Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “BAKING”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

R&D Towards High Gradient CW SRF Cavities

This talk will discuss Fermilab’s recent progress in the surface engineering of superconducting radio-frequency (SRF) cavities geared toward producing simultaneously high quality factors and high accelerating gradients in cryomodules. We investigate possible microscopic mechanisms that drive improved performance by carrying out sequential RF tests on cavities subjected to low temperature baking. We compare performance evolution to observations made with material science techniques and find correlations with material parameters. We also discuss other key advancements that enable high gradient operation in cryomodules.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Analysis of Low RRR SRF Cavities

Recent findings in the superconducting radio-frequency (SRF) community have shown that introducing certain impurities into high-purity niobium can improve quality factors and accelerating gradients. Success has been found in nitrogen-doping, diffusion of the native oxide into the niobium surface, and thin films of alternate superconductors atop a niobium bulk cavity. We question why some impurities improve RF performance while others hinder it. The purpose of this study is to characterize the impurity profile of niobium with a low residual resistance ratio (RRR) and correlate these impurities with the RF performance of low RRR cavities so that the mechanism of recent impurity-based improvements can be better understood and improved upon. Additionally, we performed surface treatments, low temperature baking and nitrogen-doping, on low RRR cavities to evaluate how the intentional addition of more impurities to the RF layer affects performance. We have found that low RRR cavities experience low temperature-dependent BCS resistance behavior more prominently than their high RRR counterparts. The results of this study have the potential to unlock a new understanding on SRF materials.

43 PARTICLE ACCELERATORS↗
DOE OSTI2019

Investigation of Frequency Behavior Near Tc of Niobium Superconducting Radio-Frequency Cavities

This paper will present a systematic investigation of the resonant frequency behavior of niobium SRF cavities subject to different surface processing (nitrogen doping, nitrogen infusion, 120°C bake, EP, etc.) near the critical transition temperature. We find features occurring in frequency versus temperature (FvsT) data near Tc that seem to vary with surface processing. Emphasis is placed on one of the observed features: a dip in the superconducting resonant frequency below the normal conducting value which is prominent in nitrogen doped cavities and appears to be a signature of nitrogen doping. This gives further insights on the mechanisms responsible for the large increase in performance of cavities subject to this surface treatment. The magnitude of this dip in frequency is studied and related to possible physical parameters such as the concentration of impurities near the surface and the design resonant frequency of the cavity. A possible explanation for the meaning of this dip is discussed, namely, that it is a result of strong coupling between electrons and phonons within the resonator.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Toward Qualifications of HB and LB 650 MHz Cavities for the Prototype Cryomodules for the PIP-II Project

High-beta (HB) and low-beta (LB) 650 MHz cryomodules are key components of the Proton Improvement Plan II (PIP-II) project. In this contribution we present the results of several 5-cell HB650 cavities that have been processed and tested with the purpose of qualifying them for the prototype cryomodule assembly, which will take place later this year. We also present the first results obtained in LB650 single-cell cavities process optimization. Taking advantage of their very similar geometry, we are also analyzing the effect of different surface treatments in FRIB’s 5-cell medium-beta 644MHz cavities. Cavities processed with N-doping and mid-T baking showed very promising results in term of both Q-factors and accelerating gradient for these low-beta structures.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

MAGNETIC FIELD MAPPING OF A LARGE-GRAIN 1.3 GHz SINGLE-CELL CAVITY

A new magnetic field mapping system for 1.3 GHz single- cell cavities was developed in order to reveal the impact of ambient magnetic field and temperature gradients during cool-down on the flux trapping phenomenon. Measurements were done at 2 K for different cool-down conditions of a large-grain cavity before and after 120 °C bake. The fraction of applied magnetic field trapped in the cavity walls was ? 50% after slow cool-down and ? 20% after fast cool-down. The results showed a weak correlation between between trapped flux locations and hot-spots causing the high-field Q-slope. The results also showed an increase of the trapped flux at the quench location, after quenching, and a local redistribution of trapped flux with increasing RF field.

Ciovati, Gianluigi↗
DOE OSTI2023

EVALUATION OF FLUX EXPULSION AND FLUX TRAPPING SENSITIVITY OF SRF CAVITIES FABRICATED FROM COLDWORK NB SHEET WITH SUCCESSIVE HEAT TREATMENT

The main source of RF losses leading to lower quality factor of SRF cavities is due to the residual magnetic flux trapped during cooldown. The loss due to flux trapping is more pronounced for cavities subjected to impurities doping. The flux trapping and its sensitivity to rf losses are related to several intrinsic and extrinsic phenomena. To elucidate the effect of recrystallization by high temperature heat treatment on the flux trapping sensitivity, we have fabricated two 1.3 GHz single cell cavities from cold-worked Nb sheets and compared with cavities made from standard fine-grain Nb. Flux expulsion ratio and flux trapping sensitivity were measured after successive high temperature heat treatments as well as after low temperature, 120 0C baking. The cavity made from cold worked Nb showed better performance after 800 0C/3hr heat treatment and similar behavior when heat treated with additional 900 0C and 1000 0C compared to standard fine-grain Nb cavity. In this contribution, we present the summary of flux expulsion, trapping sensitivity and results from RF tests at 2 K.

Khanal, Bashu↗
DOE OSTI2011

Cladding Alloys for Fluoride Salt Compatibility Final Report

This interim report provides an overview of several candidate technologies for cladding nickel-based corrosion protection layers onto high-temperature structural alloys. The report also provides a brief overview of the welding and weld performance issues associated with joining nickel-clad nickel-based alloys. From the available techniques, two cladding technologies were selected for initial evaluation. The first technique is a line-of-sight method that would be useful for coating large structures such as vessel interiors or large piping. The line-of-sight method is a laser-based surface cladding technique in which a high-purity nickel powder mixed into a polymer binder is first sprayed onto the surface, baked, and then rapidly melted using a high power laser. The second technique is a vapor phase technique based on the nickel-carbonyl process that is suitable for coating inaccessible surfaces such as the interior surfaces of heat exchangers. The final project report will feature an experimental evaluation of the performance of the two selected cladding techniques.

36 MATERIALS SCIENCE↗
DOE OSTI2011

Cladding Alloys for Fluoride Salt Compatibility

This report provides an overview of several candidate technologies for cladding nickel-based corrosion protection layers onto high-temperature structural alloys. The report also provides a brief overview of the welding and weld performance issues associated with joining nickel-clad nickel-based alloys. From the available techniques, two cladding technologies were selected for initial evaluation. The first technique is a line-of-sight method that would be useful for cladding large structures such as vessel interiors or large piping. The line-of-sight method is a laser-based surface cladding technique in which a high-purity nickel powder mixed into a polymer binder is first sprayed onto the surface, baked, and then rapidly melted using a high-power laser. The second technique is a vapor phase technique based on the nickel-carbonyl process that is suitable for cladding inaccessible surfaces such as the interior surfaces of heat exchangers. An initial evaluation for performed on the quality of nickel claddings processed using the two selected cladding techniques.

alloys↗
DOE OSTI2011

Energy Saving Melting and Revert Reduction (E-SMARRT): Precision Casting of Steel

This project addresses improvements in metal casting processes by reducing scrap and reducing the cost of production, due to scrap reduction from investment casting and yield improvement offered by lost foam casting as compared to no-bake or green sand molding. The objectives for the investment casting portion of the subtask are to improve knowledge of fracture toughness of mold shells and the sources of strength limiting flaws and to understand the effects of wax reclamation procedures on wax properties. Applying 'clean steel' approaches to pouring technology and cleanliness in investment casting of steel are anticipated to improve incoming materials inspection procedures as they affect the microstructure and toughness of the shell. This project focused on two areas of study in the production of steel castings to reduce scrap and save energy: (1) Reducing the amount of shell cracking in investment cast steel production; (2) Investigate the potential of lost foam steel casting The basic findings regarding investment casting shell cracking were: (1) In the case of post pouring cracking, this could be related to phase changes in silica upon cooling and could be delayed by pouring arrangement strategies that maintained the shell surface at temperature for longer time. Employing this delay resulted in less adherent oxidation of castings since the casting was cooler at the time o fair exposure. (2) A model for heat transfer through water saturated shell materials under steam pressure was developed. (3) Initial modeling result of autoclave de-waxing indicated the higher pressure and temperature in the autoclave would impose a steeper temperature gradient on the wax pattern, causing some melt flow prior to bulk expansion and decreasing the stress on the green shell. Basic findings regarding lost foam casting of steel at atmospheric pressure: (1) EPS foam generally decomposes by the collapse mode in steel casting. (2) There is an accumulation of carbon pick-up at the end of the casting opposite the gate. (3) It is recommended that lost foam castings in steel be gated for a quiescent fill in an empty cavity mold to prevent foam occlusion defects from the collapse mode. The energy benefit is primarily in yield savings and lower casting weight per function due to elimination of draft and parting lines for the larger lost foam castings. For the smaller investment casting, scrap losses due to shell cracking will be reduced. Both of these effects will reduce the metal melted per good ton of castings. There will also be less machine stock required per casting which is a yield savings and a small additional energy savings in machining. Downstream savings will come from heavy truck and railroad applications. Application of these processes to heavy truck castings will lighten the heavy truck fleet by about ten pounds per truck. Using ten years to achieve full penetration of the truck fleet at linear rate this will result in a fuel savings of 131 trillion BTU over ten years.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2012

Energy Saving Glass Lamination via Selective Radio Frequency Heating

This project focused on advancing radio-frequency (RF) lamination technology closer to commercial implementation, in order to reduce the energy intensity of glass lamination by up to 90%. Lamination comprises a wide range of products including autoglass, architectural safety and innovative design glass, transparent armor (e.g. bullet proof glass), smart glass, mirrors, and encapsulation of photovoltaics. Lamination is also the fastest growing segment of glass manufacturing, with photovoltaics, architectural needs, and an anticipated transition to laminated side windows in vehicles. The state-of-the-art for glass lamination is to use autoclaves, which apply heat and uniform gas pressure to bond the laminates over the course of 1 to 18 hours. Laminates consist of layers of glass or other materials bonded with vinyl or urethane interlayers. In autoclaving, significant heat energy is lost heating the chamber, pressurized air, glass racks, and the glass. In RF lamination, the heat is generated directly in the vinyl interlayer, causing it to heat and melt quickly, in just 1 to 10 minutes, without significantly heating the glass or the equipment. The main purpose of this project was to provide evidence that low energy, rapid RF lamination quality met the same standards as conventionally autoclaved windows. The development of concepts for laminating curved glass with RF lamination was a major goal. Other primary goals included developing a stronger understanding of the lamination product markets described above, and to refine the potential benefits of commercial implementation. The scope of the project was to complete implementation concept studies in preparation for continuation into advanced development, pilot studies, and commercial implementation. The project consisted of 6 main tasks. The first dealt with lamination with poly-vinyl butyral (PVB) interlayers, which prior work had shown difficulties in achieving good quality laminates, working with Pilkington North America. The second task dealt with a study of current lamination processes in the various laminate industries, and development of concepts for integrating RF lamination into new or existing processes. The third task explored the use of a non-destructive technique for analyzing laminate adhesion with the University of Illinois at Urbana-Champaign. The fourth task focused on developing concepts for curved glass lamination using RF lamination. The fifth and sixth tasks together comprised an analysis of laminate product markets, ranking for applicability and commercialization potential, and the development of commercialization strategies for those products. In addition, throughout the project as new experimental data and conventional process data were obtained, the benefits analysis of RF lamination was refined. The goals of the project described above were achieved, positioning RF lamination for the next stage growth envisioned in the original Industrial Grand Challenge proposal. Working with Pilkington North America, lamination of flat autoglass with PVB was achieved, meeting all 16 stringent industry tests. In particular, PVB laminates made with RF lamination passed environmental tests including the high temperature, 120 C bake test, without significant formation of bubbles (defects). The adhesion of PVB to glass was measured using the pummel method. Adhesion values ranging from 1 to 7 out of 10 were obtained. The significant process parameters affecting the environmental and adhesion performance were identified through a designed experiment. Pre-lamination process variables including PVB storage humidity and the de-airing process (vacuum or nip rolling) were significant, as well as the level of pressure applied to the laminate during the RF process. Analysis of manufacturing with RF lamination equipment, based on the processes developed indicated that 3 RF presses could replace a typical auto-industry autoclave to achieve equal or greater throughput with possibly less capital cost and smaller footprint. Concepts for curved lamination identifying castable molds for prototyping were developed, which allowed Ceralink to obtain commitment to begin curved tooling development. The project significantly helped to advance RF lamination past the feasibility and novelty stage and into the realm of commercial acceptance as a viable alternative to autoclaves. The demonstration of autoclave-quality autoglass produced in just 1 minute with RF lamination, with validation by Pilkington, has fueled industry motivation to seriously consider RF lamination. The industry and other contacts and outreach made in the study of laminate markets (including 3 technical publications and 5 conference presentations), has resulted in a recent surge in RF lamination activity.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2012

Energy Saving Glass Lamination via Selective Radio Frequency Heating

This project focused on advancing radio-frequency (RF) lamination technology closer to commercial implementation, in order to reduce the energy intensity of glass lamination by up to 90%. Lamination comprises a wide range of products including autoglass, architectural safety and innovative design glass, transparent armor (e.g. bullet proof glass), smart glass, mirrors, and encapsulation of photovoltaics. Lamination is also the fastest growing segment of glass manufacturing, with photovoltaics, architectural needs, and an anticipated transition to laminated side windows in vehicles. The state-of-the-art for glass lamination is to use autoclaves, which apply heat and uniform gas pressure to bond the laminates over the course of 1 to 18 hours. Laminates consist of layers of glass or other materials bonded with vinyl or urethane interlayers. In autoclaving, significant heat energy is lost heating the chamber, pressurized air, glass racks, and the glass. In RF lamination, the heat is generated directly in the vinyl interlayer, causing it to heat and melt quickly, in just 1 to 10 minutes, without significantly heating the glass or the equipment. The main purpose of this project was to provide evidence that low energy, rapid RF lamination quality met the same standards as conventionally autoclaved windows. The development of concepts for laminating curved glass with RF lamination was a major goal. Other primary goals included developing a stronger understanding of the lamination product markets described above, and to refine the potential benefits of commercial implementation. The scope of the project was to complete implementation concept studies in preparation for continuation into advanced development, pilot studies, and commercial implementation. The project consisted of 6 main tasks. The first dealt with lamination with poly-vinyl butyral (PVB) interlayers, which prior work had shown difficulties in achieving good quality laminates, working with Pilkington North America. The second task dealt with a study of current lamination processes in the various laminate industries, and development of concepts for integrating RF lamination into new or existing processes. The third task explored the use of a non-destructive technique for analyzing laminate adhesion with the University of Illinois at Urbana-Champaign. The fourth task focused on developing concepts for curved glass lamination using RF lamination. The fifth and sixth tasks together comprised an analysis of laminate product markets, ranking for applicability and commercialization potential, and the development of commercialization strategies for those products. In addition, throughout the project as new experimental data and conventional process data were obtained, the benefits analysis of RF lamination was refined. The goals of the project described above were achieved, positioning RF lamination for the next stage growth envisioned in the original Industrial Grand Challenge proposal. Working with Pilkington North America, lamination of flat autoglass with PVB was achieved, meeting all 16 stringent industry tests. In particular, PVB laminates made with RF lamination passed environmental tests including the high temperature, 120°C bake test, without significant formation of bubbles (defects). The adhesion of PVB to glass was measured using the pummel method. Adhesion values ranging from 1 to 7 out of 10 were obtained. The significant process parameters affecting the environmental and adhesion performance were identified through a designed experiment. Pre-lamination process variables including PVB storage humidity and the de-airing process (vacuum or nip rolling) were significant, as well as the level of pressure applied to the laminate during the RF process. Analysis of manufacturing with RF lamination equipment, based on the processes developed indicated that 3 RF presses could replace a typical auto-industry autoclave to achieve equal or greater throughput with possibly less capital cost and smaller footprint. Concepts for curved lamination identifying castable molds for prototyping were developed, which allowed Ceralink to obtain commitment to begin curved tooling development. The project significantly helped to advance RF lamination past the feasibility and novelty stage and into the realm of commercial acceptance as a viable alternative to autoclaves. The demonstration of autoclave-quality autoglass produced in just 1 minute with RF lamination, with validation by Pilkington, has fueled industry motivation to seriously consider RF lamination. The industry and other contacts and outreach made in the study of laminate markets (including 3 technical publications and 5 conference presentations), has resulted in a recent surge in RF lamination activity.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2012

Surveys of Microwave Ovens in U.S. Homes

The U.S. Department of Energy (DOE) is conducting test procedure and energy conservation standard rulemakings for microwave ovens. These units generally offer a “convection,” “bake,” or “combo” cooking mode on the user interface. DOE divides products under analysis into classes by the type of energy used, capacity, or other performance-related features that affect consumer utility and efficiency. Installation types are grouped as (1) countertop and (2) built-in and over-the-range. The following sub-sections summarize the existing data as well as the specific data LBNL obtained with surveys.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2015

Physics and material science of ultra-high quality factor superconducting resonator

The nitrogen doping into niobium superconducting radio frequency cavity walls aiming to improve the fundamental mode quality factor is the subject of the research in the given work. Quantitative nitrogen diffusion into niobium model calculating the concentration profile was developed. The model estimations were confirmed with secondary ion mass spectrometry technique measurements. The model made controlled nitrogen doping recipe optimization possible. As a result the robust reproducible recipe for SRF cavity walls treatment with nitrogen doping was developed. The cavities produced with optimized recipe met LCLS–II requirements on quality factor of 2.7 ∙ 10 10 at acceleration field of 16 MV/m. The microscopic effects of nitrogen doping on superconducting niobium properties were studied with low energy muon spin rotation technique and magnetometer measurements. No significant effect of nitrogen on the following features was found: electron mean free path, magnetic field penetration depth, and upper and surface critical magnetic fields. It was detected that for nitrogen doped niobium samples magnetic flux starts to penetrate inside the superconductor at lower external magnetic field value compared to the low temperature baked niobium ones. This explains lower quench field of SRF cavities treated with nitrogen. Quality factor improvement of fundamental mode forced to analyze the high order mode (HOM) impact on the particle beam dynamics. Both resonant and cumulative effects caused by monopole and dipole HOMs respectively are found to be negligible within the requirements for LCLS–II.

36 MATERIALS SCIENCE↗
DOE OSTI2013

High Power Co-Axial Coupler

A superconducting RF (SRF) power coupler capable of handling 500 kW CW RF power at 750 MHz is required for present and future storage rings and linacs. There are over 35 coupler designs for SRF cavities ranging in frequency from 325 to 1500 MHz. Coupler windows vary from cylinders to cones to disks and RF power couplers will always be limited by the ability of ceramic windows and their matching systems to withstand the stresses due to non-uniform heating from dielectric and wall losses, multipactor, and mechanical flexure. In the Phase II project, we built a double window coaxial system with materials that would not otherwise be useable due to individual VSWRs. Double window systems can be operated such that one is cold (LN2) and one is warm. They can have different materials and still have a good match without using matching elements that create problematic multipactor bands. The match of the two windows will always result from the cancellation of the two window’s reflections when they are located approximately a quarter wavelength apart or multiples of a quarter wavelength. The window assemblies were carefully constructed to put the window material and its braze joint in compression at all times. This was done using explosion bonding techniques which allow for inexpensive fabrication of the vacuum / compression ring out of stainless steel with copper plating applied to the inner surface. The EIA 3-1/8” double window assembly was then successfully baked out and tested to 12 kW in a 3-1/8” co-axial system. The thermal gradient across the window was measured to be 90 C which represents about 15 ksi tensile stress in an uncompressed window. In our design the compression was calculated to be about 25 ksi, so the net compressive force was 5 ksi at full power.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2017

Rapid and Low Temperature Densification of Gadolinia Doped Ceria Barrier Layers by Photonic Curing

Nanohmics successfully demonstrated the viability of photonic sintering as a method to form densified gadolina doped ceria (GDC) barrier layers. Photonic sintering utilizes short pulses (millisecond regime) of broad spectrum light from a xenon flash lamp to convert densely packed nanoparticle thin films to bulk films through the absorption of optical energy and its subsequent conversion to heat; this results in grain ripening and/or melt and reflow the particles. The transformation of GDC nanoparticle thin films to bulk materials was accomplished by formulating various GDC nanoparticle “inks”, spin casting or tape casting these inks onto yttria stabilized zirconia (YSZ) substrates, brief low temperature (~700°C) bake outs to remove organic binders/plastisizers, and photonically sintering these substrates with a variety of conditions and sintering aids.

03 NATURAL GAS↗
DOE OSTI2018

Mechanisms Engineering Test Loop - Phase I Status Report - FY2018 (Update to FY2017 Report)

This report documents the current status of the Mechanisms Engineering Test Loop (METL) as of August 2018. Currently, METL has completed Phase I construction, performed an initial heat-up of the METL piping, vessels, and components, baked out the facility under vacuum (minus the test vessels), addressed a variety of punchlist items, transferred sodium from 15 55-gallon drums to the dump tank, in the final commissioning/operations stage.

42 ENGINEERING↗
DOE OSTI2019

LiOH corrosion growth and thermal stability investigated by diffuse reflectance infrared Fourier Transform (DRIFT) spectroscopy

In this period, we have measured the kinetics of LiOH corrosion growth on LiH substrate at 35 ppm of moisture for over 2 months. The serial DRIFT spectra are being analyzed to build the growth kinetics for LiOH interfacial states, surface states, and bulk states. Physical chemistry insight is being employed to describe the observed parabolic-linear growth of the corrosion layer grown on LiH samples that have been previously vacuum baked then re-exposed to low moisture over a long time. The thermal stabilities of LiOH interfacial states, surface states, and bulk states are also being quantified by measuring the reduction in LiOH DRIFT signals as a function of vacuum level and temperature, and will be needed to add an on/off switch to the current outgassing modeling.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Gear Test Assembly - Status Report For FY2019

The final stages of pre-sodium commissioning were completed for the Gear Test Assembly (GTA) in late 2018 and all the components were moved to building 308 for final preparations for insertion into the Mechanisms Engineering Test Loop (METL). The GTA was fully assembled in the experimental test assembly workstation and all supporting electrical and hardware systems were installed on the METL Mezzanine. The GTA was installed in Test Vessel 1 after performing a final systems check, and the vessel and article were raised to operating temperature and held for two weeks to bake-out any moisture present in the components. Test Vessel 1 was filled with sodium and a purification process was completed using the cold trap system. When the sodium was sufficiently clean, Test Vessel 1 was isolated from the rest of METL, and experimental operation of the GTA commenced. The experimental operations consisted of rotating two shafts using Parker servomotors to apply a prototypic torque of a fuel handling mechanism removing and inserting a sodium fast reactor fuel assembly. This removing and inserting motion was repeated until the system seized, indicating component degradation of either the gears or the bearings in the test gearbox. A total of 19,600 cycles were completed, corresponding to the removal and insertion of 9,800 fuel assemblies. The system was shut down and then prepared for removal. The Flexicask System was successfully used to remove the GTA from Test Vessel 1 while keeping both vessel and article inert during the process. The GTA was installed in the Carbonation System, where the process of slowly reacting the sodium away using moist CO 2 has been started. Once the GTA is fully cleaned, it will be disassembled and the gears will undergo the same NDE process performed before testing to quantify the wear that occurred. A report on this, along with the data analysis from the experimental operations will be submitted in late 2019.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗