The melting of asteroidal-sized bodies by unipolar dynamo induction from a primordial T Tauri sun
Asteroidal parent bodies heating by electrical induction during early solar evolution
Colburn, D. S.↗
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Results for “induction heating”
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Vacuum-Induction, Vacuum-Arc, and Air-Induction Melting of a Complex Heat-Resistant Alloy
The relative hot-workability and creep-rupture properties at 1600 F of a complex 55Ni-20Cr-15Co-4Mo-3Ti-3Al alloy were evaluated for vacuum-induction, vacuum-arc, and air-induction melting. A limited study of the role of oxygen and nitrogen and the structural effects in the alloy associated with the melting process was carried out. The results showed that the level of boron and/or zirconium was far more influential on properties than the melting method. Vacuum melting did reduce corner cracking and improve surface during hot-rolling. It also resulted in more uniform properties within heats. The creep-rupture properties were slightly superior in vacuum heats at low boron plus zirconium or in heats with zirconium. There was little advantage at high boron levels and air heats were superior at high levels of boron plus zirconium. Vacuum heats also had fewer oxide and carbonitride inclusions although this was a function of the opportunity for separation of the inclusions from high oxygen plus nitrogen heats. The removal of phosphorous by vacuum melting was not found to be related to properties. Oxygen plus nitrogen appeared to increase ductility in creep-rupture tests suggesting that vacuum melting removes unidentified elements detrimental to ductility. Oxides and carbonitrides in themselves did not initiate microcracks. Carbonitrides in the grain boundaries of air heats did initiate microcracks. The role of microcracking from this source and as a function of oxygen and nitrogen content was not clear. Oxygen and nitrogen did intensify corner cracking during hot-rolling but were not responsible for poor surface which resulted from rolling heats melted in air.
Decker, R. F.↗
Low-pressure inductively coupled plasmas in hydrogen: impact of gas heating on the spatial distribution of atomic hydrogen and vibrationally excited states
Non-equilibrium inductively coupled plasmas (ICPs) operating in hydrogen are of significant interest for applications including large-area materials processing. Increasing control of spatial gas heating, which drives the formation of neutral species density gradients and the rate of gas-temperature-dependent reactions, is critical. In this study, we use 2D fluid-kinetic simulations with the Hybrid Plasma Equipment Model to investigate the spatially resolved production of atomic hydrogen in a low-pressure planar ICP operating in pure hydrogen (10–20 Pa or 0.075–0.15 Torr, 300 W). The reaction set incorporates self-consistent calculation of the spatially resolved gas temperature and 14 vibrationally excited states. We find that the formation of neutral-gas density gradients, which result from spatially non-uniform electrical power deposition at constant pressure, can drive significant variations in the vibrational distribution function and density of atomic hydrogen when gas heating is spatially resolved. This highlights the significance of spatial gas heating on the production of reactive species in relatively high-power-density plasma processing sources.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Induction ultrafast sintering
This study proposes and demonstrates induction ultrafast sintering (IUS), which enables rapid densification of refractory and other materials via two contactless modalities: direct IUS (d-IUS), where heating occurs through electromagnetic coupling with the sample, and susceptor IUS (s-IUS), where heating is achieved indirectly via an induction-heated metal case. Ultrahigh heating rates of ∼75 to >450 °C/s and temperatures exceeding 2500 °C are readily achieved. Both d-IUS and s-IUS densify molybdenum to high densities within 120 s, with only ∼1–3 % porosity observed by image analysis. Similarly, 3 mol % yttria-stabilized zirconia (3YSZ) reaches ∼97 % relative density in 30 s via s-IUS. This study further demonstrates ultrafast reactive sintering of two difficult-to-sinter materials: a refractory compositionally complex alloy–carbide (RCCA–CCC) composite, NbMoTaW–(Nb 0.37 Mo 0.11 Ta 0.39 W 0.13 ) 2 C, using d-IUS, and a compositionally complex silicide (CCS), (Mo 1/3 Nb 1/3 Zr 1/3 )Si 2 , using s-IUS. This IUS platform offers a versatile route for high-throughput materials discovery and energy-efficient fabrication of bulk refractory materials.
36 MATERIALS SCIENCE↗
Formation of the lunar crust - An electrical source of heating
A model for formation of the lunar crust based on heating by electrical induction is explored, while adherence is maintained to certain constraints associated with existing models of the solar system. The heating mechanism is based on eddy current induction from disordered magnetic fields swept outwards by an intense (T Tauri-like) plasma flow from the sun. The electrical theory is an alternative to intense short-period accretion as a source of heat for the evolution of lunar maria and highlands, provided that long-lived radioactives are not swept to the surface from too large a melt volume during the initial thermal episode. This formation of the lunar highlands does not intrinsically require rapid accretion, nor on this basis is the time of formation of the planets generally restricted to a very short time. The threshold temperature for eddy current heating is attained by either a solar nebula at 300-400 C during formation of the moon or a very low energy long-period accumulation of the moon, both leading to melting in ten to the fifth to ten to the seventh power years.
Sonett, C. P.↗
The Use of Immersion Rigs for High Temperature Hydrogen Exposure Testing Within the Nuclear Thermal Rocket Element Environmental Simulator (NTREES): NTREES-5 Hydrogen Heat Exchanger (N5HHX-01)
The Nuclear Thermal Rocket Element Environmental Simulator (NTREES) facility at NASA’s Marshall Space Flight Center (MSFC) subjects materials and components typically found on nuclear thermal propulsion (NTP) systems to non-nuclear simulations of prototypic NTP reactor thermohydraulic environments. With 1.2 MW of inductive power available, the currently employed methods to simulate nuclear heating in NTREES consist of 1) inductively heating a test specimen, which typically cannot be performed on ceramic materials, or 2) heating gas that envelops the test specimen. The latter of these has provided a basis for developing so-called “immersion rigs” to be used in NTREES. Furthermore, immersion rigs are especially useful in the case of smaller, technically challenging test specimens. One such device, the “NTREES-5 Hydrogen Heat Exchanger” (N5HHX-01), designed and deployed to test small material coupons to ~0.5 g/s of 2800 K, 500 psi Hydrogen, is discussed herein. To achieve this desired delivery temperature level, the most suitable material for the N5HHX’s construction was pure tungsten, which imposed budgetary and manufacturing challenges. Also discussed in this paper is the design of the N5HHX rig’s sample container, which became the first iteration of improving NTREES small material coupon test operations by permitting rapid changeout of different material samples.
Reactor Testing↗
Driving bubbles out of glass
Surface tension gradient in melt forces gas bubbles to surface, increasing glass strength and transparency. Conventional chemical and buoyant fining are extremely slow in viscous glasses, but tension gradient method moves 250 um bubbles as rapidly as 30 um/s. Heat required for high temperature part of melt is furnished by stationary electrical or natural-gas heater; induction and laser heating are also possible. Method has many applications in industry processes.
Mattox, D. M.↗
Observation of second harmonic electron cyclotron resonance heating and current-drive transition during non-inductive plasma start-up experiment in QUEST
Here, noninductive plasma current start-up using 2nd harmonic electron cyclotron resonance heating (ECRH) with oblique radio frequency (RF) injection is demonstrated in a Q-shu University experiment with steady-state spherical tokamak. A strong transition was observed in the heating and plasma current ramp-up. The initial bulk electron heating regime exhibits T ebulk ~ 140 eV and no hard x-ray (HXR) emission with a low I p of ~15 kA; it abruptly transitions to a regime that exhibits a low T ebulk of ~10 eV and a strong HXR emission with a high I p of ~50 kA. This behavior is distinctly different from that observed in previous fundamental ECRH experiments. The mechanism of the heating and current drive transition are investigated considering wave power absorption and plasma power balance. The results indicate that the transition is caused by the favorable heating of tail electrons where the RF power absorption at the 2nd harmonic increases nearly linearly with T etail , while the power transfer from the tail electrons to the bulk electrons decreases with 1/T etail 0.5 . This causes a rapid transition to a state with high T etail while reducing T ebulk towards colder ion temperature. The understanding of the transition mechanism helps to consider plasma current start-up using 2nd harmonic ECRH for tokamak reactors such as JT-60 SA and ITER.
QUEST↗
Experimental and Numerical Evaluation of the Thermal-Fluid Characteristics of the Helium-Cooled Modular Divertor with Multiple Jets Using a Reversed Heat Flux Approach
A single-finger unit of the Helium-Cooled Modular Divertor with Multiple Jets (HEMJ) with a plasma-facing surface (PFS) area of about 2 cm 2 has been studied in a helium (He) loop at He mass flow rates m˙ H ≤ 8 g/s and nearly prototypical conditions. Based on previous studies of the single finger of the HEMJ, our Georgia Institute of Technology group is planning to experimentally study larger divertors. Given that the HEMJ test section was heated with an induction heater and that it is impractical to scale this up to divertors with larger PFS areas, a reversed heat flux approach is being considered to measure heat transfer coefficients (HTCs). In this approach, the direction of the heat flux is reversed with water cooling and high-temperature He heating of the outer shell attached to the PFS. This work presents an initial experimental and numerical evaluation of this approach for a single HEMJ finger. Experiments with brass and copper-chromium-zirconium outer shells were conducted at dimensionless He mass flow rates or Reynolds numbers Re = 1 × 10 4 to 4.7 × 10 4 , an inlet pressure of 10 MPa, temperatures as great as 673 K, and maximum heat flux of 8.4 MW/m 2 . The experiments verify that the He-side HTCs are independent of the direction of the heat flux. Here, the results agree well with previous Nusselt number correlation and pressure loss coefficients for the HEMJ obtained using the normal heating approach.
42 ENGINEERING↗
The measurement of heats of solution of high melting metallic systems in an electromagnetic levitation field
A method was tested for measuring the enthalpies of mixing of liquid metallic alloying systems, involving the combination of two samples in the electromagnetic field of an induction coil. The heat of solution is calculated from the pyrometrically measured temperature effect, the heat capacity of the alloy, and the heat content of the added sample. The usefulness of the method was tested experimentally with iron-copper and niobium-silicon systems. This method should be especially applicable to high-melting alloys, for which conventional measurements have failed.
Frohberg, M. G.↗
Toroid Joining Gun For Fittings And Couplings
Hand-held gun used to join metal heat-to-shrink couplings. Uses magnetic induction (eddy currents) to produce heat in metal coupling, and thermocouple to measure temperature and signals end of process. Gun, called "toroid joining gun" concentrates high levels of heat in localized areas. Reconfigured for use on metal heat-to-shrink fitting and coupling applications. Provides rapid heating, operates on low power, lightweight and portable. Safe for use around aircraft fuel and has no detrimental effects on surrounding surfaces or objects. Reliable in any environment and under all weather conditions. Gun logical device for taking full advantage of capabilities of new metal heat-to-shrink couplings and fittings.
Fox, Robert L.↗
Primordial metamorphism of asteroids via electrical induction in a T Tauri-like solar wind
Possible heating mechanisms for an intense thermal cycle in the early solar system are considered, and inductive asteroid heating in a T Tauri environment is examined. Calculations of thermal models based on recent measurements of the electrical conductivity of carbonaceous meteorites are reported which are presumably more representative of actual conditions in the early solar nebula. Asteroidal thermal evolution is computed using a highly simplified code that restricts induction to the dc limit of the TM mode, approximates the complete unipolar-generation differential equation by a simple series-resistance model, and restricts the modeling of thermal conduction to a calculation of heat transfer across a thin planar shell of given thickness increasing with time, which blankets a body assumed to have an isothermal core. A grid of results is obtained for 20 combinations of asteroid radius and solar distance representing the populaton of asteroids. It is found that there is a relative heating maximum with respect to body radius, that this effect is due to the operation of two distinct heating-rate restrictions which have opposite radius dependences, and that the maximum current density is roughly proportional to the inverse of interior radius.
Herbert, F.↗
Separate-Effects Tests for Studying Temperature-Gradient-Driven Cracking in UO 2 Pellets
We report a variety of normal operation and accident scenarios can generate thermal stresses large enough to cause cracking in light-water reactor (LWR) fuel pellets. Cracking of fuel pellets can lead to reduced heat removal, higher centerline temperatures, and localized stress in cladding, all of which impact fuel performance. It is important to experimentally characterize the thermal and mechanical behavior in the pellet before and after cracking to improve cracking models in fuel performance codes. However, in-reactor observation and measurement of cracking is very challenging due to the harsh environment and logistics. Recently, an experimental pellet cracking test stand was developed for separate effects testing of normal operations and accident temperature conditions, using thermal imaging to capture the pellet surface temperature for evaluation of thermal stresses and optical imaging to capture the evolution of cracking in real time. Experiments were performed using depleted uranium dioxide (UO 2 ) pellets, which are useful for collecting data valuable for development and validation of cracking models. A combination of induction and resistance heating was used to create an average temperature gradient of 236°C/cm and 193°C/cm before and after cracking respectively. Characterization of the pellets were done before as well as after cracking. The cracking patterns are somewhat different than those expected in a typical reactor because of the differences in thermal conditions and pellet microstructure. However, if the actual conditions of these experiments are reproduced in computational models, these out-of-pile tests on UO 2 pellets provide relevant data for modeling purposes.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Evaluation of ceria as a surrogate material for UO 2 in experiments on fuel cracking driven by resistive heating
A variety of normal operation and accident scenarios can generate thermal stresses large enough to cause cracking in light-water reactor (LWR) fuel pellets. Cracking of fuel pellets can lead to reduced heat removal, larger centerline temperatures, and localized stress in cladding all of which impact fuel performance. Furthermore, pellet cracking also contributes to a temperature reduction in the pellet since the pellet fragments tend to move towards the heat sink (cladding), and the heat flow remains predominantly radial despite the presence of cracks. It is important to understand the temperature profile on the pellet before and after cracking to improve cracking models in fuel performance codes However, in-reactor observation and measurement of cracking is very challenging owing to the harsh environment and design of fuel rods. Recently, an experimental pellet cracking test stand was developed for separate effects testing of normal operations and accident temperature conditions, using thermal imaging to capture the pellet surface temperature for evaluation of thermal stresses and optical imaging to capture the evolution of cracking in real time. Cracking experiments were initially performed using ceria (CeO 2 ) as a surrogate fuel material, which is useful for developing and demonstrating the experimental approaches but is also valuable in its own right for cracking model development and validation. A combination of induction and resistance heating was used for volumetric heat generation in the pellet creating a thermal gradient. The material properties of CeO 2 and UO 2 are reviewed and compared for use in model development. Simulations of the experiment were performed to evaluate the behavior of the surrogate (CeO 2 ) fuel in BISON. The measured temperature profiles from BISON models match reasonably well with the observed experiments for the ceria pellets before cracking. The findings from this work will help improve confidence in fracture models used for fuel pellets under similar in-reactor conditions.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Heterogeneous Integration Technologies for High-temperature, High-density, Low-profile Power Modules of Wide Bandgap Devices in Electric Drive Applications (Final Technical Report)
The goal of this project is to develop packaging technologies for making high-temperature, high-density, and low-profile wide-bandgap (WBG) power electronics modules for electric drives. These modules are aimed at enabling the DOE’s University Consortium to reach its 2025 inverter targets of ≥ 100 kW/L and ≤ 2.7 $/kW. The specific objectives are to: design and fabricate SiC half-bridge power modules with double-sided cooling and parasitic inductances < 5 nH, heat flux density > 400 W/cm 2 , and working junction temperature of 200 o C; design, fabricate, and deliver a gate driver with double-sided cooled modules for the construction of a 100 kW/L inverter at Oak Ridge National Lab; and design and prototype intelligent gate drivers with integrated current sensor and a low-profile DC-DC power supply with air-core transformer for testing power modules at 200 o C junction temperature. We followed an iterative technical approach of design, simulation, fabrication, and testing of various versions of modules, current sensors, and power supply. The state-of-the-art silicon carbide devices rated at 1.2 kV and 149 A were packaged by sintered-silver bonding on an aluminum nitride direct-bond-copper substrate for high thermal conductivity, high working temperature, and high joint reliability. Porous silver posts were used to interconnect the device’s source pads to the other direct-bond-copper substrate for low mechanical stresses, ease of manufacturing, and double-sided cooling. A current sensor based on package parasitic inductance was developed to measure switching current. A dynamic feedback scheme was developed to compensate the effect of parasitic resistance and temperature variation. A constant-current class-E dc-dc converter with air-core transformer was developed. Air-core transformer was used due to the unavailability of magnetic core at high temperatures. Gate driver and power supply were integrated with the double-side cooled, high temperature SiC power modules for testing the modules at 200 o C junction temperature. Double-pulse and continuous testing of the integrated technologies validated the design and fabrication of the three component technologies. Throughout the project, we overcame the challenge for design verification caused by low prototyping yield, which then helped train the graduate students, the future workforce, to learn the engineering know-how for low-cost manufacturing of reliable products. Below is a summary of the major accomplishments of this project: development of a prototyping process for fabricating double-side cooled (1200 V, 149 A) SiC phase-leg modules capable of working to 200 o C Tj; simulation and experimental verification of the improvement of thermo-mechanical reliability of the double-side cooled SiC phase-leg module by using rigid encapsulant; design and experimental validation of a current sensor based on package parasitic inductance and a compensation solution for eliminating the effect of parasitic resistance; design and experimental validation of a low-profile power supply with six-output air-core transformer for gate driver; functional demonstration of a SiC phase-leg module integrated with its gate driver, current sensor, and an air-core power supply at 200 o C Tj in a double-pulse switching test setup and Buck converter continuous test setup; successful completion of six PhD and two MS students who are or will work at Apple Inc., Tesla Inc., Wolfspeed Inc., Microchip Inc., Monolithic Power Systems Inc., and LG Magna Inc.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Multi-harmonic electron cyclotron heating and current drive scenarios for non-inductive start-up and ramp-up in high field ST-40 spherical tokamak
We report non-inductive start-up and ramp-up is an important topic for spherical tokamak reactor design as the central solenoid implementation is highly restrictive particularly for the low-aspect-ratio tokamak configuration. In the high field spherical tokamak (ST), ST-40 with B T0 ≤ 3 T, a preparation is underway for high power ECH and ECCD current start-up/ramp-up experiments utilizing two MW-class 140/105 GHz gyrotrons. Here, we explored various ECH/ECCD scenarios for a low-field-side (LFS) launch-angle steerable waveguide launcher placed near the mid-plane region. Due to the large toroidal field variation of ST configuration, multiple cyclotron harmonic resonance layers could exist within the plasma. In this start-up and ramp-up regime, both fundamental and second harmonic ECH resonances must be considered. We find that even with the presence of X-II resonance layer in the plasma, an efficient X-I ECH and ECCD regime can be accessed for the low electron temperature T e0 as low as 200 eV which is a typical starting temperature of ECH heated plasmas in an open-field-line configuration. The presence of X-II resonance could become significant at higher T e0 as X-II absorption increases with T e0 which could reduce the current ramp-up efficiency as the power reaching X-I is reduced. Finally for the pure X-I regime where the 2Ω e resonance is moved outside the plasma with B T0 ~ 3.4 T, we find that it is possible to reach the full current of I p ~ 1 MA fully non-inductively with the ECH power of ~1 MW at n e0 ~ 1.0 × 10 19 m -3 using 105 GHz frequency gyrotron. By reducing the outer limiter position R L ~ 78 cm to 70 cm, the pure X-I regime is recovered at the rated ST-40 magnetic field of B T0 ~ 3.0 T. This X-I regime is accessible with a relatively broad range of launched n II or the launching angles. A survey of X-mode X-II ECH and ECCD at higher density regimes is also shown for completeness.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Pulsed Beam Heating Analysis of Curved Inconel Window with Pressurized Helium Gas Cooling
Los Alamos National Laboratory (LANL) is working with NorthStar medical Radioisotopes (NMR) on their efforts to produce Mo-99 through the irradiation of Mo-100 using Rodotron electron accelerators. Two Rhodotron accelerators are used to irradiate a double sided target. LANL collaborates with NMR to experimentally investigate beam effects on the target which consists of two Inconel 718 windows on either side of a stack of Mo-100 discs. LANL simulates the beam heating using an induction heater.
07 ISOTOPE AND RADIATION SOURCES↗
Window Cooling Studies using Pulsed Beam Heating
Los Alamos National Laboratory (LANL) is working with NorthStar Medical Radioisotopes (NMR) on their efforts to produce Mo-99 through the irradiation of Mo-100 using electron accelerators. Two electron accelerators are used to irradiate a double sided target. LANL collaborates with NMR to experimentally investigate beam effects on the target which consists of two Inconel 718 windows on either side of a stack of Mo-100 disks. LANL simulates the beam heating using an induction heater.
43 PARTICLE ACCELERATORS↗