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Results for “High Aspect-Ratio”

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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Ultra-high SERS detection of consumable coloring agents using plasmonic gold nanostars with high aspect-ratio spikes

Solution-based SERS detection by using a portable Raman instrument has emerged as an important tool due to its simplicity, and flexibility for rapid and on-site screening of analyte molecules. However, this method has several shortcomings, including poor sensitivity especially for weak-affinity analyte molecules, where there is no close contact between the plasmonic metal surface and analyte molecule. Examples of weak-affinity molecules include pigment molecules that are commonly used as a consumable coloring agent, such as allura red (AR), and sunset yellow (SY). As high consumption of colorant agents has been shown to cause adverse effects on human health, there is a strong need to develop a simple and practical sensing system with high sensitivity for these agents. Here we present a novel, highly sensitive solution-based SERS detection method for AR, and SY by using CTAC capped gold nanostars (GNS) having different aspect ratios (GNS-2, GNS-4, and GNS-5) without utilizing any aggregating agents which can enhance SERS signal however it reduces batch to batch reproducibility. The influence of the aspect ratio of GNS on SERS properties was investigated. We have achieved a limit of detection (LOD) of AR and SY as low as 0.5 and 1 ppb, respectively by using GNS-5 with the advantages of minimal sample preparation by just mixing the analyte solution into a well plate containing GNS solution. In addition, excellent colloidal stability and reproducibility have further enhanced the applicability in real-world samples. Altogether, our results evidence that the solution-based SERS detection platform using high aspect-ratio GNS can be applied for practical application to detect pigment molecules in real samples with satisfactory results.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

A novel hardmask-to-substrate pattern transfer method for creating 3D, multi-level, hierarchical, high aspect-ratio structures for applications in microfluidics and cooling technologies

Abstract This letter solves a major hurdle that mars photolithography-based fabrication of micro-mesoscale structures in silicon. Conventional photolithography is usually performed on smooth, flat wafer surfaces to lay a 2D design and subsequently etch it to create single-level features. It is, however, unable to process non-flat surfaces or already etched wafers and create more than one level in the structure. In this study, we have described a novel cleanroom-based process flow that allows for easy creation of such multi-level, hierarchical 3D structures in a substrate. This is achieved by introducing an ultra-thin sacrificial silicon dioxide hardmask layer on the substrate which is first 3D patterned via multiple rounds of lithography. This 3D pattern is then scaled vertically by a factor of 200–300 and transferred to the substrate underneath via a single shot deep etching step. The proposed method is also easily characterizable—using features of different topographies and dimensions, the etch rates and selectivities were quantified; this characterization information was later used while fabricating specific target structures. Furthermore, this study comprehensively compares the novel pattern transfer technique to already existing methods of creating multi-level structures, like grayscale lithography and chip stacking. The proposed process was found to be cheaper, faster, and easier to standardize compared to other methods—this made the overall process more reliable and repeatable. We hope it will encourage more research into hybrid structures that hold the key to dramatic performance improvements in several micro-mesoscale devices.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

A high accuracy/resolution spectral element/Fourier–Galerkin method for the simulation of shoaling non-linear internal waves and turbulence in long domains with variable bathymetry

A high-order hybrid continuous-Galerkin numerical method, designed for the simulation of non-linear, non -hydrostatic internal waves and turbulence in long computational domains with complex bathymetry, is presented. The spatial discretization in the non-periodic wave-propagating directions, utilizes the nodal spectral element method. Such a high-order element-based discretization allows the highly accurate representation of complex domain geometry along with the flexibility of concentrating resolution in areas of interest. Under the assumption of the normal-to-isobath propagation of non-linear internal waves, a third periodic direction is incorporated via a Fourier-Galerkin discretization. The distinct non-hydrostatic nature of non-linear internal waves and, any instabilities and turbulence therein, necessitates the numerically challenging solution of the pressure Poisson problem. A defining feature of this work is the application of a domain decomposition approach, combined with block-Jacobi/deflation-based preconditioning to the pressure Poisson problem. Such a combined approach is particularly suitable for the long high aspect-ratio complex domains of interest and enables the efficient high-accuracy reproduction of the non-hydrostatic dynamics of non-linear internal waves. Implementation details are also described in the context of the stability of the solver and its parallelization strategy. A series of benchmarks of increasing complexity demonstrate the robustness of the flow solver. The benchmarks culminate with the three-dimensional simulation of a convectively breaking mode-one non-linear internal wave over a realistic South-China-Sea bathymetric transect and background current/stratification profiles.

Deflation↗
DOE OSTI2020

Crystallographic orientation-dependent strain hardening in a precipitation-strengthened Al-Cu alloy

While the strengthening of Al-Cu alloys due to precipitation has been extensively studied, the effect of crystallographic orientation of the matrix and precipitates, as well as precipitate morphology, on the strain hardening behavior is not well understood. In this paper, we investigate this effect with in situ neutron diffraction during deformation of an Al-Cu alloy (206) after multiple aging treatments. Precipitate-dislocation interactions were found to change from precipitate shearing for microstructures predominantly containing GPI and θ" precipitates to Orowan looping for microstructures with primarily θ' and θ precipitates. Notably, significant anisotropy in strain hardening behavior was observed when θ' precipitates were present, which was attributed to crystallographic orientation dependent load transfer from the Al matrix to the θ' precipitates. The anisotropic load transfer is hypothesized to be caused by the extent of rotation of high aspect-ratio θ' precipitates, owing to dislocations looping around them during plastic deformation of the matrix. Predictions from an analytical model describing the anisotropic magnitude of load transfer from precipitate rotation agree well with experimental results, successfully validating the precipitate rotation hypothesis and explaining the anisotropic strain hardening behavior. This model allows for the prediction of stresses separately in the precipitate and matrix phases as a function of crystallographic orientation, only given the bulk mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Helical Shear-Flow Stabilization of an Astrophysically Relevant Laboratory Plasma Jet

Astrophysical jets are collimated, high-speed outflows observed to be natural features of celestial objects that spin and accrete matter. From protoplanetary nebula and young stellar objects to active galactic nuclei, common features suggest that universal mechanisms may lead to the remarkable straightness observed in many jets. Here we report observations from a new astrophysically relevant laboratory plasma jet experiment demonstrating the formation of long-lived, collimated, high aspect-ratio jets. The magnetized jets have strong helical shear flows and remain stable to instabilities over many growth times. These observations corroborate theoretical predictions that strong helical shear flows can stabilize current-driven instabilities in magnetically confined plasmas, solar prominences, and magnetically driven astrophysical jets in nature.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Pulsed radio frequency power modulation for profile control in cryogenic reactive ion etching of silicon gratings

Cryogenic silicon etching with SF 6 /O 2 plasmas enables vertical sidewalls and smooth surfaces for high–aspect-ratio structures, yet precise control of etched profiles (sidewall angle, lateral etching, and linewidth retention) remains challenging under continuous-wave excitation due to coupling among radical fluxes, ion energy distributions, and in situ passivation dynamics. In this work, we investigated pulsed radio frequency bias delivery as a process knob for profile control during cryogenic silicon etching. Systematic experiments on 500 nm-wide, 1 μm-pitch gratings etched to 0.8–1.1 μm depth at 0.5–2 kHz pulsing frequency and 25%–75% duty cycle revealed strong dependencies of etch rate, linewidth, and sidewall angle on modulation conditions. We proposed a conceptual kinetic picture combined with feature-scale electrostatic analysis to understand the alternation of ion-driven etching and passivation recovery between on/off segments and local electric field shaping and modulation of ion trajectories within the trench. Moderate duty cycles (50%–75%) near 1 kHz achieved a balance between anisotropy and etch rate. These results demonstrate pulsed-bias modulation can be utilized to tune directionality and sidewall preservation in cryogenic SF 6 /O 2 etching, which are relevant to photonic, metrology, and quantum device fabrication.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Annual report for DOE VTO

Carbon fiber (CF)/polymer composites are a transformative class of high-performance, lightweight material, where high aspect-ratio CFs reinforce a polymer matrix and exceed the strength of steel alloys at a fraction of the density. Despite the advantages of such a class of material, the broader implementation of CF composites in a range of automotive, aerospace, and energy applications is hindered by limitations of current manufacturing methods. These current techniques (e.g., hand lay-up, wet filament winding) are costly and impose severe limitations on fiber placement, orientation, and angle, and thus a composite’s ultimate properties. Today’s CF composites are expensive to manufacture, limited in form factor, and utilize costly and sub-optimal continuous filament CF. Advanced additive manufacturing (AM) processes, combined with computational design optimization and new approaches to resin development, offer alternative design and manufacturing paradigms that have the realistic potential to lift these constraints. Such integrated AM approaches could thus help to realize the full potential of CF composite materials. One relevant application of CF composite materials where manufacturing constraints limit the cost-benefit ratio is in the manufacture of high-performance composite pressure vessels for onboard compressed natural gas (CNG) storage. Current CNG storage vessels (Types 3–5) are made from load-bearing filament-wound carbon-fiber composite and are ~3.5 times as expensive as an all-metallic Type-1 vessel. This cost is invariably tied to the complex and labor-intensive nature of conventional filament winding processes and the large volumes of expensive high tensile-strength CF tow feedstock required in manufacture. Our proposed approach to CNG storage vessel manufacture is based on a combination of AM technologies for CF composite printing and design optimization tools that were pioneered at Lawrence Livermore National Laboratory (LLNL), with advances in resin/composite formulation enabled by chemical and nano-material modification. Through the successful development of this technology, LLNL seeks to demonstrate the capability for advanced CNG storage vessel manufacture at reduced cost with no reduction in performance versus the most advanced, extant Type-5 designs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2019

Balancing ion parameters and fluorocarbon chemical reactants for SiO 2 pattern transfer control using fluorocarbon-based atomic layer etching

In manufacturing, etch profiles play a significant role in device patterning. Here, the authors present a study of the evolution of etch profiles of nanopatterned silicon oxide using a chromium hard mask and a CHF 3 /Ar atomic layer etching in a conventional inductively coupled plasma tool. The authors show the effect of substrate electrode temperature, chamber pressure, and electrode forward power on the etch profile evolution of nanopatterned silicon oxide. Chamber pressure has an especially significant role, with lower pressure leading to lower etch rates and higher pattern fidelity. The authors also find that at higher electrode forward power, the physical component of etching increases and more anisotropic etching is achieved. By carefully tuning the process parameters, the authors are able to find the best conditions to achieve aspect-ratio independent etching and high fidelity patterning, with an average sidewall angle of 87° ± 1.5° and undercut values as low as 3.7 ± 0.5% for five trench sizes ranging from 150 to 30 nm. Finally, they provide some guidelines to understand the impact of plasma parameters on plasma ion distribution and thus on the atomic layer etching process.

42 ENGINEERING↗
DOE OSTI2019

Constructing stellarators with quasisymmetry to high order

Here, a method is given to rapidly compute quasisymmetric stellarator magnetic fields for plasma confinement, without the need to call a three-dimensional magnetohydrodynamic equilibrium code inside an optimization iteration. The method is based on direct solution of the equations of magnetohydrodynamic equilibrium and quasisymmetry using Garren & Boozer’s expansion about the magnetic axis ( Phys Fluids B, vol. 3, 1991, p. 2805), and it is several orders of magnitude faster than the conventional optimization approach. The work here extends the method of Landreman et al. ( J. Plasma Phys. , vol. 85, 2019, 905850103), which was limited to flux surfaces with elliptical cross-section, to higher order in the aspect-ratio expansion. As a result, configurations can be generated with strong shaping that achieve quasisymmetry to high accuracy. Using this construction, we give the first numerical demonstrations of Garren and Boozer’s ideal scaling of quasisymmetry breaking with the cube of the inverse aspect ratio. We also demonstrate a strongly non-axisymmetric configuration (vacuum rotational transform $\unicode[STIX]{x1D704} >0.4$ ) in which symmetry-breaking mode amplitudes throughout a finite volume are ${<}2\times 10^{-7}$ , the smallest ever reported. To generate boundary shapes of finite-minor-radius configurations, a careful analysis is given of the effect of substituting a finite minor radius into the near-axis expansion. In conclusion, the approach here can provide analytic insight into the space of possible quasisymmetric stellarator configurations, and it can be used to generate good initial conditions for conventional stellarator optimization.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Characteristic of cryogenic hydrogen flames from high-aspect ratio nozzles

Unintentional leaks at hydrogen fueling stations have the potential to form hydrogen jet flames, which pose a risk to people and infrastructure. The heat flux from these jet flames are often used to develop separation distances between hydrogen components and buildings, lot-lines, etc. The heat flux and visible flame length is well understood for releases from round nozzles, but real unintended leaks would be expected to be from higher aspect-ratio cracks. Here, we measured the visible flame length and heat-flux characteristics of cryogenic hydrogen flames from high-aspect ratio nozzles. Heat flux measurements from 5 radiometers were used to assess the single-point vs the multi-point methods for interpretation of heat flux sensor data, finding the axial distance of the sensor for a single-point heat flux measurement to be important. We compare the flame length and heat flux data to flames of both cryogenic and compressed hydrogen from round nozzles. The aspect ratio of the release does not affect the flame length or heat flux significantly, for a given mass flow under the range of conditions studied. The engineering correlations presented in this work enable the prediction of flame length and heat flux which can be used to assess risk at hydrogen fueling stations with liquid hydrogen and develop science-based separation distances for these stations.

08 HYDROGEN↗
DOE OSTI2025

Competing conduction mechanisms in high performance carbon nanotube fibers

The performance of carbon nanotube (CNT) cables, a contender for copper-wire replacement, is tied to its metallic and semi-conducting-like conductivity responses with temperature; the origin of the semi-conducting-like response however is an underappreciated incongruity in literature. With controlled aspect-ratio and doping-degree, over 61 unique cryogenic experiments including anisotropy and Hall measurements, CNT cable performance is explored at extreme temperatures (65 mK) and magnetic-fields (60 T). A semi-conducting-like conductivity response with temperature becomes temperature-independent approaching absolute-zero, uniquely demonstrating for the first time the necessity of heterogeneous fluctuation induced tunneling; complete de-doping leads to localized hopping, contrasting graphite's pure metallic-like response. High-field magneto-resistance (including novel +22 % longitudinal magneto-resistance near room-temperature) is analyzed with hopping and classical two-band models, both yielding a similar parameter useful for conductor development. Varying field-orientation angle uncovers significant two- and four-fold symmetries that are shown to be from Aharonov-Bohm-like corrections to the curvature-induced bandgap, a first for macroscale CNT fibers. Tight-binding calculations using Green's Function formalism model the largest, coherent transport to-date in commensurate CNT bundles in magnetic-field, revealing non-uniform transmission across bundle cross-sections with doping restoring uniformity; independent of doping, transport in bundle-junction-bundle systems are predominantly from CNTs adjacent to the other bundle—demonstrating that smaller bundles are more efficient for electronic transport. The final impact is predicting the ultimate conductivity of heterogeneous CNT cables using temperature and field-dependent transport, surpassing conductivity of traditional metals.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Ultra-high aspect ratio pores milled in diamond via laser, ion and electron beam mediated processes

Microfabrication techniques are critical for the rapid prototyping and development of applications for cutting edge materials. Recently diamond has gained considerable interest for quantum photonic, biosensing, inertial confinement fusion and magnetometer applications. In this article, ultra-high aspect ratio milling of diamond micropores by photon, ion and electron based methods is reported. A multiphoton absorption laser ablation approach is revealed to rapidly produce sub-10 μm diameter micropores in diamond with an aspect ratio of 14:1 and a tapered profile at the surface interface. Chemically active, oxygen focused ion beam milling produces high-aspect ratio pores in diamond with an aspect ratio of 65:1 and minimal tapering over the length of the pore, overcoming the physical interaction volume limitations imposed in conventional gallium based focused ion beam milling and laser ablation methods. Oxygen-mediated electron beam induced etching is revealed to negate the limitations imposed by physical sputtering mechanisms utilized in focused ion beam milling via the direct initiation of chemical reactions at the receding surface, producing aspect ratios on the order of 200:1. Numerical simulations reveal the physical basis for the superior aspect-ratio pore milling of the oxygen focused ion beam milling and electron beam induced etching methods. Our results demonstrate direct-write methods for the fabrication of ultra-high aspect micropores in diamond and provide insight into the underlying mechanisms of these physical processes. The three methods demonstrated here can be interchanged for applications based on the desired characteristic aspect ratio and process throughput.

36 MATERIALS SCIENCE↗
DOE OSTI2021

hr-Adaptivity for nonconforming high-order meshes with the target matrix optimization paradigm

In this study, we present an \(hr\) -adaptivity framework for optimization of high-order meshes. This work extends the r -adaptivity method by Dobrev et al. (Comput Fluids, 2020), where we utilized the Target-Matrix Optimization Paradigm (TMOP) to minimize a functional that depends on each element’s current and target geometric parameters: element aspect-ratio , size , skew , and rotation . Since fixed mesh topology limits the ability to achieve the target size and aspect-ratio at each position, in this paper, we augment the r -adaptivity framework with nonconforming adaptive mesh refinement to further reduce the error with respect to the target geometric parameters. The proposed formulation, referred to as \(hr\) -adaptivity, introduces TMOP-based quality estimators to satisfy the aspect-ratio target via anisotropic refinements and size target via isotropic refinements in each element of the mesh. The methodology presented is purely algebraic, extends to both simplices and hexahedra/quadrilaterals of any order, and supports nonconforming isotropic and anisotropic refinements in 2D and 3D. Using a problem with a known exact solution, we demonstrate the effectiveness of \(hr\) -adaptivity over both r - and \(h\) -adaptivity in obtaining similar accuracy in the solution with significantly fewer mesh nodes. We also present several examples that show that \(hr\) -adaptivity can help satisfy geometric targets even when \(r\) -adaptivity fails to do so, due to the topology of the initial mesh.

42 ENGINEERING↗
DOE OSTI2020

Temporal dynamics of large-scale structures for turbulent Rayleigh–Bénard convection in a moderate aspect-ratio cylinder

We investigate the spatial organization and temporal dynamics of large-scale, coherent structures in turbulent Rayleigh–Bénard convection via direct numerical simulation of a 6.3 aspect-ratio cylinder with Rayleigh and Prandtl numbers of 9.6×10 7 and 6.7, respectively. Fourier modal decomposition is performed to investigate the structural organization of the coherent turbulent motions by analysing the length scales, time scales and the underlying dynamical processes that are ultimately responsible for the large-scale structure formation and evolution. We observe a high level of rotational symmetry in the large-scale structure in this study and that the structure is well described by the first four azimuthal Fourier modes. Two different large-scale organizations are observed during the duration of the simulation and these patterns are dominated spatially and energetically by azimuthal Fourier modes with frequencies of 2 and 3. Studies of the transition between these two large-scale patterns, radial and vertical variations in the azimuthal energy spectra, as well as the spatial and modal variations in the system's correlation time are conducted. Rotational dynamics are observed for individual Fourier modes and the global structure with strong similarities to the dynamics that have been reported for unit aspect-ratio domains in prior works. It is shown that the large-scale structures have very long correlation time scales, on the order of hundreds to thousands of free-fall time units, and that they are the primary source for a horizontal inhomogeneity within the system that can be observed during a finite, but a very long-time simulation or experiment.

42 ENGINEERING↗
DOE OSTI2024

Kinetic-ballooning-bifurcation in tokamak pedestals across shaping and aspect-ratio

We use a new gyrokinetic threshold model to predict a bifurcation in tokamak pedestal width-height scalings that depends strongly on plasma shaping and aspect-ratio. The bifurcation arises from the first and second stability properties of kinetic-ballooning-modes that yields wide and narrow pedestal branches, expanding the space of accessible pedestal widths and heights. The wide branch offers potential for edge-localized-mode-free pedestals with high core pressure. For negative triangularity, low-aspect-ratio configurations are predicted to give steeper pedestals than conventional-aspect-ratio. Both wide and narrow branches have been attained in tokamak experiments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Disruption modelling for engineering and physics design of ST-E1 fusion power plant

Plasma disruptions represent a critical challenge for high-performance tokamak operations, as they can compromise machine integrity and reduce operational availability. Although future fusion devices essentially need to incorporate strategies to minimise disruption occurrence, complete avoidance remains unattainable. Consequently, assessing and characterising unmitigated disruption consequences is fundamental for the design and qualification of next-generation fusion power plants. This work supports the pre-conceptual design of ST-E1, a low aspect-ratio Tokamak Fusion Power Plant developed by Tokamak Energy Ltd., by presenting a comprehensive disruption modelling approach applied across different design stages. The methodology integrates both physics and engineering considerations to evaluate the impact of disruptions on machine performance and structural integrity. From an engineering perspective, several ST-E1 layout options were analysed to investigate the electromagnetic response of key components under disruption-induced loads, enabling comparison between alternative design solutions. On the physics side, a broad set of disruption scenarios was explored, scanning operational space parameters, plasma-material interactions, and associated thermal loads. Furthermore, the study examined variations in disruption behaviour arising from different reference equilibria, focusing on a range starting from Double Null to Single Null configurations, reflecting the increasing up-down asymmetry consequences. The results reveal significant contrasts in plasma dynamics and structures electromagnetic behaviour between configurations, highlighting the importance of disruption modelling in guiding design choices. These analyses have proven instrumental in shaping ST-E1 development, offering critical insights for mitigating risks and optimising future fusion power plant designs.

Borowiec, Katarzyna [ORNL] (ORCID:0000000335911739↗
DOE OSTI2026

The impact of kinetic and global effects on ideal ballooning 2nd stable pedestals of conventional and low aspect-ratio tokamaks

The EPED model (Snyder et al 2011 Nucl. Fusion 51 103016) has had success in describing the pedestal structure of Type-I ELM and QH-mode plasmas in tokamaks, by combining kinetic ballooning mode (KBM) and peeling–ballooning (PB) constraints. Within EPED, the KBM constraint is often approximated by a technique using calculated ideal ballooning mode (IBM) thresholds, fit to a functional form designed to capture non-local effects. It has been noted that quantitative differences between local ideal MHD and gyro-kinetic (GK) ballooning stability can be larger at low aspect ratio. KBM critical pedestals are consistent with observations in initial studies on conventional and spherical tokamaks. In this work, the application of a reduced model for the calculation of the kinetic ballooning stability boundary is presented based on a novel and newly developed gyro-fluid system (GFS) code (Staebler et al 2023 Phys. Plasmas 30 102501). GFS is observed to capture KBMs in DIII-D as well as the NSTX pedestals, opening a route to integrating this model into EPED. Finally, high but finite $n$ global ballooning modes are observed to limit the access to the local 2nd stability and thus provide a transport mechanism that constrains the pedestal evolution with $β_{p,\textrm{ped}}$. The high $n$ global ballooning stability is approximated by its ideal MHD analog using ELITE. It is shown that nearly-local high $n$ modes with $k_yρ_s$ ~ $0.25 - 0.5$ can provide a proxy for the critical $β_{p,\textrm{ped}}$ when a 2nd stable access exists on DIII-D plasmas. The use of GFS and ELITE scaling in EPED provides improved agreement to EPED1 in an initial comparison with DIII-D pedestal data.

Anastopoulos Tzanis, Michail Savvas [Oak Ridge Nat↗