SEARCH · Engineering Papers

Results for “Test Loop”

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.

SourceResearch connectionFrom yearThrough year

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

At least 415 records · Page 23

All sources NASA NTRS DOE OSTI

DOE OSTI2025

Wide-field microwave magnetic field imaging with nitrogen-vacancy centers in diamond

Non-invasive imaging of microwave (MW) magnetic fields with microscale lateral resolution is pivotal for various applications, such as MW technologies and integrated circuit failure analysis. Diamond nitrogen-vacancy (NV) center magnetometry has emerged as an ideal tool, offering micrometer-scale resolution, millimeter-scale field of view, high sensitivity, and non-invasive imaging compatible with diverse samples. However, up until now, it has been predominantly used for imaging of static or low-frequency magnetic fields or, concerning MW field imaging, to directly characterize the same microwave device used to drive the NV spin transitions. In this work, we leverage an NV center ensemble in diamond for wide-field imaging of MW magnetic fields generated by a test device employing a differential measurement protocol. The microscope is equipped with a MW loop to induce Rabi oscillations between NV spin states, and the MW field from the device-under-test is measured through local deviations in the Rabi frequency. This differential protocol yields magnetic field maps of a 2.57 GHz MW field with a sensitivity of ∼9 μT Hz −1/2 for a total measurement duration of T=357 s, covering a 340 × 340 μm 2 field of view with a micrometer-scale spatial resolution and a device-under-test input power dynamic range of 30 dB. This work demonstrates a novel NV magnetometry protocol, based on differential Rabi frequency measurement, that extends NV wide-field imaging capabilities to imaging of weak MW magnetic fields that would be difficult to measure directly through standard NV Rabi magnetometry.

crystallographic defects↗

DOE OSTI2023

Qualification and Commissioning of Helium Flow Loop Experiment for Blanket Design Measurements

Sufficient cooling of plasma-facing materials remains an outstanding challenge in the design of fusion reactor blankets in commercial power demonstration plants. Due to its chemical inertness and low neutron interaction cross section, pressurized helium is a candidate coolant fluid for such systems; however, helium has a small thermal mass compared to liquid coolants, potentially reducing heat removal performance. To address this need, a number of heat transfer enhancements have been proposed to improve the cooling efficiency of such components, thereby decreasing pumping power needs and improving overall plant efficiency. Toward this end, a helium flow loop experiment (HFLE) has been designed and commissioned to test advanced passive heat transfer enhancements in unit-cell test sections, providing necessary data for model validation and subsequent system design. The HFLE is designed to provide flow of pressurized (up to 4 MPa) helium at flow rates up to 80 g/s, enabling heat transfer and pressure drop measurements in test pieces at Reynolds numbers in excess of 180 000. To explore the effects of novel and complex heat transfer enhancements, test sections are produced via additive manufacturing, providing geometries not typically obtainable by conventional machining. Here in this work, we present results from HFLE commissioning and the initial thermal-hydraulic tests of an additively manufactured rifled-rib test section. Results are compared to smooth pipe correlations, and plans are described for future HFLE measurements. These preliminary experiments indicate the utility of the HFLE for heat transfer enhancement testing and simulation validation activities.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Sensitization of 316L Stainless Steel made by Laser Powder Bed Fusion Additive Manufacturing

Additively manufactured (AM) 316L stainless steel (SS) manufactured by laser powder bed fusion (L-PBF) and wrought 316L SS were subjected to sensitization heat treatments at 700°C up to 100 h. Using two evaluation methods, double-loop electrochemical potentiokinetic reactivation (DL-EPR) and ditching tests, degree of sensitization (DOS) and intergranular corrosion (IGC) susceptibility was evaluated. It was found that the wrought samples showed slightly lower IGC susceptibility compared to their AM counterpart. DOS and IGC attacks increased with sensitization time for all samples. Dislocation cellular structures were found to have little to no impact on DOS and IGC for the AM samples. Sensitized at 100 h, the AM sample showed significant Cr depletion along high-angle grain boundaries (12.35 wt% on average) and exhibited Cr carbide precipitation. Mo-rich particles along grain boundaries were also observed. The DL-EPR test attacks the surface oxide film and grain boundaries while the ditching test attacks the melt pool boundaries and grain boundaries (IGC and pitting). Changes to the DL-EPR and ditching standards for AM application have been proposed in this work.

316L stainless steel↗

DOE OSTI2026

From observation to replication: machine-learning-driven quantification and replication of fine-scale fish kinematics and behavior

Long-term quantification of fish behavior is essential for aquatic ecology, wildlife telemetry, and biomechanical device development. However, the observation duration required to obtain reliable behavioral and kinematic metrics remains unclear, and few tools exist to physically reproduce natural swimming motion for controlled experimentation. We address these challenges by developing a generalizable framework that models behavioral reliability (Spearman–Brown reliability index) as a function of observation duration and derives metric-specific monitoring thresholds. Using juvenile white sturgeon (Acipenser transmontanus) as a case study, we demonstrate that the minimum duration needed for reliable estimates varies substantially across kinematic features: to exceed a reliability of 0.8, total distance traveled requires 12 days, average curvature (mm?¹) 15 days, tail-beat frequency (Hz) 8 days, and average speed (body length/s) 17 days. We further bridge digital analysis and physical testing by developing a hardware-in-the-loop simulator that reconstructs machine-learning-derived swimming kinematics with high fidelity (correlation coefficient 0.98–0.99, RMSE 1.22–1.27 mm over a 5-minute segment). This platform enables realistic, repeatable motion stimuli for evaluating aquatic sensing technologies and bio-integrated devices under controlled conditions. Together, these contributions provide a scalable approach for designing long-term behavioral studies and a data-driven connection between ecological observation and robotic experimentation.

Hwang, SungJoo↗

DOE OSTI2023

An Experimental Investigation of Heat Transfer for Supercritical Carbon Dioxide Cooling in a Staggered Pin Fin Array

Pin fin geometry in the trailing edge as turbulators in tur-bine blades has been a subject thoroughly researched for the past several decades. To improve the efficiency of turbomachinery, higher turbine inlet temperatures are necessary, introducing the need for internal cooling channel features, such as pin fin arrays. These solutions are necessary to avoid material failure at higher operating conditions by enhancing the heat transfer of the blade. Over the past decade, a shift toward applying supercritical carbon dioxide or sCO2 cycles has shown increased potential compared to the industry standard air cycles. Promising higher cycle ef¬ficiency, smaller footprints, and zero greenhouse gas emissions, sCO2 has become an attractive alternative to well-established air cycles. This alternative cycle introduces the need to re-visit the heat transfer capabilities of internal cooling geometries within this novel operating fluid environment. The first objective of this paper is to experimentally demonstrate the heat transfer charac-teristics of sCO2 as the secondary internal cooling fluid environ¬ment through testing a pin fin array in a closed loop at 200 bar and 400 Celsius inlet conditions, which stands well within the supercritical region of sCO2. Secondly, the experimental process aims to validate numerical simulation methodology for studying sCO2 environments for internal cooling of turbine blades in a matching pin fin geometry.

Wardell, Ryan J↗

DOE OSTI2022

Detecting thermal crack growth on a large additive manufactured structure using acoustic emission

Large format additive manufacturing (LFAM) proved to have a great potential to become an adjacent technology to traditional manufacturing methods. One of the sectors LFAM is targeting is rapid tool/mold development for composites. This includes large mold structures used for high-temperature molding techniques (in-oven or autoclave). Although, these large printed structures (reaching hundreds of pounds) develop thermal-residual stress during cool-down and can eventually crack, turning the structure into waste. Acoustic emission (AE), a passive non-intrusive global nondestructive evaluation (NDE) technique, was used to monitor crack growth and can provide the right tools that can be used for feedback loop for corrective action. This research performs thermal testing on a large AM mold with preexisting cracks, in an attempt to monitor crack growth using AE. AE was able to detect, identify and locate the crack source by means of acoustic features, waveform characteristics, spectrum analysis, and difference in arrival times.

Spencer, Ryan↗

DOE OSTI2023

The DarkSide-20k TPC and underground argon cryogenic system

DarkSide-20k (DS-20k) will exploit the physical and chemical properties of liquid argon (LAr) housed within a large dual-phase time project chamber (TPC) in its direct search for dark matter. The TPC will utilize a compact, integrated design with many novel features to enable the 20t fiducial volume of underground argon. Underground Argon (UAr) is sourced from underground CO _2 2 wells and depleted in the radioactive isotope ^{39} 39 Ar, greatly enhancing the experimental sensitivity to dark matter interactions. Sourcing and transporting the \mathcal{O} 𝒪 (100t) of UAr for (DS-20k) is costly, and a dedicated single-closed-loop cryogenic system has been designed, constructed, and tested to handle the valuable UAr. We present an overview of the (DS-20k) TPC design and the first results from the UAr cryogenic system.

Thorpe, Thomas N.↗

DOE OSTI2024

SAM Code Enhancements for Modeling of Liquid Metal-Cooled Fast Reactor Concepts

The SAM code is under development and supported by DOE-NE’s Nuclear Energy Advanced Modeling and Simulation program as a modern system-level modeling and simulation tool for advanced non-light water reactor safety analyses. These advanced reactor concepts incorporate novel and improved approaches to achieve safety and economic feasibility. This report summarizes two major efforts in addressing the modeling gaps in SAM for liquid-metal-cooled fast reactor (LMFR) applications, i.e. thermal mixing and stratification phenomena in large pools and corrosion-oxidation of components in flowing lead. A new one-dimensional model for thermal mixing and stratification effects in large pools and enclosures is developed and implemented. Thermal mixing and stratification occur when fluid enters a pool at a temperature different than the bulk fluid itself, a scenario often encountered during transients in pool-type systems. These phenomena are critical for the safety of reactors, impacting phenomena like natural circulation, which is essential for passive cooling. The improved model in SAM addresses limitations of state-of-the-art approaches by combining one-dimensional (1D) channels, representing the coolant jet flow, with lumped-parameter zero-dimensional (0D) pools, representing the rest of coolant in the tank. Energy exchange between the 1D jet and the 0D pools is based on heat transfer correlations calibrated against 3D simulations. It is verified that this model can handle various flow configurations, including hot jets in colder pools, cold jets in hotter pools, and the presence of features like ceilings, free surfaces, and obstacles. Additionally, validation against experimental data demonstrates the ability of the model to capture mixing and stratification effects in a wide range of conditions. The flexibility and improved accuracy of the new model make it a valuable tool for reactor safety analysis, allowing for the simulation of different geometries encountered in advanced reactors. A system-level corrosion modeling capability is developed and implemented in SAM to support Lead Fast Reactor (LFR) development. Although the initial focus of this capability will be on LFR application, this can later be expanded to include other liquid metals such as Lead-Bismuth Eutectic (LBE) and PbLi. This report summarizes the common corrosion mitigation strategies and outlines the progress on implementing and validating a corrosion-oxidation model in SAM. Verification and validation of the corrosion-oxidation portion of the model was performed using analytical solution and measured data from samples tested in the non-isothermal pumped lead loop at IPPE Obninsk. The iron transport and corrosion/precipitation portion of the model was assessed using an analytical model and measured corrosion depths from a natural convection lead loop experiment performed at CEA. It is demonstrated that the model implemented in SAM performed well in these assessments.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2026

Evaluating Protection System Performance for a Real-World Weak Grid Area With High Inverter-Based Resources

This paper evaluates an existing protection scheme implemented in a real-world weak grid area with a high penetration of inverter-based resources (IBRs). The study aims to assess the reliability and adequacy of protection schemes originally designed for traditional synchronous machine systems and determine whether they can continue to operate reliably in systems with high levels of IBRs. Hardware relays are tested using a controller-hardware-in-the-loop setup. PSCAD electromagnetic transient simulation with an IBR original equipment manufacturer black-box model is used to perform fault studies and generate COMTRADE data, which are replayed by a realtime digital simulator (RTDS) to feed input to the hardware relays. Three scenarios are analyzed: normal operation, an N-1 contingency, and an IBR-only scenario. The evaluation results reveal the following: 1) the protection scheme remains reliable under normal conditions and N-1 contingencies and 2) in IBRonly scenarios, differential protection (87L) continues to operate reliably, whereas local protection elements, such as distance and directional elements, fail because of the lack of regulated negative sequence current contributed by IBRs. These findings provide utilities with valuable insights for improving their protection systems in high-IBRs.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Evaluating Protection System Performance for a Real-World Weak Grid Area With High Inverter-Based Resources: Preprint

This paper evaluates an existing protection scheme implemented in a real-world weak grid area with a high penetration of inverter-based resources (IBRs). The study aims to assess the reliability and adequacy of protection schemes originally designed for traditional synchronous machine systems and determine whether they can continue to operate reliably in systems with high levels of IBRs. Hardware relays are tested using a controller-hardware-in-the-loop setup. PSCAD electromagnetic transient simulation with an IBR original equipment manufacturer black-box model is used to perform fault studies and generate COMTRADE data, which are replayed by a real-time digital simulator (RTDS) to feed input to the hardware relays. Three scenarios are analyzed: normal operation, an N-1 contingency, and an IBR-only scenario. The evaluation results reveal the following: 1) the protection scheme remains reliable under normal conditions and N-1 contingencies and 2) in IBR-only scenarios, differential protection (87L) continues to operate reliably, whereas local protection elements, such as distance and directional elements, fail because of the lack of regulated negative sequence current contributed by IBRs. These findings provide utilities with valuable insights for improving their protection systems in high-IBRs.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Leveraging PHIL for Inverter Functionality Requirement Evaluation to Ensure a Reliable Grid

This presentation showcases NREL's ongoing research on advanced Multi-point Power Hardware-in-the-Loop (PHIL) systems, enabling comprehensive evaluation of interoperability, stability, and wide-area stability in complex power grids. Key features include high-power PHIL capabilities, seamless PHIL Interfaces for effortless Grid-Following (GFL) and Grid-Forming (GFM) mode switching, and advanced multi-domain PHIL/Controller Hardware-in-the-Loop (CHIL) capabilities for evaluating diverse technology mixes, facilitating rigorous testing and validation of emerging power systems for reliable integration, enhanced resilience, and optimal performance.

lab capabilities↗

DOE OSTI2021

Prediction of PbLi fluid flow and temperature field in a thermal convection loop for qualification of fusion materials

Two modeling tools, a thermohydraulics code and a computational model in COMSOL Multiphysics, have been developed, tested and then applied to the analysis of fluid flow and heat transfer in a thermal convection loop (TCL). Such a device has recently been used to experimentally evaluate corrosion compatibility of APMT (Fe–21Cr–5Al–3Mo) steel with high-temperature molten eutectic lead-lithium (PbLi) alloy at Oak Ridge National Lab, TN, USA. Here, the 1-D thermohydraulics code allows for rapid calculations of the loop parameters as a function of the applied heat flux. The supplemental COMSOL finite-element computations provide detailed 3-D velocity and temperature field data but are much more time consuming. Both modelling tools demonstrate an excellent agreement in the computed circulation velocity as well as maximum and minimum temperatures. The performed TCL analysis focuses on flow development in the “hot” and “cold” legs, formation of Dean vortices in corner regions, blocking effect of the immersed samples, and radiative and convective cooling effects under the experiment-relevant conditions for Prandtl number Pr = 0.015, Grashof numbers Gr ~10 7 , and Reynolds numbers Re ~10 4 .

36 MATERIALS SCIENCE↗

DOE OSTI2023

Corrosion Testing Trade Study on Testing Methods in Molten Salts

In assessing molten salt compatibility with structural materials, static testing is often reported because it is easy to conduct. However, in order to assess mass transfer, where material dissolves in the salt in the hot section and may precipitate out of the liquid in colder regions, a flowing salt experiment in a temperature gradient is needed. While a forced convection or pumped loop produces prototypic flowing conditions, it also is a multi-million dollar investment. Among the less expensive dynamic testing options, the thermal convection loop (TCL) was favored during the 1960’s development of molten salt reactor technology. Because the workforce and core facilities are currently available to conduct TCL experiments, it is the least expensive strategy to evaluate candidate structural alloys in flowing molten salt conditions.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Control and Management of Multiple Converters in a Residential Smart Grid

Power electronic systems are becoming a staple building block for electric grid networks. However, these systems have been largely designed to grid integrate in ad hoc configurations with little or no coordination of control. This work proposes a central controller and power electronic system hardware and software design for a residential system (photovoltaic, energy storage and residential building). This system supports auto-integration, plug and play capabilities, and optimal energy management to meet different use cases. Modelling and multi-day testing of the system have been conducted in a controller hardware-in-the-loop (C-HIL) testbed. Multiple use cases and pricing options have been considered as part of the simulation and testing. Results are presented of these systems as a proof of principle.

Starke, Michael↗

DOE OSTI2021

Voltage Regulation Performance Evaluation of Distributed Energy Resource Management via Advanced Hardware-in-the-Loop Simulation

This paper evaluates the performance of coordinated control across advanced distribution management systems (ADMS), distributed energy resources (DERs), and distributed energy resource management systems (DERMS) using an advanced hardware-in-the-loop (HIL) platform. This platform provides a realistic laboratory testing environment, including accurate dynamic modeling of a real-world distribution system from a utility partner, real controllers (ADMS and DERMS), physical power hardware (DERs), and standard communications protocols. One grid service—voltage regulation—is evaluated to show the performance of the coordinated grid automation system. The testing results demonstrate that the coordinated DERMS and ADMS system can effectively regulate system voltages within target operation limits using DERs. The realistic laboratory HIL testing results give utilities confidence in adopting the grid automation systems to manage DERs to achieve system-level control and operation objectives (e.g., voltage regulation). This helps utilities mitigate potential risks (e.g., instability) prior to field deployment.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Power-Hardware-in-the-Loop Experiments of a Microgrid with a Grid-Forming Battery Inverter

Microgrids continue to proliferate, and they are transitioning away from using conventional generating resources to increasingly relying on inverter-based resources (IBRs) as the voltage and frequency leaders. It is crucial to evaluate the capability of IBRs to provide microgrid stability and resilience. Hardware-in-the-loop (HIL) experiments were conducted to de-risk the field deployment of the San Diego Gas & Electric Company Borrego Springs Microgrid, where a battery inverter was upgraded with grid-forming (GFM) capability to serve as the island leader. This paper presents the HIL experimental results from an HIL test bed that uses a power-hardware-in-the-loop (PHIL) interface with a power inductor that was previously developed for PHIL simulations of microgrids where the inverters need to switch modes, i.e., between grid-following and GFM as the microgrid transitions between grid-connected and islanded operation. This paper presents more details on the interface and HIL simulation results of the planned islanding and load steps in islanded operation to show the effectiveness of the inverters in managing the voltage and frequency.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Power-Hardware-in-the-Loop Experiments of a Microgrid With a Grid-Forming Battery Inverter: Preprint

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Hardware-in-the-Loop Efficiency Analysis of Tidal Power Systems

Marine renewable energy presents an opportunity for sustainable power in areas located near and in the marine environment. In particular, tidal energy offers a consistent and reliable resource. However, tidal energy harvesting systems seeking to take advantage of this resource face challenges associated with power electronics. Power conversion electronics struggle with low efficiencies, lack of off-the-shelf options for small-scale energy harvesting systems, and limited opportunities for testing with deployed turbines. This work demonstrates a hardware-in-the-loop experimental design and methodology for characterizing efficiency of tidal turbine power electronics and control methods. The suggested method removes barriers to testing these power electronics by eliminating the need for a physical tidal turbine and generator to produce accurate harvested tidal power profiles.

tidal turbine, hardware-in-the-loop, energy conver↗