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DOE OSTI2022

Cold Spray Additive Manufacturing For New Pipeline Fabrication In Live, Natural Gas Distribution Mains

ULC Technologies (ULC) and the Penn State University Applied Research Lab (PSU ARL) developed a process and approach for rehabilitating live, natural gas distribution pipelines using Cold Spray Additive Manufacturing (CSAM). Robotic inline fabrication of a new pipe will be performed inside a natural gas main without disrupting customers. The material studied was blended with stainless steel which offers corrosion resistance, high strength and compatibility with hydrogen to enable a robust pipeline system that is future proofed. Stainless steel coatings sprayed and tested in the lab showed excellent strength, ductility, and porosity values. ULC initially sought to use methane as the process gas for compatibility with the host pipe, but after evaluating the field and lab challenges, nitrogen was deemed to be more suitable. Early robotic concepts have been developed that indicate technical feasibility. While the technology development originally targeted natural gas distribution mains, market research showed a broader need. Spot repairs performed in natural gas transmission mains may be a more economical approach for reinforcing distribution and transmission mains compared with full pipe-in-pipe rehabilitation. Additive manufacturing offers custom programming, as well as high accuracy and precision. This means custom contours can be manufactured in situ, offering flexibility in the repair solution, such as fabricating internal full circumferential sleeves. The value of the repair can be high at difficult-to-reach locations and in pipes that need reinforcement before the injection of methane-hydrogen blends.

03 NATURAL GAS↗

DOE OSTI2013

Overview and Lessons Learned of the Jefferson Lab Cryomodule Production for the CEBAF 12 GeV Upgrade

The Continuous Electron Beam Accelerator Facility (CEBAF) at Jefferson Lab is nearing completion of an energy upgrade from 6 to 12 GeV. An integral part of the upgrade is the addition of ten new cryomodules, each consisting of eight seven-cell superconducting radio-frequency (SRF) cavities. An average performance of 100+MV of acceleration per cryomodule is needed to achieve the 12 GeV beam energy goal. The production methodology was for industry to provide and deliver the major components to Jefferson Lab, where they were tested and assembled into cryomodules. The production process begins with an inspection upon receiving of all major components followed by individual performance qualification testing. The SRF cavities received their final chemical processing and cleaning at Jefferson Lab. The qualified components along with all associated hardware and instrumentation are assembled, tested, installed into CEBAF and run through an integrated system checkout in preparation for beam operations. The production process is complete and one of the first completed cryomodules has successfully produced 108 MV of acceleration with a linac beam current of 465 {micro}A.

43 PARTICLE ACCELERATORS↗

NASA NTRS2014

NASA Glenn Propulsion Systems Lab (PSL) Icing Facility Update

This oral presentation is an update to the Propulsion Systems Lab (PSL) engine ice testing. It provides a summary of the modifications done to the facility and recently completed calibrations and test program.

Propulsion Systems Lab↗

DOE OSTI2016

CSP ELEMENTS: High-Temperature Thermochemical Storage with Redox-Stable Perovskites for Concentrating Solar Power

This project was motivated by the potential of reducible perovskite oxides for high-temperature, thermochemical energy storage (TCES) to provide dispatchable renewable heat for concentrating solar power (CSP) plants. This project sought to identify and characterize perovskites from earth-abundant cations with high reducibility below 1000 °C for coupling TCES of solar energy to super-critical CO2 (s-CO2) plants that operate above temperature limits (< 600 °C) of current molten-salt storage. Specific TCES > 750 kJ/kg for storage cycles between 500 and 900 °C was targeted with a system cost goal of $15/kWhth. To realize feasibility of TCES systems based on reducible perovskites, our team focused on designing and testing a lab-scale concentrating solar receiver, wherein perovskite particles capture solar energy by fast O2 release and sensible heating at a thermal efficiency of 90% and wall temperatures below 1100 °C. System-level models of the receiver and reoxidation reactor coupled to validated thermochemical materials models can assess approaches to scale-up a full TCES system based on reduction/oxidation cycles of perovskite oxides at large scales. After characterizing many Ca-based perovskites for TCES, our team identified strontium-doped calcium manganite Ca1-xSrxMnO3-δ (with x ≤ 0.1) as a composition with adequate stability and specific TCES capacity (> 750 kJ/kg for Ca0.95Sr0.05MnO3-δ) for cycling between air at 500 °C and low-PO2 (10-4 bar) N2 at 900 °C. Substantial kinetic tests demonstrated that resident times of several minutes in low-PO2 gas were needed for these materials to reach the specific TCES goals with particles of reasonable size for large-scale transport (diameter dp > 200 μm). On the other hand, fast reoxidation kinetics in air enables subsequent rapid heat release in a fluidized reoxidation reactor/ heat recovery unit for driving s-CO2 power plants. Validated material thermochemistry coupled to radiation and convective particle-gas transport models facilitated full TCES system analysis for CSP and results showed that receiver efficiencies approaching 85% were feasible with wall-to-particle heat transfer coefficients observed in laboratory experiments. Coupling these reactive particle-gas transport models to external SolTrace and CFD models drove design of a reactive-particle receiver with indirect heating through flux spreading. A lab-scale receiver using Ca0.9Sr0.1MnO3-δ was demonstrated at NREL’s High Flux Solar Furnace with particle temperatures reaching 900 °C while wall temperatures remained below 1100 °C and approximately 200 kJ/kg of chemical energy storage. These first demonstrations of on-sun perovskite reduction and the robust modeling tools from this program provide a basis for going forward with improved receiver designs to increase heat fluxes and solar-energy capture efficiencies. Measurements and modeling tools from this project provide the foundations for advancing TCES for CSP and other applications using reducible perovskite oxides from low-cost, earth-abundant elements. A perovskite composition has been identified that has the thermodynamic potential to meet the targeted TCES capacity of 750 kJ/kg over a range of temperatures amenable for integration with s-CO2 cycles. Further research needs to explore ways of accelerating effective particle kinetics through variations in composition and/or reactor/receiver design. Initial demonstrations of on-sun particle reduction for TCES show a need for testing at larger scales with reduced heat losses and improved particle-wall heat transfer. The gained insight into particle-gas transport and reactor design can launch future development of cost-effective, large-scale particle-based TCES as a technology for enabling increased renewable energy penetration.

14 SOLAR ENERGY↗

DOE OSTI2022

Advanced Thin Film Core Technology: CIGS Final Technical Report (FTR)

Cu(In,Ga)Se 2 (CIGS) thin-film photovoltaics are a high-efficiency and reliable technology. This project completed research in two important areas and was designed to work collaboratively with industrial partners. Task 1: Alkali Science focused on alkali post-deposition treatments (PDT). PDTs have been instrumental in the dramatic voltage improvements that have moved CIGS device efficiencies from 20% to 23.35% [1]. Based on a survey of CIGS companies at the beginning of the project, the single biggest breakthrough for the CIGS community would be a mechanistic understanding of the role of alkalis in the material system. Significant accomplishments of Task 1: Alkali Science: 1) KF post-deposition treatments were shown to improve lifetime, open-circuit voltage (VOC), and efficiency of industrial partner samples, even when done as a later step, separate from the original CIGS deposition. 2) KF boosted efficiency when incorporated at the end of the third stage of NREL CIGS growth. 3) XPS characterization of CIGS surfaces with and without PDTs led to a proposed mechanism whereby K drives structural transformation at 350 degrees C that is locked in at room temperature even after K is rinsed away. 4) Published recipes for KF and RbF PDTs. Literature to date did not provide enough detail to quickly reproduce experimental results. 5) Identified most important parameters (RbF cell temperature and lamp setpoint temperature) and set boundaries for successful RbF PDTs. The purpose of Task 2: Cell-level Reliability was to overcome the largest challenges to investor confidence and long product lifetime in CIGS-based photovoltaic products: metastability, shading-induced hot spots, and potential-induced degradation (PID). Key findings were made in each of these areas by studying CIGS reliability at the cell level: 1) Published NREL's cell-level reliability testing procedures along with challenges that were encountered while developing them. These were also distributed to the community through an MRS conference presentation. 2) Decreased metastability by adding a CdS hole-injection layer between the CIGS and Zn(O,S) in the device stack. It also improved device performance. Materials other than CdS can be used for the same purpose. 3) Reduced front-glass PID by replacing soda-lime glass with low-Na borosilicate glass. 4) Found that PID depends on leakage current and light/electrical bias. This will help labs avoid test-specific degradation. 5) Discovered that CIGS can suffer from two different types of PID with different mechanisms. Front is slower and leads to shunting ZnO. Back is faster and degrades the p-n junction. 6) Holding cells at open circuit slows PID compared to short circuit. This affects testing protocols for glass/glass modules.

14 SOLAR ENERGY↗

NASA NTRS1991

Laboratory test and acoustic analysis of cabin treatment for propfan test assessment aircraft

An aircraft cabin acoustic enclosure, built in support of the Propfan Test Assessment (PTA) program, is described. Helmholtz resonators were attached to the cabin trim panels to increase the sidewall transmission loss (TL). Resonators (448) were located between the trim panels and fuselage shell. In addition, 152 resonators were placed between the enclosure and aircraft floors. The 600 resonators were each tuned to a 235 Hz resonance frequency. After flight testing on the PTA aircraft, the enclosure was tested in the Kelly Johnson R and D Center Acoustics Lab. Laboratory noise reduction (NR) test results are discussed. The enclosure was placed in a Gulfstream 2 fuselage section. Broadband (138 dB overall SPL) and tonal (149 dB overall SPL) excitations were used in the lab. Tonal excitation simulated the propfan flight test excitation. The fundamental tone was stepped in 2 Hz intervals from 225 through 245 Hz. The resonators increase the NR of the cabin walls around the resonance frequency of the resonator array. The effects of flanking, sidewall absorption, cabin adsorption, resonator loading of trim panels, and panel vibrations are presented. Increases in NR of up to 11 dB were measured.

Kuntz, H. L.↗

DOE OSTI2024

A High-Field Polarized 3 He Target for Jefferson Lab’s CLAS12 Spectrometer

Polarized 3He nuclear targets are invaluable surrogates for polarized neutron targets in spin-dependent scattering studies of the structure of matter. Traditional polarized 3He targets have seen steady improvements and active use over the last three decades, however they have been limited to operation in low magnetic fields. This has precluded their use in spectrometers that utilize high-magnetic-field tracking systems, such as Jefferson Lab's CLAS12 spectrometer. Developments in high-magnetic-field metastability exchange optical pumping of 3He, recently incorporated into the design of a polarized 3He ion source for RHIC and the EIC, could enable a new, polarized 3He fixed target to operate within high fields. Combining high-field techniques with the double-cell cryogenic target design used for the MIT-Bates 88-02 experiment, polarization and target density comparable to traditional polarized 3He targets could be reached while within a high magnetic field environment. We discuss the conceptual design for such a target, show our progress in this target's development, and outline plans for in-beams tests in Jefferson Lab's Hall B.

Maxwell, James↗

NASA NTRS2009

Developments to Increase the Performance, Operational Versatility and Automation of a Lunar Surface Manipulation System

The objective of this paper is to describe and summarize the results of the development efforts for the Lunar Surface Manipulation System (LSMS) with respect to increasing the performance, operational versatility, and automation. Three primary areas of development are covered, including; the expansion of the operational envelope and versatility of the current LSMS test-bed, the design of a second generation LSMS, and the development of automation and remote control capability. The first generation LSMS, which has been designed, built, and tested both in lab and field settings, is shown to have increased range of motion and operational versatility. Features such as fork lift mode, side grappling of payloads, digging and positioning of lunar regolith, and a variety of special end effectors are described. LSMS operational viability depends on bei nagble to reposition its base from an initial position on the lander to a mobility chassis or fixed locations around the lunar outpost. Preliminary concepts are presented for the second generation LSMS design, which will perform this self-offload capability. Incorporating design improvements, the second generation will have longer reach and three times the payload capability, yet it will have approximately equivalent mass to the first generation. Lastly, this paper covers improvements being made to the control system of the LSMS test-bed, which is currently operated using joint velocity control with visual cues. These improvements include joint angle sensors, inverse kinematics, and automated controls.

Dorsey, John T.↗

DOE OSTI2016

Charge breeder for the SPIRAL1 upgrade: Preliminary results

In the framework of the SPIRAL1 upgrade under progress at the GANIL lab, the charge breeder based on a LPSC Phoenix ECRIS, first tested at ISOLDE has been modified to benefit of the last enhancements of this device from the 1+/n+ community. The modifications mainly concern the 1 + optics, vacuum techniques, and the RF—buffer gas injection into the charge breeder. Prior to its installation in the midst of the low energy beam line of the SPIRAL1 facility, it has been decided to qualify its performances and several operation modes at the test bench of LPSC lab. This contribution shall present preliminary results of experiments conducted at LPSC concerning the 1 + to n+ conversion efficiencies for noble gases as well as for alkali elements and the corresponding transformation times.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS1996

Rapid Inspection of Aerospace Structures - Is It Autonomous Yet?

The trend to increase the usage of aging aircraft added a great deal of urgency to the ongoing need for low-cost, rapid, simple-to-operate, reliable and efficient NDE methods for detection and characterization of flaws in aircraft structures. In many cases, the problem of inspection is complex due to the limitation of current technology and the need to disassemble aircraft structures and testing them in lab conditions. To overcome these limitations, reliable field inspection tools are being developed for rapid NDE of large and complex-shape structures, that can operate at harsh, hostal and remote conditions with minimum human interface. In recent years, to address the need for rapid inspection in field conditions, numerous portable scanners were developed using NDE methods, including ultrasonics, shearography, thermography. This paper is written with emphasis on ultrasonic NDE scanners, their evolution and the expected direction of growth.

Crawling System autonomous robotics↗

DOE OSTI2026

Lab Homes

This dataset includes processed data from the Lab Homes (LH) Test Facility located on the PNNL campus in Richland, WA. This a set of 2 identical homes that allow for the side-by-side comparison/performance evaluation of different technologies under the same weather at any given time. The dataset spans December 6, 2021 to December 27, 2021 and represents a series of tests performed; calibration, set-point excitation, pre-heating, free-floating and warm up. The measurements correspond to whole building electrical power, HVAC energy use, water heating, appliances and lighting, as well as space temperatures, space humidity, window glass surface temperatures, through glass solar radiation, and meterological data from an onsite meteorological weather station. In addition to the measurements, a metadata .json file, a .ttl file to visualize the data as per BRICK schema, and a detailed .pdf description of the dataset are also provided.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Building the next high voltage dc photogun polarized source for the ILC at JLab

During the ILC Global Design Effort (2007) two 200 kV high voltage photoguns based on an inverted insulator geometry were developed in 2010 and successfully tested at Jefferson Lab (JLab). One of the photoguns has been operated at 130 kV in the CEBAF accelerator for the JLab nuclear physics program. The inverted insulator replaces the electrode support structure, consequently significantly less metal prone to field emission is biased and surfaces contributing to the vacuum load are significantly reduced. Implementing a biased anode, and using a larger laser spot size has made this the state of the art polarized beam source with ~200 C charge lifetime from SSL GaAs photocathodes. However, operating at the design 200 kV voltage has been hindered by field emission at ~190 kV. To reliably operate without field emission requires lengthy conditioning applying 50-100 kV beyond the voltage needed for beam operations, without breakdown or damage to the insulator. Over the past decade, JLab has developed two photoguns with a larger version of the commercial inverted insulators used in the ILC design. One photogun operated at 300 kV for magnetized beam studies, and the concept has been implemented in the BNL polarized photogun. The second photogun has recently been installed in CEBAF to operate at 200 kV field emission free. Higher voltage photoguns help the ILC and CLIC achieve higher bunch charge (2013 TDR), and additionally provide margin for operating with shorter laser pulse length and/or smaller laser spot size (better emittance at higher peak current). Such photogun designs need to reach ~400 kV without breakdown or insulator damage to operate field emission free at > 300 kV. This also allows for direct injection into a SRF booster. JLab submitted a proposal to HEP for developing in partnership with industry an inverted geometry insulator to fit commercial 400 kV cables. This contribution describes JLab experience developing and testing high voltage photoguns, and what is needed to sufficiently condition for voltage levels higher than beam operational voltage.

Hernandez-Garcia, Carlos↗

DOE OSTI2022

Status of SNS Proton Power Upgrade SRF Cavities Production Qualification

The Proton Power Upgrade project at Oak Ridge National Lab’s Spallation Neutron Source (SNS PPU) currently being constructed will double the proton beam power from 1.4 to 2.8 MW by adding 7 additional cryomodules, each contains four six-cell high beta (\beta = 0.81) superconducting radio frequency cavities. The cavities were built by Research Instruments, Germany, with all the cavity processing done at the vendor site, including electropolishing as the final active chemistry step. All 28 cavities needed for 7 cryomodules were delivered to Jefferson Lab, ready to be tested. The cryogenic RF qualifications and helium vessel welding were done at Jefferson Lab. The performance largely exceed the requirements, and greatly exceeded the performance of the original SNS cavity production series. Here, we present the summary of RF test on production cavities to this date.

Dhakal, P.↗

DOE OSTI2021

Status of SNS Proton Power Upgrade SRF Cavities Production Qualification

Dhakal, P.↗

NASA NTRS2022

NIAC Phase-2 Final Report for Astrophysics and Technical Lab Studies of a Solar Neutrino Spacecraft Detector

The Sun provides all the energy that our planet needs for life and has been doing so for five billion years. Understanding our Sun and its interior is one of the major goals of the NASA Science program. Still this is a very difficult task because very little makes it directly out of the Sun’s interior. The energy we see today, that warms the Earth, was made 50,000 to 80,000 years ago and is only now coming to the surface to make light. However, neutrinos penetrate matter almost without interaction and make it to Earth in only eight minutes from creation. Since neutrinos interact only weakly they are hard to detect; never-the-less within the last ten years neutrino detectors on Earth have started to reliably detect neutrinos from the fusion reactions in the interior of the Sun and scientists have started to use this information to investigate the Sun’s nuclear furnace. Changes in solar neutrino flux make it advantageous to take a neutrino detector into space since the solar neutrino intensity changes dramatically as the inverse square of the distance from the Sun, by five orders of magnitude when going from the Earth to the Sun. Launch of a neutrino detector into space toward the Sun will: a) aim to significantly increase the neutrino flux 10,000x allowing for a smaller detector which improves detector energy resolution and performance, b) attempt to completely eliminate background terrestrial neutrino sources for improved measurement accuracy, and c) conduct unique science experiments near the Sun not achievable with much larger detectors on the Earth. NASA's interest in deep space exploration has been a key factor in its unmanned spacecraft development and launch of exploration science satellites and spacecraft. NASA has done exceptional experiments in space where science benefits from the unique platform of spacecraft that provides unprecedented views. For example, the Hubble Space Telescope is really a small and very common instrument, but when it is put into an orbit high above the Earth, it becomes one of the most powerful optical observatories man has ever made. Moving neutrino observations to space is the next obvious step. The concept of putting a neutrino detector in close orbit of the sun is completely unexplored and innovative. Its scientific return is to vastly enhance the understanding of the solar interior which is a NASA major goal as stated in the decadal survey. Preliminary calculations show that such a spacecraft if properly shielded, can operate in this environment both taking data of neutrino interactions which can be distinguished from random background rates of solar Electromagnetic emissions, Galactic charged cosmic-ray, and gamma-rays by using a double pulsed signature. The NIAC Phase-1 simulations have shown this idea to be very successful in eliminating background and identifying the neutrino interaction signal, hence this spacecraft detector concept once demonstrated to be Technical Readiness Level 7 and flight mission-ready would enable a whole new type of mission to explore and study our Sun, in details that could neither be done with the largest neutrino detectors on Earth nor other types of space-craft measurements that are not using neutrino detection. Our goal in this NIAC Phase-2 was to take the detector simulation ideas and construct a prototype for testing in the lab with tagged sources to evaluate and demonstrate that the performance in the simulations are borne out by a prototype.

Neutrino↗

DOE OSTI2019

Characterization of laboratory-scale hydraulic fracturing for EGS

To investigate the impact of reservoir stimulation by hydraulic fracturing, a series of advanced lab-scale block tests were conducted with multiple measurement methods to characterize the fracture and to assess the operation and the performance of an enhanced or engineered geothermal system (EGS). The stimulation test samples were 330-mm cubic blocks of Sierra White granite with one injection well and four producers drilled into it. Acoustic emissions generated during the fracture initiation and propagation were monitored with twenty AE sensors mounted on all sides of the block to help characterize the fracture initiation and propagation process. The recorded AE signals were analyzed to obtain the event location and the failure mechanism. The localized AE events shows that due to the low viscosity of the fracturing fluid (water), the fracture propagated rapidly and took only about 1.4 s to reach near the block surface. During the fracturing phase, about 47 percent of the events were determined to be shear/mixed mode failure events, 28 percent tensile failure events, and 25 percent compressional failure events. Just after the simulation, a step-rate (constant flowrate) injection test was carried out to investigate the reservoir injectivity enhancement. During this phase additional compressional failure events were observed and the percentages of tensile failure and shear/mixed mode failure decreased. The dramatic increase of the injection rate with small increments of the injection pressure demonstrates the nonlinear response of the fracture to effective normal stress variation with much higher fracture opening increase during the low effective normal stress interval. Hydraulic fracturing tests under different stress levels show that more AE hits/events are recorded when the rock block is under higher applied stress. The reconstructed 3D fracture geometry shows good agreement with the AE monitoring results. After fracturing, a tracer test was carried out and the fracture aperture was estimated to be around 139 μm. The tracer recovery curve shows two linear portions of the tracer tail on a semi-log plot similar to that observed in some field data and predicted by numerical modeling. Laser scanning of the fracture surfaces indicates that the induced fracture has a rough surface with a joint roughness coefficient (JRC) of 12.98 and tortuosity of 1.10, both of which are slightly larger than that from the Brazilian test fracture on the same rock. The thin section and SEM observations show that the fracture follows the weak boundaries between the Quartz and Albite grains or the weak beddings in the grains.

58 GEOSCIENCES↗

DOE OSTI2018

Results from the CBC3 readout ASIC for CMS 2S-modules

The CBC3 is the latest version of the CMS Binary Chip for readout of the outer radial region of the upgraded CMS Tracker at the High Luminosity LHC. This 254-channel, 130 nm CMOS ASIC is designed to be bump-bonded to a substrate to which sensors will be wire-bonded. It will instrument double-layer 2S-modules, containing two overlaid silicon microstrip sensors, aligned with a parallel orientation. On-chip logic identifies Level-1 trigger primitives from high transverse-momentum tracks by selecting correlated clusters in the two sensors. The CBC3 was delivered in late 2016; wafer probing and performance tests have been carried out. Several prototype modules using the CBC3 have been produced and tested in the lab and in different beams. The results show that the CBC3 satisfies CMS requirements and only small corrections are needed for the final version of the chip for production.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

Novel 4x4 SiPM array readout with integrated preamplification stage, optimized for the PWO detectors of the EIC EEEMCal

Here we are reporting on a new readout circuit developed for the lead tungstate (PbWO4) scintillation detectors for the Electron Ion Collider (EIC) Electron Endcap Electromagnetic Calorimeter EEEMCal. The high magnetic field region precludes the use of photomultiplier tubes while the detector requirements specify good spectral resolution performance and fast pulse integration over a large dynamic range. We selected a silicon photomultiplier (SiPM) from Hamamatsu and produced a matrix of 4 x 4 sensors to cover the 20 mm x 20 mm scintillator coupling surface. Signal acquisition and amplification electronics boards were designed and integrated with the sensor board to produce a compact high performance readout package. A prototype detector was built and tested at Jefferson Lab with encouraging resolution and timing performance results.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗