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At least 235 records · Page 13

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DOE OSTI2024

Modernizing the Legacy Fission Wire Measurement System for the Advanced Test Reactor-Critical Facility

Operational lifetime extensions of existing research reactors have emphasized the need for refurbishment, replacements, and upgrades to supporting equipment and instrumentation. The Advanced Test Reactor (ATR) at Idaho National Laboratory (INL), which entered service in 1967, has recently completed the sixth core internals change-out and has scheduled operations until at least 2040. Reactor maintenance and operational risk management is critically important in the research reactor community, however supporting measurement systems sometimes get overlooked when maintenance is planned. The Fission Wire Measurement System (FWMS) is a custom measurement system designed in the 1960s to measure the beta-particle activity of irradiated uranium-aluminum fission wires. This measurement is conducted to determine the fission rate profile of the Advanced Reactor Test Critical (ATR-C) facility. The ATR-C is an open-pool, low-power test reactor that was purpose driven to resemble ATR and is used to qualify experiment configurations and verify core models prior to full-power experiment irradiations in ATR. A power distribution measurement in ATR-C uses uranium-aluminum wires that are distributed throughout the ATR-C core to validate simulation and modeling results. These measurements require 340 to 1500 wires to be irradiated and measured within a 12-hour window. The activity of the wires is measured in the required time with the FWMS, which was put into service in 1965 at the Radiation Measurements Laboratory (RML). The system consists of 4 measurement channels and one reference channel, each with a 2-pi proportional gas flow detector and the measurement channels each have an automated sample changer. This legacy system is crucial to the continued operations of ATR and has undergone some minor hardware upgrades since 1965, however the system presently relies on custom control boards, custom gas ion chambers, analog amplifiers/discriminators, and a user interface (UI) for the system written in outdated code. Much of the equipment and software is custom with no commercial replacements or support and limited documentation. The existing control software requires an operating system that is no longer supported, creating more vulnerabilities to continued operations. A project is underway with a third-party vendor to design, build, and document a new control and data acquisition system (CDAS) for the FWMS. The new upgrade will replace the control system, computer, UI, sample changer motors, and main power supply while maintaining the interface with existing detector hardware. The upgraded system will be operated in parallel with the current hardware and software to conduct validation testing. This equipment upgrade demonstrates the commitment at ATR to ensuring successful operations and potential future research reactors at INL.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗

DOE OSTI2020

An experimental investigation of the effectiveness of Ar-CO 2 shielding gas mixture for the wire arc additive process

Wire arc additive manufacturing (AM) is the process by which a large, metallic structure is built layer-by-layer using a welding arc to melt a wire feedstock. A novel opportunity exists to alter the shielding gas composition to fabricate distinct geometrical features without altering the other AM parameters. In this paper, shielding gases with varied concentrations of Argon (Ar) and CO 2 was used to deposit three distinct geometric shapes (walls, infill, and overhang) using a wire-based additive manufacturing system utilizing the gas metal arc welding (GMAW) surface tension transfer (STT) process. Computer-aided design (CAD) models were sliced with a custom-built slicer, and the sliced algorithm was converted into optimal robotic toolpaths. A custom virtual instrument (VI) was built in LabVIEW to compare the temperature profiles on the surface during each deposition process. After each deposition, the geometric features were scanned, and the surface waviness value was evaluated. Tensile and Charpy impact coupons were extracted from the wall geometries in the longitudinal and transverse directions and tested. The results indicated that a higher CO 2 content produced higher melt pool temperatures to an extent, while lower contents of CO 2 resulted in a dimensionally accurate geometry. The data also indicated that the 2%/98% CO 2 /Ar blend produced scatter in tensile strength and the analysis of variance (ANOVA) shows significant difference. However, the intermediate range of CO 2 (5–10%) resulted in uniform tensile properties. Altogether, these results indicate that a 5%/95% CO 2 /Ar blend is the ideal shielding gas for lowering process temperatures and improving mechanical properties in wire arc additive manufacturing using the gas metal arc welding surface tension transfer process. Additionally, varying concentrations of Ar/CO 2 can be used within the same part in order to modify the local properties or process parameters such as strength, toughness, temperature, or dimensional features. This may improve overall manufacturing quality without sacrificing specific properties.

42 ENGINEERING↗

DOE OSTI2022

Investigations in the tape-to-tape contact resistance and contact composition in superconducting CORC ® wires

Conductor on Round Core (CORC®) wires and cables, constructed from multiple layers of helically wound REBa 2 Cu 3 O 7–δ tapes, are a promising cable technology for high field magnet applications. An important feature of high-temperature superconductor cables is the ability to share current between conductors, allowing current to bypass drops in I c and minimizing the risk of hot spot formation, which could lead to potential burnout in the superconductor. In contrast to stacked-tape cables, which have continuous contact between tapes, in CORC® the transfer points occur at discrete tape crossovers. The tape-to-tape contact resistance, R c , plays a critical role in the current sharing capabilities and current distribution in cables. For the work reported here, special CORC® wires were manufactured using different winding parameters to investigate variations in R c . Variations comprised inclusion of a lubricant, different lubricant conductivity, inclusion of pre-tinning, and heating briefly to melt the solder. Cables were first tested as straight lengths, followed by bending to a 10 cm diameter. In straight cables R c values ranged from 1 to over 1000 μΩ cm 2 , depending on cabling parameters, with the highest values being found for cables made by the present 'standard' process. Bending the cables to a 10 cm diameter decreased R c by a factor 2–5. Tinning with PbSn decreased R c by three orders of magnitude compared to standard CORC® wires, and heat treating wires with tinned conductor resulted in only a small further decrease in R c . Based on the measured R c at an electric field of 1 μV cm –1 the resulting current transfer length between layers can range from a few millimeters to a tens of centimeters. Examination of contacts with a laser confocal microscope showed plastic deformation of the copper at the edges of the contact overlap area, apparently caused by thicker plating at tape edges digging into the copper of neighboring layers. These images reveal that only a fraction of the total contact surface may actually be touching when there is nothing to compensate for height differential. Images of the PbSn coated tapes indicated that application of solder produces a much more uniform contact surface and higher contact area. Furthermore, imaging of CORC® cross-sections confirmed that in the non-tinned cables there are many regions where tapes are not in contact, while in contrast the PbSn cable shows significantly more contact between the tapes. These different imaging techniques reveal that tape surface morphology is a significant parameter in determining R c .

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Critical transverse compressive stresses of straight and bent CORC® wires with and without impregnation

CORC® wires are a promising superconductor for accelerator magnet applications. While their excellent uniaxial tensile properties have been well established, potential degradation under transverse compression remains a concern for accelerator magnets, in which transverse compression is a primary stress experienced by superconductors. To evaluate the critical transverse compressive stresses of rare-earth barium copper oxide conductors, we developed an experimental system that enables testing of samples both with and without impregnation in liquid nitrogen. Furthermore, because bending strain induced during coil winding may influence the critical compressive response of CORC® wires, the apparatus was also modified to allow testing under the bending condition. In this study wires were tested for five configurations: (1) straight, non-impregnated, (2) bent, non-impregnated, (3) straight, Stycast 2850 FT-impregnated, (4) bent, Stycast 2850 FT-impregnated, and (5) bent, paraffin wax-impregnated. The transverse pressures corresponding to 3% and 5% reductions in the critical current are reported. In conclusion, the effects of wire bending and impregnation on the critical transverse pressure are analyzed, and the implications for transverse stress levels in accelerator magnet conductors are discussed.

CORC® wire↗

DOE OSTI2021

Design Optimization for Printed Melt Wire Arrays Encapsulation

As part of the Nuclear Energy Enabling Technology (NEET) Advanced Sensor and Instrumentation (ASI) Program, Idaho National Laboratory (INL) has recently established in-house capabilities to fabricate and test new advanced-manufactured sensors for measuring peak irradiation temperature within a nuclear test reactor. Although methods of real-time temperature monitoring, such as thermocouples, may be used, the complexity of feedthroughs and attachments to collect real-time measurements greatly increases the cost of the experiment. Instead, passive monitoring techniques may be used for peak- temperature measurement that exploit the melting point of well-characterized materials (standard melt wires) to infer peak reactor temperatures. However, limited available space for instrumentation during experiments introduces an additional challenge. To accommodate this, INL has expanded its temperature- detection instrumentation capabilities to include advanced manufactured (AM) melt wires for peak irradiation temperature measurements. These melt wires can determine peak temperatures while also accommodate space limitations in irradiation experiments. In an effort to improve performance reliability of AM meltwire capabilities, a process was developed and tested to identify the significance of entrapping a high purity inert atmosphere within the packaging of printed melt wire arrays. The materials used in this study were aluminum, zinc, and tin encapsulated in high purity helium within a stainless steel (SS) 316 container. Tin, with a low melting point of approximately 230°C, Zn with a mid-melting point of approximately 420°C, and Al with a high melting point of approximately 660°C. This report describes the design, fabrication process, furnace testing and X-ray Computed Tomography (XCT) evaluation. Results show a successful outcome in creating an inert gas encapsulation and high-resolution evaluation methods.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2021

Melt Wire Analyses for the Colorado School of Mines (CSM 16-10584) Irradiation in ATR

PNNL project 74242 involves the analysis of neutron fluence monitors and melt wires irradiated in the Advanced Test Reactor (ATR) at Idaho National Laboratory in accordance with MPO 00236287 and Statement of Work No. 17370, Rev. 0, PNNL Analysis of NSUF Flux and Melt Wire Capsules. This report is for the Colorado School of Mines (CSM 16-10584) experiment which was conducted in position B5 of the ATR. Neutron fluence monitor results were reported in February 2021 in report Neutron Dosimetry for the Colorado School of Mines (CM 16-10584) Irradiation in ATR. This report presents the analyses of the melt wire capsules that were included along with the neutron fluence monitors. Each capsule was identified by the ID stamp on the bottom, then opened to assess the condition of the Pb and Zn-Al wires as well as the Bi powder. Pictures are included to illustrate the results.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1952

Nonlinear theory of a hot-wire anemometer

A theoretical analysis is presented for the hot-wire anemometer to determine the differences in resistance characteristics as given by King's equation for an infinite wire length and those given by the additional considerations of (a) a finite length of wire with heat loss through its ends and (b) heat loss due to a nonlinear function of the temperature difference between the wire and the air.

HEAT TRANSMISSION - GASES & SOLIDS↗

NASA NTRS2014

Novel Wiring Technologies for Aerospace Applications

Because wire failure in aerospace vehicles could be catastrophic, smart wiring capabilities have been critical for NASA. Through the years, researchers at Kennedy Space Center (KSC) have developed technologies, expertise, and research facilities to meet this need. In addition to aerospace applications, NASA has applied its knowledge of smart wiring, including self-healing materials, to serve the aviation industry. This webinar will discuss the development efforts of several wiring technologies at KSC and provide insight into both current and future research objectives.

novel↗

NASA NTRS2017

Highly Conductive Wire: Cu Carbon Nanotube Composite Ampacity and Metallic CNT Buckypaper Conductivity

NASA is currently working on developing motors for hybrid electric propulsion applications in aviation. To make electric power more feasible in airplanes higher power to weight ratios are sought for electric motors. One facet to these efforts is to improve (increase) the conductivity and (lower) density of the magnet wire used in motors. Carbon nanotubes (CNT) and composites containing CNT are being explored as a possible way to increase wire conductivity and lower density. Presented here are measurements of the current carrying capacity (ampacity) of a composite made from CNT and copper. The ability of CNT to improve the conductivity of such composites is hindered by the presence of semiconductive CNT (s-CNT) that exist in CNT supplies naturally, and currently, unavoidably. To solve this problem, and avoid s-CNT, various preferential growth and sorting methods are being explored. A supply of sorted 95 metallic CNT (m-CNT) was acquired in the form of thick film Buckypaper (BP) as part of this work and characterized using Raman spectroscopy, resistivity, and density measurements. The ampacity (Acm2) of the Cu-5volCNT composite was 3.8 lower than the same gauge pure Cu wire similarly tested. The lower ampacity in the composite wire is believed to be due to the presence of s-CNT in the composite and the relatively low (proper) level of longitudinal cooling employed in the test method. Although Raman spectroscopy can be used to characterize CNT, a strong relation between the ratios of the primary peaks GGand the relative amounts of m-CNT and s-CNT was not observed. The average effective conductivity of the CNT in the sorted, 95 m-CNT BP was 2.5 times higher than the CNT in the similar but un-sorted BP. This is an indication that improvements in the conductivity of CNT composites can be made by the use of sorted, highly conductive m-CNT.

wire↗

NASA NTRSDate not supplied

An Examination of Causes of Multi-Wire Bias During SLD Instrumentation Testing in the IRT

The Icing Research Tunnel (IRT) at NASA Glenn Research Center has been using the SEA Multi-Element Sensor (aka, the multi-wire) as its primary liquid water content instrument since 2011. Recent tests in the IRT with four different multi-wire probes (i.e., different serial numbers) have indicated situations that can result in biasing of the probe data. The reference data used in this report are multi-wire data that have been proven to agree well with the icing blade in low-impingement rate conditions. Data from these recent tests suggest that the presence of a canister probe located 4.45 ft axially downstream and 2.5 ft to the side may have caused multi-wire data to read around 5% low at an airspeed of 150 kts. Additionally, two probes of different serial numbers were observed to measure 5-15% lower than the reference probes, and the causes have been linked to excessive solder on the sensing element and to an out of date element calibration. For these reasons, the authors suggest the community be aware of the possible aerodynamic influences on the probe inlet and outlet, as well as the importance of regular calibration and maintenance of the probes.

aircraft icing↗

NASA NTRSDate not supplied

An Examination of Causes of Multi-Wire Bias during SLD Instrumentation Testing in the IRT

aircraft icing↗

DOE OSTI2020

Effects of catalyst droplets on wire growth and the resulting branched structures during VLS growth

Vapor-liquid-solid (VLS) method is vastly employed to grow hierarchical structures with unique properties. However, key questions remain, such as what controls the branched structures and what the roles of catalyst droplet size are during the growth. Here, an in-depth understanding of the kinetics of the nucleation, growth, and subsequent coalescence processes of Bi liquid catalyst droplets is provided by direct observation of PbSe branched wire growth in an environmental transmission electron microscope. This brings a kinetic control of the branch density by varying the parameters, such as temperature. In addition, the dependence of wire growth rate on the catalyst droplet size is revealed, i.e., the smaller the catalyst size the larger the wire growth rate, unlike the wire growth controlled by Gibbs-Thomson effect, possibly due to different mass transport pathways and atomic surface diffusion. These results extend the fundamental understanding of the VLS growth mechanism of branched structures and benefit the structure design of hierarchical materials with tailored properties.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Study of SXR/EUV radiation of exploded foils and wires with spectral, spatial and temporal resolution simultaneously on KING electric discharge facility.

The results of studies of the soft X-ray and extreme ultraviolet (SXR/EUV) radiation of thin flat aluminum foils and wires under the explosion in an electric discharge on the compact high-current KING generator are presented. These studies were based on the SXR/EUV spectroscopy with a spectral resolution of 6 Å, a temporal resolution of 5 ns and a spatial resolution of 200 μm. To study the plasma radiation of exploded foils and wires in the SXR/EUV range, we used a transmission diffraction grating spectrograph which in combination with two additional slits provided spectral and spatial resolution. The spectrograph was coupled with a 4-frame recorder based on a microchannel plate for providing temporal resolution. The analysis and comparison of the spectral, spatial, temporal, and energy characteristics of the SXR/EUV radiation of plasma formed under the explosion of foils and wires of a similar mass made of aluminum was carried out. Here, the spectra were calculated as well and the plasma parameters and their changes in time and space were estimated on the basis of these calculations and comparison with relevant experimental results. Experiments have shown that when foils explode, a single intense source of SXR/EUV radiation is formed with radiated energy in the range of 10-20 J and a power of up to 100 MW in the quantum energy range from 30 to 250 eV. At the same time, the radiation power under the explosion of foils turned out to be about twice above the power under the explosion of wires of comparable mass.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Correlation of critical current density to quasi-biaxial texture and grain boundary cleanliness in fully dense Bi-2212 wires

The distinctive quasi-biaxial texture of Bi 2 Sr 2 CaCu 2 O x (Bi-2212) plays an important role in enabling high critical current density ($J_c$) in Bi-2212 round wires (RWs). Here we studied three over pressure heat treated wires with $J_c$ varying by a factor of ~10, all being fully dense. Using electron backscatter diffraction, we observed the differences in biaxial texture in these three wires. Transmission electron microscopy also revealed differences in grain boundary (GB) cleanliness and connectivity. These analyses showed that high $J_c$ is unambiguously correlated to the best biaxial texture, which is in turn correlated to slow cooling from the liquid melt into solid Bi-2212. However, at 4.2 K, there is a negligible difference in intragrain pinning in the three wires, suggesting that the $J_c$ variation by a factor of ~10 is primarily due to variable filament and intergrain connectivity. In this work, the principal determinants of intergrain connectivity is the quasi-biaxial texture and GB cleanliness. Overall, $J_c$ optimization of the Bi-2212 RW is a complex multi-variable process, but this study shows that maximizing the biaxial texture quality is an important first step in such an optimization process.

36 MATERIALS SCIENCE↗

DOE OSTI2021

WIRE: Resource-efficient Scaling with Online Prediction for DAG-based Workflows

This paper introduces WIRE that manages resources for the DAG-based workflows on IaaS clouds. WIRE predicts and plans resources over the MAPE (Monitor-Analyze-Plan-Execute) loops to: 1) Estimate task performance with online data, 2) Conduct simulations to predict the upcoming loads based on online estimates and workflow DAGs, 3) Apply a resource-steering policy to size cloud instance pools for the maximal parallelism that is consistent with low cost. We implement WIRE on Pegasus WMS/HTCondor and evaluate its performance on the ExoGENI network cloud. The results show that WIRE attains low resource cost with the performance that is typically within a factor of two of optimal.

Xie, Bing↗

DOE OSTI2024

TTW (Transition to Wire Device) [SWR-25-02]

The Transition to Wire (TTW) hardware project is a method for connecting solar research samples with fragile interconnects to robust, weatherproof and consistent commercial connectors. The Transition to Wire device is a printed circuit board designed to facilitate the transition from tab ribbon or other unsecured electrical contacts on research samples to either wires or a connector. The four pin connector provides a kelvin (4 wire) connection at the solder pad where the sample connects.

McDanold, Byron↗

DOE OSTI2021

Role of relativistic laser intensity on isochoric heating of metal wire targets

In a recent experimental campaign, we used laser-accelerated relativistic hot electrons to ensure heating of thin titanium wire targets up to a warm dense matter (WDM) state [EPL 114, 45002 (2016)]. The WDM temperature profiles along several hundred microns of the wire were inferred by using spatially resolved X-ray emission spectroscopy looking at the Ti Kαcharacteristic lines. A maximum temperature of ~30 eV was reached. Our study extends this work by discussing the influence of the laser parameters on temperature profiles and the optimisation of WDM wire-based generation. The depth of wire heating may reach several hundreds of microns and it is proven to be strictly dependent on the laser intensity. At the same time, it is quantitatively demonstrated that the maximum WDM temperature doesn’t appear to be sensitive to the laser intensity and mainly depends on the deposited laser energy considering ranges of 6×10 18 –6×10 20 W/cm 2 and 50–200 J.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Double Quarter Wave Crab Cavity Wire Stretching Measurement at BNL

The Double Quarter Wave (DQW) crab cavity is one out of the two crab cavities within Work Package 4 of the LHC (Large Hadron Collider) Hi-Lumi Program, and the RF design of the cavity was originally supported by the US LHC Accelerator Research Program (LARP) and later the LHC Accelerator Upgrade Program (AUP) funded by the DOE High Energy Physics Office in the Office of Science. Brookhaven National Laboratory (BNL) has delivered the successful DQW crab cavity RF design, and worked actively with all. The wire stretching measurement was completed on the prototype DQW crab cavity for operation practice and calibration of the measurement system. Four locations were defined to be on the electrical center plane of the crab cavity, and survey of the wire indicated all are on the same plane. The successful measurement validated the wire stretching system built at Brookhaven National Lab. The offset of the four wire locations to the fitted plane provided the error of the measurement.

43 PARTICLE ACCELERATORS↗