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DOE OSTI2026

Solvari SR, Simplifying Residential Solar to 1 SKU, with Extended Testing

Accelerated weathering and material compatibility testing for polymeric and asphaltic materials. NLR will be testing the durability of the polymeric materials proposed for use in the supporting structures designed by TESCI solar. This will include the bare materials and coupons attached to asphalt shingles. The exposure will be in damp heat and separately heat, humidity and UV light, all followed by mechanical evaluation. Modification 1 is an extension of the first round of testing with both a continuation of some of the same testing and addition of new testing methods and materials. The testing of materials in the condition of A3 looking at mechanical durability will be continued looking at the materials used in the mounting brackets. We will be adding in testing of the silicone adhesive to the module and of the module itself. For the mounting brackets, testing will also be conducted at multiple temperatures and humidity levels to allow for extrapolation to the field.

14 SOLAR ENERGY↗

DOE OSTI2022

Emerging Trends and Systemic Issues Influencing Today’s U.S. Electric Grid

With increasing shifts from vertically integrated to horizontally structured operations and from centralized to distributed electric power delivery, today’s electric power grid (the “grid”) operators and designers face the challenge of creating an architecture that accommodates a host of diverse requirements. The grid’s modes of operation must address concerns of reliability and stability, new deployments of renewable energy sources, threats from cyber-attacks and natural disasters, and increasingly distributed system operations. Grid modernization calls for a reliable, affordable, sustainable, agile, secure, and resilient grid. However, the modernization of the U.S. power grid is hampered by mounting complexity and diverging objectives from owners and operators and is consequently risky and fraught with potential missteps. Flawed architecture, design, and implementation will lead to stranded investments and lost opportunities. A principled approach to minimize risk and develop a robust grid of the future is to begin with a sound architecture for the grid to inform the design process. Architecture development starts with the context of influencing factors that provide constraints as well as driving goals. This report provides the context of emerging trends and cross-cutting systemic issues in the U.S. electric power grid and serves as a vital input for grid architecture development.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

Large-scale continuous carbon/glass fiber additive-compression molded composites

Additive Manufacturing (AM) or 3-D printing has advanced from small-scale desktop printers to large-scale printers. Most of the present large-scale printers utilize feedstock materials in the form of pellets to create composite structures. To create structurally robust composite parts, reinforcements in the form of short fibers (carbon or glass) are often used to impart mechanical properties to the printed parts. However, poor mechanical properties in Z-direction and high porosity of pellets-based printed composites compared to composite manufactured using traditional methods are serious concerns. The authors report a combined approach in the present work, where fiber reinforced composites are printed with a high-throughput continuous fiber deposition method followed by a secondary compression molding process. A specially designed end-effector mounted on a robotic arm is used to print composite preforms. Continuous comingled fibers (Thermofiber 12K CF-PA12, Thermofiber 12K S2-PA12, and Hybrid Thermofiber 12K CF-PA12+PEEK PA6) embedded in the thermoplastic nylon matrix are printed to create composite preform plaques. The printed preforms were further compression molded (CM) using a hydraulic hot-press to create highly consolidated composite parts. The mechanical properties of the continuous fiber composites produced by this combined approach are improved significantly due to the highly aligned continuous fibers and reduced porosity. Flexural strength, flexural modulus, and tensile modulus of AM-CM Thermofiber 12K CF-PA12 UD sample were 615.37 MPa, 75.65 GPa, and 122.23 GPa, respectively.

Kumar, Vipin↗

DOE OSTI2026

Design of a shipping fixture for a compact cryomodule hermetic assembly

In support of the development of a conduction-cooled 915MHz superconducting radio frequency (SRF) cryomodule, this study highlights the design of a shipping fixture for transporting the hermetic assembly 4500 km from Jefferson Lab to General Atomics in San Diego, California. The hermetic assembly consists of a 2-cell 915 MHz SRF cavity, a coaxial fundamental power coupler and warm-to-cold transition beam tubes. The two-part shipping assembly consists of an inner frame, providing direct mounting of the components, and an outer frame mounted to the ground transport vehicle. The inner frame is then connected to the outer frame by way of wire-rope isolators. Accelerometer data from ground transportation of previous projects at Jefferson Lab provides the baseline for the expected frequency and magnitude of vibrational and shock events during transit. Modal analyses were carried out in ANSYS on the inner frame assembly and critical components to identify an appropriate wire-rope isolator configuration such that peak loads are mitigated and the incurred frequencies do not correspond with the fundamental modes of the structures.

Accelerator Physics↗

DOE OSTI2022

Fabrication of Polymer Membrane-Suspended Microstructures on Printed Circuit Boards

When microelectromechanical systems are manufactured in high densities, the necessary routing layer structures can become complex and thus expensive if executed in silicon technology. If, additionally, the microstructures are also to be fabricated suspended on membranes, complex thinning processes become necessary to form these often rather fragile membranes. Here, a novel fabrication concept is demonstrated that allows for the fabrication of membrane-suspended microstructures using standard microfabrication techniques directly integrated with printed circuit boards (PCB) by laminating polyimide (PI) films over cavities in the PCB. This results in cost-effective routing layer fabrication and direct compatibility with common electronic component standards such as SMT (surface-mount technology) and THT (through-hole technology). To illustrate the capabilities of the fabrication process, we fabricated an array of membrane suspended microheaters. Individual platinum microheater elements are suspended on PI membranes that are 25 μm thick and 500 μm in diameter. The fabricated PCB carries a 10x10 array of suspended microheaters on an area of 26,mm x 26,mm. Here, the characterization of the microheater array shows that a yield of 86% functional microheaters was achieved. An individual microheater shows an almost linear heating characteristic at least up to 200°C demonstrating the viability of the technique for creating functional membrane-suspended microstructures on a PCB. [2021-0226]

47 OTHER INSTRUMENTATION↗

DOE OSTI2021

The mystery and promise of multivalent metal-ion batteries

Despite mounting interest and extensive research efforts in developing multivalent (MV) metal-ion battery chemistries (Zn 2+ , Mg 2+ , Ca 2+ , Al 3+ , etc.), the commercial prospects for these energy storage systems are still obfuscated by fundamental scientific questions and engineering challenges. In particular, the charge storage mechanism(s) of the positive electrode and the implications on achievable electrode and full cell-level performance remain intensely debated topics in the field. Here, in this minireview, we highlight some of the recent progress and uncertainty in elucidating capacity contributions and accompanying mechanisms for different charge carriers (H + , MV-ion, structural ion, anion, and charged solvates/complexes). We then present cell balancing and increasing metal anode utilization as major remaining challenges and propose design strategies and future directions for realizing practical MV metal-ion batteries.

25 ENERGY STORAGE↗

DOE OSTI2022

MAGNETICALLY SUSPENDED CANNED ROTOR PUMPS FOR THE INTEGRAL MOLTEN SALT REACTOR

This project developed a molten salt pump design for small modular reactors, concentrated solar, and Gen IV nuclear reactors with a magnetically levitated rotor that can operate at temperatures of up to 700 °C. This eliminates the need for rotating seals and roller element bearings which require maintenance and are prone to failure. The pump design is also more compact than existing molten salt pump designs which require long shafts to thermally isolate the electric motor. The aims of the project are to: 1) design and test the molten salt pump, 2) develop and test a high temperature position sensor needed for magnetic bearing control, and 3) develop and test high temperature coil fabrication methods for electric motor and magnetic bearing fabrication. To develop the high temperature coils, conductor materials were analyzed for oxidation, diffusion, cladding, and resistivity. Of the candidate conductor materials that met the requirements, silver was chosen. The long-term impact of radiation on silver resistivity was analyzed by developing a model of a generic molten salt fast reactor to model the conductor irradiation in worst case scenarios. The analysis showed that increased resistivity due to transmutation of silver decreases exponentially with the reactor reflector thickness. Different electrical insulation materials were tested and the final high temperature coils developed were able to withstand conductor to ground voltages up to 1800 V before insulation breakdown. Magnetic bearings require high-precision high-speed measurements of the rotor position to operate. Current commercial position sensors can only operate up to 550 °C so a novel position sensor was developed that can operate up to 800 °C. These sensors were also designed to measure the position of the metallic rotor through a thin metallic corrosion barrier that protects that coils, insulation, and magnetic cores so that the salt containment barrier does not have any penetrations. The high-temperature sensor was tested and had comparable performance to commercially available inductive position sensors. The sensor design and signal processing has led to several invention disclosures. The magnetically levitated molten salt pump design was completed and analyzed. The chloride salt test loop at Oak Ridge National Laboratory was chosen to test the pump and the pump hydraulics and power were designed for the test loop flow and pressure requirements. Classes of motor designs that do not utilize permanent magnetic were considered for the high-temperature motor. After extensive analysis of their performance, a synchronous reluctance motor was chosen for the pump. The design was refined and analyzed to optimize performance. The magnetic bearings were designed to meet the force and frequency requirements necessary to levitate the rotor and reject disturbances from rotor imbalance, motor forces, and hydraulic forces. Compliant mounts for the position sensors were designed that would not damage the ceramic sensor components and maintain sensor alignment over a wide temperature range. A thermal hydraulic analysis of the molten salt coolant flow used to cool the rotor and stator was performed to ensure that the maximum temperature in the rotor and stator will not exceed 725 °C. The corrosion barrier and casing were designed to maintain the salt fluid boundary by using compliant features to absorb large expansion mismatches due to different coefficients of thermal expansion (CTE). Finally, the salt drain and fill systems were designed along with the pump support structure, integration with the test loop, and thermal insulation and heating. Corrosion barrier fabrication experiments were performed to assess using laser cladding to apply a sub-millimeter corrosion barrier to the surface of a Fe-Co-V magnetic core material. The cladding method showed minimal mixing between materials at their interface and withstood temperature cycling without damage to the cladding. The technology commercialization is focused on the high-temperature position sensors and there has been significant interest from the nuclear industry in utilizing these sensors along with some interest from the aerospace industry. The project also led to a research collaboration with a fusion energy industrial partner to study barriers to scaling the pump design from the kW size to the MW size. This research collaboration will also study methods to create high-temperature coils that have conductor to ground breakdown voltages above 5 kV. The successful development of high-temperature electromagnetic coils and high-temperature position sensors greatly increases the temperature limits for electromagnetic devices that don’t rely on permanent magnets. This includes electric motors, magnetic bearings, linear actuators, rotary position and velocity sensing, actuated valves, and generators to name a few. This will fill a current need in molten salt reactors, concentrated solar, and fusion energy for these critical peripheral devices needed for practical reactor designs that do not currently have commercial solutions.

Hines, J Wesley↗

DOE OSTI2021

Pipeline Monitoring Using Highly Sensitive Vibration Sensor Based on Fiber Ring Cavity Laser

A vibration fiber sensor based on a fiber ring cavity laser and an interferometer based single-mode-multimode-single-mode (SMS) fiber structure is proposed and experimentally demonstrated. The SMS fiber sensor is positioned within the laser cavity, where the ring laser lasing wavelength can be swept to an optimized wavelength using a simple fiber loop design. To obtain a better signal-to-noise ratio, the ring laser lasing wavelength is tuned to the maximum gain region biasing point of the SMS transmission spectrum. A wide range of vibration frequencies from 10 Hz to 400 kHz are experimentally demonstrated. In addition, the proposed highly sensitive vibration sensor system was deployed in a field-test scenario for pipeline acoustic emission monitoring. An SMS fiber sensor is mounted on an 18” diameter pipeline, and vibrations were induced at different locations using a piezoelectric transducer. The proposed method was shown to be capable of real-time pipeline vibration monitoring.

47 OTHER INSTRUMENTATION↗

DOE OSTI2021

Autonomous Sensor System for Wind Turbine Blade Collision Detection

This paper presents an automated blade collision detection system for use on wind turbines, toward the goal of supporting monitoring and quantitative assessment of wind energy impacts on wildlife. A wireless, multisensor module mounted at the blade root measures surface vibrations, and a blade-mounted camera provides image capture of colliding objects. Using sensor data recorded during field testing of the system on an operational wind turbine, we present the development, training, and testing of automated detection algorithms for collision detection using machine-learning approaches. In particular, we compare the use of a new two-step, anomaly-based classification algorithm with conventional adaptive boosting and amplitude-based detection techniques, where the two-step approach improves average precision for the experimental data set. This integrated sensor and classification systems demonstrates a new approach for automated, on-blade collision detection for wind turbines, with broad utility across structural health monitoring applications.

17 WIND ENERGY↗

DOE OSTI2023

State of the Art of Molecular Visualization in Immersive Virtual Environments

Abstract Visualization plays a crucial role in molecular and structural biology. It has been successfully applied to a variety of tasks, including structural analysis and interactive drug design. While some of the challenges in this area can be overcome with more advanced visualization and interaction techniques, others are challenging primarily due to the limitations of the hardware devices used to interact with the visualized content. Consequently, visualization researchers are increasingly trying to take advantage of new technologies to facilitate the work of domain scientists. Some typical problems associated with classic 2D interfaces, such as regular desktop computers, are a lack of natural spatial understanding and interaction, and a limited field of view. These problems could be solved by immersive virtual environments and corresponding hardware, such as virtual reality head‐mounted displays. Thus, researchers are investigating the potential of immersive virtual environments in the field of molecular visualization. There is already a body of work ranging from educational approaches to protein visualization to applications for collaborative drug design. This review focuses on molecular visualization in immersive virtual environments as a whole, aiming to cover this area comprehensively. We divide the existing papers into different groups based on their application areas, and types of tasks performed. Furthermore, we also include a list of available software tools. We conclude the report with a discussion of potential future research on molecular visualization in immersive environments.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Examining Infrasound Propagation at High Spatial Resolution Using a Nodal Seismic Array

Infrasound—acoustic waves in the atmosphere below 20 Hz—is a useful monitoring tool. Topography and atmospheric structure strongly control infrasound propagation, and at common source–receiver distances neither of these effects can be ignored when quantitative source constraints are sought. Detailed spatial measurements of the infrasound wavefield would inform propagation models and improve source estimates. However, the “large-N” deployment strategy now well-known in seismology has not yet been realized for infrasound studies. Here, we use the 900-node seismic array from the 2014 Imaging Magma Under St. Helens (iMUSH) experiment as a proxy for a large-N infrasound network, by leveraging acoustic–seismic coupled arrivals. The active-source component of iMUSH consisted of 23 shallowly buried explosions around Mount Saint Helens volcano; these explosions produced epicentral infrasound recorded on the nodes. We find that the bulk presence of ground-coupled infrasound on the nodes is controlled by wind noise and source–receiver distance, with observed arrivals for eight explosions. Explosions with the most extensive coupling produce complex spatial waveform patterns across the array. These patterns are related to both topographic and atmospheric propagation effects, as well as spatially variable site (coupling) effects. We compare our observations to simple topographic diffraction and high-resolution wind advection models, and full-wave numerical simulations. We find strong spatial correlations between (a) coupled arrival strength and modeled topographic obstruction and (b) coupled arrival time and along-path winds. Our seismoacoustic analyses and results are applicable to other existing and future nodal seismic data sets and can expand the utility of such deployments.

58 GEOSCIENCES↗

DOE OSTI2021

High-pressure synthesis and thermodynamic stability of PdH 1±ε up to 8 GPa

Palladium hydride alloys are superconductors and hydrogen storage materials. One synthesis route is compression of Pd to high pressure in a hydrogen-rich environment. Here we report the evolution of the unit cell volume of PdH x synthesized by compressing Pd in a pure H 2 medium to pressures from 0.2 to 8 GPa in a diamond anvil cell at room temperature. The volume of the face-centered cubic unit cell changes nonmonotonically with pressure, increasing upon compression from 0.2 to 1 GPa and decreasing upon compression from 1 to 8 GPa. Volume is reversible upon decompression and is independent of whether the sample was heated to 600 K at low pressure (P < 2 GPa). The x-ray diffraction data show no evidence for a phase transition between 0.2 and 8 GPa. The volume maximum at 1 GPa must be caused by progressive hydrogenation from 0 to 1 GPa. Assuming a pressure-volume-composition equation of state derived from previously published data, the [H]:[Pd] ratio in this study increases to a maximum value of x = 1 ± 0.02 at 2 ± 0.5 GPa and remains stable upon further compression to and from 8 GPa. These results add to a mounting body of evidence that PdH 1±ϵ is in thermodynamic equilibrium with pure H 2 at room temperature from 2 GPa to at least 8 GPa. Here, the simplest interpretation is that H atoms occupy all octahedral sites and no tetrahedral sites in face-centered cubic PdH 1.0 .

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2020

Multi-Temporal Predictive Modelling of Sorghum Biomass Using UAV-Based Hyperspectral and LiDAR Data

High-throughput phenotyping using high spatial, spectral, and temporal resolution remote sensing (RS) data has become a critical part of the plant breeding chain focused on reducing the time and cost of the selection process for the “best” genotypes with respect to the trait(s) of interest. In this paper, the potential of accurate and reliable sorghum biomass prediction using visible and near infrared (VNIR) and short-wave infrared (SWIR) hyperspectral data as well as light detection and ranging (LiDAR) data acquired by sensors mounted on UAV platforms is investigated. Predictive models are developed using classical regression-based machine learning methods for nine experiments conducted during the 2017 and 2018 growing seasons at the Agronomy Center for Research and Education (ACRE) at Purdue University, Indiana, USA. The impact of the regression method, data source, timing of RS and field-based biomass reference data acquisition, and the number of samples on the prediction results are investigated. R2 values for end-of-season biomass ranged from 0.64 to 0.89 for different experiments when features from all the data sources were included. Geometry-based features derived from the LiDAR point cloud to characterize plant structure and chemistry-based features extracted from hyperspectral data provided the most accurate predictions. Evaluation of the impact of the time of data acquisition during the growing season on the prediction results indicated that although the most accurate and reliable predictions of final biomass were achieved using remotely sensed data from mid-season to end-of-season, predictions in mid-season provided adequate results to differentiate between promising varieties for selection. The analysis of variance (ANOVA) of the accuracies of the predictive models showed that both the data source and regression method are important factors for a reliable prediction; however, the data source was more important with 69% significance, versus 28% significance for the regression method.

09 BIOMASS FUELS↗

DOE OSTI2021

Potential environmental effects of deepwater floating offshore wind energy facilities

Over the last few decades, the offshore wind energy industry has expanded its scope from turbines mounted on fixed platforms driven into the seafloor and standing in less than 50 meters of water, to floating turbines moored in 120 meters of water, to prospecting the development of floating turbines moored in ~1000 meters of water. Since there are few prototype turbines and mooring systems of these deepwater, floating offshore wind energy facilities (OWFs) currently deployed, their effects on the marine environment are largely unknown. Using the available scientific literature concerning appropriate analogs, this study provides the first synthesis of the potential environmental effects of deepwater, floating OWFs during operation, as well as potential mitigation measures to some of the risks. Potential effects we identify and evaluate include changes to atmospheric and oceanic dynamics, electromagnetic fields, habitat alterations, noise, structural impediments, and changes to water quality that could affect a variety of marine species across trophic levels. Our synthesis suggests that many of these potential effects could be mitigated to pose a low risk to the marine environment if developers adopt appropriate mitigation strategies and best-practice protocols. This review takes the necessary first steps in summarizing the available information on the potential environmental effects of deepwater, floating OWFs and can serve as a valuable reference document for marine scientists and engineers, the energy industry, permitting agencies and regulators of the energy industry, project developers, and concerned stakeholders such as coastal residents, conservationists, and fisheries.

Farr, Hayley K.↗

DOE OSTI2024

Coupled Experimental/Computational Investigation of the Dynamics of Interacting Magnetized Plasmas

The interaction, or interpenetration, of magnetized plasmas of different density and/or pressure occurs in a wide variety of natural and man-made systems. Such systems include extragalactic jets propagating into the intergalactic medium, solar coronal mass ejections into background solar wind, compact toroid (CT) fueling of magnetic fusion plasmas, and jets of capsule shell impurities into DT fusion fuel, which can lead to enhanced impurity mix in inertial fusion implosions. These plasmas may take the form of jets, with open, helical magnetic structure, or plasma “bubbles” with closed magnetic fields (B-fields), such as spheromaks or CT’s. Such structures, both open and closed B-field cases, can transport heat, particles and magnetic flux or magnetic helicity into background plasma regions. For example, the origin of extragalactic magnetic fields may be due, at least in part, to transport by astrophysical jets. The goal of this proposed work was to elucidate the detailed plasma and magnetic field dynamics of high-density plasma jets (open B-field) and bubbles (closed B-field) propagating into lower density background magnetized plasma through controlled laboratory experiments and closely coupled nonlinear MHD modeling. These experiments were conducted in the HelCat (Helicon-Cathode) linear plasma device at the University of New Mexico (UNM). Plasma jets and bubbles were launched via an existing compact coaxial plasma gun, mounted on the HelCat device. This gun produced plasmas tens of cm in scale and lasting tens of microseconds, thereby allowing detailed multipoint, space- and time-resolved measurements to be made routinely. The experiments were directly modeled using the extended magnetohydrodynamic (XMHD) PERSEUS code, developed at Cornell University [23,24]. Both experimental and numerical modeling work are ongoing. The main results to date are reported here. Additional supplemental funding for one year (8/1/2019 – 7/31/2020) supported numerical investigation of photoionization processes important in many low temperature plasmas, including the HelCat device. Initial results of this modeling work is also reported.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

High resolution identification and quantification of diffuse deep groundwater discharge in mountain rivers using continuous boat-mounted helium measurements

Discharge of deeply sourced groundwater to streams is difficult to locate and quantify, particularly where both discrete and diffuse discharge points exist, but diffuse discharge is one of the primary controls on solute budgets in mountainous watersheds. The noble gas helium is a unique identifier of deep groundwater discharge because groundwater with long residence times is commonly enriched in helium. In this study, a portable mass spectrometer was used to measure longitudinal variation in dissolved helium concentrations in two mountainous rivers at high spatial resolution not feasible with traditional sampling techniques. Helium profiles were then simulated using a mass-balance model to quantify longitudinal variation in groundwater discharge to the receiving rivers. Results indicate helium concentrations were enriched by multiple orders of magnitude above atmospheric equilibrium in both rivers and that this persisted for up to 18 km below observed pulse inputs in the Colorado River. Helium mass-balance models match observed longitudinal patterns with the exception of sharp initial increases in helium observed in the rivers. Increased longitudinal groundwater discharge rates correspond to mapped geologic structures in both watersheds that likely transport deep geothermal water. Models show variable sensitivity to spatial assignment of input variables representing the groundwater source, illustrating the importance of collecting data from discrete groundwater discharges where possible. The methodology shows promise for field experiments designed to assess air–water exchange rates and to quantify total groundwater discharge from a combination of discrete and diffuse sources.

Deep groundwater↗

DOE OSTI2023

Robotic pendant drop: containerless liquid for μs-resolved, AI-executable XPCS

Abstract The dynamics and structure of mixed phases in a complex fluid can significantly impact its material properties, such as viscoelasticity. Small-angle X-ray Photon Correlation Spectroscopy (SA-XPCS) can probe the spontaneous spatial fluctuations of the mixed phases under various in situ environments over wide spatiotemporal ranges (10 −6 –10 3 s /10 −10 –10 −6 m). Tailored material design, however, requires searching through a massive number of sample compositions and experimental parameters, which is beyond the bandwidth of the current coherent X-ray beamline. Using 3.7-μs-resolved XPCS synchronized with the clock frequency at the Advanced Photon Source, we demonstrated the consistency between the Brownian dynamics of ~100 nm diameter colloidal silica nanoparticles measured from an enclosed pendant drop and a sealed capillary. The electronic pipette can also be mounted on a robotic arm to access different stock solutions and create complex fluids with highly-repeatable and precisely controlled composition profiles. This closed-loop, AI-executable protocol is applicable to light scattering techniques regardless of the light wavelength and optical coherence, and is a first step towards high-throughput, autonomous material discovery.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Design and Analysis of High Heat Flux Plasma-Facing Components for NSTX Upgrade

The National Spherical Tokamak Experiment (NSTX) upgrade (NSTX-U) requirements lead to enhanced heat loads on plasma-facing components (PFCs) especially in the divertor regions, where normal heat flux density can reach up to 8 MW/m 2 . For these high heat flux (HHF) regions, the PFCs were redesigned, to use castellations which relieved the thermal stresses associated with high incident heat flux. Another design feature of HHF PFCs is the absence of front face mounting holes which create localized areas of high temperature and thermal stress concentrations. Optimized shaping of the front face of the HHF PFCs eliminates regions where the front face is perpendicular to the heat flux direction during normal helicity operation and spreads the heat load. A unique mechanism was designed to connect PFC tiles to the NSTX-U center stack casing using locking features accessible from the low heat flux regions. Isotropic graphite was selected as the HHF PFC tile material. Initial tile design parameters were accessed using analytical expressions for pulsed heat flux loading. A working prototype of the locking mechanism was created during the initial stages of the design to prove the concept performance. This article presents an overview of the divertor HHF PFC design and the results of the thermal and structural analyses performed using ANSYS software. The results of the analyses cover normal operating conditions and disruptions which impose electromagnetic (EM) loads from eddy and halo currents. The 3-D, transient, nonlinear analyses took into account the temperature-dependent properties of the materials, friction interfaces between the parts, and variable electric properties of the parts and interfaces. The results confirm that the HHF PFC tiles remain within the allowable limits for the loads defined by the NSTX-U Recovery Project. In addition, tolerance stack up analyses were performed to ensure tile performance in the worst possible assembly configuration. Finally, the design process was completed successfully, and the NSTX HHF PFC tiles are currently in the production phase.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗