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DOE OSTI2025

Self-consistent modeling of tokamak edge plasma transport with lithium sources

Magnetic confinement fusion devices require effective heat and particle exhaust solutions on the divertor plates to operate sustainably, especially under reactor-relevant conditions. Liquid lithium divertors have been proposed to address two major challenges: control of excessive heat flux to plasma-facing components through vapor shielding and minimization of core plasma contamination from impurities. The National Spherical Torus Experiment-Upgrade (NSTX-U) will explore lithium as a divertor material due to its potential to meet both objectives. We present a self-consistent coupling framework between the plasma boundary transport code UEDGE and the lithium wall transport code Wall–Li to evaluate the feasibility and operational limits of lithium-based divertors. The model aims to optimize lithium sourcing levels to prevent core plasma contamination via fuel dilution while ensuring divertor protection through vapor shielding. This integrated framework, applicable to any tokamak with lithium sources, dynamically adjusts lithium sourcing based on local plasma conditions and surface temperature. The coupled model is tested using NSTX-like geometry and plasma conditions to assess its performance and reliability. Wall–Li calculates lithium fluxes from plasma-facing components, incorporating physical sputtering, thermally enhanced sputtering, and evaporation driven by surface temperature and ion flux. These fluxes are reintroduced into UEDGE as neutral lithium atoms, enabling simulation of their transport and distribution within the plasma. UEDGE computes plasma and neutral transport, surface heat flux, and iteratively feeds this information back to Wall–Li. A small time step is employed to ensure numerical stability and convergence, enabling accurate simulations over typical tokamak discharge durations. This integrated modeling approach provides a robust tool for identifying operational regimes that balance effective lithium sourcing with minimal core plasma contamination, offering critical insights for optimizing lithium-based divertor systems in current and future fusion devices.

Magnetic confinement fusion↗

DOE OSTI2024

Secondary Beamline Lattice Design at the MeV Test Area (MTA)

The MTA is currently configured to produce a secondary pion beam from a tungsten target, which subsequently generates muons from decay in flight. In its present lattice configuration, the currently installed air core quadrupoles are strength-limited in their ability to deliver a high muon flux to the end user. Recently, seven strong iron-core quadrupole spares from the 400-MeV Linac were acquired. Based on these quadrupoles, a new lattice has been designed that maximizes both pion transport and muon capture the line based on significantly shorter magnetic lengths, strong magnetic gradients, and consequently an enhanced angular acceptance. For this project, we demonstrated that the ratio of muons to pions increased by over an order of magnitude (approximately 75 for lattice configurations were studied), successfully capturing a phase space area as large as 13.2 [mm] x 24 [mRad] in simulation.

Winter, Wesley↗

DOE OSTI2024

Effect of Pressure on Crystal Structure and Phonon Density of States of FeSi

The strongly correlated material FeSi displays several unusual thermal, magnetic, and structural properties under varying pressure-temperature (P-T) conditions. It is a potential thermoelectric alloy and a material with several geochemical implications as a possible constituent at the Earth's core-mantle boundary (CMB). Previous theoretical studies predicted a pressure-induced B20-B2 transition at ambient temperature below 40 GPa; however, experimentally, the structural transition is observed only at high P-T conditions. In this study, we have performed high-pressure powder X-ray diffraction (XRD) up to 90 GPa and Nuclear Resonant Inelastic X-ray Scattering (NRIXS) measurements up to 120 GPa to understand the phase stability and lattice dynamics. Our study provides evidence for a non-hydrostatic stress-induced B20-B2 transition in FeSi at around 36 GPa. We deduced the Fe partial phonon density of states (PDOS) and thermal parameters from NRIXS measurements up to 120 GPa and compared them with density functional theory (DFT) calculations. Furthermore, the computations show pressure-induced metallization and the band gap closing around 12 GPa.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Effect of heteroatom incorporation on electronic communication in metal chalcogenide nanoclusters

Metal chalcogenide nanoclusters (NC), specifically of type TM 6 E 8 (L) 6 (TM = transition metal, E = chalcogen, L = ligand) have garnered attention in recent years as promising catalysts and biosensors due to their remarkable electronic and magnetic properties, as well as their ability to undergo supramolecular assembly into 2D materials. Furthermore, the undercoordinated metal chalcogenide NCs have shown distinct surface reactivity, which is strongly dependent on the composition of the TM core. The differences in the reactivity of the undercoordinated species have been attributed to differences in ligand binding energies. Although ligand binding energies in homometallic NCs have been extensively studied, little is known about the effect of heteroatoms in the core on the strength of ligand binding in metal chalcogenide NCs. In this work, we provide new insights into this topic by examining the relative stability of [Co 6−x Fe x S 8 (PEt 3 ) 6 ] + (x = 0–6) NCs towards fragmentation using collision energy-resolved collision-induced dissociation (CID) experiments. We observe that the ligand binding energy gradually decreases until four Fe atoms are incorporated into the cluster core and then gradually increases until all the Co atoms are replaced with Fe. This experimental trend was compared with the results of density functional theory (DFT) calculations, which indicate drastic differences in the electronic communication between Co and Fe atoms in the TM core. By understanding the effect of heteroatom incorporation on ligand binding energy to the NC core, our work provides important insights into the effect of atom-by-atom substitution on the functional properties of tunable nanostructures.

Havenridge, Shana [Argonne National Laboratory (AN↗

DOE OSTI2026

STM/S Grid LDOS Data and Analysis Code for Deciphering Majorana Zero Modes in Topological Superconductor

This dataset provides raw millikelvin scanning tunneling microscopy/spectroscopy (STM/S) grid spectroscopy data and Python analysis scripts supporting the manuscript “Deciphering Majorana Zero Modes in Topological Superconductor FeTe0.55Se0.45 with Machine-Learning-Assisted Spectral Deconvolution.” The dataset includes a raw grid spectroscopy file acquired on FeTe0.55Se0.45 at 40 mK under magnetic field, together with Python/Jupytext analysis scripts used for STM/S data processing, visualization, spectral deconvolution, Lorentzian peak fitting, feature extraction, machine-learning-assisted clustering, and figure generation. These files support the analysis of vortex-core local density of states and the identification of zero-bias-peak-related spectral components from complex in-gap states. The dataset is intended to provide a citable archival record of the data and analysis code associated with the published manuscript and to support transparency and reproducibility of the reported STM/S and machine-learning workflow.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2024

Regulation of Solar Wind Electron Temperature Anisotropy by Collisions and Instabilities

Abstract Typical solar wind electrons are modeled as being composed of a dense but less energetic thermal “core” population plus a tenuous but energetic “halo” population with varying degrees of temperature anisotropies for both species. In this paper, we seek a fundamental explanation of how these solar wind core and halo electron temperature anisotropies are regulated by combined effects of collisions and instability excitations. The observed solar wind core/halo electron data in ( β ∥ , T ⊥ / T ∥ ) phase space show that their respective occurrence distributions are confined within an area enclosed by outer boundaries. Here, T ⊥ / T ∥ is the ratio of perpendicular and parallel temperatures and β ∥ is the ratio of parallel thermal energy to background magnetic field energy. While it is known that the boundary on the high- β ∥ side is constrained by the temperature anisotropy-driven plasma instability threshold conditions, the low- β ∥ boundary remains largely unexplained. The present paper provides a baseline explanation for the low- β ∥ boundary based upon the collisional relaxation process. By combining the instability and collisional dynamics it is shown that the observed distribution of the solar wind electrons in the ( β ∥ , T ⊥ / T ∥ ) phase space is adequately explained, both for the “core” and “halo” components.

Yoon, Peter H. (ORCID:0000000181343790)↗

DOE OSTI2025

Impact of error fields and error field correction on heat fluxes in SPARC

Using a single toroidal array of coils to reduce the m,n = 2,1 resonant error field (EF) produced by the misalignment of the axisymmetric coils in SPARC can result in the enhancement of the local divertor heat fluxes. Managing high divertor heat fluxes (q ∥ $\simeq$ 10 GW m -2 ) poses a challenge for compact tokamak devices such as SPARC. The presence of non-axisymmetric magnetic field perturbations adds complexity to the problem by generating intricate 3D edge magnetic topologies that alter the heat flux distributions on the target plates. The aim of this work is to investigate the impact of the EF correction (EFC) on the heat fluxes at the divertor plates in SPARC. The MHD code M3DC1 has been used to simulate the 3D magnetic perturbations generated by the shift and tilt of several axisymmetric coils within specified tolerances, as well as from the array of EFC coils located at the midplane. Using a heuristic model that extends the concept of an axisymmetric heat flux layer to 3D plasmas, the resultant heat flux distributions is derived from magnetic footprints calculated with the MAFOT code. The results show that the EFC could either decrease or further enhance the local heat flux when used to correct the m,n = 2,1 resonant EF to enhance the core plasma performance.

3D fields↗

DOE OSTI2024

Enriched Molecular-Level View of Saline Wetland Soil Carbon by Sensitivity-Enhanced Solid-State NMR

Soil organic matter (SOM) plays a major role in mitigating greenhouse gas emission and regulating earth’s climate, carbon cycle, and biodiversity. Wetland soils account for one-third of all SOM; however, globally, coastal wetland soils are eroding faster due to increasing sea-level rise. Our understanding of carbon sequestration dynamics in wetlands lags behind that of upland soils. Here, we employ solid-state nuclear magnetic resonance (ssNMR) to investigate the molecular-level structure of biopolymers in wetland soils spanning 11 centuries. High-resolution multidimensional spectra, enabled by dynamic nuclear polarization (DNP), demonstrate enduring preservation of molecular structures within herbaceous plant cores, notably condensing aromatic motifs and carbohydrates, even over a millennium, with the preserved cores constituting a decreasing minority among molecules from decomposition and repolymerization with depth and age. Such preserved cores occur alongside molecules from the decomposition of loosely packed parent biopolymers. These findings emphasize the relative vulnerability of coastal wetland SOM when exposed to oxygenated water due to geological and anthropogenic changes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Reducing waste of the hydride-dehydride process for U-6 wt% Nb spherical powders through lower impact and targeted milling

The breakdown of solid metal into powder during the hydride-dehydride process is commercially important for the formation of titanium and other metal powders. Typically, the milling of the brittle hydride powder occurs in a ball mill, where milling media impacts powder particles to break them down. The milling media can impact particles that are larger than desired, as desired, or smaller than desired, indiscriminately making all particles smaller. In this work, we investigate how to minimize waste powder production during milling using two different milling methods, planetary ball milling and milling in a sieve shaker (sieve-milling). Both processes yielded similar amounts of 20–75 μm diameter powder (the target size range); however, sieve-milling generated a significantly smaller amount of undersized waste powder. The powders were characterized by X-ray diffraction, SEM/STEM, and magnetic susceptibility. Several differences between ball milling and sieve-milling processes are discussed. We then conclude that the decreased yield of undersized powder in sieve-milling was due to a combination of lower impact energy in sieve-milling, unreacted metallic cores in the hydride flakes, and the ability to mill target particle sizes during sieve-milling. While these results are from the milling of brittle hydride powder, similar methods may be applicable to other brittle powders, including ceramics or salts.

Chemistry↗

DOE OSTI2024

Magnetorotational dynamo can generate large-scale vertical magnetic fields in 3D GRMHD simulations of accreting black holes

ABSTRACT Jetted astrophysical phenomena with black hole engines, including binary mergers, jetted tidal disruption events, and X-ray binaries, require a large-scale vertical magnetic field for efficient jet formation. However, a dynamo mechanism that could generate these crucial large-scale magnetic fields has not been identified and characterized. We have employed three-dimensional global general relativistic magnetohydrodynamical simulations of accretion discs to quantify, for the first time, a dynamo mechanism that generates large-scale magnetic fields. This dynamo mechanism primarily arises from the non-linear evolution of the magnetorotational instability (MRI). In this mechanism, large non-axisymmetric MRI-amplified shearing wave modes, mediated by the axisymmetric azimuthal magnetic field, generate and sustain the large-scale vertical magnetic field through their non-linear interactions. We identify the advection of magnetic loops as a crucial feature, transporting the large-scale vertical magnetic field from the outer regions to the inner regions of the accretion disc. This leads to a larger characteristic size of the, now advected, magnetic field when compared to the local disc height. We characterize the complete dynamo mechanism with two time-scales: one for the local magnetic field generation, $t_{\rm gen}$, and one for the large-scale scale advection, $t_{\rm adv}$. Whereas the dynamo we describe is non-linear, we explore the potential of linear mean field models to replicate its core features. Our findings indicate that traditional $\alpha$-dynamo models, often computed in stratified shearing box simulations, are inadequate and that the effective large-scale dynamics is better described by the shear current effects or stochastic $\alpha$-dynamos.

Astronomy & Astrophysics↗

DOE OSTI2024

Turbulence link to L-mode, I-mode, and H-mode confinement in the DIII-D tokamak

Understanding the physics of low-confinement (L-), improved-confinement (I-), and high-confinement (H-) modes is critical for fusion reactors. The finding herein reports observations of two types of turbulence coexisting near the L-mode edge, one magnetohydrodynamic (MHD)-like and another micro-tearing mode (MTM)-like, linked to the H-mode and I-mode confinement in the DIII-D tokamak. Ion-scale magnetic and density turbulence is measured using a Faraday-effect radial-interferometer-polarimeter and beam-emission-spectroscopy (BES). Broadband turbulence spectra of up to ~600 kHz are observed in two discharges where transitions between L-mode, I-mode, and H-mode occurs. Turbulence is found to be inversely correlated with confinement, meaning lower turbulence power at higher confinement. Distinctively, the high-frequency (HF, >~100 kHz) magnetic turbulence power changes by the most (55%) during transitions primarily involving energy confinement change, whereas the low-frequency (LF, <~100 kHz) magnetic and density turbulence power changes by the most (80%) during transitions primarily involving particle confinement change. The LF turbulence amplitude oscillates with and leads to deuterium-alpha emission oscillations before an H-mode. These results imply that HF turbulence mainly affects energy confinement whereas LF turbulence can affect particle confinement. The magnetic and density turbulence exhibits coherence up to 0.6 and cross-phase magnitude close to π/2 in most cases, suggesting they have a common origin in both the LF and HF ranges. BES suggests that LF turbulence resides at the edge (ρ = 0.95) and HF turbulence can be at the outer core (ρ = 0.8) or edge (ρ = 0.95). Comparisons of measurements, theory, and gyrokinetic simulations suggest that HF turbulence is MTM-like in all cases, whereas LF turbulence is more consistent with MHD-like modes and the exact instability might change during transitions—except that a drift-wave origin is possible in a low collisionality H-mode. These results suggest that the H-mode involves suppressed MHD-like turbulence, whereas the I-mode mitigates MTM-like turbulence along with largely unchanged MHD-like turbulence.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Electron transport barrier and high confinement in configurations with internal islands close to the plasma edge of W7-X

The low magnetic shear in the Wendelstein 7-X (W7-X) stellarator makes it feasible to shape the separatrix by the large islands constituting an island-divertor, and this can be exploited to access various magnetic configurations, including samples of different internal island sizes and locations. To investigate the configuration effects on the plasma confinement, a configuration scan was performed by changing the coil currents to vary the rotational transform between values 5/4 and 5/6 at the plasma boundary with different power levels (2, 4, 6 MW) of electron cyclotron resonance heating (ECRH) at a maximum plasma density of 8 × 10 19 m -2 . neutral beam injection (NBI) heating was also applied during some configurations of the scan to create a density ramp and access high densities beyond the X2 ECRH cutoff. For the magnetic configurations, where the 5/5 and 5/6 island chains were moved closer to separatrix but remaining inside the last closed flux surface, the electron cyclotron emission shows that an electron temperature, T e , pedestal develops already during ECRH heated plasma buildup phase indicating a transport barrier, and the barrier sustains irrespective of changed plasma heating conditions such as NBI in the later part of discharge. The transport barrier is broken by subsequent fast crashes, observed with multiple plasma diagnostics with characteristics such as tokamak edge localized modes, and the corresponding crash amplitude and frequency vary with plasma pressure. The impact of the transport barrier on plasma confinement can be seen through the increased core T e profile, which could be responsible for the overall increase in the stored diamagnetic energy by approximately 10% for these configurations. After the plasma heating is terminated, a backwards transition to a degraded confinement state is also observed. These observations indicate a configuration triggered high confinement mode in low shear W7-X. This work focuses on the occurrence of this transport barrier for different magnetic configurations and its relation to internal magnetic islands.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Understanding the formation of a low-pressure pedestal in the presence of a strong internal transport barrier in DIII-D high β p plasmas

As a promising scenario for fusion reactors, the high poloidal-beta (β P ) scenario is characterized by a strong large radius internal transport barrier (ITB), which significantly enhances the overall confinement quality and the bootstrap current fraction for fully non-inductive operation. It is frequently observed that in the presence of a strong ITB, the pedestal height is lower and is accompanied by small edge localized modes (ELMs), which further improves the compatibility of a high performance core with an edge solution. A mechanism for the formation of the low pedestal is proposed in this paper. It is found that the strong ITB creates an off-axis bootstrap current to clamp the local safety factor q, and thus the magnetic shear in the outer core/pedestal region is increased. Gyrokinetic simulations with the CGYRO code show that the higher magnetic shear brings the experimental profiles into the range where the growth rate of drift-wave instabilities and thus transport is higher, and therefore a lower pedestal gradient is expected. Here, the combination of low pedestal and high magnetic shear further enhances the turbulent transport across the whole pedestal, consistent with power balance analysis. Such a positive feedback mechanism ultimately results in a lower pressure pedestal as observed in experiments. Under such a low pedestal, linear simulations with BOUT++ predict the growth rates of peeling–ballooning modes to be lower across the whole toroidal mode number spectra, and the nonlinear BOUT++ simulation exhibits lower saturated fluctuation intensity as well, consistent with the experimentally observed lower ELM size.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Description of FY25 Theory and Simulation Performance Target: Development of an integrated modeling framework for fusion reactor design and assessment

The urgency to deliver fusion power is growing now more than ever, with increasing pressure for both public programs and private companies to meet milestones timelines and overcome significant remaining technical challenges to ensure growth of a nascent fusion industry in time to meet rapidly growing clean energy demands. With incredible advancements in computation and years of investment in fusion model development and validation, integrated modeling is poised to fill a key role in accelerating the timeline to a fusion pilot plant (FPP). Future fusion pilot plants will operate in regimes far beyond current experience, and device design will rely on physics-based prediction and extrapolation. Many concepts will also rely on simulation to assess safety (shielding, tritium management, materials activation and lifetimes), economics and scalability before the decision to build. Importantly, integrated simulation can be used to reveal and solve the complexities of system integration that may otherwise not be apparent in physical components or models developed in isolation. New experimental test facilities that produce relevant conditions to validate and resolve key technical challenges for various subsystems (materials, blankets, fuel cycle, etc.) have been repeatedly called for by the fusion community but are not yet realized. Integrated modeling has an important role in identifying realistic load conditions (thermal, electromagnetic, plasma, neutron and photon loads, etc.) and defining the components and experiments for these test facilities in order to ensure meaningful validation that sufficiently reduces modeling uncertainties and technical risk for the full integrated reactor. The Fusion REactor Design and Assessment (FREDA) SciDAC project is building a component-based integrated modeling framework & data structure to enable self-consistent, multi-fidelity, iterative optimization workflows for the fusion reactor design process. FREDA aims to shorten the time to viable designs by providing a set of flexible workflows to support the various stages of the design process using an integrated model hierarchy, ranging from the simple analytic descriptions to the highest fidelity, theory-based plasma and engineering modeling developed by the fusion and fission communities. These tools are expected to be needed for timely support of FPP design in the milestone program and in the FIRE collaboratives. The plasma simulation backbone of FREDA is IPS-FASTRAN with newly developed coupled Core-Edge Pedestal-SOL (CESOL) workflows, which is being extended to the far-SOL region up to the plasma facing components. FREDA incorporates the FERMI engineering modeling suite and will enable self-consistent evaluation of the thermal shields, limiters, blanket, magnets, and other surrounding structures with predictions of temperatures, erosion, dpa, activation, tritium generation and transport, creep, corrosion, material degradation, etc. Parametric generation of 3D CAD enables rapid iteration of component geometry in response to plasma and loading specifications.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Discovery of a Ferromagnetic Nickel Chalcogenide Nanocluster Ni 3 S 3 H(PEt 3 ) 5

Atomically precise ligated nanoclusters (NC) are promising cluster-based materials with novel molecular architectures and tunable magnetic properties. Herein, the synthesis and characterization of a nickel sulfide NC Ni 3 S 3 H(PEt 3 ) 5 (PEt 3 = triethylphosphine) with distinct magnetic properties are reported. Magnetization measurements reveal its magnetic moment of 1.5 µ B in the solid phase, consistent with the existence of one unpaired electron predicted by density functional theory (DFT) calculations. Additionally, experimental measurements indicate the presence of ferromagnetic ordering within each Ni 3 S 3 H(PEt 3 ) 5 NC and strong coercivity at temperatures below 20 K. Ion mobility-mass spectrometry is employed in conjunction with DFT calculations and collision cross-section simulations to investigate the structure of the isolated Ni 3 S 3 H(PEt 3 ) 5 . Theoretical studies show that [Ni 3 S 3 H(PEt 3 ) 5 ] + has a planar Ni 3 S 3 core where three Ni atoms are arranged in a triangle with three bridging S atoms residing in the same plane. This structure is preserved in both solution and solid phases, which is confirmed by spectroscopic studies of Ni 3 S 3 H(PEt 3 ) 5 . Additionally, DFT calculations indicate that all spins at the Ni sites are aligned parallel, confirming the presence of ferromagnetic coupling. Overall, this study provides key insights into the structure and magnetic properties of Ni 3 S 3 H(PEt 3 ) 5 , which will facilitate the design of new NC-based magnetic materials.

Nickel sulfide nanocluster↗

DOE OSTI2024

Full-wave simulations on helicon and parasitic excitation of slow waves near the edge plasma

Helicon waves are thought to be promising in various tokamaks, such as DIII-D, because they can penetrate reactor-grade high-density cores and drive the off-axis current with higher efficiency. In the frequency regime ~476 MHz, both slow electrostatic and fast electromagnetic helicon waves can coexist in DIII-D. If the antenna parasitically excites the slow mode, these waves can propagate along the magnetic field line into the scrape-off layer (SOL). Although the importance of the misalignment of the Faraday screen and the electron density in the SOL on the excitation and propagation of slow modes is well known, the conditions for minimizing slow mode excitation have yet to be optimized. Using the Petra-M simulation code in the 2D domain, we analyze the effects of the misalignment of the antenna in the poloidal direction, the misalignment of the Faraday screen in the toroidal direction, and the density in front of the antenna on slow mode generation. Our results suggest that the misalignment of the Faraday screen is a critical factor in reducing the slow mode and that the misalignment angle should be below ~5° to minimize the slow wave excitation. When the electron density is higher than 3.5 x 10 18 m –3 in the SOL, the generation of the slow mode from the antenna is minimized and unaffected by the misalignment of the Faraday screen.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Nondestructive flash cathode recycling

Effective recycling of end-of-life Li-ion batteries (LIBs) is essential due to continuous accumulation of battery waste and gradual depletion of battery metal resources. The present closed-loop solutions include destructive conversion to metal compounds, by destroying the entire three-dimensional morphology of the cathode through continuous thermal treatment or harsh wet extraction methods, and direct regeneration by lithium replenishment. Here, we report a solvent- and water-free flash Joule heating (FJH) method combined with magnetic separation to restore fresh cathodes from waste cathodes, followed by solid-state relithiation. The entire process is called flash recycling. This FJH method exhibits the merits of milliseconds of duration and high battery metal recovery yields of ~98%. After FJH, the cathodes reveal intact core structures with hierarchical features, implying the feasibility of their reconstituting into new cathodes. Relithiated cathodes are further used in LIBs, and show good electrochemical performance, comparable to new commercial counterparts. Life-cycle-analysis highlights that flash recycling has higher environmental and economic benefits over traditional destructive recycling processes.

25 ENERGY STORAGE↗

DOE OSTI2026

Additive Manufacturing of Cryogenic Austenitic Steel JK2LB via Wire-Fed Directed Energy Deposition (DED) for Fusion Energy Applications

This study explores the feasibility of fabricating cryogenic austenitic steel JK2LB via both laser-based directed energy deposition (laser-DED) and arc-based directed energy deposition (arc-DED) additive manufacturing processes for potential application in fusion reactors. JK2LB, a low-nickel, high-manganese stainless steel developed for ITER, offers excellent cryogenic toughness, radiation resistance, and decay-to-clearance characteristics. Although JK2LB was originally designed to endure cyclic stresses at cryogenic temperatures in tokamaks, its low-temperature mechanical integrity and radiation tolerance also make it a promising candidate for structural components, such as the coil case/support structure in nonplanar high-temperature superconducting magnet assemblies in stellarators. Directed energy deposition (DED) additive manufacturing was selected for this study due to its capability to fabricate large structures with complex geometries. Here, to address the long lead time and high cost associated with acquiring conventional JK2LB solid wire, JK2LB powder-cored wire was developed as the feedstock material. Testing blocks were then fabricated using both wire-fed laser-DED and arc-DED processes. Microstructural and compositional analyses revealed that both DED approaches yield fully austenitic phase and columnar grain structures. Mechanical testing at room temperature revealed that both DED routes achieved yield strength and elongation comparable to those of conventionally processed JK2LB via vacuum melting, electroslag remelting, extrusion, and drawing, though ultimate tensile strength was reduced due to Mn loss and large columnar grains. As a study mainly focusing on the additive manufacturing process, this work demonstrates the potential of additive manufacturing for fusion energy applications and provides a basis for optimization and future cryogenic mechanical evaluation.

Cryogenic steel↗