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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.

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At least 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
NASA NTRS2024

Preliminary Measurements of Partial Discharge Inception Voltage Degradation with Constant Temperature Aging of Magnet Wire Twisted Pairs for Electric Aircraft Motors

Electric aircraft require high reliability electric motors to meet the stringent safety standards of the aviation industry. Motor winding insulation lifetime and reliability models for electric aircraft applications are needed to enable design of high reliability and high-performance electric motors for aviation applications. Three primary stresses effect the lifetime of motor winding insulation: thermochemical, mechanical, and electrical. This paper presents preliminary experiments on twisted pairs of magnet wire targeting understanding the thermo-chemical degradation of motor winding insulation through constant temperature thermal aging. Three types of magnet wire twisted pairs where tested: polyimide insulated magnet wire, epoxy coated polyimide insulated magnet wire, and epoxy potted polyimide magnet wire. The degradation of the samples over time at temperature was tracked using partial discharge inception voltage measurements. These initial experiments were used for development of procedures and expertise in partial discharge testing and thermo-chemical aging to inform future testing. The preliminary nature of these experiments should be noted when viewing the results. Lessons learned from the experiments are documented.

Thomas Tallerico↗
DOE OSTI2015

Transverse Beam Halo Measurements at High Intensity Neutrino Source (HINS) using Vibrating Wire Monitor

The measurement and control of beam halos will be critical for the applications of future high-intensity hadron linacs. In particular, beam profile monitors require a very high dynamic range when used for the transverse beam halo measurements. In this study, the Vibrating Wire Monitor (VWM) with aperture 60 mm was installed at the High Intensity Neutrino Source (HINS) front-end to measure the transverse beam halo. A vibrating wire is excited at its resonance frequency with the help of a magnetic feedback loop, and the vibrating and sensitive wires are connected through a balanced arm. The sensitive wire is moved into the beam halo region by a stepper motor controlled translational stage. We study the feasibility of the vibrating wire for the transverse beam halo measurements in the low-energy front-end of the proton linac.

43 PARTICLE ACCELERATORS↗
DOE OSTI2016

Method of fabricating high-density hermetic electrical feedthroughs using insulated wire bundles

A method of fabricating electrical feedthroughs coats of a plurality of electrically conductive wires with an electrically insulating material and bundles the coated wires together in a substantially parallel arrangement. The bundled coated wires are secured to each other by joining the electrically insulating material of adjacent wires together to form a monolithic block which is then cut transverse to the wires to produce a block section having opposing first and second sides with a plurality of electrically conductive feedthroughs extending between them.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Structures of and methods for forming vertically aligned Si wire arrays

A structure consisting of vertically aligned wire arrays on a Si substrate and a method for producing such wire arrays. The wire arrays are fabricated and positioned on a substrate with an orientation and density particularly adapted for conversion of received light to energy. A patterned oxide layer is used to provide for wire arrays that exhibit narrow diameter and length distribution and provide for controlled wire position.

Kayes, Brendan M.↗
DOE OSTI2022

System and method for liquid crystal display system incorporating wire grid polarizers for large scale and large volume stereolithography

The present disclosure relates to a liquid crystal display (LCD) system. The system in one example has a light source for generating unpolarized light, and an LCD screen arranged in a path of transmittance of the unpolarized light. First and second wire grid polarizers are arranged adjacent to the LCD screen and each have a plurality of nano-scale wires, with the first and second wire grid polarizers have differing polarizations. A pitch of each of the nano-scale wires is no larger than one-third a wavelength of the unpolarized light from the light source. The wire grid polarizers create, in connection with operation of the LCD screen, a 2D light mask suitable for initiating the polymerization of an optically curable material.

Duoss, Eric B.↗
DOE OSTI2023

Superconducting wires for quench detection

A superconducting device includes a first superconducting wire configured to carry a first current in a superconducting state, and to generate thermal energy upon occurrence of a hot spot during conduction. The device includes a second superconducting wire, thermally coupled to and electrically isolated from the first superconducting wire. The second superconducting wire is configured to conduct a second current in a superconducting state below, but sufficiently near its critical surface to be quenched to a non-superconducting state upon conduction of the thermal energy from the first superconducting wire.

Van Der Laan, Daniel Cornelis↗
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 OSTI2013

Entrapment of Guide Wire in an Inferior Vena Cava Filter: A Technique for Removal

Entrapment of a central venous catheter (CVC) guide wire in an inferior vena cava (IVC) filter is a rare, but reported complication during CVC placement. With the increasing use of vena cava filters (VCFs), this number will most likely continue to grow. The consequences of this complication can be serious, as continued traction upon the guide wire may result in filter dislodgement and migration, filter fracture, or injury to the IVC. We describe a case in which a J-tipped guide wire introduced through a left subclavian access without fluoroscopic guidance during CVC placement was entrapped at the apex of an IVC filter. We describe a technique that we used successfully in removing the entrapped wire through the left subclavian access site. We also present simple useful recommendations to prevent this complication.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2018

Monofilamentary In Situ Fe/MgB{sub 2} Superconducting Wires Fabricated by Pellet-in-Tube Method

Thin monofilamentary Fe/MgB{sub 2} superconducting wires without barriers are investigated by means of electrical transport measurements and surface and structural analysis methods. Small diameter wires are fabricated by pellet-in-tube method (PeIT) to obtain a high uniform initial filling density and heat treated as a function of various sintering temperatures and times. The results are discussed in terms of the grain connectivity, Fe{sub 2}B phase formation, and the relation between wire diameter and sintering conditions. We suggest that PeIT has a crucial importance to achieve homogeneous initial filling density, which leads to the fabrication of uniform long-length MgB{sub 2} wires.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2018

Influence of Bias Current on Off-Diagonal Magnetoimpedance in Composite Wires

The off-diagonal magnetoimpedance in a composite wire consisting of a highly conductive inner core covered by a soft magnetic layer is studied theoretically. In the presence of bias current, the field dependence of the off-diagonal magnetoimpedance becomes asymmetric due to the combination of the circular magnetic field produced by the bias current and a helical anisotropy in the magnetic layer of the composite wire. The dependences of the asymmetric off-diagonal magnetoimpedance on the external field, frequency, and bias current are investigated. It is demonstrated that the off-diagonal magnetoimpedance in composite wires has high field sensitivity and exhibits nearly linear behavior at low external fields. The influence of the wire parameters such as the anisotropy axis angle, the magnetic layer thickness, and conductivity on the field sensitivity of the off-diagonal magnetoimpedance is analyzed. The results obtained may be useful for development of weak magnetic-field sensors.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

Customized MgB{sub 2} Superconducting Wire Toward Practical Applications at Sam Dong in Korea

MgB{sub 2} superconducting wire from Sam Dong Co., Ltd. in Korea is suitable for various applications, including medical resonance imaging, fault current limiters, power cables, and transformers. So far, issues related to the wire production cost, current-carrying capacity, and conductor length (kilometers) are very important for further commercialization. Since 2014, our intensive research efforts have led to notable progress. Herein, we summarize and discuss our advanced research for achieving high-performance, scalable, and cost-effective MgB{sub 2} wires at Sam Dong. Based on our accumulated technical know-how, we will continue to fabricate more competitive and efficient MgB{sub 2} superconducting wires that will be suitable for the customer’s purposes.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2018

Simulating the effects of underground nuclear explosions with an exploding wire

Exploding wires can deposit significant amounts of energy (1000’s of Joules on a nano-microsecond timescales) into a very confined space. Under the right conditions they can even produce neutrons. While most exploding wire studies have been performed in open air and to a lesser extent liquids we have started to investigate enclosing the wire element in solid matrices like concrete to mimic the effects of an underground nuclear explosion. The temperatures and pressures achieved are quite sufficient to induce structural cracking and localized flash melting in the enclosing media like a real underground nuclear detonation. As a result exploding wires would appear to form the perfect trigger for releasing confined chemical species including gases in geological media to study migration behavior in a controlled environment. Details of the apparatus and some illustrations of it potential will be given.

Underground Nuclear Explosions, Exploding Wires, X↗
DOE OSTI2019

Microstructure and mechanical properties of pure copper wire produced by shear assisted processing and extrusion

Shear assisted processing and extrusion (ShAPE) process can consolidate powdered materials and simultaneously extrude wire or tube with improved properties. We successfully produced copper wire extrusions from powder and solid materials for the first time. The extrusion pressure of ShAPE process is at least two times less than that required for conventional extrusion. We used optical microscopy to inspect and validate the integrity of extrudates. It shows that the microstructure was refined and dynamically recrystallized to equiaxial grains. Compared to the annealed copper wire, ShAPE processed wire has 80% higher yield strength, 15% higher ultimate tensile strength and 20% higher ductility. These were correlated with refined grain size and sub-structuring observed via electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM).

Copper, Wire, Shear Assisted Processing and Extrus↗
DOE OSTI2013

A momentum source model for wire-wrapped rod bundles—Concept, validation, and application

Large uncertainties still exist in the treatment of wire-spacers and drag models for momentum transfer in current lumped parameter models. Here, to improve the hydraulic modeling of wire-wrap spacers in a rod bundle, a three-dimensional momentum source model (MSM) has been developed to model the anisotropic flow without the need to resolve the geometric details of the wire-wraps. The MSM is examined for 7-pin and 37-pin bundles steady-state simulations using the commercial CFD code STAR-CCM+. The calculated steady-state inter-subchannel cross flow velocities match very well in comparisons between bare bundles with the MSM applied and the wire-wrapped bundles with explicit geometry. The validity of the model is further verified by mesh and parameter sensitivity studies. Furthermore, the MSM is applied to a 61-pin EBR-II experimental subassembly for both steady state and PLOF transient simulations. Reasonably accurate predictions of temperature, pressure, and fluid flow velocities have been achieved using the MSM for both steady-state and transient conditions. Significant computing resources are saved with the MSM since it can be used on a much coarser computational mesh.

42 ENGINEERING↗
DOE OSTI2019

One-way coupled simulation of FIV in a 7-pin wire-wrapped fuel pin bundle

A normal fuel geometry found in sodium cooled reactor designs is the hexagonal lattice of wire-wrapped fuel pins. The wire-wrappers, which replace the more common spacer grids, act as a spacer between the fuel pins, while simultaneously increasing the fluid mixing between subchannels. The induced transverse flow, while good for mixing, increases the force load experienced by the fuel pins, increasing the possibility of problematic flow induced vibrations. The primary source of vibrations is turbulent buffeting, so very small in amplitude, but capable of rupturing the fuel cladding by fretting. The vast majority of research on fretting has been for bare rods with spacer grids. There are several significant ways that wire-wrapped fuel pins differ from bare rods that may have significant impact on the vibrations present. The increased transverse flow and asymmetrical flow pattern may result in larger and imbalanced force loads on the pins. The helical bracing of each pin may result in unique vibration patterns, and gaps may form between pins affecting how they are braced. Simulation allows for the observation of the forces present, how the flow field affects these forces, and how the structure responds and can be repeated for multiple cases for relatively low cost. Here, simulation of the flow induced vibrations for a 7-pin wire-wrapped fuel pin bundle is carried out by coupling Nek5000, a spectral element LES/DNS solver with DIABLO, a finite element CSM solver. The small amplitude vibrations allow for the assumption that the structure motion has negligible effect on the fluid flow, permitting the much less computationally expensive one-direction coupling. In order to gather significant force history data for the 2.63 helical pitch structure, a scheme was developed to artificially create force history from the power spectrum density of the one-pitch CFD simulation forces. The vibrations could then be simulated in the structure multiple times varying the contact and gaps between various pins. This provides for the search of worst-case scenarios and informs about the types of fretting that might be present. The simulation geometry is based on an experiment for comparison. However, the viscosity of the simulation was increased by a factor of four to make the simulation computationally feasible. While validation is not possible, comparisons are still valuable.

42 ENGINEERING↗
DOE OSTI2014

t matrix of metallic wire structures

To study the electromagnetic resonance and scattering properties of complex structures of which metallic wire structures are constituents within multiple scattering theory, the t matrix of individual structures is needed. We have recently developed a rigorous and numerically efficient equivalent circuit theory in which retardation effects are taken into account for metallic wire structures. Here, we show how the t matrix can be calculated analytically within this theory. We illustrate our method with the example of split ring resonators. The density of states and cross sections for scattering and absorption are calculated, which are shown to be remarkably enhanced at resonant frequencies. The t matrix serves as the basic building block to evaluate the interaction of wire structures within the framework of multiple scattering theory. This will open the door to efficient design and optimization of assembly of wire structures.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2014

Numerical and experimental investigations on the interaction of light wire-array Z-pinches with embedded heavy foam converters

The interaction of a light tungsten wire-array Z-pinch with an embedded heavy foam converter, whose mass ratio is typically less than 0.16, is numerically analyzed and experimentally investigated on the 1.3 MA “QiangGuang I” facility. Computational results show that this implosion process can be divided into three stages: acceleration of the tungsten wire-array plasma, collision, and stagnation. The tungsten plasma is accelerated to a high speed by the J × B force and interacts weakly with the foam plasma in the first stage. Strong energy conversions take place in the second collision stage. When the high speed tungsten plasma impacts on the foam converter, the plasma is thermalized and a radial radiation peak is produced. Meanwhile, a shock wave is generated due to the collision. After the shock rebounds from the axis and meets the W/Foam boundary, the plasma stagnates and the second radial radiation peak appears. The collision and stagnation processes were observed and the two-peak radial radiation pulse was produced in experiments. Increasing the wire-array radius from 4 mm to 6 mm, the kinetic energy of the tungsten plasma is increased, causing a stronger thermalization and generating a higher first radiation peak. Experimental results also showed a higher ratio of the first peak to the second peak in the case of larger wire-array radius. If we add a thin CH film cover onto the surface of the embedded foam converter, the first radiation peak will be hardly changed, because the acceleration of the tungsten plasma is not evidently affected by the film cover. However, the second radiation peak decreases remarkably due to the large load mass and the corresponding weak compression.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗