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DOE OSTI2022

Experiments and modelling of adhesive failure initiation of an epoxy underfill: a study of electronic packaging survivability

Epoxy underfills can be implemented in electronic packaging to enhance solder joint reliability of surface mounted components. However, it is important for an engineer to have a failure criterion that can be used for failure predictions and redesign of electronic assemblies. For this study, data from epoxy bond failure in mock electronic part assemblies were correlated to finite element analyses to predict adhesive failure initiation. Experiments were performed to determine failure loads for various loading locations and nonlinear viscoelastic analyses were performed for the same loading locations to determine a maximum principal strain failure parameter. Predictions showed that a maximum principal strain failure parameter defined from one test could be used as an indicator of adhesive failure of an epoxy bond undergoing other modes of loading. Failure initiation predictions matched experimental data using a maximum principal strain failure parameter for an epoxy bond undergoing mixed modes of loading for both unfilled and alumina oxide filled 828DEA epoxy. Such experimental setup is deemed appropriate for future epoxy testing.

42 ENGINEERING↗

DOE OSTI2025

Predictive dynamic wetting, fluid–structure interaction simulations for braze run-out

Brazing and soldering are metallurgical joining techniques that use a wetting molten metal to create a joint between two faying surfaces. Here, the quality of the brazing process depends strongly on the wetting properties of the molten filler metal, namely the surface tension and contact angle, and the resulting joint can be susceptible to various defects, such as run-out and underfill, if the material properties or joining conditions are not suitable. In this work, we implement a finite element simulation to predict the formation of such defects in braze processes. This model incorporates both fluid–structure interaction through an arbitrary Eulerian–Lagrangian technique and free surface wetting through conformal decomposition finite element modeling. Upon validating our numerical simulations against experimental run-out studies on a silver-Kovar system, we then use the model to predict run-out and underfill in systems with variable surface tension, contact angles, and applied pressure. Finally, we consider variable joint/surface geometries and show how different geometrical configurations can help to mitigate run-out. This work aims to understand how brazing defects arise and validate a coupled wetting and fluid–structure interaction simulation that can be used for other industrial problems.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Real-Time Defect Correction in Large-Scale Polymer Additive Manufacturing via Thermal Imaging and Laser Profilometer

Defects can result in a failed part and are costly in terms of time and material. This cost is even greater in the context of large-scale additive manufacturing where the objects can be very large. As a result, a great deal of research has focused on defect identification and mitigation. To address defects during object construction, researchers at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility investigated an in-situ control system comprised of two sensors: a thermal camera and laser profilometer. This control system adjusted material flow and build speed to mitigate three types of defects: low layer times, underfill, and overfill. Several test objects were constructed. The control system was found to adjust build parameters to handle low layer times of approximately 15 seconds and height deviations from -100% underfill (the absence of a layer) to 50% overfill. Within two layers, height deviations could be returned to within 10% of the expected layer height. Further, preliminary results suggest the system can compensate for uneven build surfaces.

Borish, Michael↗

DOE OSTI2025

Defect Detection Model Development for Large Scale Thermoplastic Printing

Large-format additive manufacturing (LFAM) offers several advantages, including high throughput, cost-effective pellet-fed extrusion, and the capability to produce large-scale structures. The main pain points of LFAM include start and stops during the printing process, warpage, long layer times that lead to bead freezing, and bead separation due to shrinkage. These issues can lead to overfill, underfill and buildup of material in different sections of a print. This can lead to hidden defects embedded within the printed layers, or even ultimate failure of the printed structure. This ensures these defects can only be identified through nondestructive testing (NDT) inspection methods after printing, which can be timely and costly. Aligned Vision work specializes in 2D projectors with visual inspection systems and machine learning. Traditionally system is used for composite layup and layup inspections. In this work we used the LFAM system at Oak Ridge National Laboratory to create defect rich samples. The Aligned Vision inspection system then performed in-situ monitoring of the print process after each part was printed. This in-situ vision inspection system was used to develop a layer-by-layer inspection model that looks for overfill, underfill, and the buildup of defects using only a camera-based vision system. This leads to the assurance of high-quality production components.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Smart CNG Dispenser Deployment

This final technical report documents the work performed under DOE Award DE‑EE0008799 by GTI Energy over the course of the project period. The project focused on advanced fueling methods for compressed natural gas (CNG) vehicles which have historically suffered from underfilling.

03 NATURAL GAS↗

DOE OSTI2025

Phenomena Identification and Ranking Table (PIRT) for heat pipes

Heat pipes are advanced passive thermal management devices that utilize phase change and capillary action to achieve efficient heat transfer. However, due to the complexity of the phenomena coupled in heat pipes, including capillary, phase change, turbulence, and compressibility effects, there are high uncertainties in the predictability of their operational regimes and performance. This PIRT exercise, conducted as a collaborative effort involving the Department of Energy (DOE) Microreactor Program (MRP), the Nuclear Regulatory Commission (NRC), and university partners systematically identifies, reviews, and prioritizes critical phenomena affecting the operation of heat pipes based on their importance and knowledge levels. Additional analyses and discussion are provided for phenomena with high importance and low knowledge, such as wick de-wetting, critical heat flux, contact angles, and pressure dynamics. The discussions included the recognizing challenges and proposing future research directions for both modeling and simulation and experimental efforts. Additionally, the report addresses phenomena with medium importance and low knowledge that could impact heat pipe operation during non-normal or transient operation, including frozen startup, laminar to turbulent transition, geyser boiling, wick priming, underfilling conditions, surface roughness of the wick, NCGs trapped in the wick, and the timescales of startup and shutdown. In conclusion, this comprehensive evaluation serves as a valuable resource for guiding future research and development efforts, supporting the successful integration of heat pipes into critical applications such as nuclear reactors, and contributing to the advancement of heat pipe technologies in safety-critical industries.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

DOE OSTI2020

Water Uptake by Silica Nanopores: Impacts of Surface Hydrophilicity and Pore Size

Water uptake at 298 K by two mesoporous silicas with different pore sizes was studied using volumetric vapor sorption. Here, through variation of sample pretreatment temperature and time, the number of surface hydroxyl groups was varied, leading to marked changes in the water sorption behavior. With increasing surface hydroxyl density, the adsorption of water to the pore surfaces increases, leading to formation of a thicker and denser water sorption layer. The BET model was used to measure surface hydroxyl density from low pressure parts of water adsorption isotherms. Adsorption of water molecules scales with the number density of surface hydroxyl groups, and monolayer coverage is reached at reduced pressure of ca. 0.3. The onset of adsorption pore condensation of water shifts to lower reduced pressure with increasing surface hydroxyl density, indicating growing thickness of adsorption layers. However, the water pore condensation step of the desorption branch shifts to smaller reduced pressure with increasing surface hydroxylation, reducing the adsorption-desorption hysteresis width. An adsorbed phase model is utilized to calculate the distribution of pore water molecules between adsorbed and pore condensation phases, and characterize the density and thickness of the water sorption phase. In the smaller pores, the adsorbed phase forms a sparse monolayer, while approximately a bilayer is formed in the wider pores. The previously reported silica nanopore underfilling by water is confirmed and rationalized by a significantly reduced water density in the adsorbed phase with respect to bulk, while the pore core is filled with water of approximately bulk density.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Pressure suppresses the density wave order in kagome metal LuNb 6 ⁢Sn 6

The density waves that develop in kagome metals ScV 6 ⁢Sn 6 and LuNb 6 ⁢Sn 6 at low temperature appear to arise from underfilled atomic columns within a V-Sn or Nb-Sn scaffolding. Compressing this network with applied pressure in ScV 6 ⁢Sn 6 suppressed the structural transition temperature by constraining atomic rattling and inhibiting the shifts that define the structural modulation. We predicted that the density wave transition in LuNb 6⁢ Sn 6 at 68 K would be suppressed by pressure as well. In this Letter, we examine the pressure dependence of the density wave transition by measuring resistance vs temperature up to 2.26 GPa. We found the transition temperature is smoothly depressed and disappears around 1.9 GPa. In conclusion, this result not only addresses our prediction, but strengthens the rattling chains origin of structural instabilities in the HfFe 6⁢ Ge 6 -type kagome metals.

Charge density waves↗

DOE OSTI2020

K-space algorithmic reconstruction (KAREN): a robust statistical methodology to separate Bragg and diffuse scattering

Diffuse scattering occurring in the Bragg diffraction pattern of a long-range-ordered structure represents local deviation from the governing regular lattice. However, interpreting the real-space structure from the diffraction pattern presents a significant challenge because of the dramatic difference in intensity between the Bragg and diffuse components of the total scattering function. In contrast to the sharp Bragg diffraction, the diffuse signal has generally been considered to be a weak expansive or continuous background signal. In this paper, using 1D and 2D models, it is demonstrated that diffuse scattering in fact consists of a complex array of high-frequency features that must not be averaged into a low-frequency background signal. To evaluate the actual diffuse scattering effectively, an algorithm has been developed that uses robust statistics and traditional signal processing techniques to identify Bragg peaks as signal outliers which can be removed from the overall scattering data and then replaced by statistically valid fill values. This method, described as a 'K-space algorithmic reconstruction' (KAREN), can identify Bragg reflections independent of prior knowledge of a system's unit cell. KAREN does not alter any data other than that in the immediate vicinity of the Bragg reflections, and reconstructs the diffuse component surrounding the Bragg peaks without introducing discontinuities which induce Fourier ripples or artifacts from underfilling `punched' voids. The KAREN algorithm for reconstructing diffuse scattering provides demonstrably better resolution than can be obtained from previously described punch-and-fill methods. The superior structural resolution obtained using the KAREN method is demonstrated by evaluating the complex ordered diffuse scattering observed from the neutron diffraction of a single plastic crystal of CBr 4 using pair distribution function analysis.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Solidification of SRPPF Aqueous Recovery Liquid: Process Disruptions

Savannah River National Laboratory has identified a magnesium oxysulfate grout formulation to solidify the liquid effluent from the Savannah River Plutonium Processing Facility (SRPPF) Aqueous Recovery System (ARS). The formulation uses reactive, light burnt MgO, anhydrous MgSO 4 , and dead burnt MgO and provides good mixability, similar density to the original Portland Cement-based mix, and a leachate pH of 9.39, within the assumed Waste Isolation Pilot Plant (WIPP) brine pH range. The formulation will solidify the effluent using a solid first, lost paddle design, within a 55-gallon drum. A series of seven different process disruptions, or irregular processing during the expected ARS liquid effluent solidification process, were completed to assess the severity of the impact of the process disruption and how the formulation behaves under these conditions. Seven process disruptions were investigated including: No Mixing, Partial Mixing, Compacted/Stratified, Sealed, Overfilled, Underfilled, and Undermixed. The impact on solidification, leachate pH, Er (a Pu/Am surrogate) distribution, and density of the resulting grout were established. Overall, four of the process disruptions, No Mixing, Partial Mixing, Compacted/Stratified, and Overfilled, resulted in basic, unabsorbed liquid that would require additional solidification to be acceptable for WIPP. Most solids generated in this testing met the expected WIPP leachate pH requirements. Solids from the Compacted/Stratified process disruption test, however, produced a leachate pH slightly above the assumed range in the WIPP performance assessment. The distribution of Er for most of the tests was relatively consistent. The No Mixing process disruption test, however, resulted in non-homogeneous Er distribution, indicating that radioactive material would not be evenly distributed throughout this solid’s matrix. The Overfilled test is the only mix with a density slightly below the acceptable value. The Sealed and Overmixed tests produced a solid closest to the standard mix with no unabsorbed liquid, expected leachate pH levels, consistent Er concentrations, and expected density, indicating these process disruptions do not have a negative impact on the final grout form. Based on the other process disruptions, it is critical to have premixed dry materials and a well-defined mixing process to produce a solid, homogeneous magnesium oxysulfate cement, with no unabsorbed liquid. These process disruption tests show that the lack of adequate mixing is fundamental to creating an improperly solidified material that may require remediation.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

BVR{sub c}I{sub c} Observations, Third-body Orbital Study, and Analysis of the UV Leo-type, Pre-W UMA Binary V642 Virginis

V642 Vir is a polar spotted, well-detached, UV Leo-type, low-mass, pre-WUMa (T1 ~ 4250K, ~K6V) eclipsing binary. It was observed in 2020 April, May, and June at the Dark Sky Observatory in North Carolina, USA with the 0.81 m reflector of Appalachian State University. A total of 88 timings were used in our 22-year period study which included 12 Transiting Exoplanet Survey Satellite (TESS) timings. The O - C plots show a low-amplitude oscillation of residuals that points to the existence of an orbiting third body, a dwarf of minimum mass, 0.15 M {sub ⊙} in an eccentric orbit (e = 0.41), with an orbital period of 20.07 yr. The odd light curves of V642 Virginis indicate that it has polar spots similar to UV Leo and the recently published V1023 Per. Its present large polar spot region indicates that it must have a strong magnetic field and that it is synchronously rotating. The BVR{sub c}I{sub c} simultaneous Wilson–Devinney Program solution gives a detached binary (primary and secondary components are underfilling their respective Roche Lobes, with 76% and 78% fill outs respectively). The cool spot region models near the pole of the primary component (centered at 10° colatitude) and is angled toward the secondary component. Its large radius (68°) and T-fact (T{sub spot}/T{sub surface} = 0.69) also attest to the conclusion of the strength of the magnetic field. The small ΔT in the components (~318 K) and mass ratio near unity (0.9542 ± 0.0005) show that the stars are similar in spectral type (secondary ~K9V). The inclination is high, ~86.87 ± 0.04°, yet there is no time of constant light due to the two stars’ essentially equal radii.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2024

Radiopaque particle processing additive

A radiopaque processing medium comprising a plurality of radiopaque particles and a non-radiopaque processing medium. The plurality of radiopaque particles is added to the non-radiopaque processing medium to increase a bulk density of the processing medium thereby forming the radiopaque processing medium. The radiopaque processing medium allows excess process media to be located and characterized during X-ray inspection of an electronic device on which the radiopaque processing medium was used. The radiopaque processing medium may also be used to locate and identify flaws/defects of the electronic device based on the location of excess radiopaque processing medium. The radiopaque processing medium may also be used as an underfill material to reinforce electronic chips soldered to the electronic device.

Diamond, Louis↗

DOE OSTI2025

Phenomena Identification and Ranking Table (PIRT) for Heat Pipes

This Phenomena Identification and Ranking Table (PIRT) report provides an evaluation of key phenomena affecting the performance and operational regimes of heat pipes, particularly in the context of heat pipe microreactors (HPMRs). Heat pipes are advanced passive thermal management devices that utilize phase change and capillary action to achieve efficient heat transfer. However, due to the complexity of the phenomena coupled in the heat pipe, including phase change, turbulent transition, and compressibility effects, among others, there is high uncertainty in identifying and ranking the important phenomena affecting the operation of heat pipes and the current knowledge for their modeling and simulation and experimental measurements and instrumentation. This PIRT exercise, conducted as a collaborative effort involving the Department of Energy (DOE) Microreactor Program (MRP), the Nuclear Regulatory Commission (NRC), and university partners systematically identifies, reviews, and prioritizes critical phenomena affecting the operation of heat pipes based on their importance and knowledge levels. The report analyzes phenomena with high importance and low knowledge, such as wick de-wetting, critical heat flux, contact angles, and pressure dynamics, discussing challenges and future research directions for improving their modeling and simulation and experimental measurements. Additionally, the report addresses phenomena with low knowledge that could impact heat pipe operation during non-normal or transient operation, including frozen startup, laminar to turbulent transition, geysering, wick priming, underfilling conditions, surface roughness of the wick, NCGs trapped in the wick, and the timescales of startup and shutdown. This comprehensive evaluation serves as a valuable resource for guiding future research and development efforts, supporting the successful integration of heat pipes into critical applications such as nuclear reactors, and contributing to the advancement of heat pipe technologies in safety-critical industries.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

DOE OSTI2025

Material Needs and Measurement Challenges for Advanced Semiconductor Packaging: Understanding the Soft Side of Science

This Perspective builds upon insights from the National Institute of Standards and Technology (NIST)-organized workshop, “Materials and Metrology Needs for Advanced Semiconductor Packaging Strategies,” held at the 35th annual Electronics Packaging Symposium in Binghamton, NY, on September 5, 2024. It outlines critical challenges and opportunities related to polymer-based “soft” materials in advanced semiconductor packaging, with emphasis on polymer science, measurement science (metrology), and the strategic development of Research-Grade Test Materials (RGTMs). These efforts, led by the NIST CHIPS team, aim to advance the fundamental understanding of structure-property-processing relationships, promote standardized guidelines and innovative methods for material characterization, and accelerate the development, qualification, and adoption of next-generation packaging materials. The Perspective also distills key insights from the panel discussion with industry experts, emphasizing the need for close collaboration among materials scientists, process engineers, and metrology experts to enable a holistic strategy, further highlighting the importance of cross-sector partnerships among industry, academia, and government to address pressing challenges in packaging materials and processes.

97 MATHEMATICS AND COMPUTING↗