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Pan, Heng

Publications and source records attributed to Pan, Heng.

At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Enable superior performance of ultra-high loading electrodes through the cost-efficient solvent-free electrode manufacturing technology

This research explores an innovative solvent-free method for fabricating ultra-high loading NMC811 and graphite electrodes (~6mAh∙cm -2 ), showcasing remarkable electrochemical performance enhancements compared to the electrodes prepared by the conventional slurry-casting method. Here, the optimized microstructure with dry-printed (DP) electrodes enhanced electrolyte penetration and minimized lithium-ion diffusion tortuosity resulting in improved rate performance at high current rates. Additionally, this innovative electrode manufacturing approach enables more uniform CEI and SEI formation and growth, which effectively doubles the cycle life of single-layer pouch cells with DP electrodes. Beyond the performance enhancements, this method also offers a notable 29.2 % overall cost advantages, potentially revolutionizing future battery manufacturing. The findings presented in this work underscore the potential of solvent-free manufacturing technology as a high-loading capable and cost-efficient path for advanced battery production.

25 ENERGY STORAGE↗
DOE OSTI2023

Roll-to-roll solvent-free manufactured electrodes for fast-charging batteries

In response to the growing demand for lithium-ion batteries (LIBs), we demonstrate a solvent-free manufacturing technology that can avoid toxic organic solvents and form unique electrode structures to overcome the bottlenecks in low costs and fast charging. The lower tortuosity achieved by the open pores in the dry-printed (DP) electrode allows for a shorter Li+ diffusion pathway, which leads to better rate performance. The DP pouch cells exhibit higher capacity retention of 78% and 69% at 3C and 4C, respectively, compared with 67% and 52% for the slurry cast (SL) cells at the same rates. Moreover, the coating layer on the surface of active materials prevents the excess side reaction between active materials and electrolytes, which prolongs the cycle life of the DP cells. This manufacturing process is a roll-to-roll system with immense potential to be scaled up, providing a more efficient and economical way for battery manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Lessons Learned From the Prototypes of the MQXFA Low-Beta Quadrupoles for HL-LHC and Status of Production in the US

With the successful test of the first two pre-series magnets the US HL-LHC Accelerator Upgrade Project has started production of the MQXFA magnets to be used in Q1/Q3 inner triplet elements of the HL-LHC. This good start comes after the test of two prototypes with limited performance, and it demonstrates the importance of learning from past issues. Therefore, in this paper we want to share the most important lessons learned so far, focusing on those which may be more interesting for similar projects. Additionally, we will present the status of MQXFA fabrication in the US.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

Fracture Failure Analysis for MQXFA Magnet Aluminum Shells

The High-Luminosity LHC Accelerator Upgrade Project (HL-LHC AUP) is approaching the production phase of the US-contributed Q1 and Q3 Interaction Region Quadrupoles (MQXFA). The structures for the MQXFA prototypes were design and inspected by the US-LARP (LHC Accelerator Research Program), AUP developed criteria, which will be used for the pre-series structures. As the first two full-length prototypes with 4.2 m magnetic length, MQXFAP1 and MQXFAP2, were designed and assembled at Lawrence Berkeley National Laboratory (LBNL), and tested at Brookhaven National Laboratory (BNL). The end aluminum short shell of MQXFAP2 was fractured along the shell length during the test, and tests were stopped. Analytical and Finite Element analysis were performed in light of the graded procedure defined in the Structure Design Criteria to investigate the fracture failure for MQXFAP2. In this paper, we report the fracture analysis of the current shell design, including the elasto-plastic simulations with submodel technique, and calculations with Linear Elastic Fracture Mechanics (LEFM). Test material properties are also presented. The results of this analysis explain why the end shell of MQXFAP2 failed, and suggest fillets on the end shell notches to meet the margin specified in the Structural Design Criteria.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

Preload Characterization of Short Models of MQXF the Nb 3 Sn Low-β Quadrupole for the Hi-Lumi LHC

MQXF is the Nb3Sn Low-β Quadrupole magnet that the HL-LHC project is planning to install in the LHC interaction regions in 2026 as part of an upgrade to increase the LHC inte-grated luminosity by about a factor of ten. The magnet will be fab-ricated in two different lengths: 4.2 m for MQXFA, built in the US by the Accelerator Upgrade Project (AUP), and 7.15 m for MQXFB, fabricated by CERN. In order to qualify the magnet de-sign and characterize its performance with different conductors, cable geometries and pre-load configuration, five short model magnets, called MQXFS, were fabricated, assembled and tested. The latest model, MQXFS6, uses a new powder-in-tube (PIT) su-perconducting wire, featuring a bundle barrier surrounding the filaments. The coil and the support structure were equipped with strain gauges and optical fibres to monitor strain during assembly, cool-down and excitation. In this paper we further develop the conventional azimuthal preload analysis and introduce a new set of tools for MQXF coil pack characterization which we use to an-alyse the behaviour of MQXFS6 room temperature preload and to reanalyse all the short models tested at CERN. A comparison is made between all the studied magnets revealing new characteriz-ing preload parameters.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

Mechanical Performance of the First Two Prototype 4.5 m Long Nb$_3$Sn Low-$β$ Quadrupole Magnets for the Hi-Lumi LHC Upgrade

The U.S. High-Luminosity LHC Accelerator Upgrade Project (HL-LHC AUP) team is collaborating with CERN in the design and fabrication of the first 4.5 m long MQXFA magnets, a 150 mm aperture high-field Nb$_3$Sn quadrupole magnet that uses the aluminum shell-based bladder-and-key technology. The first two prototype magnets, MQXFAP1 and MQXFAP2, were assem-bled and tested while the first pre-series structure (MQXFA03) was in fabrication. This paper summarizes the mechanical perfor-mance of these prototype structures based on the comparison of measured strain gauge data with finite element model analyses from all load steps to powering. The MQXFAP1 magnet almost reached ultimate current before a short to ground was detected and the test was stopped. The MQXFAP2 magnet experienced a low training performance due to a fractured aluminum shell. MQXFAP1b was rebuilt with a new replacement coil, but an old coil limited the magnet from achieving the ultimate current. The mitigations and analyses of these prototype magnets are discussed in the context of the transition to pre-series production.

43 PARTICLE ACCELERATORS↗
DOE OSTI2019

Customizable Nonplanar Printing of Lithium‐Ion Batteries

Abstract Lithium‐ion batteries (LIBs) are widely used in consumer electronics due to their rechargeability and high energy density. Commercial LIBs are fabricated in fixed geometries such as cylinder, coin, and pouch. However, for specialized applications such as wearable electronics and on‐device power systems, customizable LIBs with arbitrary geometry on three‐dimensional (3D) structures need to be developed. For this purpose, aerosol printing is uniquely suitable due to its flexible working distance, allowing deposition on nonplanar substrates with multiscale surface topologies. Aerosol printing of LiFePO 4 cathodes and Li 4 Ti 5 O 12 anodes for LIBs is presented. Electrodes with an arbitrary geometry, tailorable thickness and on nonplanar substrates can be realized. The highest areal capacity achieved is ≈7.1 mAh cm −2 , which is at least twice that of conventional electrodes. Furthermore, to package the printed electrodes, 3D enclosures are fabricated via fused deposition modeling of polyvinylidene fluoride. The printed electrodes packaged in 3D enclosures exhibit 78.4% capacity retention after 30 cycles. With the two additive manufacturing processes, customizable LIBs on targeted objects can be realized. A nonplanar LIB conformably covering the edge of a block with specific capacity of 135 mAh g −1 is demonstrated.

Yu, Xiaowei↗
DOE OSTI2019

Failure Assessments for MQXF Magnet Support Structure with a Graded Approach

The High-Luminosity Large Hadron Collider (HLLHC) upgrade requires new quadrupoles, MQXF, to replace the present LHC inner triplets. The MQXFA magnet is the first prototype that has a 150 mm aperture and uses Nb 3 Sn superconducting technology in a 4.2 m magnetic length structure. The support structure design of the MQXFA magnet is based on the bladder-and-key technology, where a relatively low pre-stress at room temperature is increased to the final preload targets during the cool-down by the differential thermal contraction of the various components. The magnet support structure components experience different load levels from pre-load to cool-down and excitation. Consequently, a few parts experience high stresses that may cause localized plastic deformations or internal fracture development. The concept presented in this paper for the failure assessment of support structures integrates nonlinear finite element analysis with detailed sub-models and fracture mechanics into an advanced engineering tool. The nonlinear FE solutions enable estimations of the structural response to the given loads, and the advanced fracture analysis with failure assessment diagram (FAD) assesses the structure safety index of results obtained from the FE model. The study describes how the MQXFA shell end segments are being optimized based on the failure analyses.

43 PARTICLE ACCELERATORS↗
DOE OSTI2019

Mechanical Study of a Superconducting 28-GHz Ion Source Magnet for FRIB

The superconducting electron cyclotron resonance (ECR) source magnet for the facility for rare isotope beams at Michigan State University was designed and built by the Superconducting Magnet Group at Lawrence Berkeley National Laboratory (LBNL) in 2017. The 28 GHz NbTi ion source magnet features a sextupole-in-solenoids configuration which is comparable to the VENUS ECR magnet operated at LBNL. However, the mechanical design of this magnet utilizes a shell-based support structure which allows fine adjustments to the sextupole preload and reversibility of the magnet assembly process. The magnet has been assembled and tested to operational currents at LBNL. This paper describes the mechanical analyses performed to estimate the sextupole's and solenoids' preloads. We will report on the 3-D finite element analysis during room temperature assembly, cool-down, and magnet excitation, and then describe the magnet preload operations. To conclude, we will describe the performance of the support structure during the quench training.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

Summary of the Mechanical Performances of the 1.5 m Long Models of the Nb $_{3}$ Sn Low- $\beta$ Quadrupole MQXF

The Nb 3 Sn quadrupole MQXF is being developed as a part of the large hadron collide (LHC) High Luminosity upgrade. The magnet design was tested on 1.5-m-long short models, sharing the same cross section with the full-length magnets. Various azimuthal and longitudinal preloads were applied, studying the impact on the magnet training and on its mechanical performances. The experiments demonstrated the possibility to control the magnet prestress. However, various factors, coil size among the others, may affect the stress variation between and within each winding. This variation could prevent the magnets from reaching the magnet performances, as for example as a result of the critical current reduction of the Nb 3 Sn strands. This paper analyzes the mechanical performances of the short models, studying in particular the stress variation on different coils. The measured coil size was used as input in the numerical simulations, and the results were then compared with the strain gauge measurements. Lastly, the short model experience was used to evaluate the feasibility of a loading operation that does not rely on the strain measurements.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

Field Quality Measurement of a 4.2-m-Long Prototype Low- $\beta$ Nb $_3$ Sn Quadrupole Magnet During the Assembly Stage for the High-Luminosity LHC Accelerator Upgrade Project

The U.S. High-Luminosity LHC Accelerator Upgrade Project, in collaboration with CERN, is developing Nb 3 Sn quadrupole magnets (MQXFA) to be installed at the interaction region of the LHC. The project will deliver 20 MQXFA magnets in 10 cold masses. These magnets need to meet the stringent requirements on field quality at the nominal operating current. Compared to the mature NbTi accelerator magnet technology, achieving excellent field quality can be challenging for Nb 3 Sn magnets. To help track, understand, and allow effective correction of geometric field errors, field quality measurements at room temperature during the MQXFA assembly stage was planned for the project. The measurements also intend to evaluate the magnetic axis and twist angle along the magnet aperture. We report the first measurement on a prototype MQXFA magnet using a recently developed measurement system. The magnetic axis and twist angle met the acceptance criteria. Further development needs for the room-temperature measurements were discussed. Here, we expect that statistics obtained from such measurements throughout the project will provide insight into future applications of high-performance Nb 3 Sn accelerator magnets.

43 PARTICLE ACCELERATORS↗
DOE OSTI2019

Assembly of a Mechanical Model of MQXFB, the 7.2-m-Long Low-$\beta$ Quadrupole for the High-Luminosity LHC Upgrade

The ${\rm Nb_{3}Sn}$low-$\beta$quadrupole MQXF is being developed as a part of the High-Luminosity large hadron collider (LHC) upgrade project. The magnet will be produced in two different configurations, sharing the same cross section but with different lengths. A 7.2-m mechanical model of MQXFB was recently assembled at european organization for nuclear research (CERN) with one copper coil, two low-grade coils, and one rejected coil. Coil dimensions were measured with a portable coordinate measurement machine. The coil pack shimming was designed in order to optimize the field quality and the contacts between the coils and the collars. The azimuthal preload target was defined using the short models experience. The mechanical behavior during loading was monitored by means of strain gauges. The results demonstrated that the structure can provide the required prestress to the coils.

43 PARTICLE ACCELERATORS↗
DOE OSTI2018

Fabrication and Assembly Performance of the First 4.2 m MQXFA Magnet and Mechanical Model for the Hi-Lumi LHC Upgrade

Here, the LHC accelerator research program (LARP), in collaboration with CERN and under the scope of the high luminosity upgrade of the Large Hadron Collider, is in the prototyping stage in the development of a 150 mm aperture high-field Nb 3 Sn quadrupole magnet called MQXF. This magnet is mechanically supported using a shell-based support structure, which has been extensively demonstrated on several R&D models within LARP, as well as in the more recent short (1.2 m magnetic length) MQXF model program. The MQXFA magnets are each 4.2 m magnetic length, and the first mechanical long model, MQXFA1M (using aluminum surrogate coils), and MQXFAP1 prototype magnet (the first prototype with Nb 3 Sn coils) have been assembled at the LBNL. In this paper, we summarize the tooling and the assembly processes, and discuss the mechanical performance of these first two assemblies, comparing strain gauge data with finite element model analysis, as well as the near-term plans for the long MQXF magnet program.

43 PARTICLE ACCELERATORS↗
DOE OSTI2017

Summary of Test Results of MQXFS1—The First Short Model 150 mm Aperture Nb 3 Sn Quadrupole for the High-Luminosity LHC Upgrade

The development of Nb 3 Sn quadrupole magnets for the High-Luminosity LHC upgrade is a joint venture between the US LHC Accelerator Research Program (LARP)* and CERN with the goal of fabricating large aperture quadrupoles for the LHC interaction regions (IR). The inner triplet (low-β) NbTi quadrupoles in the IR will be replaced by the stronger Nb3Sn magnets boosting the LHC program of having 10-fold increase in integrated luminosity after the foreseen upgrades. Previously, LARP conducted successful tests of short and long models with up to 120 mm aperture. The first short 150 mm aperture quadrupole model MQXFS1 was assembled with coils fabricated by both CERN and LARP. The magnet demonstrated a strong performance at Fermilab's vertical magnet test facility reaching the LHC operating limits. This paper presents the latest results from MQXFS1 tests with changed prestress levels. The overall magnet performance, including quench training and memory, ramp rate, and temperature dependence, is also summarized.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2017

Mechanical Design Analysis of MQXFB, the 7.2-m-Long Low- $\beta$ Quadrupole for the High-Luminosity LHC Upgrade

As part of the High-Luminosity Large Hadron Collider (LHC) Project, a set of Nb 3 Sn quadrupoles are being developed, aiming to enhance the performance of the inner triplets. The new magnets, identified as MQXFA and MQXFB, will share the same cross section with two different lengths, 4.2 and 7.2 m, respectively. During the magnet development, three short models were tested, along with a number of mechanical models, demonstrating the capability of the magnet cross section to achieve the specified performances. The same performances are now required for the full-length magnets. To ensure this, the authors studied the impact of the magnet length on the capability of the structure to provide an adequate support to the coils. Finite element and simplified analytical models were used to evaluate the impact of the magnet length on the stresses in the magnet ends and coil elongation during powering. Lastly, the models were calibrated using the results from the short model tests, and used to provide an indication on the required prestress and its foreseen impact on the magnet performance.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2017

Analysis of the Training Behavior of the MICE Spectrometer Solenoid

Muon ionization cooling is theoretically well understood but has never been fully demonstrated experimentally. Ionization cooling is regarded as an important technology both in terms of cost and performance for a Neutrino Factory and is absolutely essential for a Muon Collider. The MICE experiment (Muon Ionization Cooling Experiment), based at the Rutherford Appleton Laboratory, U.K., is currently collecting data to prove the concept. Part of MICE are two spectrometer magnets, each consisting of five superconducting large bore solenoids. The spectrometer solenoid is designed for a peak field of 4T. Both spectrometer magnets required about 15 quenches to reach the design current. However, it was discovered that both spectrometers do not remember their training; after a warm-up the spectrometers have to be retrained, following a very similar training curve. The MICE spectrometer was analyzed using 2-D and 3-D finite element software to understand the quench and training behavior; the analysis revealed a clamping mechanism, leading to a stick-slip situation for one of the coils in its coil pocket. This paper summarizes the results and makes suggestions how to improve the design.

43 PARTICLE ACCELERATORS↗