Mg 2 Si and either MgO + Al or MgAl 2 O 4 + Al, facilitating the reduction of Al 2 O 3 and allowing Al/Al metallic bonds to form. Total pressure variation had a negligible influence on the oxygen partial pressure, and consequently, the reaction product formation. Oxygen partial pressure variation as a function of temperature and initial amount of Al 2 O 3 determined the formation of either MgO or MgAl 2 O 4 . Experimental Hot Isostatic Pressure (HIP) bonding at 723 K and 833 K under a constant pressure of 1017 atm documented the cooling rate-dependent formation of β–Mg 2 Si precipitates. High-resolution transmission electron microscopy imaging and selected area electron diffraction patterns verified the formation of β–Mg 2 Si and MgO at the interface but did not detect MgAl 2 O 4 . In conclusion, findings from this study clarify the role of thermochemical interactions in oxide disruption and bonding mechanisms during HIP diffusion bonding of AA6061 and provide guidance for optimizing joining processes for monolithic nuclear fuel assemblies.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Bipolar plate flow channel designs for vanadium redox flow battery: a review

Vanadium redox flow battery is one of the preferred systems for grid scale energy storage due to long service life (>20000 cycles), higher efficiency (>85 %), deep discharge capability (>95 % DoD), and inherent scalability and safety. Among system components, flow field is most critical as it governs electrolyte distribution, mass transport and hydraulic performance. Here, this review examines emerging flow channel geometries, highlighting the impact of channel width (0.66 to 1.5 mm), depth (1 to 1.5 mm) and land width (0.5 to 1.5 mm) can reduce pressure drop to <10 kPa while enabling power densities above 600 mW.cm -2 . A key finding is that low channel width to depth ratio (<1) enhances voltage and energy efficiencies by improving under rib convection. The review also provides an overview of progress and perspective in bipolar plate materials, manufacturability, and shunt current mitigation strategies for stack scaling up. Cost analysis emphasizes the influence of flow field designs on the levelized cost of storage and pathways towards the US DOE's $\$$0.05 per kWh energy generation cost target. In addition, opportunities for AI/ML/DT tools assisted design and data driven optimization strategies are also outlined to accelerate next generation flow field development.

Efficiency optimization↗

DOE OSTI2026

Unravelling fast-charging degradation in NMC/Gr pouch cells: Lithium plating and SEI properties

As fast-charging technology expands across the electric vehicle and emerging energy-storage applications, understanding its impact on battery performance and longevity is critical. In this study, 1.8 Ah LiNi 0.6 Mn 0.2 Co 0.2 O 2 /graphite pouch cells were charged at various charging rates (0.5C, 2C, 4C, and 6C) to investigate the degradation mechanisms. Our results showed that well-designed NMC/Gr pouch cells could reach over 1000 cycles with a 2C charging rate, while only reaching around 500 cycles with 4C and 6C charging rates. Fast-charging effects on NMC and graphite electrodes were obtained through a series of post-mortem characterizations, including electrochemical impedance spectroscopy (EIS), Raman spectroscopy, X-ray photoelectron spectroscopy (XPS), and scanning electron microscopy (SEM) with energy-dispersive X-ray spectroscopy (EDS). Although higher charging rates cause pulverization of NMC secondary particles, the dominant degradation mechanism driving the fading of fast-charging-related performance lies in the graphite anode, where lithium plating and LiF-rich solid electrolyte interphase (SEI) formation result in Li inventory loss and impedance growth. The postmortem results suggest that the formation of a LiF-rich SEI, which exacerbates anode impedance and some irreversible Li + ion loss, is likely driven by the substantial decomposition of PF 6 − during fast charging, an effect often overlooked in smaller laboratory-scale studies.

Luo, Mei [Argonne National Laboratory (ANL), Argon↗

DOE OSTI2025

Tailoring copper current collector roughness and crystallographic orientation to improve lithium plating

Secondary lithium metal batteries are of great interest due to a high theoretical energy density, but rechargeability is limited by the formation of lithium dendrites that lead to internal short circuits and catastrophic cell failure. Mitigating dendrites through uniform current distribution at the current collector is a promising solution to enabling long cycle life of lithium metal electrodes. Here, the impact of copper crystal orientation and roughness on electrochemically deposited lithium morphology is studied. For 50 cycles, the capacity retention from greatest to least followed polycrystalline copper 95 ± 1 % (MC-PC) ≥ 94.55 ± 0.01 % Cu (110) > 93.0 ± 0.4 % Cu(111) > 75.8 ± 0.1 % Cu(100). Cu(100) performed the worst in all cases with shorts occurring frequently before reaching 50 cycles. Cryo-scanning electron microscopy images showed that after 50 cycles, MC-PC Cu had the best lithium morphology, but at early cycles, Cu(111) formed the densest lithium layer. MC-PC Cu had the most uniform lithium nucleation which may have been caused by increased roughness relative to the single crystal samples. When polycrystalline Cu (F-PC) roughness was systematically controlled, the cumulative Coulombic efficiency increased from about 0.3–0.5 with increasing roughness from an Ra of about 10–40 nm. Lastly, plating rates were studied. Slower rates of 0.25 mA/cm 2 exhibited denser lithium morphology in all cases as compared to 0.5 and 1.0 mA/cm 2 , but the relative porosity of Li deposited on the different current collectors depended on the rate applied.

Copper↗

DOE OSTI2025

Progress in the development of an ultrafast pulsed ponderomotive phase plate for cryo-electron tomography

Cryo-electron tomography (cryo-ET) is a powerful modality for resolving cellular structures in their native state. While single-particle cryo-electron microscopy excels in determining protein structures purified from recombinant or endogenous sources due to an abundance of particles, weak contrast issues are accentuated in cryo-ET by low copy numbers in crowded cellular milieux. Continuous laser phase plates offer improved contrast in cryo-ET; however, their implementation demands exceptionally high-peak optical intensities. Instead, a novel experimental approach to enhance contrast in cryo-ET is to manipulate the phase of scattered pulsed electrons using ultrafast pulsed photons. Here, we outline the experimental design of a proof-of-concept electron microscope and demonstrate synchronization between electron packets and laser pulses. Furthermore, we show ultrabright photoemission of electrons from an alloy field emission tip using femtosecond ultraviolet pulses. These experiments pave the way toward exploring the utility of the ponderomotive effect using pulsed radiation to increase phase contrast in cryo-ET of subcellular protein complexes in situ, thus advancing the field of cell biology.

Du, Daniel X. [Columbia Univ., New York, NY (Unite↗

DOE OSTI2024

Characterization of the response of radiochromic film to quasi-monoenergetic x rays through a cross-calibration with image plates

Radiochromic film (RCF) and image plates (IPs) are both commonly used detectors in diagnostics fielded at inertial confinement fusion (ICF) and high-energy-density physics (HEDP) research facilities. Due to the intense x-ray background in all ICF/HEDP experiments, accurately calibrating the optical density of RCF as a function of x-ray dose, and the photostimulated luminescence per photon of IPs as a function of x-ray energy, is necessary for interpreting experimental results. Various measurements of the sensitivity curve of different IPs to x rays have been performed [Izumi et al., Proc. SPIE 8850, 885006 (2013) and Rosenberg et al., Rev. Sci. Instrum. 90(1), 013506 (2019)]; however, calibrating RCF is a tedious process that depends on factors such as the orientation in which the RCF is scanned in the film scanner and the batch of RCF used. These issues can be mitigated by cross-calibrating RCF with IPs to enable the use of IPs for the determination of dose on the RCF without scanning the RCF. Here, the first cross-calibration of RCF with IPs to quasi-monoenergetic titanium, copper, and molybdenum K-line x rays is presented. It is found that the IP-inferred dose rates on the RCF for the Ti and Mo x rays agree well with the measured dose rates, while the IP-inferred dose rate for the Cu x rays is larger than the measured dose rate by ∼2×. Explanations for this discrepancy and plans for future work are discussed.

Instruments & Instrumentation↗

DOE OSTI2024

Characterization of the image plate multi-scan response to mono-energetic x-rays

Image plates (IPs), or phosphor storage screens, are a technology employed frequently in inertial confinement fusion (ICF) and high energy density plasma (HEDP) diagnostics because of their sensitivity to many types of radiation, including, x rays, protons, alphas, beta particles, and neutrons. Prior studies characterizing IPs are predicated on the signal level remaining below the scanner saturation threshold. Since the scanning process removes some signal from the IP via photostimulated luminescence, repeatedly scanning an IP can bring the signal level below the scanner saturation threshold. This process, in turn, raises concerns about the signal response of IPs after an arbitrary number of scans and whether such a process yields, for example, a constant ratio of signal between the nth and n + 1st scan. Here, the sensitivity of IPs is investigated when scanned multiple times. It is demonstrated that the ratio of signal decay is not a constant with the number of scans and that the signal decay depends on the x-ray energy. As such, repeatedly scanning an IP with a mixture of signal types (e.g., x ray, neutron, and protons) enables ICF and HEDP diagnostics employing IPs to better isolate a particular signal type.

Instruments & Instrumentation↗

DOE OSTI2024

Image plate multi-scan response to fusion protons in the range of 1–14 MeV

Image plates (IPs) are a quickly recoverable and reusable radiation detector often used to measure proton and x-ray fluence in laser-driven experiments. Recently, IPs have been used in a proton radiography detector stack on the OMEGA laser, a diagnostic historically implemented with CR-39, or radiochromic film. The IPs used in this and other diagnostics detect charged particles, neutrons, and x-rays indiscriminately. IPs detect radiation using a photo-stimulated luminescence (PSL) material, often phosphor, in which electrons are excited to metastable states by ionizing radiation. Protons at MeV energies deposit energy deeper into the IP compared with x rays below ∼20 keV due to the Bragg peak present for protons. This property is exploited to discriminate between radiation types. Doses of mono-energetic protons between 1.7 and 14 MeV are applied to IPs using the MIT linear electrostatic ion accelerator. This paper presents the results from consecutive scans of IPs irradiated with different proton energies. The PSL ratios between subsequent scans are shown to depend on proton energy, with higher energy protons having lower PSL ratios for each scan. This finding is separate from the known energy dependence in the absolute sensitivity of IPs. The results can be compared to complimentary work on x rays, showing a difference between protons and x rays, forging a path to discriminate between proton and x-ray fluence in mixed radiation environments.

Instruments & Instrumentation↗

DOE OSTI2024

Target development using the method of High-Intensity Vibrational Powder Plating (HIVIPP) at the Center for Accelerator Target Science (CATS) at Argonne National Laboratory (ANL)

One of the primary goals of the Center for Accelerator Target Science (CATS) is to provide targets and foils in support of the ATLAS User Facility and the Low-Energy community at large. While a wide array of target production techniques are available at CATS, new methods that must be explored invariably arise. One such technique, the High-Intensity Vibrational Powder Plating (HIVIPP), was first reported in 1997 by Isao Sugai. It was developed to produce targets and stripper foils that were difficult to make by standard methods. At Argonne National Laboratory (ANL), we have successfully constructed and tested a simple system for this purpose. We have produced targets of carbon and titanium on various metal backings using the HIVIPP method. We are currently in the exciting phase of exploring the production of other elements, including isotopically enriched and radioactive material. This work is in progress and will be further detailed with specific examples.

47 OTHER INSTRUMENTATION↗

DOE OSTI2026

Comprehensive earthquake catalogue update and spatiotemporal distribution analysis for Iraq and surrounding regions, northeastern Arabian Plate

The updated earthquake catalogue for Iraq covers the period from 1900 to the end of 2021 and includes over 37 000 recorded earthquakes. To create this comprehensive catalogue, five key steps were taken: compiling bulletins, calculating moment magnitudes, harmonizing magnitudes, establishing empirical conversion relations and evaluating the completeness of the catalogue. A notable enhancement in this update is the direct calculation of moment magnitudes for approximately 2800 earthquakes, achieved through the coda envelope technique and waveform data from the Mesopotamian Seismological Network (MPSN) in Iraq. This updated catalogue serves as a valuable resource for examining the spatiotemporal distribution of earthquakes, with respect to earthquake density, maximum moment magnitude and seismogenic depths. Additionally, the Gutenberg–Richter relationship was applied to calculate the a- and b-values specific to Iraq. The findings show that the Zagros Fold-Thrust Belt has a seismogenic layer (source) that ranges from 2 to 33 km deep and experiences high seismic activity. In contrast, the Mesopotamian Foredeep has a seismogenic layer ranging from 1 to 25 km deep and has lower seismic activity. The greatest seismic activity is concentrated around the Mandili-Badra-Teeb fault, which has experienced significant ruptures over time. The Outer Arabian Platform is identified as the main area of seismic activity, while additional activity occurs on the Inner Arabian Platform. Three major tectonic boundaries define the distribution of earthquakes in the northeastern Arabian Plate. These boundaries are defined by the Main Zagros Reverse Fault, the Zagros Foredeep Fault and the Anah Graben and Abu Jir-Euphrates Fault Zone. These boundaries highlight variations in seismicity levels and the spatial distribution of deformation in the region. The updated earthquake catalogue presented in this study is expected to play a vital role in regional seismicity assessments and seismic hazard analyses for Iraq and its surrounding areas.

58 GEOSCIENCES↗

DOE OSTI2024

Parallel-plate avalanche counters for heavy-ion beam tracking: History and mysteries

Despite being an old detector concept, position-sensitive parallel-plate avalanche counters (PPACs) remain widely used today for heavy-ion position and timing measurements. In modern rare isotope beam facilities and large-acceptance fragment separators, PPACs are used to characterize beam properties (diagnostics), facilitate beam delivery (tuning), and provide event-by-event beam tracking for particle identification (PID). Most popular particle localization methods in PPAC detectors are based on strip electrodes electrically connected to resistive-chain circuits or delay lines. More exotic systems include optical readouts based on recording electroluminescence light with high-granularity photodetector arrays or high-resolution resistive anode electrodes. PPACs with conventional resistive-chain or delay-line readouts achieve typical position and time resolutions of below 1 mm ( σ ) and around 150 ps ( σ ), respectively. In addition, delay-line systems are capable of counting rates above several hundred kHz for beam areas of a few millimeters square, and around 1 MHz for larger beam sizes. Resistive-chain readouts have limited rates of a few tens of kHz. A review of the operation principles and performance of PPAC detectors is presented in this paper. We will discuss decades-long experience building and operating PPACs developed at the National Superconducting Cyclotron Laboratory, and then refined at the Facility for Rare Isotope Beams (FRIB), mostly focusing on the delay-line readout technique (DLPPAC). We will also discuss problems that arise due to electric discharges at high rates and briefly describe ongoing developments at FRIB. Published by the American Physical Society 2024

Physics↗

DOE OSTI2024

Status of the Top Plate and Anticryostat for High Field Cable Test Facility at Fermilab

Fermi National Accelerator Laboratory (Fermilab) is currently constructing a new High Field Vertical Magnet Test Facility (HFVMTF) designed for testing High Temperature Superconducting (HTS) cables under high magnetic fields. This facility is expected to offer capabilities similar to those of EDIPO at PSI and FRESCA2 at CERN. The background magnetic field of 15 T will be generated by a magnet supplied by Lawrence Berkeley National Laboratory. The primary function of HFVMTF will be to serve as a superconducting cable test facility, facilitating tests under high magnetic fields and a broad spectrum of cryogenic temperatures. Additionally, the facility will be utilized for testing high-field superconducting magnet models and demonstrators, including hybrid magnets, developed by the US Magnet Development Program (MDP). This paper provides a comprehensive description of the current status of two pivotal components of the facility: the Top/Lambda Plates Assembly and the Anticryostat for the Test Sample Holder. The latter will serve as a principal interface component connecting cable test samples with the facility's cryostat.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Direction-dependent elastic wave scattering and mode coupling in elastic plates

Asymmetric scattering is a phenomenon in which the field scattered from a discontinuity is dependent on the direction of incidence. In waveguide systems such as elastic plates, the existence of multiple propagating modes provides a platform to explore asymmetric scattering through direction-dependent mode coupling. This paper describes this concept in the context of reciprocal systems and how to utilize it in a general manner.

Haberman, Michael↗

DOE OSTI2025

Impact of Testing Method on Safety Assessment of Aged Li-Ion Cells: Part II – Aged Cells Without Li Plating

Understanding the safety profile of aged Li-ion batteries is essential for developing effective battery management and hazard mitigation strategies. However, most safety assessments have focused on fresh batteries, with just a few calorimetry studies on aged batteries with metal oxide positive electrodes. This study provides a broad assessment of commercial 18650-type Li-ion batteries with NCA, NMC, and LFP positive electrodes, both uncycled and aged under conditions that promoted solid electrolyte interphase (SEI) growth as the dominant degradation mechanism. The cells underwent mechanical (nail penetration, crush), electrical (overcharge, overdischarge), and thermal (accelerating rate calorimetry) abuse tests. Safety was rated on general characteristics such as mass loss, maximum temperature, and EUCAR (European Council for Automotive R&D) hazard level, as well as characteristics specific to individual abuse tests. Generally, aged cells with SEI growth exhibited similar or improved safety compared to uncycled cells, contrasting with our previous findings on NCA cells with Li plating as the dominant aging mechanism (Part I of this series). Yet, some tests and characteristics indicated reduced aged cell safety, such as earlier triggering of mechanical failure. These results emphasize the need to examine aged battery safety across diverse empirical techniques, degradation modes, and chemistries.

Lithium-ion cells↗

DOE OSTI2024

CFD Modeling of High-Flux Plate-and-Frame Membrane modules for industrial carbon capture

In this work, we explore the use of CO2-selective flat sheet membranes for capturing CO2 from point sources. We employ Computational Fluid Dynamics (CFD) models to design high-flux plate-and-frame membrane modules to achieve uniform flow distribution among membrane elements, minimize dead-end zones, and ease the common concentration polarization issue for gas separation membranes. The goal is to drive membrane technology improvements by providing better module designs for given membrane properties and operating conditions.

Dosso, Cheick↗

DOE OSTI2024

CFD Modeling of High-Flux Plate-and-Frame Membrane Modules for Industrial Carbon Capture

Dosso, Cheick↗

DOE OSTI2024

Calibration of Al7075 with Plate-Puncture Predictions

The following details calibration of a material model for Al7075-T6511. This aluminum alloy is commonly used across a host of engineering applications. Owing to its widespread prevalence, there is great benefit in improving simulation predictions for this alloy. In the present effort, a calibration is performed of its elastic-plastic response accounting for both rate and temperature dependence. The calibration is informed by a series of tests that include specimens of different geometries tested at different rates and temperatures. All specimens are derived from the same barstock, 3.5 inches in diameter. The fitted model itself uses an anisotropic, Hill yield surface coupled with a Johnson-Cook hardening model. Failure predictions are had by means of a modified Wilkins failure criterion. Following calibration of the material model, a validation exercise is performed against platepuncture experiments. These experiments include multiple probe shapes, probe diameters, and plate thicknesses. The puncture experiments are replicated in simulation with mesh studies performed to assess uncertainty. Key quantities of interest, notably the absorbed energy up to failure, are compared between simulation and experiment providing a means to assess the suitability of the calibration in puncture simulations.

36 MATERIALS SCIENCE↗

DOE OSTI2025

WHA Sphere Impacting RHA Plate: Modeling Brittle Behavior in Metal Alloys

Brittle behavior of metal alloys is often critical to modeling ballistic impact and penetration. The ALEGRA multiphysics finite element software incorporates calibrated models for the equation of state, elasticity, yield stress, plasticity and fracture, but simulations do not always capture expected metal fracture. Here we report concerted efforts to do so for one important case where experiments clearly show shear fractures: a tungsten sphere impacting a steel plate at various angles. Our best simulations show fractures that are qualitatively similar to experiments, but there are significant differences in quantitative metrics. Specifically, velocities of tracers used to quantify simulated plug parameters consistently fall short of measured plug velocities. Also, simulated plugs break apart more than expected from experimental evidence. We attribute these shortfalls to the lack of an explicit shear fracture mechanism in the material models, leading to over-estimated resistance to plug formation and movement.

36 MATERIALS SCIENCE↗