Microstructure Quantification of Wire Additive Manufacturing of Titanium Alloys using Polarized Light Microscopy
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Salem, Ayman↗
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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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Low-cost Manufacturing of Round REBCO Wires for Accelerator Magnets
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Sandra, Jithin sai [AMPeers LLC; AMPeers LLC; AMPe↗
Multi-Strand Transposed Cables of Round REBCO Wires for Accelerator Magnets
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Source record↗
Ultra-low magnetization and hysteresis loss in APC Nb 3 Sn superconductors
For the accelerator magnets of the next hadron collider, reducing superconductor persistent-current magnetization is not only important for achieving the desired field quality, but also crucial for its sustainability because the magnetization loss is the major heat load to the magnet cold mass. For conventional Nb 3 Sn conductors this requires reduction of effective subelement size (D eff ). For the restacked-rod-process (RRP ® ) conductors a physical subelement size (D sub ) as small as 35 µm (corresponding to a D eff close to 45 µm) can be reached, but at a significant price in J c . Another way to reduce the magnetization is by introducing artificial pinning centers (APC) using the internal oxidation approach. APC conductors outperform conventional Nb 3 Sn wires in two aspects: 1) higher J c at high fields, and 2) much lower J c and magnetization at low fields (e.g. below 5 T). Here, in this work we explored the fabricability of APC wires with small D sub . A 180-stack APC wire was produced and drawn to 0.7- and 0.5 mm diameters with good quality, with D sub s of 34 and 24 µm (D eff s of 36 and 25 µm), respectively. For the 34 µm-D sub wire, its non-Cu J c is higher than that of an RRP ® wire used for the High-Luminosity Large Hadron Collider (HL-LHC) project above 13 T (e.g. 36% higher at 4.2 K, 18 T), while its non-Cu magnetization at 1 T, ΔM(1 T), is only 29% of the RRP ® wire. Its non-Cu hysteresis loss for a cycle between 1 and 14 T, Q h (1–14 T), is 37% of the RRP ® wire. For the 24 µm-D sub wire, its non-Cu J c surpasses the HL-LHC RRP ® wire above 17.5 T, while its ΔM(1 T) and Q h (1–14 T) are only 17% and 23% of the RRP® wire, respectively. Its non-Cu Q h (±3 T) even meets the specification of the International Thermonuclear Experimental Reactor project.
Xu, X [Fermi National Accelerator Laboratory (FNAL↗
Assessment of Thin Plastic Scintillation Detectors for Beta-Particle Measurements at the Advanced Test Reactor Critical Facility
The Fission Wire Measurement System 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 facility. The Advanced Test Reactor Critical facility is an open-pool, low-power test reactor used to qualify experiment configurations and verify core models prior to full-power experiment irradiations in the Advanced Test Reactor. Power distribution measurements in ATR-C use uranium-aluminum wires that are distributed throughout the core to validate simulation and modeling results. These measurements require from 340 to 1500 wires to be irradiated and measured within a 12-hour window. 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. The gas flow detectors are of a custom design for this detector system that use methane gas with a large anode wire compared to modern proportional counters. These detectors, which are nearly 60 years old are irreplaceable. The measurements from these gas detectors are affected by the gas flow rate, atmospheric and line pressure, and are very sensitive to the applied high voltage. Recent improvements have been made to the control and data acquisition system, but the detectors have remained the same. The nature of the measurement of the fission product decay activity is such that the energy spectrum of the signal is changing with time. Thin, 250-um thick, plastic scintillators were commercially obtained as a potential replacement for the gas flow detectors. The original calibration of the uranium-aluminum fission wires was conducted in 1965 using a series of irradiations of gold foils and the wires in a well-characterized thermal neutron field. These measurements provided a time-dependent fission rate conversion factor from the gold foil data to calibrate the fission wires based on the response from the 2-pi proportional gas detectors. Transitioning to the new detectors requires qualification and testing. The sensitivity of the scintillators to changes in the energy spectrum of the fission wires and translation of the calibration factor have been completed. These measurements indicated that the sensitivity of the scintillators over time changes at a different rate than the sensitivity of the gas flow detectors. However, the inverse activity of measurements of both detector types is linear with time. Initial results indicate that the scintillator detectors will be a sufficient replacement for the gas detectors with minor adjustments to the fission rate conversion factor. Replacement of the detectors will improve the fission wire measurements and provide a more stable and reliable measurement system.
46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗
Nanometal-Interconnected Carbon Conductors (NICCS) for Advanced Electric Machines (RIT Final Technical Report)
Recent advancements in carbon nanotube (CNT) research have enabled lightweight, conductive wires as a transformative technology. Metal-carbon nanotube (CNT) hybrid conductors aim to combine the high conductivity of traditional metals with the low mass and temperature coefficient of resistance (TCR) of carbon nanotubes. The high conductivity of copper makes it a promising candidate to combine with CNTs in a hybrid structure, but there is limited physical and electrical interaction between copper and CNTs. The use of an interfacial layer offers one method of improving the interconnection of a Cu-CNT hybrid conductor. Over the course of this grant, a joule heating-driven chemical vapor deposition (CVD) technique was developed to deposit nanometal seeds throughout a porous, low-density (0.12 g/cm 3 , ~10 tex or mg/m) CNT roving template. Modification of the applied current to the CNT roving allows for the tuning of depositions towards either hot-spot site-specificity or overall uniformity. The effects of temperature, pressure, precursor mass, and the interval of applied current were investigated, demonstrating nanometal depositions ranging from less than 5 % w/w to over 85 % w/w. The versatility of CVD allows for a wide variety of metals to be deposited including copper, titanium, nickel, silver, tungsten, palladium, platinum, ruthenium, rhodium, and iridium. One preferred demonstration involved using platinum depositions to improve the electrical properties of metal-seeded CNTs across all mass loadings studied. Moreover, when the metal-seeded CNT wires were electroplated with copper, densified, and annealed under hydrogen/argon; the result was a Cu-CNT hybrid conductor with the highest conductivities reported to date. The good interconnection of the metal and CNT portions results in a stable conductor. An electrical conductivity of 16-20 MS/m was achieved for multiple Cu-CNT hybrid conductors at 150 °C, which exceeds the program goal for conductivity of greater than 15 MS/m for a 1 m long CNT wire. Overall, the research outcomes from the project showed improvements in CNT wire fabrication from roll-to-roll CVD grown carbon nanotube wires using nanometal interconnects to bridge CNT-to-CNT junctions, thus mitigating network contact resistances. Advanced nanometal interconnected carbon conductors (NICCs) were developed as a means to achieve novel light-weight wiring appropriate for applications that require the conductivity of metallic (i.e., Cu, Al, etc.) wires at elevated temperatures. High conductivity, low TCR electrical conductors such as the nanometal interconnected Cu-CNT hybrids have numerous future applications towards high efficiency motors, generators, and transformers. Specifically, the advanced wires have the ability to operate at lower resistance during conditions for standard electric motors at 150 °C, which would improve the electrical efficiency while lowering energy needs.
36 MATERIALS SCIENCE↗
Three-omega thermal-conductivity measurements with curved heater geometries
The three-omega method, a powerful technique to measure the thermal conductivity of nanometer-thick films and the interfaces between them, has historically employed straight conductive wires to act as both heaters and thermometers. When investigating stochastically prepared samples such as two-dimensional materials and nanomembranes, residue and excess material can make it difficult to fit the required millimeter-long straight wire on the sample surface. There are currently no available criteria for how diverting three-omega heater wires around obstacles affects the validity of the thermal measurement. In this Letter, we quantify the effect of the wire curvature by performing three-omega experiments with a wide range of frequencies using both curved and straight heater geometries on SiO 2 /Si samples. When the heating wire is curved, we find that the measured Si substrate thermal conductivity changes by only 0.2%. Similarly, we find that wire curvature has no significant effect on the determination of the thermal resistance of an ~65 nm SiO 2 layer, even for the sharpest corners considered here, for which the largest measured ratio of the thermal penetration depth of the applied thermal wave to radius of curvature of the heating wire is 4.3. This result provides useful design criteria for three-omega experiments by setting a lower bound for the maximum ratio of the thermal penetration depth to wire radius of curvature.
77 NANOSCIENCE AND NANOTECHNOLOGY↗
Bragg edge imaging (BEI) of B12W and M8N socket sections of the Arecibo telescope
From neutron user principal investigator: We kindly request the public release of three neutron imaging datasets through ONCat. All datasets were collected from two forensic specimens, B12W and M8N, sectioned from zinc-filled steel-wire sockets recovered from the collapsed Arecibo Telescope. The dataset titled “Neutron radiographs of B12W and M8N socket sections of the Arecibo telescope” contains normalized two-dimensional (2D) neutron radiographs of the specimens, showing the geometry and spatial distribution of the steel wires embedded within the zinc matrix, as well as internal features such as voids and cracks. The dataset titled “Neutron computed tomography of B12W and M8N socket sections of the Arecibo telescope” contains normalized 2D neutron projection images acquired over a range of specimen rotation angles for one selected region of each specimen. These projection images were used to reconstruct three-dimensional (3D) tomographic volumes that reveal the embedded-wire geometry and internal defects. The dataset titled “Bragg edge imaging (BEI) of B12W and M8N socket sections of the Arecibo telescope” contains six time-of-flight (TOF) neutron imaging datasets, three from each specimen, acquired at regions of interest selected based on the radiographs. The spatially resolved 2D TOF images show the zinc matrix and embedded steel wires, and the wavelength-dependent neutron transmission data were used to characterize crystallographic texture within the zinc. All components and their condition are in the public domain as they are the property of the National Science Foundation (NSF). The neutron imaging data, part geometries, and detailed forensic information have been widely published in the Arecibo Telescope Collapse Forensic Report by Thornton Tomasetti Engineers and others (NASA report and NASEM report).
Bilheux, Hassina↗
Control of Weld Residual Stress in a Thin Steel Plate through Low Transformation Temperature Welding Consumables
Low transformation temperature welding (LTTW) consumables are characterized by a low martensite start temperature and a large fraction of martensite forming in the weld. It can efficiently reduce the tensile residual stress because the volume expansion associated with the martensitic transformation compensates for the thermal contraction during cooling. In this work, a LTTW wire, designated as EH200B, was created for the arc welding of advanced high-strength steel thin plates. In comparison to conventional ER70S-3 wires, this LTTW wire generated an opposite distortion pattern. Neutron diffraction measurements along the center thickness of the welded plates showed the maximum residual stress along the longitudinal direction (LD) in the weld region, and the heat-affected zone (HAZ) immediately adjacent to the weld region was reduced from ~330 MPa to below 240 MPa by using the LTTW wire. A finite element (FE) model was developed to predict the residual stress distributions of the plates welded under these two wires. The simulation results showed reasonable agreement with the volume-average neutron diffraction data. Compressive residual stress in the weld region using the LTTW wire was predicted by the FE method. Electron backscattered diffraction and x-ray diffraction measurements confirmed ~90% martensite was present in the LTTW weld. The fatigue life of DP980 steel lap joint panels using EH200B wire nearly doubled that of ER70S-3 wire. This improvement was attributed to the high strength and low LD residual stress in the weld and HAZ immediately adjacent to the weld.
36 MATERIALS SCIENCE↗
Passive Temperature Sensors for Nuclear Applications
Thermocouples are generally used to provide real-time temperature indications in instrumented tests performed at material and test reactors. Passive temperature monitors, such as Silicon Carbide (SiC) and melt wires, may be included in such tests as an independent technique of detecting peak temperatures experienced during irradiation. In less expensive static (drop-in) capsule tests, which have no leads attached for real-time data transmission, melt wires, and SiC temperature monitors (TMs) are essentially the only possibility for peak temperature indication. A melt wire involves placing materials (wires) of a known composition and melting temperature in a test. An inventory is maintained at Material Science Laboratory (MSL) for melt wires ranging in temperatures from 30°C to 1500°C. Unfortunately, melt wires are limited in that it can only detect whether a single temperature is or is not exceeded (melt wire melted or not). SiC TMs, which can also be used to detect peak irradiation temperatures, are advantageous because a single monitor can allow to determine the peak temperature reached within a relatively broad range (100 – 1200°C) resulting in accuracies within ±20°C. Irradiation temperature is determined by measuring a property change after isochronal annealing or during a continuously monitored annealing process using specialized equipment at MSL. Recent research has produced a passive monitor known as sublime temperature monitor. This passive sensor has the capability of recording temperature gradients and pinpointing exactly where a temperature is located along that gradient. Long measurement lengths are achieved with very high accuracy in the location of desired temperature measurements (±2 mm over a 1 m span); however, this sensor has not been deployed in a nuclear reactor. This article will focus only on passive temperature sensors currently being researched and implemented under the Advanced Sensors and Instrumentation (ASI) program at Idaho National Laboratory (INL).
11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
New generation bunch shape monitor for ion accelerators
Measuring longitudinal beam parameters is important for operation and development of high intensity linear accelerators, but it is notoriously difficult for proton and ion beams at non-relativistic energies. The Bunch Shape Monitor (BSM) is a device used for measuring the longitudinal bunch distribution in ion linacs. The existing BSM models have poor electron collection efficiency from the wire and are limited to one-dimensional measurements of the phase coordinate. In response to this problem, we have developed a new generation BSM with improved performance. The proposed design incorporates three major innovations: First, the collection efficiency was improved by adding a focusing field between the wire and the entrance slit, which will also allow measurements over a much wider dynamic range. Second, an improvement in the measurement speed was achieved by sampling longitudinal profiles of multiple energy slices simultaneously, where the BSM wire is placed at the exit of an ion spectrometer so that ions with different energies hit the wire at different horizontal coordinates along the wire. Finally, the design incorporates a motion system that can shift the wire and deflecting cavity together, enabling transverse profile measurements like a wire scanner. Here, in this paper, we will provide the design of the new BSM and report on its beam test results at the Spallation Neutron Source facility in Oak Ridge National Laboratory.
43 PARTICLE ACCELERATORS↗
Regal Beloit Final Technical Report
The original project proposal submitted from NovaTorque Inc (NovaTorque) in 2016 was to improve the existing motor with 95% efficiency by reducing the losses by 21% to achieve 96%. A few months after the proposal was submitted, NovaTorque lost funding and went out of business. The assets of NovaTorque were then acquired by Regal Beloit Corporation (“Regal Beloit” or “Regal”). When the NovaTorque proposal was selected, the project was transferred to Regal Beloit. Once we had production samples from the new Regal production line, they were tested at the Regal Beloit test lab in Wausau, WI. The original NovaTorque motor had an efficiency of 95%, but when the technology was transferred to Regal Beloit, there were multiple manufacturing improvements made, even though the basic electromagnetic design did not change. The test results in Wausau showed that the motors made at the Regal Beloit plant had an efficiency of 96%. Since the goal of the project was to reduce the losses by 21%, a new efficiency target of 96.8% became the project objective. In the first budget period, motors were tested to get the baseline performance. We then used FEA modeling with ANSYS Maxwell to model the existing motor to get correlation between the FEA simulations and the actual test results. Once the model was validated, we evaluated some changes that could be made to the stator to reduce the losses and improve efficiency without changing the rotor or stator housing, keeping the modifications easy to implement. The changes were primarily in the area of making the stator axially shorter and adding Soft Magnetic Composite (SMC) tooth tips. In the second budget period, we proceeded to design and build the new stator that was identified above and identified additional improvements in the process that included a stator machining modification and the use of rectangular wire. When we actually built the motor, the choice of rectangular wire turned out to be a problem. The wire was made by squishing round wire to get the rectangular shape, which caused work hardening, making the wire too stiff to make the desired coils. We shifted to annealed square wire which was better, but we still could not maintain the proper coil envelope. The result was that we had reduced cross section area for stator laminations. We also had to have a radial offset resulting in a radial misalignment between the stator and rotor because of the oversized coils. After the motor was completed, it was shipped to Texas A&M University for testing. With the loss of flux from these issues, the measured motor efficiency was only 96.3%. The primary focus of this motor was to make sure our FEA simulation model predicted the measured losses and overall efficiency, this we moved on to the FEA simulation. The FEA simulations of the motor “as built” with misalignments had good correlation with the test results, so the next step was to use that model to optimize the design of the motor for a final build. This time we considered changes to the stator and rotor and also minor changes to the housing diameter. In the third budget period, we did the detailed design and construction of the final prototypes. The final prototypes had a slight increase in the stator diameter to fit in a standard Regal Beloit housing. We shortened the stator and use more layers of wire in the coils. We also increased the cone angle of the rotor and stator from the original 110 degrees to 130 degrees to get some additional efficiency and optimized the stator cross section. The predicted efficiency from the FEA simulations was 96.9%. When completed, the motors were tested. We were a little short of reaching our target efficiency goal of 96.8%. We were only able to get to 96.7% efficiency. While it may be possible with additional iterations in designs and future builds to gain that additional 0.1%, we believe that we are close to the best we can achieve from a practical viewpoint, and additional iterations would be more work than the potential gains would be worth. No other motor in this class can even reach the 96% that we started with.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Additive Manufacturing of Miniaturized Peak Temperature Monitors for In-Pile Applications
Passive monitoring techniques have been used for peak temperature measurements during irradiation tests by exploiting the melting point of well-characterized materials. Recent efforts to expand the capabilities of such peak temperature detection instrumentation include the development and testing of additively manufactured (AM) melt wires. In an effort to demonstrate and benchmark the performance and reliability of AM melt wires, we conducted a study to compare prototypical standard melt wires to an AM melt wire capsule, composed of printed aluminum, zinc, and tin melt wires. The lowest melting-point material used was Sn, with a melting point of approximately 230 °C, Zn melts at approximately 420 °C, and the high melting-point material was aluminum, with an approximate melting point of 660 °C. Through differential scanning calorimetry and furnace testing we show that the performance of our AM melt wire capsule was consistent with that of the standard melt-wire capsule, highlighting a path towards miniaturized peak-temperature sensors for in-pile sensor applications.
36 MATERIALS SCIENCE↗
Methods and apparatus for embedding heating circuits into articles made by additive manufacturing and articles made therefrom
Methods of embedding a heating circuit in an article fabricated by additive manufacturing. The methods describe techniques such as co-extruding a wire, capable of being heated, along with print material in additive manufacturing of the article, and placing a pre-shaped wire capable of being heated between adjacent layers of the article. A third method includes dispensing a wire, capable of being heated, during the additive manufacturing of the article, and compacting the wire into the printed material. An apparatus for embedding a heating circuit in an article fabricated by additive manufacturing. The apparatus contains a wire dispenser, a cutter to control the length of the wire dispensed, and a compactor capable of embedding the wire capable of being heated into the printed material. An article made by additive manufacturing is disclosed. The article contains at least one heating element embedded in the article during the additive manufacturing process.
Barocio, Eduardo↗
Advanced Graphite Creep Uncertainty Analysis
Radiation damage estimation is an important component of the post irradiation analysis of the Advanced Graphite Creep (AGC) experiment. It depends primarily on the fast fluence, which is determined using well established methods of spectral adjustment. These are based on best estimates from models such as Monte Carlo N-Particle (MCNP), input cross-sections, and measured activities from flux wires in the experiment. Each of these parameters can propagate uncertainties which will affect the uncertainty in the calculated dose levels for AGC, or any experiment irradiated within a reactor. While the methods of propagating uncertainty are well-established, the final uncertainty estimates they provide are only as good as the estimates of uncertainty in the inputs on which they are based. The purpose of this work is to outline some deficiencies in the ways these input uncertainties are presently estimated, and to outline a methodology by which they can be improved. The fast fluence and radiation damage received by graphite specimens irradiated in the Advanced Graphite Creep (AGC) experiments is presently estimated using spectral adjustment methods that are based on both flux wire activity measurements, and MCNP model predictions. This work describes an ongoing effort to quantify and propagate uncertainties in inputs to the spectral adjustment process, and thereby quantify the resultant error in radiation damage (dpa) estimates. The effort is multi-faceted, and we consider the impacts of both the set of flux wires selected, and the counting process. An expanded set of flux wires is identified that provides a more comprehensive data set on the fast spectrum. To address the counting process itself, a series of round-robin measurements in several reactor metrology laboratories across the Department of Energy (DOE) complex and nuclear industry are being undertaken to refine the American Society for Testing and Materials (ASTM) standards for flux wire measurements. To address the contribution of uncertainty in the MCNP model predictions, an uncertainty quantification (UQ) tool has been developed that statistically samples the model input parameters, runs a series of cases, and assimilates the results to provide an overall uncertainty. The impact of the MCNP UQ tool results is demonstrated by re-analyzing previous AGC flux wire and irradiation data. While the expanded flux wire set obviously cannot be added to these experiments retroactively, plans for future graphite irradiations are outlined.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
MEASUREMENT OF THE NEUTRON FLUENCE-RATES IN THE ADVANCED TEST REACTOR
The axial neutron fluence-rate distribution at the Advanced Test Reactor (ATR) is determined using a combination of pure nickel and cobalt-aluminium alloy dosimeter wires. Most irradiation programs at ATR need to know the fast neutron fluence-rate surrounding their experiment to correlate post-irradiation examination results with neutron dose. The activated dosimeter wires, which extend beyond the full fuelled region of the reactor core, are highly radioactive following the full cycle in ATR and must therefore be measured in the ATR canal. The system that is employed for these measurements is mechanical scanning mechanism is used to scan the activated wires across the face of a columnated shield and a NaI detector. This detector is not sufficiently calibrated to provide absolute activity measurements, therefore, the count-rate is recorded and normalized to the highest activity for that wire. Then, an approximately 3-mm long portion of the wire is removed from the highest activity region in the wire. The wires are then transferred, and an absolute activity measurement is made using a calibrated ionization chamber. These measurements are combined with corrections for decay, neutron energy spectrum, burnup, dosimeter composition, reactor power fluctuations, and reactor outages to determine the average axial neutron fluence-rate at various locations within ATR during the cycle.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Methods and apparatus for embedding heating circuits into articles made by additive manufacturing and articles made therefrom
Methods of embedding a heating circuit in an article fabricated by additive manufacturing. The methods describe techniques such as co-extruding a wire, capable of being heated, along with print material in additive manufacturing of the article, and placing a pre-shaped wire capable of being heated between adjacent layers of the article. A third method includes dispensing a wire, capable of being heated, during the additive manufacturing of the article, and compacting the wire into the printed material. An apparatus for embedding a heating circuit in an article fabricated by additive manufacturing. The apparatus contains a wire dispenser, a cutter to control the length of the wire dispensed, and a compactor capable of embedding the wire capable of being heated into the printed material. An article made by additive manufacturing is disclosed. The article contains at least one heating element embedded in the article during the additive manufacturing process.
Barocio, Eduardo↗
Methods for making high-temperature thermocouples
Methods of manufacturing thermocouples having a first thermoelement wire comprises a molybdenum-lanthanum based material and a second thermoelement wire comprises a phosphorus-doped niobium, may involve exposing a first thermoelement wire and a second thermoelement wire to a temperature in a range extending from about 50° C. to about 60° C. above an intended operational temperature of the first and second thermoelement wires and until a rate of change of a normalized voltage output of the first thermoelement wire and the second thermoelement wire is about 0.001 normalized Volts per hour or less.
Skifton, Richard S.↗