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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Wire Crimp Termination Verification Using Ultrasonic Inspection

The development of a new ultrasonic measurement technique to quantitatively assess wire crimp terminations is discussed. The amplitude change of a compressional ultrasonic wave propagating through the junction of a crimp termination and wire is shown to correlate with the results of a destructive pull test, which is a standard for assessing crimp wire junction quality. Various crimp junction pathologies such as undercrimping, missing wire strands, incomplete wire insertion, partial insulation removal, and incorrect wire gauge are ultrasonically tested, and their results are correlated with pull tests. Results show that the nondestructive ultrasonic measurement technique consistently (as evidenced with destructive testing) predicts good crimps when ultrasonic transmission is above a certain threshold amplitude level. A physics-based model, solved by finite element analysis, describes the compressional ultrasonic wave propagation through the junction during the crimping process. This model is in agreement within 6% of the ultrasonic measurements. A prototype instrument for applying this technique while wire crimps are installed is also presented. The instrument is based on a two-jaw type crimp tool suitable for butt-splice type connections. Finally, an approach for application to multipin indenter type crimps will be discussed.

Perey, Daniel F.↗
NASA NTRS2007

Fabrication of a Thermally Isolated and Pre-amplified Transistor Module with Polyimide Micro-wires for Cryogenic Detectors

For use in cryogenic applications such as bolometer and x-ray microcalorimeter arrays, pre-amplifying Junction Field Effect Transistors (JFETs) are often required for the readout electronics. The optimum operating temperature of the JFETs is 130 Kelvin while the cryogenic detectors operate in the milli-Kelvin range. Thus, the JFETs must be heated up but thermally isolated from the surrounding cryogenic instruments. In the past, the thermal isolation was accomplished by suspending the JFETs with low conductance wires such as manganium or stainless steel on a Kevlar support platform [I]. This also achieved electrical connections. However, this assembly required manual soldering work, which could raise a reliability issue for the cryogenic applications. In order to eliminate the manual work, polyimide micro-wires were developed [2]. The wires must be of sufficient length to decrease the heat load and in tension to prevent microphonic noise from vibration of the wires: the polyimide wires were patterned into llS"shaped curves over a thin metal wires such as aluminum, titanium, or niobium. The bilayer of the films were then suspended by etching silicon substrate thus to make freestanding air bridges (enough explanation?). In this paper, we present a method to fabricate micromachined JFET mechanical modules suspended by polyimide Pyraline micro-wires and heated up with built-in aluminum micro-heaters.

Oh, L. H.↗
NASA NTRS2007

Wire Crimp Connectors Verification using Ultrasonic Inspection

The development of a new ultrasonic measurement technique to quantitatively assess wire crimp connections is discussed. The amplitude change of a compressional ultrasonic wave propagating through the junction of a crimp connector and wire is shown to correlate with the results of a destructive pull test, which previously has been used to assess crimp wire junction quality. Various crimp junction pathologies (missing wire strands, incorrect wire gauge, incomplete wire insertion in connector) are ultrasonically tested, and their results are correlated with pull tests. Results show that the ultrasonic measurement technique consistently (as evidenced with pull-testing data) predicts good crimps when ultrasonic transmission is above a certain threshold amplitude level. A physics-based model, solved by finite element analysis, describes the compressional ultrasonic wave propagation through the junction during the crimping process. This model is in agreement within 6% of the ultrasonic measurements. A prototype instrument for applying the technique while wire crimps are installed is also presented.

Cramer, K. Elliott↗
NASA NTRS2006

Ultrasonics Equipped Crimp Tool: A New Technology for Aircraft Wiring Safety

We report on the development of a new measurement technique to quantitatively assess the condition of wire crimp connections. This ultrasonic (UT) method transmits high frequency sound waves through the joint under inspection. The wire-crimp region filters and scatters the ultrasonic energy as it passes through the crimp and wire. The resulting output (both time and frequency domains) provides a quantitative measure of the joint quality that is independent and unaffected by current. Crimps of poor mechanical and electrical quality will result in low temporal output and will distort the spectrum into unique and predictable patterns, depending on crimp "quality". This inexpensive, real-time measurement system can provide certification of crimps as they are made and recertification of existing wire crimps currently in service. The measurements for re-certification do not require that the wire be disconnected from its circuit. No other technology exists to measure in-situ the condition of wire joints (no electrical currents through the crimp are used in this analytical technique). We discuss the signals obtained from this instrument, and correlate these signals with destructive wire pull tests.

Yost, William T.↗
NASA NTRS2013

Use of beam deflection to control an electron beam wire deposition process

A method for controlling an electron beam process wherein a wire is melted and deposited on a substrate as a molten pool comprises generating the electron beam with a complex raster pattern, and directing the beam onto an outer surface of the wire to thereby control a location of the wire with respect to the molten pool. Directing the beam selectively heats the outer surface of the wire and maintains the position of the wire with respect to the molten pool. An apparatus for controlling an electron beam process includes a beam gun adapted for generating the electron beam, and a controller adapted for providing the electron beam with a complex raster pattern and for directing the electron beam onto an outer surface of the wire to control a location of the wire with respect to the molten pool.

Taminger, Karen M.↗
NASA NTRS2007

Next Generation Wiring

Wiring is a major operational component on aerospace hardware that accounts for substantial weight and volumetric space. Over time wire insulation can age and fail, often leading to catastrophic events such as system failure or fire. The next generation of wiring must be reliable and sustainable over long periods of time. These features will be achieved by the development of a wire insulation capable of autonomous self-healing that mitigates failure before it reaches a catastrophic level. In order to develop a self-healing insulation material, three steps must occur. First, methods of bonding similar materials must be developed that are capable of being initiated autonomously. This process will lead to the development of a manual repair system for polyimide wire insulation. Second, ways to initiate these bonding methods that lead to materials that are similar to the primary insulation must be developed. Finally, steps one and two must be integrated to produce a material that has no residues from the process that degrades the insulating properties of the final repaired insulation. The self-healing technology, teamed with the ability to identify and locate damage, will greatly improve reliability and safety of electrical wiring of critical systems. This paper will address these topics, discuss the results of preliminary testing, and remaining development issues related to self-healing wire insulation.

Medelius, Petro↗
DOE OSTI2025

Fabrication and Test of C3a: A Six-Layer Subscale Canted $\cos \theta$ Dipole Magnet Using High-Temperature Superconducting corc Wires

REBCO coated conductors have a strong potential for high-field magnet applications. The REBCO technology, however, is still in its infancy for accelerator magnet applications. As part of the U.S. Magnet Development Program (MDP), we developed a six-layer canted cos θ dipole magnet, C3a, using CORC® wires developed by Advanced Conductor Technologies LLC. All the layers were wound using a semi-automated winding machine. Three layers of the magnet used CORC® wires containing the SuperPower “AP” REBCO tapes and the remaining layers used the wires containing the “HM” tapes. At 77 K, both kinds of CORC® wires showed 5% to 10% degradation, after bending to a minimum bend radius of 30 or 35 mm, with respect to the self-field critical current measured before winding. At 4.2 K, the magnet reached 9.5 kA at a ramp rate of 9 A s -1 and generated a dipole field of 1.4 T. Further, the critical current of one layer degraded by 4% after a current transient up to 10.5 kA ramped in an averaged rate of 175 kA s -1 or 20 T s -1 . We confirmed the HM CORC® wire can carry a higher current than the AP CORC® wire at 4.2 K. The test results of the C3a magnet showed that the fabrication and assembly procedure can be used for the upcoming full-scale C3 magnet.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

Wire-Based Additive Manufacturing of Stainless Steel Components

In this work three different wire-fed additive manufacturing (AM) processes were employed to evaluate differences between laser, arc, and electron beam heat sources used for high-deposition-rate AM on the order of 1 kg/h. Optimum weld and build parameters were developed independently to match the characteristics of each heat source using 308L stainless steel welding wire as the feedstock. Laser-wire AM was made with the lowest energy per unit length of weld and had the best control of the melt pool and surface finish. Wire arc-based AM had an intermediate energy per unit length of weld of approximately 5× that of the laser process, while electron beam wire AM had the highest energy per unit length of weld at approximately 10× that of the laser process. Analysis of the parts that were built included evaluation of mechanical properties and microstructures, and these properties are discussed with respect to the difference in input energy and cooling rates. Results show that all three processes build parts with properties that exceed those of annealed 304L wrought stainless steel. However, significant differences exist between the processes, and the results presented here can be used to help select the best wire-fed process for a given high-deposition-rate application.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Simultaneous Multiple Preoperative Localizations of Small Pulmonary Lesions Using a Short Hook Wire and Suture System

PurposeThe aim of the study was to retrospectively evaluate simultaneous multiple hook wire placement outcomes before video-assisted thoracoscopic surgery (VATS).Materials and MethodsThirty-eight procedures were performed on 35 patients (13 men and 22 women; mean age, 59.9 years) with 80 lung lesions (mean diameter 7.9 mm) who underwent simultaneous multiple hook wire placements for preoperative localizations. The primary endpoints were technical success, complications, procedure duration, and VATS outcome; secondary endpoints included comparisons between technical success rates, complication rates, and procedure durations of the 238 single-placement procedures performed. Complications were also evaluated.ResultsIn 35 procedures including 74 lesions, multiple hook wire placements were technically successful; in the remaining three procedures, the second target placement was aborted because of massive pneumothorax after the first placement. Although complications occurred in 34 procedures, no grade 3 or above adverse event was observed. The mean procedure duration was 36.4 ± 11.8 min. Three hook wires dislodged during patient transport to the surgical suite. Seventy-four successfully marked lesions were resected. Six lesions without hook wires were successfully resected after detection by palpation with an additional mini-thoracotomy or using subtle pleural changes as a guide. The complication rates and procedure durations of multiple-placement procedures were significantly higher (P = 0.04) and longer (P < 0.001) than those in the single-placement group, respectively, while the technical success rate was not significantly different (P = 0.051).ConclusionsSimultaneous multiple hook wire placements before VATS were clinically feasible, but increased the complication rate and lengthened the procedure time.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2018

Heterobinuclear Light Absorber Coupled to Molecular Wire for Charge Transport across Ultrathin Silica Membrane for Artificial Photosynthesis

Coupling of robust, all-inorganic heterobinuclear light absorbers to metal oxide catalysts for water oxidation across an ultrathin product-separating silica membrane requires charge transfer through organic molecular wires embedded in the silica. A synthetic approach for assembling the bimetallic units on the silica surface is introduced that is compatible with the presence of encapsulated organic molecules. Accurate selection and fine tuning of the concentration of embedded conducting wires are enabled by a two-step method consisting of surface attachment of a tripodal anchor, trimethoxysilyl aniline, followed by attachment of p-oligo(phenylene vinylene) through amide linkage. Each step of the assembly process was monitored and characterized by a combination of Fourier transform infrared, Fourier transform-Raman, and UV-vis spectroscopy techniques. Hole transfer was observed from transient Co III , formed by Ti IV OCo II → Ti III OCo III charge transfer excitation of the chromophore, to p-oligo(phenylene vinylene) molecule within the 8 ns width of the photolysis laser pulse by transient optical absorption spectroscopy of the wire radical cation. The rectifying property of the light absorber-wire assembly enabled by appropriate selection of redox potentials of metals and embedded wire obviates the need for a molecularly defined linkage between the components. Combined with the previously observed ultrafast hole injection from the embedded wires to Co oxide catalyst, the result implies visible-light-induced hole transfer from visible-light-excited binuclear light absorber to water oxidation catalyst across the silica separation membrane in a few nanoseconds or faster. Finally, demonstration and understanding of this interfacial charge-transfer step is critical for developing nanoscale core-shell architectures for complete photosynthetic cycles.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

Effects of load voltage on voltage breakdown modes of electrical exploding aluminum wires in air

The effects of the load voltage on the breakdown modes are investigated in exploding aluminum wires driven by a 1 kA, 0.1 kA/ns pulsed current in air. From laser probing images taken by laser shadowgraphy, schlieren imaging, and interferometry, the position of the shockwave front, the plasma channel, and the wire core edge of the exploding product can be determined. The breakdown mode makes a transition from the internal mode, which involves breakdown inside the wire core, to the shunting mode, which involves breakdown in the compressed air, with decreasing charging voltage. The breakdown electrical field for a gaseous aluminum wire core of nearly solid density is estimated to be more than 20 kV/cm, while the value for gaseous aluminum of approximately 0.2% solid density decreases to 15–20 kV/cm. The breakdown field in shunting mode is less than 20 kV/cm and is strongly affected by the vaporized aluminum, the desorbed gas, and the electrons emitted from the wire core during the current pause. Ohmic heating during voltage collapses will induce further energy deposition in the current channel and thus will result in different expansion speeds for both the wire core and the shockwave front in the different modes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2018

Multi frame synchrotron radiography of pulsed power driven underwater single wire explosions

We present herein the first use of synchrotron-based phase contrast radiography to study pulsed-power driven high energy density physics experiments. Underwater electrical wire explosions have become of interest to the wider physics community due to their ability to study material properties at extreme conditions and efficiently couple stored electrical energy into intense shock waves in water. The latter can be shaped to provide convergent implosions, resulting in very high pressures (1-10 Mbar) produced on relatively small pulsed power facilities (100s of kA-MA). Multiple experiments have explored single-wire explosions in water, hoping to understand the underlying physics and better optimize this energy transfer process; however, diagnostics can be limited. Optical imaging diagnostics are usually obscured by the shock wave itself; and until now, diode-based X-ray radiography has been of relatively low resolution and rather a broad x-ray energy spectrum. Utilising phase contrast imaging capabilities of the ID19 beamline at the European Synchrotron Radiation Facility, we were able to image both the exploding wire and the shock wave. Probing radiation of 20-50 keV radiographed 200 μm tungsten and copper wires, in ~2-cm diameter water cylinders with resolutions of 8 μm and 32 μm. The wires were exploded by a ~30-kA, 500-ns compact pulser, and 128 radiographs, each with a 100-ps X-ray pulse exposure, spaced at 704 ns apart were taken in each experiment. Abel inversion was used to obtain the density profile of the wires, and the results are compared to two dimensional hydrodynamic and one dimensional magnetohydrodynamic simulations.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

High-speed imaging of transition from fluid breakup to phase explosion in electric explosion of tungsten wires in air

High-speed visible imaging of sub-microsecond electric explosion of wires at the low specific energy deposition threshold reveals three distinct modes of wire failure as capacitor charge voltage and energy deposition are increased. For 100 micron diameter gold-plated tungsten wires of 2 cm length, deposited energies of 1.9 eV/atom produces a liquid column that undergoes hydrodynamic breakup into droplets with radii of order of wire diameter on timescales of 200 μs. Instability growth, column breakup, and droplet coalescence follow classic Rayleigh-Plateau predictions for instability of viscous fluid column. Above 3.2 eV/atom of deposited energy, wires are seen to abruptly transition to an expanding mixture of micron scale liquid-droplets and vapor within one frame (less than 3.33 μs), which has been termed ‘phase explosion’ in literature. Between these two limits, at 2.5 eV/atom of deposited energy, wire radius is unchanged for the first 10 μs before the onset of a rapid expansion and disintegration that resembles homogenous nucleation of mechanically unstable bubbles. Here, thermodynamic calculations are presented that separate cases by temperature obtained during heating: below boiling point, near boiling point, and exceeding boiling point.

42 ENGINEERING↗
DOE OSTI2020

Initial Temperature Testing of Advanced Manufactured Melt Wire Package

As a part of the In-Pile Instrumentation Program, The Idaho National Laboratory (INL) has recently established in-house capabilities to fabricate and test new advanced manufactured sensors for measuring the peak irradiation temperature inside a nuclear test reactor. Although nuclear test reactors can use standard methods of real-time temperature monitoring, such as thermocouples, the complexity of feedthroughs and attachment complications to collect real-time measurements greatly increases the cost of the experiment. Passive monitoring techniques may be utilized that exploit the melting point of well characterized material (standard melt wires), however, the limited space available for instrumentation during experiments is also a challenge. To accommodate the challenge, INL has expanded its temperature detection instrumentation capabilities paired with the advancement of in-house advanced manufacturing options to include printed melt wires for peak irradiation temperature measurement. The advanced manufactured melt wire package can determine peak temperatures in experiments that can fit the challenging space available during irradiation. Recent results and knowledge from this ongoing work have made it possible to develop unique temperature sensors that can accomplish user specific temperature ranges inside the harsh environments experienced during radiation testing. This report summarizes the initial temperature testing using fabricated melt wires with two different melting temperatures, silver (melting temperature of ~960 °C) and solder (melting temperature of ~160 °C), that were initially tested for their relative melting points using non-standard method of furnace and hot plate testing under normal air conditions. Future work will include more controlled way of testing printed melt wires under inert gas with multiple temperature measurements followed by comparison of standard melt wire package performance for baseline characterization.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Additive manufacturing enabled hot-wire apparatus with suppressed edge effect error

This invention describes a method of structuring a metal or metal coated wire in a manner such that it provides enhanced accuracy when used in a hot-wire apparatus for transient thermal conductivity measurements for low-density materials. This is accomplished by using a diameter varying structure with two ends of the wire of sufficiently small diameter that the edge-effect induced error can be reduced by generating a more uniform temperature profile along the wire, whereas in conventional apparatus the temperatures always drop at the ends of a finite wire due to its ends that are being cooled by the wire-supports.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Surface characteristics and damage distributions of diamond wire sawn wafers for silicon solar cells

This paper describes surface characteristics, in terms of its morphology, roughness and near-surface damage of Si wafers cut by diamond wire sawing (DWS) of Si ingots under different cutting conditions. Diamond wire sawn Si wafers exhibit nearly-periodic surface features of different spatial wavelengths, which correspond to kinematics of various movements during wafering, such as ingot feed, wire reciprocation, and wire snap. The surface damage occurs in the form of frozen-in dislocations, phase changes, and microcracks. The in-depth damage was determined by conventional methods such as TEM, SEM and angle-polishing/defect-etching. However, because these methods only provide local information, we have also applied a new technique that determines average damage depth over a large area. This technique uses sequential measurement of the minority carrier lifetime after etching thin layers from the surfaces. The lateral spatial damage variations, which seem to be mainly related to wire reciprocation process, were observed by photoluminescence and minority carrier lifetime mapping. Our results show a strong correlation of damage depth on the diamond grit size and wire usage.

14 SOLAR ENERGY↗
DOE OSTI2015

Transfissural Route Used for Preoperative Localization of Small Pulmonary Lesions with a Short Hook Wire and Suture System

PurposeWe retrospectively evaluated the results of the transfissural route for preoperative localization with a short hook wire and suture system for video-assisted thoracoscopic surgery (VATS).MethodsEleven patients with 11 tumors underwent CT-guided transfissural placement of a hook wire before VATS. This route was selected for all patients, because the distance between the tumor and interlobar fissure was much shorter than the required distance traversed using the conventional approach. Complications were evaluated using the National Cancer Institute Common Terminology Criteria for Adverse Events Version 4.0.ResultsThe hook wire was successfully placed using the transfissural route in all but one case. Of these ten successful placements, two tumors needed a second puncture for optimal placement, because the CT scan showed that the first hook wire was not properly placed in the lung. In one patient, we did not attempt replacement after the first placement was incorrect. In ten successful procedures, the mean distance traversed in the parenchyma of the unaffected lung lobe was 27.9 mm. The distance between the pleura and placed hook wire was significantly shorter than the estimated distance between the pleura and hook wire using the conventional route (mean 16.3 vs. 40.9 mm; P = 0.0002). Grade 1 adverse events occurred (11 pneumothoraxes and 4 pulmonary hemorrhages). No grade 2 or higher adverse event was observed.ConclusionsThe transfissural route used for preoperative localization before VATS is useful for selected patients because this route may allow for more limited lung parenchyma resection.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2015

Charge Transport through Organic Molecular Wires Embedded in Ultrathin Insulating Inorganic Layer

Dense phase silica layers with thickness of a few nanometers featuring embedded organic molecular wires of type p-oligo(phenylenevinylene) are shown by visible light sensitized electrochemical measurements to transport charges across the insulating membrane. Here, we find that such hybrid materials combination allows electronic charge transport only through the wires, while blocking molecular transport. Embodiment of the wire molecules in the silica was accomplished by atomic layer deposition under mild temperature conditions. Grown on Co oxide films for water oxidation, with the wire molecules covalently anchored on the oxide surface, the layer functions as a proton conducting separation membrane. Characterization by XPS, FT-IR and STEM/EDX confirms the integrity of the silica-encapsulated organic wires. Cyclic voltammetry with redox couple of selected potential relative to the energy levels of the wire molecules shows that the membrane is free of pinholes. The new type of membrane allows separation of incompatible redox reaction environments on the length scale of nanometers while enabling controlled electron transport between them. Finally, this opens up the coupling of carbon dioxide reduction with water oxidation, the essential reactions of artificial photosynthesis, in an integrated nanoscale photosystem.

36 MATERIALS SCIENCE↗