Combining AM and FAST for Multi-Functional Refractory Plasma Facing Materials
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36 MATERIALS SCIENCE↗
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Research and Development to Reduce Impurity Production and Transport of the Impurities to the Target in Linear Plasma Devices Using Helicon Plasma Sources
Linear plasma devices used to test plasma facing materials (PFMs) and components for fusion reactors are often suffering under the production of intrinsic impurities from the plasma source system. Most linear plasma devices use internal electrodes (hollow cathodes, reflex arc, or cascading arc), which typically are the source of the main impurities. The next-generation plasma generators use radio frequency (RF) plasma sources like helicons to avoid internal electrodes. However, high power operation of helicons has proven to result in impurity production due to the high rectified sheath voltages created. Depending on the plasma parameters and magnetic configuration, these impurities can be transported to the target and deposited there to unacceptable high levels. Here, in this contribution, the experimental results from Proto-MPEX are summarized, and the conclusions of the impurity source physics are given. Methods to reduce the impurity production, the impurity transport, and the net deposition on the target are presented. These methods to reduce the impurity production include Faraday screens to reduce the sheath voltage drop, high-Z refractory coatings to reduce the erosion yield, and wall conditioning methods. Methods to reduce the impurity transport include changes in the magnetic configuration as well as electron heating to change axial and radial temperature profiles. Preliminary results on the effectiveness of some of these methods are presented.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Temperature effects of ion irradiation on the nanostructural features in ductile-phase-toughened tungsten composites
Ductile-phase toughened tungsten (DPT W) composites have emerged as promising candidates for load-bearing components behind the plasma-facing tungsten armor in fusion reactors due to their enhanced thermomechanical properties. This study focuses on a composite consisting of W particles embedded in a ductile NiFeW solution matrix, hot-rolled to a thickness reduction of 87% (87R DPT W). Sequential irradiations with Ni2+ and He+ ions were performed to identical doses and helium concentrations at room temperature (RT) and 1273 K. Irradiation at RT produced no discernible nanostructural features due to the immobility of mono-vacancies, whereas cavity formation was observed at 973 K. At 1273 K, the W phase exhibited larger cavities, reduced cavity number density, and lower volumetric swelling compared to 973 K. Notably, nanosized NiFeW precipitates formed within the W phase at 1273 K, a phenomenon absent at 973 K. A new phase of cubic (NiFe)6W6C was also observed at the interphase boundary. In contrast, the NiFeW matrix showed no nanostructural changes at 1273 K, likely due to cavity dissociation. Separate irradiations at 1273 K indicated that Ni2+ ions induced precipitate formation in the W phase, while He+ ions exclusively caused cavity formation. The microstructure of 87R DPT W irradiated at RT and subsequently annealed at 1273 K closely resembled that of material irradiated directly at 1273 K. Like oxide-dispersion-strengthened steels, the observed nanoparticle-embedded W can inhibit dislocation propagation, potentially delaying the ductile-to-brittle transition temperature. These findings highlight the potential of NiFeW nanoparticle-reinforced W composites as irradiation-resistant materials for fusion reactors.
Jiang, Weilin (ORCID:0000000183028313)↗
Down-selection of Innovative Fusion Materials
The goal of this proposal is to develop and fundamentally understand the microstructure of refractory multi-component alloys (MCA) as fusion-relevant plasma facing and structural materials, a step to down-select innovative fusion materials prior to the process of advancing their technology readiness level (TRL). Developing materials is paramount to enable fusion as energy source since no existing material is capable of coping with such extreme conditions. We will aim at understanding the role of chemistry and microstructure in these complex multi-component alloys systematically comparing their performance with pure tungsten materials in terms of mechanical properties and manufacturability. Such understanding will open opportunities to optimize MCAs for fusion applications and has a potential of attracting industry partnership.
36 MATERIALS SCIENCE↗
Simulation of Channel Flow with Square Ribs for Blanket First-Wall Cooling: Geometry-Specific Tuning of k-ω Model Using Adjoint Method
Cooling of the plasma-facing first wall is challenging in the design of blanket components because of the high heat flux (on the order of 𝑀𝑊/𝑚2) from the plasma, especially when a low thermal mass medium like helium is chosen as the coolant. Therefore, heat transfer enhancement in which the convective heat transfer rate is augmented by the addition of turbulence-promoting structures becomes a key initiative for providing sufficient cooling capability with helium. Previously, computational fluid dynamics simulations had been performed on pipe flows with different transverse and longitudinal ribbed geometries at Oak Ridge National Laboratory to compare the enhancement performance among different ribbed geometries. Rib shape morphing had been conducted to obtain an optimized rib profile. In the work presented here, the adjoint method is adopted in the ANSYS Fluent solver for turbulence model augmentation, and the Generalized k-ω (GEKO) turbulence model is employed because of its ability of tuning the turbulence model. The Nusselt number and pressure drop obtained from the channel flow with bottom ribbed wall experiments are used as the targets. Sensitivity analysis provides information as guidance to improve the turbulence model accuracy. The augmented GEKO model is tuned for the studied ribbed channel geometry and flow conditions, providing improved predictive accuracy within this context. Extension to other configurations offers potential but may require additional tuning and validation.
Xu, Tracy [ORNL] (ORCID:0009000193700887)↗
An Experimental Investigation of the Effects of Charging on the International Space Station
An experimental investigation has been undertaken to determine the effects associated with operating the International Space Station (ISS) without a Plasma Contactor Unit (PCU). The role of the PCU is to maintain the potential of the ISS to within 40 volts of the ambient plasma potential. In the event of a PCU failure, ISS structure may charge to - 160 volts with respect to the Low Earth Orbit (LEO) plasma, due to the use of high voltage photovoltaic solar arrays. Operation without a PCU will result in the charging of the oxide layers on anodized aluminum components facing into the RAM direction. In this investigation, arcs were observed as a result of anodized materials charging in a plasma environment. Actual ISS materials were used in the investigation. The materials included meteoroid and debris shield samples, as well as components from the Extravehicular Mobility Unit (EMU). Results show that the occurrence of arcs was dependent on several factors including material composition and applied voltage. The breakdown thresholds for the materials tested will be shown, as well as the voltage and current waveforms during an arc event. The damage resulting from an arc will also be described. In addition, a description of associated operational hazards resulting from arcing on the spacecraft will be provided.
Schneider, Todd↗
Bonding of vanadium- and Iron-based alloys as interlayers for plasma-facing and structural materials in fusion systems
Vanadium alloys and FeCrAl were investigated as interlayers between tungsten and reduced activation ferritic martensitic steel for fusion system components to avoid formation of intermetallic phase at operating temperatures between 550 and 1100 °C, while maintaining a body centered cubic phase throughout the interface. Physical and mechanical properties need to be graded between tungsten and steel, but recent results showed a significant hardness increase at the FeCrAl to vanadium alloy interface. Here, a sintered sample of these alloys was annealed for extended time, and the microstructure was investigated to provide a better understanding of the phenomena. A comparison with an additively manufactured interface of the same material is provided. An unexpected L2 1 intermetallic phase formation has been revealed using microscopy and synchrotron techniques and will inform future additive manufacturing approaches of the interface. A Cr layer interface as a preliminary solution was proposed between the Vanadium alloy and FeCrAl alloy interface.
Additive manufacturing↗
Erosion of high-Z refractory coatings for helicon plasma source window
Proto-MPEX (Materials Plasma Exposure eXperiment), a linear plasma device (LPD), using a high power radio frequency (RF) (⩾100 kW, 13.56 MHz) helicon plasma source, has suffered RF sheath-induced window erosion. The sputtered impurities from the window surface transport toward the downstream target affecting plasma-material interaction studies. The rectified sheath voltage formed was high enough to cause window erosion by light ions due to its low-Z components (e.g. Si 3 N 4 and AlN). Hence, we are proposing impurity mitigation strategies, which involve the application of a Faraday screen to lower the rectified sheath voltage and the application of high-Z refractory coatings on the existing window plasma-facing surface. In this work, we report the erosion of two different coatings, i.e., tantalum oxide (Ta 2 O 5 ) and hafnium oxide (HfO 2 ) on a silicon nitride (Si 3 N 4 ) window material under conditions of low-energy deuterium (D) ion impact, well below the Ta 2 O 5 sputtering energy threshold (i.e. 250 eV). The test samples were RF-biased and exposed to a high D-ion fluence (∼10 26 m −2 ) in Plasma Interaction with Surface Component Experimental Station (PISCES-A) LPD. The experimentally measured sputtering yields of the high-Z refractory coatings below the sputtering energy threshold of Ta 2 O 5 indicate an increased erosion due to the plasma impurities, especially due to oxygen. Improving the vacuum level could reduce the oxygen impurities and increase the lifespan of the coated helicon window for plasma operation. Post-surface analysis indicates no preferential erosion of oxygen or enrichment of the high-Z surface component. This is likely due to an effective energy transfer from the impurity ion for sputtering of the high-Z component in the coating. With the reduced rectified sheath voltage at the window surface and improved vacuum conditions, the proposed high-Z refractory coatings offer a promising solution for reducing window erosion in future MPEX plasma operations at ORNL.
RF bias↗
Comprehensive analysis of disruption mitigation methods using gas and pellet-like injections in ITER-like Tokamaks
Abstract Inert-gas shielding could be an effective mechanism for protection of plasma facing surfaces (PFS) against plasma particles impact and photon radiation heat loads during transient events in fusion devices. Neutral gas injection is one promising way to mitigate erosion of tokamak components and contamination. The objective of this work is to study and optimize mitigation methods using neutral gas and pellet-like injections to decrease the heat load to the divertor surfaces and to prevent vaporization of the various internal surfaces due to transient events in ITER-like devices. The integrated self-consistent models implemented in the HEIGHTS package was used for detailed analysis of the potential secondary plasma generation from the injected inert gas, its radiative characteristics, and shielding effectiveness. We varied the density, size, and location of an argon gas cloud to minimize the disruption energy deposited into the divertor components. We also investigated innovative ways for minor changes in ITER-like internal design to mitigate disruptions. We found the optimum parameters to fully protect ITER tokamak surfaces from erosion and vaporization during plasma instabilities. This preliminary analysis showed that using Ar gas injection methods could lead to enhancement in components lifetime in ITER-like and future DEMO devices with minor design changes.
Science & Technology - Other Topics↗
Directed energy deposition of functionally graded V-4Cr-4Ti to Fe-9Cr transition for fusion power systems
This study proposes a graded structure via additive manufacturing for divertor and first wall blanket applications in fusion reactors. Materials were selected based on thermodynamic calculations to operate from 1100 °C at the plasma-facing level to 550 °C at the structural steel level. Conventional joining methods often lead to failures due to discrete reaction layers with significant mechanical property differences. Using laser beam-directed energy deposition (LB-DED), this study demonstrates the fabrication of a VCrTi-Gr91 steel functionally graded component through a novel process parameter optimization framework. A systematic approach included powder characterization, single-track depositions, and construction of printability maps. Near full-density specimens of each interlayer were additively manufactured, and a transition from V-based alloys to reduced activation ferritic martensitic steels was achieved. Computational material selection of interlayer alloys and thermodynamic/diffusion kinetics simulations prevented most interface incompatibilities. A brittle intermetallic formed at one interface, causing cracking, which was not predicted by current thermodynamic models. Transition alloy design approach was updated with a more recent database and a mitigation strategy has been proposed to eliminate the formation of deleterious intermetallic phases. Ultimately, LB-DED has proven effective for producing multi-material graded systems for fusion applications, with the demonstrated process parameter optimization framework applicable to various materials.
Additive manufacturing↗
Orthostatic stress is necessary to maintain the dynamic range of cardiovascular control in space
In the upright position, gravity fills the low-pressure systems of human circulation with blood and interstitial fluid in the sections below the diaphragm. Without gravity one pressure component in the vessels disappears and the relationship between hydrostatic pressure and oncotic pressure, which regulates fluid passage across the capillary endothelium in the terminal vascular bed, shifts constantly. The visible consequences of this are a puffy face and "bird" legs. The plasma volume shrinks in space and the range of cardiovascular control is reduced. When they stand up for the first time after landing, 30-50% of astronauts suffer from orthostatic intolerance. It remains unclear whether microgravity impairs cardiovascular reflexes, or whether it is the altered volume status that causes the cardiovascular instability following space flight. Lower body negative pressure was used in several space missions to stimulate the cardiovascular reflexes before, during and after a space flight. The results show that cardiovascular reflexes are maintained in microgravity. However, the astronauts' volume status changed in space, towards a volume-retracted state, as measurements of fluid-regulating hormones have shown. It can be hypothesized that the control of circulation and body fluid homeostasis in humans is adapted to their upright posture in the Earth's gravitational field. Autonomic control regulates fluid distribution to maintain the blood pressure in that posture, which most of us have to cope with for two-thirds of the day. A determined amount of interstitial volume is necessary to maintain the dynamic range of cardiovascular control in the upright posture; otherwise orthostatic intolerance may occur more often.
manned↗
Avoidance of disruptions on KSTAR due to vertical displacement events via novel real-time stability assessment
Disruption avoidance via the DECAF approach has been achieved on KSTAR using a novel real-time vertical stability assessment and a multiactuator feedback control strategy. The development of disruption avoidance strategies with reactor-relevant reliability is an urgent activity, enabling future fusion power plants. The stability metric employed is based on a new formulation of a vertical force gradient balance metric evaluated across the poloidal cross section of the plasma, with parameters tuned using historical data. Evaluation of this metric on a validation set of 400 recent KSTAR shots indicates >82% of Vertical displacement events can be avoided via feedback control. Essential to its calculation is the two-dimensional toroidal current density distribution in the plasma. Measurement of this profile faster than fully-converged equilibrium reconstructions can deliver is found to improve forecaster performance and is achieved with a surrogate model that takes as input magnetic diagnostic measurements and outputs the current profile on a basis comprising the top principal components of historical current profiles (from past equilibrium reconstructions). This method solves the non-uniqueness problem typically faced when reconstructing current profiles directly from diagnostics, while improving computational time and accuracy. On average, profiles produced by this model reach coefficients of determination of >0.99 with respect to those from equilibrium reconstructions. The avoidance actuators employed include poloidal field coils and an electron cyclotron current drive system. The multiactuator approach, as shown in this first demonstration, allows disruption avoidance while minimizing impact to operational performance. This ability, along with its flexibility and speed, makes this new approach an attractive option for avoiding these types of disruptions in reactors.
Tobin, Matthew [Columbia Univ., New York, NY (Unit↗
The origin and energetics of CTB 80
Deep narrow-band images of the core of the unusual supernova remnant CTB 80 are presented, and the origin and energetics of the remnant are discussed. Based on a description of the core as a wind-blown bubble or bow shock around a pulsar, a scenario is presented relating the core and extended components to a single supernova explosion about 100,000 yr ago. The physical nature of the interface between the pulsar wind and the ambient thermal plasma is considered, and it is concluded that the pulsar is probably moving through shock-compressed material associated with the evolved remnant. It is argued that the core geometry is probably a bow shock viewed partially face-on.
Hester, J. Jeff↗
NASA Tech Briefs, June 2005
Topics covered include: Apparatus Characterizes Transient Voltages in Real Time; Measuring Humidity in Sealed Glass Encasements; Adaptable System for Vehicle Health and Usage Monitoring; Miniature Focusing Time-of-Flight Mass Spectrometer; Cryogenic High-Sensitivity Magnetometer; Wheel Electrometer System; Carbon-Nanotube Conductive Layers for Thin-Film Solar Cells; Patch Antenna Fed via Unequal-Crossed-Arm Aperture; LC Circuits for Diagnosing Embedded Piezoelectric Devices; Nanowire Thermoelectric Devices; Code for Analyzing and Designing Spacecraft Power System Radiators; Decision Support for Emergency Operations Centers; NASA Records Database; Real-Time Principal- Component Analysis; Fuzzy/Neural Software Estimates Costs of Rocket- Engine Tests; Multicomponent, Rare-Earth-Doped Thermal-Barrier Coatings; Reactive Additives for Phenylethynyl-Containing Resins; Improved Gear Shapes for Face Worm Gear Drives; Alternative Way of Shifting Mass to Move a Spherical Robot; Parylene C as a Sacrificial Material for Microfabrication; In Situ Electrochemical Deposition of Microscopic Wires; Improved Method of Manufacturing SiC Devices; Microwave Treatment of Prostate Cancer and Hyperplasia; Ferroelectric Devices Emit Charged Particles and Radiation; Dusty-Plasma Particle Accelerator; Frozen-Plug Technique for Liquid-Oxygen Plumbing; Shock Waves in a Bose-Einstein Condensate; Progress on a Multichannel, Dual-Mixer Stability Analyzer; Development of Carbon- Nanotube/Polymer Composites; Thermal Imaging of Earth for Accurate Pointing of Deep-Space Antennas; Modifications of a Composite-Material Combustion Chamber; Modeling and Diagnostic Software for Liquefying- Fuel Rockets; and Spacecraft Antenna Clusters for High EIRP.
Source record↗
Covisualization in living onion cells of putative integrin, putative spectrin, actin, putative intermediate filaments, and other proteins at the cell membrane and in an endomembrane sheath
Covisualizations with wide-field computational optical-sectioning microscopy of living epidermal cells of the onion bulb scale have evidenced two major new cellular features. First, a sheath of cytoskeletal elements clads the endomembrane system. Similar elements clad the inner faces of punctate plasmalemmal sites interpreted as plasmalemmal control centers. One component of the endomembrane sheath and plasmalemmal control center cladding is anti-genicity-recognized by two injected antibodies against animal spectrin. Immunoblots of separated epidermal protein also showed bands recognized by these antibodies. Injected phalloidin identified F-actin with the same cellular distribution pattern, as did antibodies against intermediate-filament protein and other cytoskeletal elements known from animal cells. Injection of general protein stains demonstrated the abundance of endomembrane sheath protein. Second, the endomembrane system, like the plasmalemmal puncta, contains antigen recognized by an anti-beta 1 integrin injected into the cytoplasm. Previously, immunoblots of separated epidermal protein were shown to have a major band recognized both by this antibody prepared against a peptide representing the cytosolic region of beta 1 integrin and an antibody against the matrix region of beta 1 integrin. The latter antiboby also identified puncta at the external face of protoplasts. It is proposed that integrin and associated transmembrane proteins secure the endomembrane sheath and transmit signals between it and the lumen or matrix of the endoplasmic reticulum and organellar matrices. This function is comparable to that proposed for such transmembrane linkers in the plasmalemmal control centers, which also appear to bind cytoskeleton and a host of related molecules and transmit signals between them and the wall matrix. It is at the plasmalemmal control centers that the endoplasmic reticulum, a major component of the endomembrane system, attaches to the plasma membrane.
Non-NASA Center↗
Long-Duration Wear Testing of the ASTRAEUS Thruster, Phase I: 50 kg Xe Throughput
The thruster component of the Ascendant Sub-kW Transcelestial Electric Propulsion System successfully completed a propellant throughput demonstration of 50 kg Xe. The thruster was operated for a total of 3,287 h, of which 97.9% was spent at 300 V – 1000 W, and generated 790 kN-s of total impulse. Thrust, telemetry, and temperature measurements periodically recorded at four operating conditions spanning 200 – 500 V and 200 – 1000 W revealed constant performance across the full test duration. High-fidelity plasma simulations of the erosion of the thruster’s downstream faces suggest a theoretical lifetime capability of >30 kh, corresponding to propellant throughput of >450 kg Xe and a total impulse of >7 MNs, at the 300 V – 1000 W operating condition. The test was voluntarily paused after 50 kg Xe throughput to take these erosion measurements before the test was resumed at a different operating condition.
Goebel, Dan↗
Optical Characterization of Component Wear and Near-Field Plasma of the Hermes Thruster
Optical emission spectral (OES) data are presented which correlate trends in sputtered species and the near-field plasma with the Hall-Effect Rocket with Magnetic Shielding (HERMeS) thruster operating condition. The relative density of singly-ionized xenon (Xe II) is estimated using a collisional-radiative model. OES data were collected at three radial and several axial locations downstream of the thruster's exit plane. These data were deconvolved to show the structure for the near-field plasma as a function of thruster operating condition. The magnetic field is shown to have a much greater affect on plasma structure than the discharge voltage with the primary ionization/acceleration zone boundary being similar for all nominal operating voltages at constant power. OES measurement of sputtered boron shows that the HERMeS thruster is magnetically shielded across its operating envelope. Preliminary assessment of carbon sputtered from the keeper face suggest it increases significantly with operating voltage, but the uncertainty associated with these measurements is very high.
Electric Propulsion↗
Texturing Blood-Glucose-Monitoring Optics Using Oxygen Beams
A method has been invented for utilizing directed, hyperthermal oxygen atoms and ions for texturing tips of polymeric optical fibers or other polymeric optical components for use in optical measurement of concentration of glucose in blood. The required texture of the sensory surface of such a component amounts to a landscape of microscopic hills having high aspect ratios (hills taller than they are wide), with an average distance between hills of no more than about 5 m. This limit on the average distance between hills is chosen so that blood cells (which are wider) cannot enter the valleys between the hills, where they could obstruct optical sensing of glucose in the blood plasma. On the other hand, the plasma is required to enter the valleys, and a high aspect ratio is intended to maximize the hillside and valley surface area in contact with the plasma, thereby making it possible to obtain a given level of optical glucose- measurement sensitivity with a relatively small volume of blood. The present method of texturing by use of directed, hyperthermal (particle energy >1 eV) oxygen atoms and ions stands in contrast to a prior method of texturing by use of thermal monatomic oxygen characterized by a temperature of the order of 0.5 eV. The prior method yields low-aspect- ratio (approximately hemispherical) craters that are tens of microns wide . too wide to exclude blood cells. The figure schematically depicts parts of a typical apparatus for texturing according to the present method. One or more polymeric optical components to be textured (e.g., multiple optical fibers bundled together for simultaneous processing) are mounted in a vacuum chamber facing a suitable ion- or atom-accelerating device capable of generating a beam of oxygen atoms and/or ions having kinetic energies >1 eV. Typically, such a device includes a heated cathode, in which case it is desirable to interpose a water-cooled thermal-radiation shield to prevent melting of the polymeric component(s) to be textured. In operation, the chamber is evacuated to a pressure .10.5 torr (less than or equal to approximately 1.3 mPa), then the beam is turned on. The resulting texture is characterized by approximately conical hills having aspect ratios greater than 1. In experiments, it was demonstrated that separations between adjacent hills can be made .1 m and that the separations and heights of the hills can be varied by varying the fluence of monatomic oxygen and/or oxygen ions.
Banks, Bruce↗