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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Improving the Performance of Mid-T Baked Niobium Cavities through Post-Bake Surface Treatment

he Medium temperature (mid-T) baking of niobium superconducting radio-frequency cavities at 300 350 C in a vacuum furnace is known to enhance the quality factor (Q₀). However, despite this improvement, cavities treated with this process often exhibit premature quench at relatively low accelerating fields. This limitation is suspected to arise from the formation of surface contaminants, such as niobium carbides, during the furnace bake at 350 C for 3 h. To investigate the influence of potential surface contamination, this study applied an ultralight chemical removal to 1.3 GHz and 650 MHz single-cell cavities that had undergone medium-temperature baking. The removal of the top RF surface layer led to a notable improvement in the quench field and Q₀, indicating a beneficial effect of eliminating possible surface residues introduced during the bake.

Chouhan, Vijay [Fermilab]↗
DOE OSTI2026

Improving the performance of mid-T baked niobium cavities through post-bake surface treatment

The Medium temperature (mid-T) baking of niobium superconducting radio-frequency cavities at 300 350 C in a vacuum furnace is known to enhance the quality factor (Q₀). However, despite this improvement, cavities treated with this process often exhibit premature quench at relatively low accelerating fields. This limitation is suspected to arise from the formation of surface contaminants, such as niobium carbides, during the furnace bake at 350 C for 3 h. To investigate the influence of potential surface contamination, this study applied an ultralight chemical removal to 1.3 GHz and 650 MHz single-cell cavities that had undergone medium-temperature baking. The removal of the top RF surface layer led to a notable improvement in the quench field and Q₀, indicating a beneficial effect of eliminating possible surface residues introduced during the bake.

Chouhan, V. [Fermilab] (ORCID:0000000282004931)↗
DOE OSTI2025

Understanding Surface Contamination Effects in Mid-T Baked Cavities

Medium-temperature baking is applied to niobium SRF cavities to enhance their quality factor. However, mid-T baking performed in the 300-350 °C range may lead to the formation of surface carbides, which can prevent the cavities from exhibiting the full benefit of mid-T baking. To investigate the effect of potential surface contaminants, the top RF layer of mid-T-baked cavities was removed using an ultralight electropolishing process. The performance of the mid-T baked cavities was significantly improved after applying this ultralight EP. This presentation summarizes the latest results on this study.

Chouhan, Vijay [Fermilab]↗
DOE OSTI2024

Mitigation of distortion of Al/steel part under simulated paint baking condition: Experiment and numerical model studies

Multi-material joining of lightweight structures is essential to reduce vehicle weight for more energy savings and less greenhouse gas emission. However, mismatch of thermal expansion coefficient for dissimilar materials during the paint baking process can induce part distortion and joint failure for adhesive bonding. Here, in the present work, a thermomechanical model based on contact mechanics and large deformation theory was developed for dissimilar high-strength Al alloy and steel components to study the distortion mechanism and influential factors of the residual gap. The established model was used to optimize joint conditions, such as pitch distance and part geometry. When a weld pitch is shorter than 100 mm, the maximum gap between Al and steel part can be greatly reduced to 0.1 mm, and the local stress and plastic strain around the joint during the oven heating and cooling cycle are also substantially reduced compared with the long pitch case (900 mm). The numerical modeling results revealed that a comparable bending stiffness ratio between the steel and Al cross sections is critical to the minimization of gap and distortion under paint baking condition. Digital image correlation technique was used to measure the overall part distortion and local strain distribution that were used to validate the model prediction. Weld bonding (adhesive bonding with friction bit joining) process was successfully employed to join Al to steel component without gap opening in adhesive after the paint baking and cooling.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Performance enhancement of medium temperature baked niobium SRF cavity by surface contamination removal

Medium temperature baking (300- 350 °C) enhances the quality factor of niobium superconducting radio frequency cavities. However, surface contamination introduced during vacuum furnace baking limits the quench field and may also degrade the quality factor of the cavity. To investigate this effect, a 1.3 GHz single-cell Nb cavity underwent mid-T baking, followed by a chemical treatment to remove the surface contaminants. Post-treatment measurements revealed a significant improvement in both the quality factor and the quench field.

Chouhan, Vijay [Fermilab] (ORCID:0000000282004931)↗
DOE OSTI2025

Performance Enhancement of Medium Temperature Baked Nb SRF Cavity by Surface Contamination Removal

Medium-temperature (mid-T) baking, typically conducted at 300 350 C, enhances the quality factor of niobium (Nb) superconducting radio frequency cavities. However, surface contamination introduced during vacuum furnace baking can limit the cavity performance. To investigate this effect, a 1.3 GHz single-cell Nb cavity underwent mid-T baking, followed by a chemical treatment to remove the surface contaminants. Post-treatment measurements revealed a significant improvement in both the quality factor and the quench field.

Chouhan, Vijay [Fermilab]↗
DOE OSTI2025

IOTA Pre-Bake Test Development

The poster presentation prepared for the IOTA (Integrable Optics Test Accelerator) Pre-Bake Test Development project consists of introducing the background of the project, the work completed, and the new test configurations available with the newly designed assembly. It explains the scale of the projects, both within the IOTA ring assembly and test assembly, and describes the purpose in baking or incrementing and holding exterior heat on the beampipe to reduce impurities in the vacuum. The originally designed test, Configuration One, uses RCA scans on the interior of the pipe, increments and holds heat for a set amount of time, and is scanned again to check for water evaporation. Configuration Two begins with the same test for Configuration One but has a second cross section of beampipe separated by a gate valve. After configuration one is complete, the gate valve opens, and after a period of cooling the other side is heated, molecular movement is scanned and observed.

Seagrave, Kayla [DuPage Coll.]↗
DOE OSTI2026

Preliminary Introduction of the IOTA Bake System

The Integrable Optics Test Accelerator (IOTA) ring is vital to the advancement of accelerator sciences, and a large part of its attractiveness to accelerator physicists is its modularity and the versatility that this function provides. Up until this point, the FAST accelerator has provided electron beam for the studies in IOTA. With the soon to be commissioned IOTA Proton Injector in lieu, the requirement for better vacuum to support future proton studies in the ring have arrived. Our solution is the IOTA Bake System which has the goal of facilitating this requirement.

Thompson, T. K. [Fermilab]↗
DOE OSTI2025

Bipartisan Infrastructure Law (BIL) – Illinois Rare Earth Novel Extraction and Supply (IRENES) - Report on Technology Down Select No. 1 - Acid Baking vs. Heap Leaching

An essential step for recovering rare earth and critical minerals from coal mine waste is one that achieves adequate dissolution of the target elements into a pregnant leachate solution. The simplest technical approach was thought to be heap-leaching that could proceed using mild acid dosing or naturally generated acid from biological activity. For this reason, the University of Kentucky at Lexington (UKY) undertook two efforts to evaluate feasibility, including a laboratory column leaching evaluation and a pilot heap-leaching demonstration. Later, the UK evaluated a pyrometallurgical approach using roasting combined with acid baking and tank leaching at elevated temperatures to improve extraction efficiencies. This report surveys the previously reported leaching yields and calculates the gross value of rare earth oxides as a basket in the pregnant leachate solution.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Vacuum-baking provides many advantages for LiH

In vacuum applications, the thermal decomposition of LiOH corrosion on LiH causes undesirable hydrogen outgassing. The quantity of outgassing is dependent on the thermal stability of the corrosion layer, which depends on sample treatment. We have measured the decomposition of LiOH on as-polished LiH and on previously vacuum-baked LiH (i.e., Li 2 O-covered LiH) which both experienced moisture re-exposure.

36 MATERIALS SCIENCE↗
DOE OSTI2025

IOTA Bake System

The IOTA ring is vital to the advancement of accelerator sciences, and a large part of its attractiveness to accelerator physicists is its modularity and the versatility that this function provides. Up until this point, the FAST accelerator has provided electron beam for the studies in IOTA. With the soon to be commissioned IOTA Proton Injector in lieu, the requirement for better vacuum to support future proton studies in the ring have arrived. Our solution is the IOTA Bake System which has the goal of facilitating this requirement.

Thompson, Travante [Fermilab]↗
DOE OSTI2025

BBN-simple: How to bake a universe-sized cake

Big Bang Nucleosynthesis (BBN), the process of creation of lightest elements in the early universe, is a highly robust, precise, and ultimately successful theory that forms one of the three pillars of the standard hot-Big-Bang cosmological model. Existing theoretical treatments of BBN and the associated computer codes are accurate and flexible, but are typically highly technical and opaque, and not suitable for pedagogical understanding of the BBN. Here we present BBN-simple - a from-scratch numerical calculation of the lightest element abundances pitched at an advanced undergraduate or beginning graduate level. We review the physics of the early universe relevant for BBN, provide information about the reaction rates, and discuss computational-mathematics background that is essential in setting up a BBN calculation. Here, we calculate the abundances of the principal nuclear species in a standard cosmological model, and find a reasonably good agreement with public precision-level BBN codes.

Big bang nucleosynthesis↗
DOE OSTI2025

IOTA Pre-Bake Test Development

The IOTA (Integrable Optics Test Accelerator) Bakeout project is intended to improve the quality of the vacuum within the IOTA ring. Impurities consisting of hydrogen and oxygen that build within the beampipe are reduced through applying heat to the beampipe’s exterior. Two versions of the Bakeout project exist, one as a smaller scale test setup, and one five times larger located within the IOTA ring. During my internship, I worked together with a team to bring this project from an effectively dormant state to ready for testing, working together to create full documentation of the PLC (Programmable Logic Controller) programs, making multiple new hardware configurations of this test possible, as well as an additional safety system.

Seagrave, Kayla [DuPage Coll.; Fermilab]↗
DOE OSTI2025

Enhancing the performance of solvent-borne poly(ethyl methacrylate) coatings for high-power laser applications via low-temperature drying

Organic polymers are a versatile class of materials employed in a broad range of optical coating applications. However, their use as coatings in high-power laser applications, particularly in the UV spectral region, has been limited in scope due to their relatively low laser-induced damage thresholds (LIDTs), which decrease further with exposure to multiple pulses. This study explores the effect of post-deposition drying temperature and residual solvent on the LIDT of solvent-borne polymer coatings. In this work, poly(ethyl methacrylate) (PEMA) coatings were deposited by first spin coating solutions of PEMA (dissolved in 2,2,2-trichloroethanol (TCE)) onto fused silica substrates, then baking at temperatures of either 130°C (soft-bake) or 180°C (hard-bake). Analysis of the two coatings revealed that the soft-bake coating retained a significant amount of TCE within the polymer matrix, which functioned to plasticize the coating and reduce internal stress. The laser-induced damage resistance of the two coatings was evaluated using 351-nm, 1-ns laser pulses. The testing protocols included single-pulse (1-on-1), 1-pulse ramp (R-on-1), and a 1000-pulse ramp (1000R-on-1) test. The results showed that the plasticized, soft-bake coating exhibits a significantly increased LIDT, especially for multipulse irradiation conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2025

The Kinetics of the Coherent Stage of Hydroxide Corrosion on Li 2 O-Covered LiH

The capability to model LiOH growth on vacuum-baked LiH is a necessary precursor to making kinetic predictions of undesirable hydrogen outgassing from corroded LiH materials when placed in sealed-system applications. Here, in this work, LiH samples with initial LiOH surface corrosion layers less than 1.1 μm were outgassed by vacuum baking at high temperature to convert LiOH to Li 2 O. Diffuse-reflectance infrared Fourier transform (DRIFT) spectroscopy was used to measure the subsequent LiOH regrowth during exposure to 25–375 ppm of H 2 O vapor at room temperature. Logarithmic kinetics best model the growth of this coherent hydroxide corrosion layer (up to 1.5 μm) on previously vacuum-baked LiH samples. The logarithmic kinetics are attributed to the dissociation of H 2 O on the corrosion layer and the establishment of a H + /OH – electric field across the thickening LiOH corrosion layer. A time-dependent model of LiOH corrosion growth as a function of both initial LiOH thickness before vacuum baking and moisture partial pressures during re-exposure was developed to help researchers better assess the unwanted hydrogen outgassing potential from LiH/LiD materials.

Matt, Sarah M. [Lawrence Livermore National Labora↗
DOE OSTI2025

Outgassing measurements of bare and magnetite-coated low-carbon steel vacuum chambers

The outgassing properties of bare and magnetite-coated AISI 1020 low-carbon steel vacuum chambers were evaluated to establish material selection criteria for extreme high vacuum applications, namely, to explore the possibility of using these materials to build next-generation spin-polarized photoelectron guns. Water outgassing measurements using the throughput method revealed that the magnetite-coated chamber exhibited five times lower outgassing at room temperature prior to baking, but this advantage disappears after 80 °C baking. Hydrogen outgassing measurements demonstrated significant differences after intensive heat treatment: the bare low-carbon steel vacuum chamber achieved a specific outgassing rate of 9.6 × 10 −16 Torr L s −1 cm −2 after 400 °C/50 h bake plus additional heat treatment at lower temperatures, 25 times lower than the magnetite-coated low-carbon steel chamber. Residual gas analysis showed >99% hydrogen composition after heat treatment for both materials, with carbon species below detection limits for bare low-carbon steel versus 0.8% for magnetite-coated surfaces. These measurements indicate that properly conditioned bare low-carbon steel can achieve the <10 −12 Torr pressures required for next-generation spin-polarized photogun applications. In conclusion, the paper includes various analysis techniques intended to explain observed behaviors: isotherm analysis of pump-down plots, Arrhenius analysis of hydrogen outgassing rate data, and residual gas composition tracking.

Adsorption isotherm↗
DOE OSTI2025

Hybrid chemical characterization of latent images in EUV resist with 12 nm half-pitch features

With the advancement of high numerical aperture extreme ultraviolet (EUV) lithography, the new platform will enable chipmakers to achieve critical dimensions of 8 nm. However, resist materials face significant challenges in delivering increased sensitivity while managing rising stochastic variations. We aim to develop comprehensive techniques to characterize the chemical profile of latent images, stored in EUV resists after exposure and postexposure baking, which is essential for understanding the origin of stochastic effects. Infrared photo-induced force microscopy (IR PiFM) is a bimodal atomic force microscopy technique combined with an infrared light source, allowing for simultaneous sub-5 nm topographic and chemical characterization within a localized environment. Critical-dimension resonant soft X-ray scatterometry (CD-RSoXS) provides statistical data that reveal structural and chemical information for comparative analysis. For the first time, IR PiFM has been used to chemically map the latent images of EUV resists (after exposure and postexposure baking) at a record high resolution of 12 nm half-pitch, enabling nondestructive analysis of patterns prior to development. Furthermore, CD-RSoXS offers direct experimental observation and comparison of exposed, postexposure baked, and developed patterns, which align with the IR PiFM results. We demonstrate that the IR PiFM technique offers valuable insights into both high spatial resolution and local chemical information simultaneously. In addition, CD-RSoXS provides statistical results that support our main findings. This hybrid metrology approach leverages a multifaceted dataset by combining the most reliable information from each source, which is essential for a comprehensive understanding of the stochastic effects in EUV lithography processes.

O’Reilly, Padraic↗