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DOE OSTI2023

ac susceptibility studies of intra- and intergrain properties of high-$J_c$ Bi-2212 wires

Bi 2 Sr 2 CaCu 2 O x (Bi-2212) is the only high-$T_c$ superconductor (HTS) available as a multifilamentary round wire with multiple architectures and it is a very promising conductor for the realization of high-field applications. Despite their relatively simple wire fabrication by the powder-in-tube technique, Bi-2212 wires require a tightly controlled overpressure heat treatment (HT) with a multi-parameter time-temperature schedule to achieve high critical current density, $J_c$. Further, the variation of these HT parameters, changes in the wire design, wire diameter and powder quality can lead to variations in both the microstructure and the superconducting performance. Particularly noticeable are variations in $J_c$ performance and degree of filament bridging. In this work, we focus on the use of different magnetic characterization techniques to estimate the bridging level and assess the balance of INTER-grain and intra-grain superconducting properties including the irreversibility field ($H_{\text{irr}}$) and the pinning energy ($U_0$) in differently processed wires. Regardless of the actual bridging level, we find that the supercurrent flows at the filament bundle level, not just at the individual filament level. Moreover, using AC susceptibility we identify two distinct supercurrent contributions, one related to the intra-grain and one to the INTER-grain properties, whose irreversibility fields are different but without large sample-to-sample variation. Moreover, an additional component of intra-grain pinning mechanism becomes effective at low temperatures with positive effects also on the INTER-grain performance. The work clearly shows that detailed magnetic characterizations can become valuable tools to investigate the performance of differently processed Bi-2212 wires, correlating their microstructure and overall transport $J_c$, to obtain a deeper understanding of the causes of performance variation and paths to achieve further improvement.

2212↗

DOE OSTI2016

Finite-element analysis of transverse compressive and thermal loads on Nb 3 Sn wires with voids

High-field superconducting magnets play a very important role in many large-scale physics experiments, particularly particle colliders and fusion confinement devices such as Large Hadron Collider (LHC) and International Thermonuclear Experimental Reactor (ITER). The two most common superconductors used in these applications are NbTi and Nb 3 Sn. Nb 3 Sn wires are favored because of their significantly higher J c (critical current density) for higher field applications. The main disadvantage of Nb 3 Sn is that the superconducting performance of the wire is highly strain sensitive and it is very brittle. This strain sensitivity is strongly influenced by two factors: plasticity and cracked filaments. Cracks are induced by large stress concentrators that can be traced to the presence of voids in the wire. We develop detailed 2-D and 3-D finite-element models containing wire filaments and different possible distributions of voids in a bronze-route Nb 3 Sn wire. We apply compressive transverse loads for various cases of void distributions to simulate the stress and strain response of a Nb 3 Sn wire under the Lorentz force. Furthermore, this paper improves our understanding of the effect voids have on the Nb 3 Sn wire's mechanical properties, and in so, the connection between the distribution of voids and performance degradation such as the correlation between irreversible strain limit and the void-induced local stress concentrations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Voltage-Current Behavior of a Superconducting STAR ® Wire in a 6-Around-1 Cable Configuration

A 6-around-1 transposed cable using superconducting STAR® wires can be useful for future circular collider applications. We made three cable samples using single STAR® wires with a diameter of 1.3 mm. The first two samples, made with a cabling machine, used STAR® wires consisting of a 0.7 mm diameter Nb-Ti core. The third cable sample was manually wound and used a STAR® wire made with a 0.81 mm diameter Cu core. The first sample showed severe degradation after the cable was bent to a 75 mm radius. The current-carrying capability of the innermost and outermost REBCO tapes in the STAR® wire degraded by 42% to 98% and the middle REBCO tapes remained intact. This was also the case for the second and straight cable sample. After fabrication of the third cable sample, we observed only about 5% reduction in the current along the wire, measured at different locations inside the terminations. Finally, the results indicate that the differences in architecture or fabrication of the STAR® wires could have caused differences in critical current retention after cabling.

6-around-1 cable↗

DOE OSTI2017

Anisotropic Thermal Response of Packed Copper Wire

The apparent thermal conductivity of packed copper wire test specimens was measured parallel and perpendicular to the axis of the wire using laser flash, transient plane source, and transmittance test methods. Approximately 50% wire packing efficiency was produced in the specimens using either 670- or 925-μm-diameter copper wires that both had an insulation coating thickness of 37 μm. The interstices were filled with a conventional varnish material and also contained some remnant porosity. The apparent thermal conductivity perpendicular to the wire axis was about 0.5–1 W/mK, whereas it was over 200 W/mK in the parallel direction. The Kanzaki model and an finite element analysis (FEA) model were found to reasonably predict the apparent thermal conductivity perpendicular to the wires but thermal conductivity percolation from nonideal wire-packing may result in their underestimation of it.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2025

Analysis Background & Noise in Stretched Wire Alignment Technique Measurements

The Stretched-Wire Alignment Technique (SWAT) is one method of magnet alignment for linear induction accelerators. The applications of SWAT have been implemented for aligning solenoid magnets on the Scorpius linear induction accelerator which will be sited at the Nevada National Security Site and the Flash X-Ray (FXR) linear induction accelerator at Lawrence Livermore National Laboratory’s Contained Firing Facility. This article describes both systematic (repeatable) and random sources of background and noise as well as practical ways to eliminate or reduce them to acceptable levels. Systematic sources include reflections from wire ends, rapid sag due to ohmic heating of the wire, magnetic materials, and shot rate. Random sources include air currents, vibration of nearby equipment, mechanical stability of test equipment, and the instruments used to measure the wire motion. Mitigations include curve fitting and adaptive noise signal cancellation, and mechanical damping. Finite Element Analysis (FEA) was used to identify and resolve a repeatable wire vibration frequency interfering with the signal resolution. Two stretched wire alignment technique set ups from Sandia National Labs and Lawrence Livermore National Lab have shown background noise sources and ways of mitigating them by either analysis methods or change of mechanical configuration. Conclusions that were drawn included the severe sensitivity of the deflection to even small external interferences of the SWAT wire such that it requires attention to detail in mechanical set up and analysis.

Linear Inductive Accelerator↗

DOE OSTI2012

Correlating Electronic Transport to Atomic Structures in Self-Assembled Quantum Wires

Quantum wires, as a smallest electronic conductor, are expected to be a fundamental component in all quantum architectures. The electronic conductance in quantum wires, however, is often dictated by structural instabilities and electron localization at the atomic scale. Here we report on the evolutions of electronic transport as a function of temperature and interwire coupling as the quantum wires of GdSi{sub 2} are self-assembled on Si(100) wire-by-wire. The correlation between structure, electronic properties, and electronic transport are examined by combining nanotransport measurements, scanning tunneling microscopy, and density functional theory calculations. A metal-insulator transition is revealed in isolated nanowires, while a robust metallic state is obtained in wire bundles at low temperature. The atomic defects lead to electron localizations in isolated nanowire, and interwire coupling stabilizes the structure and promotes the metallic states in wire bundles. This illustrates how the conductance nature of a one-dimensional system can be dramatically modified by the environmental change on the atomic scale.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2020

EVALUATION OF PRESSURE DROP CORRELATIONS FOR THE WIRE-WRAPPED ROD BUNDLES

The accurate prediction of pressure drop in the fuel rod bundle is of importance for the design and thermal-hydraulic analysis of nuclear reactor system. Due to very complex geometry of wire-wrapped fuel rod bundle geometry for the Sodium Fast Reactor (SFR), a simple method using hydraulic (equivalent) diameter is not sufficient to predict the pressure drop of rod bundle accurately. For several decades, many experimental works have been performed to develop an accurate correlation for wire-wrapped fuel bundle friction factor. In these works, the friction factor correlation of wire-wrapped fuel bundle has been developed as a function of Reynolds number of the flow and the design parameters such as fuel pin diameter, wire diameter, rod pitch, and wire lead length. The Cheng and Todreas correlations are well-known and used in many subchannel analysis code, such as CADET, TRIO-U, MATRA-LMW, SE2-ANL, etc. Novendstern model, Rehme model, Baxi and Dalle Donne model are also well-known and widely referred. Computational Fluid Dynamics is another typical approach to predict the pressure drop of wire-wrapped fuel rod bundle, but it requires the model validation because the accuracy of pressure drop prediction by the CFD simulation depends on what turbulence model is employed. The present work aims at evaluating the existing pressure drop correlations for the wire-wrapped fuel rod bundle and evaluating the pressure drop of 217-pin rod bundle by the CFD analysis.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2018

Highly Densified Cu Wirings Fabricated from Air-Stable Cu Complex Ink with High Conductivity, Enhanced Oxidation Resistance, and Flexibility

The microstructure of printed Cu wirings fabricated from air-stable Cu complex inks is greatly modified by low-temperature curing followed by intense pulsed light densification enhancement treatment. The resulting almost full densification of printed Cu wirings enables them to possess a high electrical conductivity of 50% bulk Cu. The dense structure also largely prevents the permeation of oxygen and water into the inner side of the Cu wirings, thereby improving their oxidation resistance and maintaining a stable resistance (R/R0 < 1.5) even after 1000 h aging at 85 °C-85% RH. In addition, the dense and robust structure can improve the resistance to crack generation and propagation in Cu wirings during the bending, so as to improve their flexibility. The relative resistance of Cu wirings can be kept below 1.2 after 1000 bending cycles. All the results indicate that these highly densified Cu wirings fabricated from air-stable Cu complex inks can be used to replace the noble metallic Au and Ag wirings for practical application in flexible electronics.

Li, Wanli↗

DOE OSTI2018

Electronic Structure of HgBa{sub 2}CuO{sub 4+δ} with Self-organized Interstitial Oxygen Wires in the Hg Spacer Planes

While recent experiments have found that at optimum doping for the highest critical temperature in HgBa{sub 2}CuO{sub 4+y} (Hg1201) the oxygen interstitials (O-i) are not homogeneously distributed but form one-dimensional atomic wires, there are no available information of its electronic structure considering self-organized O-i atomic wires. Here we report the calculated electronic structure of HgBa{sub 2}CuO{sub 4+y} where oxygen interstitials form atomic wires along (1,0,0) crystal direction in the Hg layer. We find that at optimum doping for superconductivity the chemical potential is tuned near an electronic topological Lifshitz transition for the appearing of a second quasi 1D Fermi surface. A first large Fermi surface coexists with a second incipient quasi one-dimensional (1D) Fermi surface related with atomic wires of oxygen interstitials. Increasing oxygen doping the chemical potential is driven to the band edge of the second 1D-band giving a peak in the density-of-states. The new 1D electronic states are confined near the oxygen interstitial wires with a small spread only on nearby sites. Spin-polarized calculations show that the magnetic response is confined in the oxygen-poor domains free of oxygen interstitials wires and it is quite insensitive to the density of O-i wires.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2018

Study on the Microstructure, Mechanical Properties and Corrosion Behavior of Mg-Zn-Ca Alloy Wire for Biomaterial Application

Due to their excellent biocompatibility and biodegradability, magnesium alloy wires have attracted much attention for biomaterial applications including orthopedic K-wires and sutures in wound closure. In this study, Mg-3Zn-0.2Ca alloy wires were prepared by cold drawing combined with proper intermediate annealing process. Microstructures, texture, mechanical properties and corrosion behavior of Mg-3Zn-0.2Ca alloy wire in a simulated body fluid were investigated. The results showed that the secondary phase and average grain size of the Mg-3Zn-0.2Ca alloy were refined in comparison with the as-extruded alloy and a strong (0002)<10-10>//DD basal fiber texture system was formed after multi-pass cold drawing. After the annealing, most of the basal planes were tilted to the drawing direction (DD) by about 35°, presenting the characteristics of random texture, and the texture intensity decreased. The as-annealed wire shows good mechanical properties with the ultimate tensile strength (UTS), yield strength (YS) and elongation of 253 ± 8.5 MPa, 212 ± 11.3 MPa and 9.2 ± 0.9%, respectively. Electrochemical and hydrogen evolution measurements showed that the corrosion resistance of the Mg-3Zn-0.2Ca alloy wire was improved after the annealing. The immersion test indicated that the Mg-3Zn-0.2Ca wire exhibited uniform corrosion behavior during the initial period of immersion, but then exhibited local corrosion behavior.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Investigating Electron Conductivity Regimes in the Bacterial Cytochrome Wire OmcS

The anaerobic bacterium Geobacter sulfurreducens produces extracellular, electronically conductive cytochrome polymer wires that are conductive over micron length scales. Structure models from cryo-electron microscopy data show OmcS wires form a linear chain of hemes along the protein wire axis, which is proposed as the structural basis supporting their electronic properties. However, the mechanism by which this heme arrangement supports long-range electronic conduction remains unknown. Structure models from cryo-electron microscopy data show these wires form a linear chain of hemes along the protein wire axis, which is proposed as the structural basis supporting their electronic properties. Existing computational models using static heme redox potentials and coupling energies fail to explain experimental observations, predicting conductances 10,000 to 100,000 times lower than measured values. Here, we investigate how dynamic disorder affects site energies, interheme coupling, and long-range electronic conductivity within these cytochrome wires. We introduce an approach to extract charge carrier site information directly from Kohn–Sham density functional theory, without employing projector schemes, and show that site and coupling energies are highly sensitive to changes in interheme geometry and the surrounding electrostatic environment. Unlike models that incorporate dynamic disorder as a thermally averaged quantity, our quantum charge carrier model incorporates proxies for dynamic disorder through decoherence corrections, yielding predicted diffusion coefficient closer to what is expected from experiment and comparable with other organic-based electronic materials. Based on these simulations, we propose that the instantaneous fluctuations of the local electrostatic environment can transiently lift energy degeneracies and delocalize charge carriers. Furthermore, these studies reveal how incorporating dynamic fluctuations associated with the environment resolves the discrepancy between theory and experiment in microbial cytochrome wires and highlight design principles for bioinspired, heme-based conductive materials.

Bioinorganic chemistry↗

DOE OSTI2023

The Simons Observatory: A fully remote controlled calibration system with a sparse wire grid for cosmic microwave background telescopes

For cosmic microwave background (CMB) polarization observations, calibration of detector polarization angles is essential. We have developed a fully remote controlled calibration system with a sparse wire grid that reflects linearly polarized light along the wire direction. The new feature is a remote-controlled system for regular calibration, which has not been possible in sparse wire grid calibrators in past experiments. The remote control can be achieved by two electric linear actuators that load or unload the sparse wire grid into a position centered on the optical axis of a telescope between the calibration time and CMB observation. Furthermore, the sparse wire grid can be rotated by using a motor. A rotary encoder and a gravity sensor are installed on the sparse wire grid to monitor the wire direction. They allow us to achieve detector polarization angle calibration with an expected systematic error of 0.08°. The calibration system will be installed in small-aperture telescopes at Simons Observatory.

47 OTHER INSTRUMENTATION↗

DOE OSTI2020

Etching sharp tips from thin metallic wires for tuning-fork-based scanning probe microscopy

Sharp tips are critical for obtaining high resolution images in scanning probe microscopy (SPM), particularly in samples with large variations in topography. For tuning-fork-based SPM, such tips are commonly obtained by electrochemical etching of metallic wires (e.g., tungsten). Electrochemical etching of metallic wires is the preferred means of preparing tips for scanning tunneling microscopy (STM), and techniques for obtaining sharp tips have been investigated extensively. However, the requirements for STM and tuning-fork-based SPM are different. In particular, the wires used in STM are typically 250-500 μ m in diameter, while the wires used for tuning-fork-based SPM are usually an order of magnitude narrower in order to minimize loading of the tuning fork: 25-50 μ m and sometimes down to a few micrometers in diameter. Consequently, many of the recipes developed for etching thicker metallic wires for STM tips do not give optimal results for smaller diameter wires. The authors describe here a modification of the etching circuit of Ibe et al . that significantly improves the reproducibility and reliability of the etching process for thin wires, and discuss the parameters that affect the aspect ratio of produced tips.

42 ENGINEERING↗

DOE OSTI2022

WIRE-21 Sensor Irradiation Experiment Ready for HFIR Insertion

The ability to deploy new nuclear fuels for current or future reactor concepts requires a wealth of data regarding fuel performance during normal operation, anticipated operational occurrences, and design-basis accidents. Most of these data have historically been collected during experiments in materials test reactors, ideally with online instrumentation to collect as much data as possible. However, advanced instrumentation could also allow for in situ monitoring of fuel operating conditions during commercial reactor operation to maximize fuel utilization, reduce unnecessary conservativism in design margins, and improve operator understanding of limiting peaking factors. The latter approach would complicate fuel handling, particularly during refueling, unless the instrumentation could be placed inside the fuel rods and transmitted wirelessly to a receiver located outside the fuel’s primary pressure boundary. To this end, Westinghouse Electric Company (WEC) developed wireless sensors based on inductive coupling that can transmit information regarding fuel centerline temperatures and rod internal pressures wirelessly from within a fuel rod to a nearby instrument thimble. After testing these sensors in lower-power university research reactors, the next step is to perform high neutron fluence testing to characterize the performance of these wireless sensors under conditions that are more representative of the intended application—in this case, light-water reactors (LWRs). The removable Be (RB) positions of the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL) provide the neutron flux, experiment volume, and access to instrument leads required to achieve these sensor testing goals. This report summarizes the design, analysis, and assembly of the Wireless Instrumented RB Experiment 2021 (WIRE-21). This is the most highly instrumented irradiation experiment ever performed in HFIR. The experiment will use seven different sensing techniques to measure temperature, pressure, neutron flux, and neutron fluence during reactor operation. In addition to WEC’s wireless temperature and pressure sensors, WIRE-21 includes an array of thermocouples, self-powered neutron detectors, spatially distributed fiber optic temperature sensors, passive SiC temperature monitors, and flux wires. The design of WIRE-21 and the cabling that was installed in HFIR also provide the infrastructure to enable accelerated, economical testing of advanced sensor technologies while leveraging the extremely high neutron flux that is available in HFIR. The containment for WIRE-21 is similar to previous RB irradiation vehicles but includes a few modifications, most notably the use of integrated compression seals to pass a larger number of sensor leads through the experiment’s pressure boundary. In addition to the sensor leads, inert gas lines are passed into the experiment to enable active temperature control and the ability to pneumatically actuate a bellows-driven pressure sensor. WIRE-21 is targeting component temperatures (300–350°C) and neutron fluence levels (~10 22 n/cm 2 ) that would be expected in the plenum region of LWR fuels, except for the active sensing region of the wireless temperature sensor, which is targeting LWR fuel centerline temperatures (~800–1,100°C). WIRE-21 was successfully assembled, passed all nondestructive examination, and was delivered to HFIR for insertion during upcoming cycle 498 (April 2022).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1972

Development of explosively bonded TZM wire reinforced Columbian sheet composites

Methods of producing TZM molybdenum wire reinforced C129Y columbium alloy composites by explosive welding were studied. Layers of TZM molybdenum wire were wound on frames with alternate layers of C129Y columbium alloy foil between the wire layers. The frames held both the wire and foils in place for the explosive bonding process. A goal of 33 volume percent molybdenum wire was achieved for some of the composites. Variables included wire diameter, foil thickness, wire separation, standoff distance between foils and types and amounts of explosive. The program was divided into two phases: (1) development of basic welding parameters using 5 x 10-inch composites, and (2) scaleup to 10 x 20-inch composites.

Otto, H. E.↗

NASA NTRS1976

Impact tensile testing of wires

The test consists of fixing one end of a wire specimen and allowing a threaded falling weight to strike the other. Assuming the dynamic stress in the wire to be a function only of its strain, energy considerations show for negligible wire inertia effects that the governing dynamic stress-strain law can be determined directly from impact energy vs. wire elongation data. Theoretical calculations are presented which show negligible wire inertia effects for ratios of wire mass to striking mass of the order of .01 or less. The test method is applied to soft copper wires and the dynamic stress-strain curve so determined is found to be about 30 percent higher than the corresponding static curve.

Dawson, T. H.↗

NASA NTRS1978

Wire stripper

An insulation stripper is described which is especially useful for shielded wire, the stripper including a first pair of jaws with blades extending substantially perpendicular to the axis of the wire, and a second pair of jaws with blades extending substantially parallel to the axis of the wire. The first pair of jaws is pressed against the wire so the blades cut into the insulation, and the device is turned to form circumferential cuts in the insulation. Then the second pair of jaws is pressed against the wire so the blades cut into the insulation, and the wire is moved through the device to form longitudinal cuts that permit easy removal of the insulation. Each of the blades is located within the concave face of a V-block, to center the blades on the wire and to limit the depth of blade penetration.

Economu, M. A.↗

NASA NTRS1995

Hot-wire calibration in subsonic/transonic flow regimes

A different approach for calibrating hot-wires, which simplifies the calibration procedure and reduces the tunnel run-time by an order of magnitude was sought. In general, it is accepted that the directly measurable quantities in any flow are velocity, density, and total temperature. Very few facilities have the capability of varying the total temperature over an adequate range. However, if the overheat temperature parameter, a(sub w), is used to calibrate the hot-wire then the directly measurable quantity, voltage, will be a function of the flow variables and the overheat parameter i.e., E = f(u,p,a(sub w), T(sub w)) where a(sub w) will contain the needed total temperature information. In this report, various methods of evaluating sensitivities with different dependent and independent variables to calibrate a 3-Wire hot-wire probe using a constant temperature anemometer (CTA) in subsonic/transonic flow regimes is presented. The advantage of using a(sub w) as the independent variable instead of total temperature, t(sub o), or overheat temperature parameter, tau, is that while running a calibration test it is not necessary to know the recovery factor, the coefficients in a wire resistance to temperature relationship for a given probe. It was deduced that the method employing the relationship E = f (u,p,a(sub w)) should result in the most accurate calibration of hot wire probes. Any other method would require additional measurements. Also this method will allow calibration and determination of accurate temperature fluctuation information even in atmospheric wind tunnels where there is no ability to obtain any temperature sensitivity information at present. This technique greatly simplifies the calibration process for hot-wires, provides the required calibration information needed in obtaining temperature fluctuations, and reduces both the tunnel run-time and the test matrix required to calibrate hotwires. Some of the results using the above techniques are presented in an appendix.

Nagabushana, K. A.↗