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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 OSTI2023

Passively pumped, polycrystalline ceramic high and ultra-high vacuum chambers

A sealed, passively pumped, polycrystalline ceramic vacuum chamber and method for fabricating the chamber are disclosed. The body of the vacuum chamber is made from a polycrystalline ceramic, for example, alumina. The vacuum chamber includes one or more windows made from a transparent ceramic, for example, sapphire, to accommodate optical access, while remaining amorphous-glass free to minimize or eliminate helium permeation. The vacuum chamber components are joined via laser welding or furnace brazing and the completed chamber is bakeable at temperatures up to 400° C. The vacuum chamber can operate at high or ultra-high vacuum pressures for an extended period through the use of one or more getter-based pumps. The vacuum chamber may include one or more atomic sources depending upon the application.

Walker, Charles A.↗
DOE OSTI2024

Characterization of compositional variation and solidification condition on rapid solidification behavior of beta stabilized titanium

Rapid solidification (RS) is a field of study that has increased in importance due to the rise of additive manufacturing (AM) techniques. The breakdown of equilibrium at the solid-liquid interface results in an inability to use traditional solidification models that have been applied to great success in casting. As such, there is a current need for a high-throughput testing method to screen alloys at rapid solidification conditions without the significant cost for powder atomization. In this work, twin hammer splat quenching (SQ) is utilized and theoretically developed as a technique uniquely placed to test alloy systems for AM applications. Using analytical thermal spray models and numerical heat transfer simulations, the cooling rate and solidification conditions of splat quenching are compared across several parameters to evaluate the key parameters for generating cooling rates relevant to AM process. Once a framework for the cooling rates and relevancy of SQ are developed, SQ was used to process alloy compositions in the Ti5553 alloy space (AMS 7026) to study the formation of detrimental secondary phases occurring upon rapid quenching from the melt. A martensitic phase is found to occur at the lower end of the standard, but the composition listed in the standard were found to be safe. Finally, the rapid solidification behavior of Ti-5553 is evaluated by comparing splat quenching, laser welding, and plasma atomization that offer a wide window of solidification conditions. The segregation and solidification structure are analyzed and compared to models to provide a deeper understanding of the solidification behavior of beta stabilized titanium alloys.

Williamson, Christopher J.↗
DOE OSTI2022

Weldability of irradiated Stainless Steel 304 materials harvested from the National Research Universal (NRU) reactor

In this work, the weldability of the neutron-irradiated Stainless Steel 304 (SS 304) materials containing estimated helium levels of 12 to 44 appm has been studied through a Collaborative Research and Development Agreement between the Canadian Nuclear Laboratories and Oak Ridge National Laboratory. The work utilizes a SS 304 component harvested from the National Research Universal reactor. Laser beam welding was used to explore suitable welding conditions and associated parameters, to determine helium concentration limits for successful welding of irradiated stainless-steels. The experimental results show that maximum fusion zone void sizes, fusion zone void quantity and total heat affected zone helium-induced crack length generally increased with increasing He levels and effective weld heat input. A proper combination of welding parameters with low effective heat input, such as, laser power, weld travel speed and wire feed speed, were shown to improve the welding quality, and potentially reduce the length and probability of the formation of grain boundary helium-induced cracking and voids of irradiated SS 304 even with He concentrations as high as about 44 appm.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Some Physics Fundamentals of High Energy Density Welding

The purpose of this section of this document is to provide a brief summary of the physics aspects of high energy density welding (HEDW). One reason for this is to help elucidate some of the differences between EBW and LBW. A fundamental understanding of these differences can help guide an appropriate choice of process for a particular application.

42 ENGINEERING↗
DOE OSTI2025

Metallurgical Analysis and Forward Modeling of Weld Distortion in SMR Containment Vessels

This work aimed to apply Sandia’s expertise in metallurgy and modeling to enable the use of hybrid laser arc welding for building nuclear reactor containment structures, via a collaboration with Holtec International. Experimental observations were coupled with finite element analysis to resolve microstructure development, mechanical properties, distortion, and residual stress in welds relevant to the production of the Holtec SMR-160. High residual stresses were observed in welds that were not subjected to preheat. Meanwhile, the microstructure of the welds generally exhibited a narrow heat affected zone relative to conventional arc welds. FEA appeared to be effective in simulating the thermal/mechanical conditions that occur during hybrid laser arc welding of simplified and instrumented test welds. Subsequently, FEA was used to perform sensitivity analyses for various weld geometries that would be prohibitively costly to assess with physical experiments. Insights from the study were used to inform Holtec’s welding process, and successful production welds were performed in 2025.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Microstructure and mechanical behavior of laser remelted amorphous Al-Ni-La welds

To explore the feasibility of using laser powder bed fusion systems to print bulk amorphous Al alloys, a single autogenous weld produced by laser remelting on a cast Al-5La-9Ni (at.%) alloy was studied for its microstructure and mechanical behavior. The solidification rates experienced by material within the welds were high enough to produce entirely amorphous regions within the welds. Welds were characterized using SEM, STEM, and APT and were found to contain Ni-rich amorphous clusters. Micropillar compression tests were used to assess mechanical properties of the welds and found that all of the amorphous regions exhibited yield strengths around 1 GPa. In conclusion, these results are discussed in the context of diffusivity of Ni and rare earth elements in liquid, glass forming ability, thermodynamic driving force for phase formation during solidification, free volume concentrations in bulk metallic glasses, and cluster-related softening.

APT↗
DOE OSTI2020

Production of Medium-Scale Metal Additive Geometry With Hybrid Manufacturing Technology

Oak Ridge National Lab’s (ORNL) Metal Big Area Additive Manufacturing (mBAAM) and Hybrid Manufacturing teams in the Manufacturing Demonstration Facility (MDF) was tasked with developing a part that exceeded 24 inches in length and 100lbs in weight on a laser hotwire welding system. The Mazak VC-500A/5X AM HWD hybrid 5-axis CNC laser hotwire system was leveraged to complete the task. The proposed geometry was manufactured with 410 stainless steel on AISI1018 steel substrate in just over 36 hours of build time. The proposed geometry was sliced and additively manufactured in three segments; the base, and two extrusions measuring 10 inches in length and 14 inches in length. Production of this component demonstrated hybrid capabilities requiring fixed 5-axis rotations to complete geometry that exceeded the defined build volume of the machine. Multiple repairs of the part were conducted in-situ leveraging the additive and subtractive capabilities of the Mazak hybrid system. Significant overbuilding challenges were encountered and manually addressed by leveraging subtractive capabilities of the hybrid system. Future processes are presented for development to reduce overheating of top layers. Final part measurements exceeded 107 lbs. in weight and 24.5 inches in length along the principal axis; the largest and heaviest part created by a hybrid system at the MDF.

Saleeby, Kyle↗
DOE OSTI2025

On-target uniformity of the OMEGA 60-beam inertial confinement fusion laser

Successful direct-drive inertial confinement fusion (ICF) experiments require excellent on-target laser 9 irradiance uniformity maintained over the duration of the pulse. Achieving this symmetry relies on maintaining an 10 energy, power, and fluence balance among all beams in a multibeam laser system. As a result of the improvements 11 described in this paper, the OMEGA 60-beam laser performance has been assessed at approximately 2% on-target 12 irradiance nonuniformity using an updated performance assessment metric that accounts for the laser diagnostic noise 13 floor. The performance is measurement-limited, prompting the need for an improved diagnostic suite. This manuscript 14 provides a comprehensive first-order assessment of extant status of on-target energy, power, and fluence uniformity 15 and explores avenues for improvements.

Diagnostics↗
DOE OSTI2024

Imaging Enhanced Simulation Validation for Directed Energy Deposition Additive Manufacturing (Final CRADA Report – NFE-22-09107)

Directed Energy Deposition (DED) is a welding-based metal Additive Manufacturing (AM) process that relies on the programmed rastering of an electric arc or laser induced weld pool to construct a component in a layerwise fashion. The induced complex thermal field and uneven thermal contraction depends on the printed geometry and scan pattern, and as such, accumulated residual stresses and distortions are complex and difficult to predict. Several prior works have resulted in tools to combat this issue; ANSYS has developed a thermoplastic simulation package targeting DED AM, and ORNL has developed an in-situ imaging sensor package ‘Stereo Correlated Optical and Pyrometric System’ (SCOPS) that can spatially monitor temperature and full field strain. In this CRADA, these tools are compared in order to validate the results and complimentarily address the weaknesses in each other.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Time-Dependent 600 °C Post-Weld Heat Treatment Response of Laser-Wire-Directed Energy Deposited Austenitic Stainless Steel Claddings on Carbon Steel

Austenitic stainless steel overlay claddings are often used to protect nuclear reactor pressure vessels from corrosion. Arc welding processes are traditionally employed, which require a high heat input to bond the dissimilar metals, creating a large heat-affected zone and high residual stress that demands a lengthy stress-relieving post-weld heat treatment, up to 48 hours. High energy beam (e.g., laser, electron beam) directed energy deposition-based overlay cladding processes show promise for fabricating claddings with superior performance compared to arc welded ones because of their localized heat input; however, their necessity and time of post-weld heat treatment are currently unclear. In this research, we investigate the time dependence of a 600 C stress-relieving post-weld heat treatment of austenitic stainless steel clad on low carbon steel by laser-wire-directed energy deposition, comparing the microstructure and mechanical properties of the as-fabricated condition to 2-, 10-, and 48-hour heat treatment times. Diffusion simulations and microscopy show a gradual carburization of the stainless steel cladding and decarburization of the heat-affected zone/base metal. Nanoindentation testing shows up to a 1.8–2.69 embrittlement in the cladding and a 0.33 to 0.69 softening in the heat-affected zone after the 48-hour post-weld heat treatment. Tensile testing of the cladding composites reveals that increasing post-weld heat treatment time raises clad cracking susceptibility due to intergranular carbide formation and shows that laser-wire-directed energy deposition claddings may not require post-weld heat treatment.

Coating↗
DOE OSTI2021

Time-Resolved Geometric Feature Tracking Elucidates Laser-Induced Keyhole Dynamics

In this report, during laser melting of metals, localized metal evaporation resulting in the formation of a keyhole shaped cavity can occur if processing conditions are chosen with high power density. An unstable keyhole can have deleterious effects in certain applications (e.g., laser powder bed fusion) as it increases the likelihood of producing defects such as porosity. In this work, we propose a pipeline that enables complete segmentation and extraction of various geometric features in keyholing conditions. In situ synchrotron high-speed X-ray visualization at the Advanced Photon Source provides large datasets of experimental images with a high spatio-temporal resolution across a range of laser parameters for Ti-6Al- 4 V. Computer vision image processing techniques were used to extract time-resolved quantitative geometric features (e.g., depth, width, front wall angle) throughout keyhole evolution which were subsequently analyzed to understand the relationship between the variation of local keyhole geometry and processing conditions. This analysis is the first to employ a data-driven approach to further our understanding of the keyholing process regime.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Status and prospects for inertial fusion energy via lasers

Fusion energy is the ultimate clean and limitless energy source, but its development requires overcoming many scientific and technological challenges. For the first time in the 60-year long history of fusion research, ignition and target gain above unity (G>1) were demonstrated in the laboratory at the National Ignition Facility at the Lawrence Livermore National Laboratory in 2022. Turning laser fusion into an energy source requires that the results from single shot experiments be replicated at much higher repetition rates of many shots per second to produce high average power at relatively low cost. Furthermore, this requires the development of new laser technologies, mass production of suitable targets, accurate injection and tracking systems and new materials for the reactor chamber components and final optics. Ultra broadband and deep UV light are laser advances that can dramatically improve the laser energy coupling to the target thereby reducing the laser energy and power requirements.

Fusion energy↗
DOE OSTI2021

USAMP Low-Cost Mg Sheet Component Development and Demonstration Project

The overarching objective of this USAMP project was to develop and demonstrate door panels made from magnesium (Mg) sheet with a cost penalty over conventional steel stampings of no more than $\$5.50$/kg saved. The technical approach integrated experiments with advanced computational tools based on Integrated Computational Materials Engineering (ICME) methods to develop new alloy chemistries and their thermomechanical processing that promise improved formability and lower forming temperatures. A penultimate task before finally forming the stampings was to incorporate actual microstructure into models that would enable formability simulations. This approach would, for the first time, account for individual magnesium grains moving in an anisotropic fashion unlike that for aluminum or steel that have isotropic properties upon which the current simulation tools are based. In separate activities, new coatings and lubricants to facilitate forming and improved corrosion protection and joining strategies, were developed to ensure that the door could be produced with stated product requirements. A technical cost model, which included parts production, assembly, and paint for a door specifically designed for Mg sheet, showed the cost penalty to be between $\$4.26$ to $\$6.60$/kg saved, which enveloped the project’s cost targets. The cost of the coated Mg sheet was identified as the key driver for the cost penalty. The mass of the Mg-intensive door was 7.9 kg, which was 54% less than the baseline steel door.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Low-Cost Magnesium Alloy Sheet Component Development and Demonstration Project

The overarching objective of this USAMP project was to develop and demonstrate door panels made from magnesium (Mg) sheet with a cost penalty over conventional steel stampings of no more than $5.50/kg saved. The technical approach integrated experiments with advanced computational tools based on Integrated Computational Materials Engineering (ICME) methods to develop new alloy chemistries and their thermomechanical processing that promise improved formability and lower forming temperatures. A penultimate task before finally forming the stampings was to incorporate actual microstructure into models that would enable formability simulations. This approach would, for the first time, account for individual magnesium grains moving in an anisotropic fashion unlike that for aluminum or steel that have isotropic properties upon which the current simulation tools are based. In separate activities, new coatings and lubricants to facilitate forming and improved corrosion protection and joining strategies, were developed to ensure that the door could be produced with stated product requirements. A technical cost model, which included parts production, assembly, and paint for a door specifically designed for Mg sheet, showed the cost penalty to be between 4.26 USD to 6.60 USD/kg saved, which enveloped the project’s cost targets. The cost of the coated Mg sheet was identified as the key driver for the cost penalty. The mass of the Mg-intensive door was 7.9 kg, which was 54% less than the baseline steel door.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Specifications of FIPD Fission Gas Release Data

All fission gas release data stored in the Fuels Irradiation & Physics Database (FIPD) was originally measured using the Gas Assay, Sample and Recharge (GASR) System in the Hot Fuel Examination Facility (HFEF). It is therefore called GASR data in FIPD. During the measurement of a sample, such as an irradiated EBR-II fuel element/capsule, a pinhole-sized region near the top of the element plenum was melted by a laser. Plenum gas then expanded into a calibrated volume (note: in this document, “sample” and “capsule/element” are used interchangeably consistent with GASR documents in FIPD). The pressure rise in the volume was recorded. Helium backfilling and expansion was then performed to determine the sample (e.g., fuel element plenum) volume using Boyle’s Law and assuming ideal gas behavior at constant temperature. With the plenum volume and the recorded pressure rise, the sample (e.g., fuel element plenum) pressure was derived with assumption of ideal gas law behavior. The plenum volume and pressure as well as the cladding temperature during the measurement were collected (GASR data in FIPD). Other records associated with the fission gas release data include: raw GASR data records including volumes and post-puncture pressures of seal head/sealing head and manifold, calibration data, backfilling gas pressure data, and the data analysis records. A sample(s) of the fission gas released from the plenum was collected by the GASR system into sample bottles. The chemical and isotopic composition of the gas sample was analyzed separately from GASR data, and will be discussed in a separate specification. The plenum volume, pressure, and cladding temperature during the measurement are typically utilized to determine the number of moles of gas in the plenum. This quantity is often compared to the number of moles of gas generated by fission events. However, calculating these values and their associated uncertainty is beyond the scope of this document, as it necessitates additional assumptions. The most important document to understand the FIPD fission gas data is the GASR operational manual (title: Gas Assay, Sample and Recharge System (GASR) operation and maintenance manual, HFEF/N OMM 4381, DOC. NO. W0018-0032-ES-00). This manual provides: (1) description of the GASR and the functions of each component (laser drilling, welding, seal head/sealing head, manifold, vacuum system, sample system, purge and gas tag system, etc.); (2) step-by-step guidance on calibrations, operations, and measurements; and (3) maintenance procedures and other details relating to the structure and operation of the GASR. Note that the original GASR operated until 2020. A new GASR with the same design and measurement methodology was installed in 2021. The specifications of the GASR presented on the HFEF website at this time are consistent with the ones given in the operational manual. The methods to calculate the plenum volume and pressures were not included in the operational manual, but were recorded in the legacy data analysis files. Details of the methods are given in Chapter 3.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗