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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Effect of impurities on phase transformation and precipitation in a low-carbon steel

Impurity elements have been added to a commercial low carbon steel grade to simulate the levels that could arise as a result of increased scrap recycling during steel production. In this study, continuous cooling transformation (CCT) diagrams were constructed for the steels with varying levels of impurities, and it is shown that impurities suppress the phase transformation across a wide range of cooling rates. It was found that a step was formed in the start temperature curve, separating the reconstructive and displacive transformations. The influence of impurities on both the reconstructive transformation and displacive transformation are discussed. Additionally, Cu precipitates were observed using scanning transmission electron microscopy (STEM) in the highest impurity-containing steel after slow cooling (0.05°C/s), fast cooling (5°C/s) and interrupted cooling. It was found that the precipitation kinetics is in the following order: cementite within the secondary phase and cementite at secondary phase-ferrite interface> ferrite grain boundaries> ferrite grain matrix. Atom-probe tomography (APT) revealed Cu precipitates formed on the surface of cementite lamellae, but not within it. This work offers insights for the phase transformation control and precipitation regulation during the thermomechanical processing of low carbon steels containing impurity elements due to scrap recycling.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Multiphysics Co-Optimization Design and Analysis of Double-Side Cooled Silicon Carbide-Based Power Module: Preprint

With the rapid growth of Electric Vehicles (EVs) and Hybrid Electric Vehicles (HEVs), much more rigorous design targets have been set for automotive power electronics, including high power density, high reliability, and low cost. Novel power module and inverter technologies based on wide bandgap (WEG) semiconductors have been developed to meet these design targets, while providing optimal power semiconductor operating temperature and promising thermomechanical performance. Compared with conventional cooling techniques which are normally applied only on one side of power module, double-side cooling approach is now believed to be the solution to enable high power density and low thermal resistance of WEG semiconductor-based power electronics. In this work, we develop a three-phase power module that is double-sided cooled using dielectric fluid jet impingement. In each phase, four silicon carbide (SiC) power semiconductors are bonded to copper busbars without electrical insulation layers. A finite element analysis (FEA) model is created for thermal and thermomechanical analysis. Based on FEA modeling results, we select particular dimensions for a parametric study to optimize thermal and mechanical performance. Using a multi-objective genetic algorithm (MOGA)-based optimization method, we have minimized the maximum junction temperature and thermal stresses within the power module. The multiphysics co-optimization approach has enabled an efficient design process of power modules with greatly reduced computational cost, as compared to conventional processes that rely on exhaustive numerical simulations and iterations.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Assembly of the MOLLER Toroidal Magnets at Jefferson Lab

The MOLLER experiment at the Thomas Jefferson National Accelerator Facility (JLab) aims to precisely measure the weak interaction between electrons. This experiment leverages the 12 GeV electron beam and will run for three years. A crucial component of MOLLER is a system of five uniquely shaped water-cooled toroidal magnets. These magnets, possessing seven-fold symmetry, are designed to focus particles by separating electrons scattered off hydrogen in a liquid hydrogen target. The five magnets separate electrons scattered off electrons (Møller scattering) and protons (elastic e-p scattering) within target into approximately circular rings at the detector. Here, this paper presents the assembly process for these five toroidal magnets, detailing critical steps including epoxy application, pin insertion, soldering and brazing, coil assembly, and alignment, all performed to meet stringent magnet specifications. Additionally, it discusses challenges encountered during construction and highlights lessons learned, offering insights for future magnet development projects.

Lamont, Joseph [Thomas Jefferson National Accelera↗
DOE OSTI2025

Initial in-orbit operation of the soft X-ray spectrometer Resolve onboard the X-ray imaging and spectroscopy mission satellite

The X-Ray Imaging and Spectroscopy Mission satellite was launched on September 6, 2023 (UT). Its Resolve instrument is a high-resolution X-ray spectrometer enabled by a microcalorimeter array thermally anchored to a 50-mK heat sink. Many sensitive, critical sub-systems comprise Resolve, including a multistage cryogenic cooling system, thin-film aperture filters, low-noise electronics, on-board signal processing, and several sources of X-rays for calibration. We summarize the initial on-orbit power-on and checkout of Resolve that commenced immediately after launch. Soon after launch, the cryocoolers were activated, and their operation was successfully established. On October 9, 2023, the first cycle of the adiabatic demagnetization refrigerator was carried out, bringing the sensors to their steady-state operational temperatures. Following this, the energy resolution at 5.9 keV was successfully measured. The energy scale of the system is highly sensitive to the thermal environment surrounding both the sensors and their analog electronics. Gain correction was performed using reference X-ray lines from onboard calibration sources. To optimize cooler frequency settings, noise spectra were collected across a range of frequencies, and the most suitable frequency pair was selected based on the in-orbit environment. During the final phase of the checkout, an attempt was made to open the gate valve, which is designed to protect the Dewar’s interior from external pressure during ground operations and launch. Unfortunately, this attempt was unsuccessful. As a result, the checkout process was temporarily paused, and a stable operational strategy was subsequently developed to enable Resolve to function effectively with the gate valve remaining closed.

X-ray micro-calorimeter↗
DOE OSTI2024

Single-gap isotropic s- wave superconductivity in single crystals AuSn 4

In this article, London, λ L (T), and Campbell, λ C (T), penetration depths were measured in single crystals of a topological superconductor candidate AuSn 4 . At low temperatures, λ L (T) is exponentially attenuated and, if fitted with the power law, λ(T) ~ T n , gives exponents n > 4, indistinguishable from the isotropic single s- wave gap Bardeen-Cooper-Schrieffer (BCS) asymptotic. The superfluid density fits perfectly in the entire temperature range to the BCS theory. The superconducting transition temperature, T c = 2.40 ± 0.05 K, does not change after 2.5 MeV electron irradiation, indicating the validity of the Anderson theorem for isotropic s- wave superconductors. Campbell penetration depth before and after electron irradiation shows no hysteresis between the zero-field cooling (ZFC) and field cooling (FC) protocols, consistent with the parabolic pinning potential. Interestingly, the critical current density estimated from the original Campbell theory decreases after irradiation, implying that a more sophisticated theory involving collective effects is needed to describe vortex pinning in this system. In general, our thermodynamic measurements strongly suggest that the bulk response of the AuSn 4 crystals is fully consistent with the isotropic s- wave weak-coupling BCS superconductivity.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Beam Dynamics simulations for ERDC project -- SRF linac for industrial use

Compact conductively cooled SRF industrial linacs can provide unique parameters of the electron beam for industrial applications. (up to 10MeV, 1MW). For ERDC project we designed normal conducting RF injector with thermal RF gridded gun integrated in first cell of multi-cell cavities. For design of the RF gun we used MICHELLE software to simulate and optimize parameters of the beam. Output file was converted to ASTRA format and most beam dynamic simulations in multi-cell normal conducting cavity and cryomodule were performed by using ASTRA software. For cross-checking we compare results of MICHELLE and AS-TRA in first few cells. At the end of injector beam reach ~250keV energy which allow to trap bunch in acceleration regime without losses in TESLA like 1.3 GHz cavity. Short solenoid at the end of injector allow to regulate transverse beam size in cryomodule to match beam to extraction system and also reduce charge losses in accelerator.

43 PARTICLE ACCELERATORS↗
DOE OSTI2026

Microstructure Validation of Graph Theory Model-Derived Cooling Rates in the Wire Arc Additive Manufacturing of ER70S-6 Steel

Wire arc additive manufacturing (WAAM) enables high-rate fabrication of large metallic components, but spatial variations in thermal history can lead to microstructural heterogeneity that requires efficient process models to evaluate. This study evaluates whether cooling rates extracted from a graph theory model (GTM)-based thermal simulation are consistent with the microstructural evolution observed in an ER70S-6 WAAM wall. Thermal histories from the model were analyzed at selected build heights, and cooling rates were extracted from the final thermal excursion through the austenite phase field. Microstructures at corresponding locations were characterized using electron backscatter diffraction (EBSD) to quantify grain size distributions, and pearlite interlamellar spacing was used as an additional indicator of cooling behavior. The modeled cooling rates were highest near the substrate and generally decreased with build height, consistent with the observed reduction in the fine grain fraction and the progressive shift in the grain size distribution as build height increased. Pearlite spacing trends also supported the modeled cooling rate variation. These results indicate that GTM-derived thermal histories can be post-processed into metallurgically meaningful cooling rate estimates for WAAM steel builds and linked to dataset specific empirical grain size distribution relationships for process–thermal history–microstructure assessment.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Minimization of thermal deformation in crystal optics for high repetition-rate FEL

Minimizing thermal deformation in X-ray crystal optics is crucial for preserving coherence and wavefront in high-repetition-rate free-electron lasers (FELs). This study presents two approaches to reduce pulse-by-pulse transient thermal deformation in diamond crystals used in cavity-based X-ray FELs (CBXFELs): (1) cryogenic cooling with liquid nitrogen (LN₂), and (2) second-order correction via focusing optics. We revisit the temperature-dependent thermal-mechanical properties of diamond and silicon, implement a finite-element analysis (FEA) method to accelerate convergence to a quasisteady-state regime. Results show that LN₂-cooled diamond crystals meet the stringent deformation requirement of less than 15 pm RMS for the pulse at mJ scale at 1 MHz repetition frequency, and up to 1.5 mJ for 100 kHz. Second-order correction by using focusing elements within the cavity can reduce the impact of thermal deformation for both liquid nitrogen and water cooling.

free electron laser↗
DOE OSTI2025

Dual Photoluminescence in Low-Temperature Phase of CsSnI 3 Nanocrystals

The expression of metal lone-pair electrons is hypothesized to underpin many of the interesting properties of inorganic halide perovskite semiconductors. Recently, a stable low-temperature monoclinic polar phase was predicted for CsSnBr 3 and CsSnI 3 , opening the possibility of direct investigation of a ferroelectric distorted structure compared to the undistorted structure. To date, there have been no experimental reports of such a structure in CsSnI 3 , and the low-temperature optical properties of CsSnI 3 nanocrystals have remained unexplored. Here we report optical and structural evidence of a phase transition around 240 K in 8.9 nm CsSnI 3 nanocrystals. Several changes in optical behavior occur below this transition point, including high-energy photoluminescence (PL) that emits concurrently with the exciton PL. The emergence of this high-energy PL is correlated with X-ray diffraction (XRD) and differential scanning calorimetry (DSC) supporting a phase transition from the orthorhombic structure between 240-200 K. Transient absorption measurements show an increase in the excited state lifetimes, i.e., slowed carrier cooling, at 200 K when photoexciting with photon energies above the high-energy state, consistent with slowed carrier cooling and emergence of high-energy PL. We hypothesize that the slowed carrier cooling is distinctive to this phase transition that modifies both the electronic and phonon structures that dictate excited-state carrier dynamics, and we discuss these changes.

14 SOLAR ENERGY↗
DOE OSTI2026

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

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

Grain orientation↗
DOE OSTI2024

Fusion Development and Technology (Final Technical Report for FC02-93ER54186)

The project is divided into three major tasks: 1) Magnet R&D i) Magnets Task 1 - Development of HTS Twisted Stacked-Tape Cable (TSTC) conductors for high field, high current magnets ii) Magnets Task 2– Development of Cryogenic Magnet Cooling Technology iii) Magnets Task 3 - National and International Collaboration 2) Electron Cyclotron Heating (ECH) of plasmas 3) FNSF Liquid Metals Study.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

Magnetic Field Mapping Design for the MOLLER Spectrometer Magnets at Jefferson Lab

The Thomas Jefferson National Accelerator Facility (JLab) has developed a unique spectrometer system to study the weak interaction between electrons. The "Measurement of Lepton-Lepton Electroweak Reaction" (MOLLER) experiment, utilizing JLab's recent 12 GeV electron beam upgrade, is scheduled to operate for three years. Central to the MOLLER experiment are five water-cooled toroidal magnets, each with a unique geometry and seven-fold symmetry, designed to focus the particles. These magnets generate the magnetic field needed to separate incident beam electrons scattered from target electrons (Møller scattering) and protons (elastic e-p scattering) within a liquid hydrogen target. Here, this paper details the magnet field measuring technique developed to map all five MOLLER toroidal magnets at multiple locations inside and along the bore. It covers the design, mounting, and operation of the probe, along with the calibration procedure to determine the field and to prepare a field map for GEANT4 analysis. Additionally, the paper addresses the challenges of accurately measuring low magnetic fields.

Ghoshal, Probir K. [Thomas Jefferson National Acce↗
DOE OSTI2025

Pulse-by-pulse transient thermal deformation in crystal optics under high-repetition-rate FEL

Time-domain modeling of the thermal deformation of crystal optics can help define acceptable operational ranges across the pulse-energy repetition-rate phase space. In this paper, we have studied the transient thermal deformation of a water-cooled diamond crystal for a cavity-based X-ray free-electron laser (CBXFEL), either an X-ray free-electron laser oscillator (XFELO) or a regenerative amplifier X-ray free-electron laser (RAFEL), by numerical simulations including finite-element analysis and advanced data processing. Pulse-by-pulse transient thermal deformation of a 50 µm-thick diamond crystal has been performed with X-ray pulse repetition rates between 50 kHz and 1 MHz. Results for temperature and thermal deformation have been compared with the results of transient analysis using a continuous wave (CW) power loading. Temperature and thermal deformation results from pulse-by-pulse transient analysis vary with time about the results for the CW case for the same average power. The variation amplitude increases with pulse energy and decreases with repetition rate. When the repetition rate increases to infinity, both temperature and thermal deformation converge to the results for the CW case. Two critical time scales for the operation of crystal optics in a CBXFEL are (1) first-turn time, i.e. the time for the XFEL pulse to complete the first turn around the cavity so that the crystal sees the recirculated XFEL pulse, and (2) period-end time, i.e. the time that the next electron bunch arrives for the amplification, so that the crystal outcouples the amplified FEL power. For the same average power, simulation results show that the crystal thermal deformation seen by the XFEL beam decreases with repetition rate at the first-turn time of a 300 m-long cavity and increases with repetition rate at the period-end time. For the wavefront preservation requirement of the crystal optics, a pulse-energy versus repetition-rate phase space has been established. The upper bounds of the pulse energy at both first-turn and period-end times decreases with repetition rate, especially at the period-end time. The upper bound of the thermal deformation of the crystal at the period-end time for any repetition frequency can be estimated from the CW case. For a water-cooled diamond crystal of dimension 5 mm × 5 mm × 0.05 mm, the time to reach a quasi steady-state is about 50 ms for temperature and 50 µs for thermal deformation.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2025

Multiple Carrier Generation at an Exceptionally Low Energy Threshold

Multiple carrier generation (MCG), a process wherein two or more carriers are generated from a single high-energy absorbed photon, holds immense promise for quantum sensing, metrology, low-threshold lasers, and photovoltaics. Despite its potential, MCG has faced obstacles such as low efficiency and a high threshold photon energy at least twice the band gap (2?Eg) of the semiconductor, limiting its application only to a class of materials with low Eg. Here, we present a new approach that overcomes this limitation by leveraging carrier-donor scattering to excite secondary electrons from donor states strategically positioned below the conduction band. Our method relies on strong Coulomb interaction, reduced dielectric screening, slow hot carrier cooling, and strictly follows the energy conservation rules. We experimentally demonstrated this idea in a model system of monolayer (1L) MoS2 by exploiting electron-donating chalcogen vacancy states. We observed an exceptionally low MCG threshold of ~1.12?Eg for the first time in 1L MoS2. Remarkably, the quantum yield can be further increased to >3 by increasing the photon energy to 1.65?Eg, representing a substantial advancement over existing methods. Our findings extend the horizon of MCG into next-generation high-performance optoelectronic devices with an on-demand operating spectral range spanning from infrared to ultraviolet.

CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSICS↗
DOE OSTI2024

Ubiquitous short-range order in multi-principal element alloys

Recent research in multi-principal element alloys (MPEAs) has increasingly focused on the role of short-range order (SRO) on material performance. However, the mechanisms of SRO formation and its precise control remain elusive, limiting the progress of SRO engineering. Here, leveraging advanced additive manufacturing techniques that produce samples with a wide range of cooling rates (up to 10 7 K s –1 ) and an enhanced semi-quantitative electron microscopy method, we characterize SRO in three CoCrNi-based face-centered-cubic (FCC) MPEAs. Surprisingly, irrespective of the processing and thermal treatment history, all samples exhibit similar levels of SRO. Atomistic simulations reveal that during solidification, prevalent local chemical order arises in the liquid-solid interface (solidification front) even under the extreme cooling rate of 10 11 K s –1 . This phenomenon stems from the swift atomic diffusion in the supercooled liquid, which matches or even surpasses the rate of solidification. Therefore, SRO is an inherent characteristic of most FCC MPEAs, insensitive to variations in cooling rates and even annealing treatments typically available in experiments.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Design of a Structure for Assembly and Cooling the Magnet of the Next-Generation 45 GHz ECR Ion Source MARS-D

Here, the current Electron Cyclotron Resonance Ion Sources (ECRISs), constructed with Nb-Ti wires and the conventional racetrack-and-solenoid structure, have achieved operating frequencies up to 28 GHz and utilized about 90% of the critical current of the Nb-Ti wire. A Mixed Axial and Radial field System Demonstrator (MARS-D) is being developed at Lawrence Berkeley National Laboratory (LBNL). This system, which consists of an innovative hexagonal Closed-Loop Coil (CLC) and a set of solenoids, can generate higher magnetic fields (up to 150% ) while requiring only about 50% of the superconducting wire, enabling Nb-Ti wires to be used in the next-generation 45 GHz ECRIS. However, the assembly and cooling of such an efficient and compact magnet are particularly challenging due to the small radial gap between the CLC and solenoids, as well as the tight operating temperature margin. To address these challenges, a structure was developed that combines a three-section radially split solenoid mandrel with a series of shrink-fit reinforcement rings and cooling channels. This paper presents the detailed structure, manufacturing method, assembly procedure, impregnation method, mechanical Finite Element Analysis (FEA) comparison, and thermal FEA comparison.

ECR ion sources↗
DOE OSTI2026

Thermal Studies of CMS High-Granularity Calorimeter (HGCAL) Cassettes for the HL-LHC Upgrade

The CMS High Granularity Calorimeter (HGCAL) is a key endcap upgrade for the High-Luminosity LHC, designed to operate in an environment of extreme radiation and high particle rates. Each HGCAL cassette integrates silicon and scintillator modules, front-end ASICs, and a copper cooling plate that provides both mechanical integrity and thermal coupling using two-phase CO₂ cooling. Stable and uniform temperature control is essential to ensure reliable performance of the front-end electronics and to limit radiation-induced leakage currents in the silicon sensors. We present results from thermal characterization studies of pre-series HGCAL cassettes assembled and tested at Fermilab. Embedded RTD/PT1000 temperature sensors were used to measure gradients across copper cooling plates, module layers, and cassette edges under powering conditions representative of operation. The measured thermal behavior demonstrates effective heat transport through the cassette stack and highlights small but systematic variations correlated with geometry and assembly tolerances. These results validate the cooling performance of HGCAL cassettes.

Wang, Jinglu [Northwestern U.]↗
DOE OSTI2025

Effects of Landau quantization on neutrino emission and absorption

Some neutron stars known as magnetars possess very strong magnetic fields, with surface fields as large as 10 15 G and internal fields that are possibly stronger. Recent observations of the radio pulsar GLEAM-X J1627 suggest it may have a surface field as strong as 10 16 G. In the presence of a strong magnetic field, Leinson and Perez showed and Baiko and Yakovlev confirmed that the energy levels of electrons and protons are quantized and the direct Urca process allows neutron stars to cool rapidly, even at low density. For the case of magnetic fields 𝐵 ≳ 10 16 G, we find features in the emissivity due to energy quantization that are not captured by the frequently employed quasiclassical approximation where energy levels are treated as nearly continuous. Resonances can result in amplification of the neutrino emissivity at specific densities compared to a calculation that neglects quantization, particularly at low temperature. These effects are not important for the thermal evolution of an entire neutron star, but may be relevant for phenomena that depend on behavior at specific densities. Here, we present a fully relativistic calculation of the direct Urca rate in a strong magnetic field using the standard V-A weak Lagrangian incorporating mean field nuclear effects and discuss approaches to the numerical challenge the modified wave functions present and a new semianalytic approximation. These tools are also applicable to calculating neutrino opacities in strong magnetic fields in the ejecta of binary neutron star mergers. We calculate the opacities for neutrinos capturing on free nucleons at subsaturation densities and temperatures exceeding an MeV. We find an enhancement to capture processes of the lowest energy neutrinos by an order of magnitude or more due to suppression of electron Pauli blocking in the case of capture on neutrons, and from the effect of the nucleon magnetic moments in the case of capture on protons.

astrophysical electromagnetic fields↗