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DOE OSTI2024

A Co-Registered In-Situ and Ex-Situ Dataset of Electrical, Acoustic, and CT Characteristics from Wire Arc Additive Manufacturing Process

Recent progress in sensing techniques and data analytics tools have significantly accelerated the development of Wire Arc Additive Manufacturing (WAAM) systems. This data centric approach emphasizes leveraging available data throughout the production process to optimize performance. Integration of extensive data analysis provides the opportunity to improve precision, reduce waste, and enhance the quality of produced parts. This method relies on AI/ML models and optimization techniques, which are developed using the data collected from various sources, including in-situ sensors, ex-situ imaging, and manufacturing process parameters. The quality and diversity of this data, along with the alignment between different data streams (achieved through spatiotemporal registration) are critical for the successful development of AI/ML and optimization models. In this work, we present a spatiotemporally registered dataset generated during the WAAM process of deposition of a rectangular block. The dataset includes the comprehensive description of deposition process, process parameters, in-situ collected welding characteristics, acoustic data, and X-Ray Computed Tomography analysis data for the build. Dataset A Co-Registered In-Situ and Ex-Situ Dataset of Electrical, Acoustic, and CT Characteristics from Wire Arc Additive Manufacturing Process has arisen under UT-Battelle, LLC’s Prime Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy (DOE) to manage and operate the Oak Ridge National Laboratory. UT-Battelle, LLC will not assert any rights under United States law or under the Prime Contract it has in the dataset against any user of the dataset, including any copyrights or patent rights. UT-Battelle, LLC requests that attribution to the dataset is provided as academically appropriate.

42 ENGINEERING↗

DOE OSTI2024

Geant4 Simulations on Faraday Cup Design for PIP-II Laser Wire Scanner System

The Proton Improvement Plan-II (PIP-II) accelerator upgrade at Fermilab represents a groundbreaking leap forward in high-energy physics research. This ambitious initiative involves enhancing Fermilab's accelerator complexby replacing the current linear accelerator (linac) with awarm front end (WFE) capable of accelerating H- beamsup to 2.1 MeV. Subsequently, a superconducting linac further accelerates these beams up to 800 MeV. To preciselymeasure the transverse beam profile, a combination of traditional wire scanners at the WFE section and Laser wirescanners along the superconducting linac are planned forimplementation. This investigation is centered on refiningthe Faraday cup design for the PIP-II Laser wire scannersby utilizing GEANT4, a Monte Carlo simulation toolkit.Leveraging this method enables a comprehensive analysisof particle trajectories, energy deposition, secondary particle emission, backscattering, etc., facilitating optimizationthrough adjustments to cup geometries, materials, andplacement to maximize its efficacy in beam diagnostics.

43 PARTICLE ACCELERATORS↗

DOE OSTI2021

A multi-institution collaboration to study copper wire hybrid and laser-cut foil X-pinches

X-pinches are a pulsed power wire-array configuration that produce nanosecond and micron-scale X-ray sources with numerous applications. The earliest embodiment of the X-pinch inspired its name, as it is typically composed of two or more fine (5-50 µm) wires crossed into the shape of an X (Fig. 1a). The ‘X’ ablates when subjected to large (10 1 -10 4 kA), fast-rising (~1 kA/ns) currents, and extreme magnetic pressure at the cross-point constricts the ablated plasma, which develops instabilities and then pinches to near-zero radius, localized ‘hot spots’, emitting X-rays from a sub-nanosecond and 1 µm scale source characteristic of a hot (~1 keV), dense (10% solid density) plasma. A subsequent gap forms where the hot spot(s) occurred, across which substantial potential accelerates electron beams (e-beams) that generate larger, longer-lasting X-ray bursts composed of harder X-rays.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2021

Single Photon Emitters Coupled to Photonic Wire bonds

This project will test the coupling of light emitted from silicon vacancy and nitrogen vacancy defects in diamond into additively manufactured photonic wire bonds toward integration into an "on-chip quantum photonics platform". These defects offer a room-temperature solid state solution for quantum information technologies but suffer from issues such as low activation rate and variable local environments. Photonic wire bonding will allow entanglement of pre-selected solid-state defects alleviating some of these issues and enable simplified integration with other photonic devices. These developments could prove to be key technologies to realize quantum secured networks for national security applications.

42 ENGINEERING↗

DOE OSTI2020

Magnetic Potential of a Finite Wire

The wire segment in question travels in a straight line from position a to b and carries current I in the direction towards b . The magnetic field of this segment alone will not be Maxwellian because the current does not satisfy the continuity equation. However, the field sum of a loop of such wires will be.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

WIRE-21 Experiment Irradiation Conditions and In-Situ Data Collection

This report summarizes the in situ data collected during three cycles of irradiation (~75 days) of the Wireless Instrumented Removable Beryllium Experiment 2021 (WIRE-21) in the removable beryllium (RB) positions of the High Flux Isotope Reactor (HFIR). The experiment was designed primarily to evaluate the effects of high neutron flux and fluence on the performance of wireless temperature and pressure sensors being developed by Westinghouse Electric Company (WEC). WEC’s sensors could provide critical data regarding the evolution of centerline temperatures and pressurization due to fission gas release during fuel operation in light-water reactors (LWRs) or various advanced reactor applications. In addition to WEC’s wireless sensors, many other sensors were interrogated, including thermocouples, self-powered neutron detectors (SPNDs), distributed fiber optic temperature sensors, and passive neutron flux wires and silicon carbide thermometry.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

Multi material/functionally graded wire arc additive manufacturing of high strength steel valves clad with nickel alloy 625 used for oil extraction

This Phase 1 technical collaboration project (ORNL/TM-2022/2683) began on August 1st, 2020 and concluded on July 31st, 2022. The collaboration partner Schlumberger is a large business enterprise assisting oil companies to extract oil from land and subsea cost competitively and safely. It is based in Houston, Texas USA. In this work as study of additive deposition of AWS EF100S-G and AWS ERNiCrMo-3 wires via wire-arc process was conducted.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Uncertainty Analysis of the NOvA Test Beam Wire Chambers

The Fermilab Test Beam is a beam designed for R&D for a variety of experiments taking place at Fermilab, for instance the NOvA experiment. An essential component of the NOvA Test Beam is four wire chambers which measure the transverse position of particles travelling along the beamline. Occasionally, a particle will not produce a hit in one of the four wire chambers resulting in a “3 hit track” instead of the usual “4 hit track”. In our research, we explored the possibility of including these 3 hit tracks into analysis, and how they impact relevant statistics.

Scheuermann, Elizabeth↗

DOE OSTI2022

Status of the MicroBooNE Inclusive Single Photon Selection Using Wire-Cell Reconstruction

MicroBooNE is a Liquid Argon Time Project Chamber (LArTPC) detector whose primary design goal is to understand the “low-energy-excess” anomaly seen by MiniBooNE. MicroBooNE’s currently published results see no excess consistent with the MiniBooNE observation, therefore creating a need for searches in more channels. This note summarizes MicroBooNE’s inclusive single photon selection using Wire-Cell reconstruction and pattern recognition, which will be used to search for a low-energy-excess (LEE) anomaly in the inclusive single photon channel. The selection is similar to the Wire-Cell inclusive electron neutrino selection, but with a different signal definition and some modifications and additions to the pattern recognition tools. A selection with 15.2% efficiency and 18.5% purity is achieved for simulated Standard Model single photon events.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2022

Status of the MicroBooNE inclusive single photon selection using Wire-Cell reconstruction

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2023

Magnetic Properties of Cables with Meandering Wires through a Multipole-based Cable Braid Electromagnetic Penetration Model

In this paper, we employ our first principles multipole-based cable braid electromagnetic penetration model to evaluate the transfer inductance of cables exhibiting meandering wires. We concentrate on a cable structure with two wires, and consider the dependence on the transfer inductance as a function of braid angle and amplitude of the meandering. We compare the results from the first principles model to analytical estimations, confirming the accuracy and correctness of our model. In turn, this makes the multipole-based model readily available for the modeling of realistic cable geometries by accounting for the full dependence on the actual cable geometry.

36 MATERIALS SCIENCE↗

DOE OSTI2024

A hybrid-kinetic simulation tool for non-thermal warm x-ray z-pinch sources, with gas-puff and wire array exemplars

Increasing the fluence of z-pinch x-ray radiation sources above ∼ 10 keV has been a long-standing goal for scientists at Sandia National Laboratories’ Z Machine. Optimizing sources for non-thermal “cold Kα” emission in higher atomic-number materials appears to be a promising path to increase warm x-ray yield. However, this emission is generated by supra-thermal electrons, which are not treated in the magnetohydrodynamic (MHD) codes that are typically used in z-pinch source development. MHD codes do not allow for charge separation or space-charge-generated electric fields, and constrain particle kinematics to Maxwellian distributions. The kinetic codes which do accommodate discrete, non-thermal energy distributions are computationally prohibitive when modeling plasmas near solid density and when modeling/tracking higher ionization states. Thus, modeling non-thermal z-pinch sources requires a new simulation tool. In this report, we present a new hybrid modeling capability that uses the fast features of MHD-type particles to the greatest extent possible, then transitions to the slower but more complete kinetic particle treatment to correctly capture the particle energy spectra that generate non-thermal emission. This capability is founded on the fully-relativistic particle-in-cell code Chicago, which already includes fluid particle treatments. The governing equations and hybrid methodology presented here are applied in simulations of an argon gas-puff and a molybdenum wire-array to provide preliminary code validation. The argon simulation is compared to measured implosion times and yields from Jones et al., Phys. Plasmas 22, 020706 (2015). The simulated x-ray yield is within 25% of measurements and the implosion times agree within a few percent. The molybdenum wire array simulation captures the implosion timing reported in Hansen et al., Phys. Plasmas 21, 031202 (2014), but work is needed to verify the available EOS table. These exemplar simulations represents the type of non-thermal sources that will be developed using the hybrid code capability going forward.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Setup and Testing of the RS105 Wire Array Pulser

The report covers the RS105 Wire Array Pulser testbed. The setup of the wire array at Reapplication, building 996, is laid out. Setup instructions are provided. Details of the commissioning test are given. Measurement data from the commissioning test shows the field output of the array exceeds 50 kV/m and that tuning the pulser output with a peaking switch can provide a rise time of ~2.3 ns and a pulse width of ~23 ns. The field levels and timeframes shown are within the tolerance conditions of

42 ENGINEERING↗

DOE OSTI2024

Validation of Exploding Wire Tests Using Alegra-NG

Exploding wire tests are used to characterize materials undergoing high voltage loading and to validate computational models in a simple configuration. In this report, the materials emphasized are gold, aluminum, copper and nickel wires. Model validation is presented using the nominal model (no uncertainty) in the form of heat maps (per material) that show model bias across scalar quantities and initial voltage. Mesh convergence and uncertainty quantification is also presented.

36 MATERIALS SCIENCE↗

DOE OSTI2023

ER4047 Filler Wire Development - Initial Studies

This report describes the results of bead on pipe welding trials for the purpose of evaluating commercial off the shelf (COTS) 0.047” ER4047 filler material vendors for down selection of the of best candidate filler material for future Gas-metal Arc Welding (GMAW) development efforts. Four candidate COTS ER4047 filler wires were evaluated during this work - Astrolite, Alcotec, Hobart, and Lincoln. The storage condition of each of these filler wires was documented and visual inspection was performed.

36 MATERIALS SCIENCE↗

DOE OSTI2022

MicroBooNE BNB Inclusive Overlay Sample (With Wire Info)

MicroBooNE samples are provided for collaborative development in two different formats: HDF5, targeting the broadest audience, and artroot, targeting users that are familiar with the software infrastructure of Fermilab neutrino experiments and more in general of HEP experiments. The HDF5 files are stored on Zenodo, together with a list of artroot files accessible with xrootd.This sample includes simulated interactions of neutrinos from the Booster Neutrino Beam (BNB), overlaid on top of cosmic ray data. The sample is inclusive, i.e. it includes all types of neutrinos and interactions, with relative abundance matching our nominal flux and cross section models. Interactions are simulated in in the whole cryostat volume.The HDF5 files in this sample include the information at the wire waveform level (after deconvolution and finding of regions of interest). As this information significantly increases the file size, this sample contains about 17% of the events of the corresponding sample without wire information.More documentation, including detailed description of content, recipes, and example usage, at https://github.com/uboone/OpenSamples.Suggested text for acknowledgment is the following:We acknowledge the MicroBooNE Collaboration for making publicly available the data sets [data set DOIs] employed in this work. These data sets consist of simulated neutrino interactions from the Booster Neutrino Beamline overlaid on top of cosmic data collected with the MicroBooNE detector [2017 JINST 12 P02017].In addition, we request that software products resulting from the usage of the datasets are also made publicly available.

Abratenko, Polina↗

DOE OSTI2022

MicroBooNE BNB Electron Neutrino Overlay Sample (With Wire Info)

MicroBooNE samples are provided for collaborative development in two different formats: HDF5, targeting the broadest audience, and artroot, targeting users that are familiar with the software infrastructure of Fermilab neutrino experiments and more in general of HEP experiments. The HDF5 files are stored on Zenodo, together with a list of artroot files accessible with xrootd.This sample includes simulated interactions of neutrinos from the Booster Neutrino Beam (BNB), overlaid on top of cosmic ray data. The sample is restricted to charged-current electron neutrino interactions within the argon active volume of the time projection chamber.The HDF5 files in this sample include the information at the wire waveform level (after deconvolution and finding of regions of interest). As this information significantly increases the file size, this sample contains about 20% of the events of the corresponding sample without wire information.More documentation, including detailed description of content, recipes, and example usage, at https://github.com/uboone/OpenSamples.Suggested text for acknowledgment is the following:We acknowledge the MicroBooNE Collaboration for making publicly available the data sets [data set DOIs] employed in this work. These data sets consist of simulated neutrino interactions from the Booster Neutrino Beamline overlaid on top of cosmic data collected with the MicroBooNE detector [2017 JINST 12 P02017].In addition, we request that software products resulting from the usage of the datasets are also made publicly available.

Abratenko, Polina↗

DOE OSTI2021

Nanowire and micro wire fabrication technique and product

A continuous or semi-continuous process for fabricating nanowires or microwires makes use of the substantially planar template that may be moved through electrochemical solution to grow nanowires or microwires on exposed conductive edges on the surface of that template. The planar template allows fabrication of the template using standard equipment and techniques. Adhesive transfer may be used to remove the wires from the template and in one embodiment to draw a continuous wire from the template to be wound around the drum.

Sumant, Anirudha V.↗