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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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12 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Predicting EBW detonator failure using DSC data

Exploding bridgewire detonators (EBWs) containing pentaerythritol tetranitrate (PETN) exposed to high temperatures may not function following discharge of the design electrical firing signal from a charged capacitor. Knowing functionality of these arbitrarily facing EBWs is crucial when making safety assessments of detonators in accidental fires. Orientation effects are only significant when the PETN is partially melted. Here, the melting temperature can be measured with a differential scanning calorimeter. Nonmelting EBWs will be fully functional provided the detonator never exceeds 406 K (133 °C) for at least 1 h. Conversely, EBWs will not be functional once the average input pellet temperature exceeds 414 K (141 °C) for a least 1 min which is long enough to cause the PETN input pellet to completely melt. Functionality of the EBWs at temperatures between 406 and 414 K will depend on orientation and can be predicted using a stratification model for downward facing detonators but is more complex for arbitrary orientations. A conservative rule of thumb would be to assume that the EBWs are fully functional unless the PETN input pellet has completely melted.

42 ENGINEERING↗
DOE OSTI2026

Exploding Bridgewire (EBW) Detonators: An Example of Synergistic Multiphysics

Exploding bridgewire (EBW) detonators are highly temporally reproducible explosive devices that require the rapid discharge of a high‐voltage capacitance to operate and so are immune to most of the accidental hazards associated with traditional electric detonators. They have been demonstrated to be safe enough for use in high‐consequence explosive applications. Despite continued use for over 82 years, understanding the exact mechanism of operation has remained elusive. Various researchers have ascribed either deflagration‐to‐detonation (DDT) or shock‐to‐detonation (SDT) phenomena observed in other explosive events to explain the science behind the successful engineering; however, a rigorous justification has been absent. Previously, we have demonstrated a complex interaction in EBW detonators between large electrical currents, non‐equilibrium thermodynamic material states, plasma physics, powder compaction phenomena, shock physics, photochemistry, and rapid conventional explosive chemical reaction processes. Specifically, we have made progress in understanding the complex multiphysics that operates in these detonators and demonstrating that it is a serendipitous synergy between UV light emitted from the arc formed as the bridge is electrically exploded and the accompanying short‐duration shock transmitted into the explosive powder bed that allows these devices to function at practical capacitor sizes and charge voltages. This insight not only places the topic on a firmer scientific footing but potentially enables new approaches to safe detonator design.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Non-Intrusive Load Monitoring of EBW Processes A Second Study [Slides]

The Objective is to Determine if induced off-nominal welding disturbances: (1) Beam arc out (weld on high vapor pressure aluminum plate); (2) Pulsed beam voltage; (3) Pulsed beam current; and (4) Pulsed beam focus current can be observed in the input power to the high-voltage cabinet powering the EB gun, ie Non-Instrusive Load Monitoring (NILM).

36 MATERIALS SCIENCE↗
DOE OSTI2026

Manufacturing Full-Scale High Gradient Copper Accelerators: Electron Beam Welding and Allied Processes

This DOE ARDAP-funded study examines the technical and business feasibility of manufacturing high-gradient normal conducting RF (NCRF) copper accelerating structures using electron beam welding (EBW) instead of conventional high-temperature brazing. The core motivation is material performance: brazing softens copper significantly, while hard copper alloys have demonstrated ~75% higher operational gradients in SLAC tests, making cold-joining techniques highly attractive. EBW, applied to split-cell (half or quadrant) structure designs, preserves copper hardness away from the weld joint and simplifies machining — but industrial process optimization remains immature and a substantial learning curve is expected. The business case was modeled for two scenarios: a greenfield EBW linac company (> $10M upfront costs, viable above ~30 units/year) and an EBW division added to an existing accelerator firm to reduce risk and upfront costs, at the expense of being less optimal structure for the higher volume production. The study concludes that without a significant increase in demand, private investment alone cannot sustain this capability, and recommends federal support through R&D grants, procurement incentives, and CAPEX cost-sharing to incubate domestic EBW-NCRF manufacturing — with the existing-company model.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Broadband and Tunable Microwave Absorption Properties from Large Magnetic Loss in Ni–Zn Ferrite

Highly effective electromagnetic (EM) wave absorber materials with strong reflection loss (RL) and a wide absorption bandwidth (EBW) in gigahertz (GHz) frequencies are crucial for advanced wireless applications and portable electronics. Traditional microwave absorbers lack magnetic loss and struggle with impedance matching, while ferrites are stable, exhibit excellent magnetic and dielectric losses, and offer better impedance matching. However, achieving the desired EBW in ferrites remains a challenge, necessitating further composition design. In this study, impedance matching is successfully enhanced and EBW in Ni–Zn ferrite is broadened by successive doping with Mn and Co , without incorporation of any polymer filler. It is found that Ni 0.4 Co 0.1 Zn 0.5 Fe 1.9 Mn 0.1 O 4 material exhibits exceptional EM wave absorption, with a maximum RL of −48.7 dB. It also featured a significant EBW of 10.8 GHz, maintaining a 90% absorption rate (RL < −10 dB) for a thickness of 4.5 mm. These outstanding properties result from substantial magnetic losses and favorable impedance matching. These findings represent a significant step forward in the development of microwave absorber materials, addressing EM wave pollution concerns within GHz frequencies, including the frequency band used in popular 5G technology.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Simulation of electron Bernstein waves using FullWave with a 2D non-local hot plasma model

Hot plasma wave simulation capability is expanded in the FullWave code by updating the hybrid iterative solver in the code with a semi-implicit time stepping method. The new approach is used to simulate Electron Bernstein Wave (EBW) heating in over-dense spherical tokamak plasmas. The code’s hybrid iterative solver circumvents the prohibitive memory cost of direct methods by combining a time evolution of Maxwell’s equations with frequency-domain relaxation, while the conductivity kernel, calculated via 3D particle tracking, captures the essential non-local wave–particle interactions. One-dimensional EBW simulations verify the algorithm’s accuracy by demonstrating mode conversion from X-mode wave to EBW at the upper hybrid resonance and a strong cyclotron damping near the plasma core. Two-dimensional simulation reproduces the predicted short EBW wavelength and quantitatively matches the hot-plasma dispersion relation. This study demonstrates the fidelity of the hybrid solver for the electron cyclotron frequency range.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Investigation of thermal damage in explosive bridgewire detonators via discrete element method simulations

Exploding bridgewire (EBW) detonators are used to rapidly and reliably initiate energetic reactions by exploding a bridgewire via Joule heating. While the mechanisms of EBW detonators have been studied extensively in nominal conditions, comparatively few studies have addressed thermally damaged detonator operability. We present a mesoscale simulation study of thermal damage in a representative EBW detonator, using discrete element method (DEM) simulations that explicitly account for individual particles in the pressed explosive powder. We use a simplified model of melting, where solid spherical particles undergo uniform shrinking, and fluid dynamics are ignored. The subsequent settling of particles results in the formation of a gap between the solid powder and the bridgewire, which we study under different conditions. In particular, particle cohesion has a significant effect on gap formation and settling behavior, where sufficiently high cohesion leads to coalescence of particles into a free-standing pellet. This behavior is qualitatively compared to experimental visualization data, and simulations are shown to capture several key changes in pellet shape. We derive a minimum and maximum limit on gap formation during melting using simple geometric arguments. In the absence of cohesion, results agree with the maximum gap size. With increasing cohesion, the gap size decreases, eventually saturating at the minimum limit. In conclusion, we present results for different combinations of interparticle cohesion and detonator orientations with respect to gravity, demonstrating the complex behavior of these systems and the potential for DEM simulations to capture a range of scenarios.

cohesive powders↗
DOE OSTI2026

Gigacycle Fatigue Strength Evaluation of Welded 316L Stainless Steels for Mercury Target Vessel

At the Materials and Life Science Experimental Facility (MLF) in J-PARC, liquid mercury target for the pulsed spallation neutron source is in operation. An enclosure vessel for the liquid mercury target made of type 316L stainless steel (SS316L) suffers two kinds of cyclic stress during operation. One is the thermal stress due to the internal heating and swings by proton beam trip. The other is the impulsive stress by the pressure waves generated by the proton beam injection. The total number of loading cycles for the former is ∼104, and the latter is ∼4 × 108 for a year operation in the J-PARC mercury target vessel. The target vessel is assembled by an electron beam welding (EBW) and a gas tungsten arc welding (GTAW). However, fatigue data of welded SS316L up to gigacycle is limited. Ultrasonic fatigue testing, applying load cycles by utilizing ultrasonic resonance, for the welded SS316L was performed to investigate the effect of welding on fatigue behavior up to a gigacycle. The result showed that the fatigue strength degradation by EBW and EBW with GTAW were not recognized up to 109 cycles. Crack initiation in welded specimens nucliated at off-center areas of the specimen whereas the cracks in base metal specimen originated at the specimen center.

Naoe, Takashi [Japan Atomic Energy Agency (JAEA)]↗
DOE OSTI2025

Welding investigation of a wrought FeMnAl steel for armor application

A new wrought FeMnAl steel contains high Mn content and high Al content. This steel has high strength. When it is compared to conventional steels with the similar strength, its density is lower. FeMnAl steels can be used in armor vehicle manufacturing, in which welding is a common practice to join the steel plates together. The welding of FeMnAl steels has not been sufficiently studied before. Here, this work studied the weldability and weld microstructure of an FeMnAl steel and provided useful data for the welding practice of FeMnAl steels. The influences of weld filler metals and shielding gases were studied, using single-pass bead-on-plate gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW) two processes. The optimal filler metals and shielding gases have been determined to achieve the better weldability. Autogenous GTAW and electron beam welding were also conducted. Cracks were found in the HAZ in the GMAW welds and electron beam welds. Fewer or no cracks were found in the HAZ of GTAW welds. SEM, SEM/EDX, TEM, TEM/EDX, and EBSD were used to analyze the grain boundaries in the HAZ and the cracks. The grain boundaries of FeMnAl base metal are mostly high angle grain boundaries (HAGBs), which attract impurity and solute atoms and cause intergranular cracking. The proposed cracking mechanisms are liquation cracking and ductility-dip cracking. It was found that GTAW provides much better weldability for the FeMnAl steel than GMAW and EBW.

FeMnAl steel↗
DOE OSTI2024

Development of a Half-Meter Scale Traveling-Wave (TW) SRF Cavity

While a demonstration of TW resonance excitation in the 3-cell structure in 2K liquid helium had been prepared and carried out at Fermilab in collaboration with Euclid Techlabs, the RF design process of 0.5~1 meter scale TW cavity was begun at Fermilab as the next step of TW development towards an accelerator-scale one. Considering the physical dimensions of existing SRF facilities (for fabrication, processing, and cryogenic testing), Fermilab has proposed a half-meter scale TW RF design consisting of a 7-cell structure and a power feedback waveguide (WG) loop. The WG loop design includes the new RF configurations for TW resonance control during a high-power operation. 1-year US-Japan collaboration program focused on EBW optimization for the TW shape iris joint within the narrow gap was awarded and the efforts has been made by Fermilab, Jlab, and KEK. 1-year LDRD program of Fermilab is awarded recently to fabricate a low-cost mockup of the WG loop with new RF configurations and validate them. Here we will present a preliminary 7-cell TW RF design and will report the progress and challenges through the programs awarded.

43 PARTICLE ACCELERATORS↗
DOE OSTI2026

A&L Annual Report: GRM-MAPS

Exploding Bridge Wire (EBW) is an important design for initiating detonators relevant to several LLNL systems. In such designs, a metal bridge wire is in direct contact with a porous secondary high explosive (HE), typically pressed to around 50% of its crystalline density. Initiation is believed to occur through shock waves generated when the bridge wire is made to explode via the rapid passing of a strong current pulse. Permeametry is an important characterization tool for the porous powdered HE (PETN, HMX, etc.) component in such devices. Such powders are well known to coarsen with age, with an accompanying deterioration in performance, which includes increased function time and sensitivity. Among various material characteristics, one that has been shown to correlate the most with such performance parameters is the flow-permeable surface area (FSSA), measured using air-permeametry. Commercially available permeametry apparatuses, such as that from Fisher Scientific or a more modern version from Micromeritics suffer from a few drawbacks, most notably as related to monitoring age-related changes in FSSA. This is because it requires re-compaction of the aged powder into the permeametry tube, which in most cases leads to an unwanted increase in FSSA. To address this and a few other shortcomings, we have been developing a modern version of the permeameter, Gee-Reinstein-Maiti Modern Air-Permeametry System (GRM-MAPS). In this report, we summarize progress made in FY25 toward perfecting and calibrating the instrument, which we aim at deploying within surveillance in FY26.

36 MATERIALS SCIENCE↗