Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Wire”

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

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

At least 667 records · Page 37
All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Thermal Analysis of Potted Litz Wire for High-Power-Density Aerospace Electric Machines

Increasing the power density and efficiency of electric machines (motors and generators) is integral to bringing Electrified Aircraft (EA) to commercial realization. To that end an effort to create a High Efficiency Megawatt Motor (HEMM) with a goal of exceeding 98% efficiency and 1.46 MW of power has been undertaken at the NASA Glenn Research Center. Of the motor components the resistive losses in the stator windings are by far the largest contributor (34%) to total motor loss. The challenge is the linear relationship between resistivity and temperature, making machine operation sensitive to temperature increases. In order to accurately predict the thermal behavior of the stator the thermal conductivity of the Litz wire-potting-electrical insulation system must be known. Unfortunately, this multi material system has a wide range of thermal conductivities (0.1 W/m-K – 400 W/m-K) and a high anisotropy (axial vs transverse) making the prediction of the transverse thermal conductivity an in turn the hot spot temperatures in the windings is difficult. In order to do this a device that simulates the thermal environment found in the HEMM stator was designed. This device is not unlike the motorettes (little motors) that are described in IEEE standards for testing electrical insulation lifetimes or other electric motor testing. However, because the HEMM motor design includes significant rotor electrical and thermal considerations the term motorette was not deemed appropriate. Instead statorette (or little stator) was adopted as the term for this test device. This paper discussed the design, thermal heat conjugate analysis (thermal model), manufacturing and testing of HEMM's statorette. Analysis of the results is done by thermal resistance network model and micro thermal model and is compared to analytical predictions of thermal conductivity of the insulated and potted Litz wire system.

Motor↗
NASA NTRS2023

Assessment of Electrical, Electronic, and Electromechanical (EEE) Parts Copper Wire Bonds for Space Programs

The NASA Electronic Parts and Packaging Program co-manager, requested the NASA Engineering and Safety Center (NESC) to compile a body of publicly available knowledge on copper (Cu) wire bonds and perform reliability testing and analysis on these bonds, including environment tests, sample destructive physical analysis, and bond pull/shear tests during environment test intervals. The goal was to understand the risks of using Cu wire bonds for space applications and develop guidelines on Cu bond pull/shear limits for NASA applications. This document contains the results of the NESC assessment.

Electrical, Electronic, and Electromechanical↗
DOE OSTI2019

LDRD 19A42-015, Multi-Wire Arc Additive Manufacturing

Additive manufacturing (AM) techniques can efficiently and cost-effectively fabricate components with both geometrical and compositional complexities, where functionally-graded compositions in a component allow multiple service requirements to be simultaneously addressed, such as corrosion and high temperature structural requirements. High cost alloy compositions need only be deposited in local areas where they are needed. A multi-wire arc additive manufacturing (m-WAAM) system was developed to enable functionally-graded, additively manufactured complex structures. The m-WAAM system utilizes multiple filler wire alloys, allowing control of composition and composition gradients in the component during additive fabrication. Ultimately, this project successfully developed a high deposition rate, arc-based, additive manufacturing process with the truly novel capability of enabling spatial composition tailoring during the build of the component. System capabilities and process science will be studied in a follow-on LDRD starting next year.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Development of Bismuth and Platinum Bi-Metallic Nanoparticles to Enhance Melt Wire Temperature Resolution

Advanced manufacturing (AM) based on direct-write (DW) technologies has emerged as the predominant enabler for the fabrication of active and passive sensors to be deployed in harsh operating environments seen in a nuclear reactor. Recently, Idaho National Laboratory and Boise State University have recently established capabilities to incorporate advanced manufacturing (AM) methods to accelerate, modernize and enhance functionality of nuclear sensors and instrumentation to achieve the goal of enhancing the safety and efficiency of nuclear reactors. A significant thrust of this work includes the development of nuclear relevant feedstock materials compatible with a variety of direct-write processes for the development, fabrication and testing of AM sensors for peak temperature detection and neutron flux monitoring. For this report, bismuth and bismuth/platinum (BiPt) bi-metallic nanoparticles were synthesized using wet chemical approaches to develop bi-metallic feedstock materials to enhance the sensitivity of melt wires for peak temperature detection. Nanoparticle characterization was performed with Transmission Electron Microscopy (TEM) for nanoparticle composition and size, Transmission X-Ray Diffraction Fluorescence (TXRF) for nanoparticle composition, and Differential Scanning Calorimetry to elucidate the melting point of BiPt bi-metallic nanoparticles. Preliminary results indicate bi-metallic BiPt nanoparticles as a viable pathway for fabricating high resolution AM melt wires.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Nek5000 Large-Eddy Simulations for Thermal-Hydraulics of Deformed Wire-Wrap Fuel Assemblies

A well-characterized validation program has been defined for the thermal-hydraulic CFD modeling of 61-pin hexagonal packed fuel assemblies with helically wire-wrapped pins for both non-deformed beginning-of-life geometries and deformed later-in-life geometries typical of sodium-cooled fast reactors. The motivation for this work is the need to validate CFD codes to accurately model the flow and thermal performance of wire-wrapped fuel assemblies, particularly the deformed later-in-life bundles. The effect of pin and duct deformation is increasingly important as reactor designs look toward longer assembly lifetimes. As a part of a larger collaborative project with TerraPower, Texas A and M University (TAMU), and AREVA, this validation work consists of CFD simulations of four con-current experiments. Pre-test numerical simulations corresponding to each of the experiments has been conducted and are planned to be followed by post-test simulations that will incorporate test information as it becomes available to account for any as-built differences in geometry of test section and its specifications including the differences in boundary conditions of the actual tests. This paper focuses on Nek5000 LES results for the isothermal/TAMU undeformed configuration as a first step toward and initial conditions for the deformed isothermal/TAMU and/or conjugate heat transfer/AREVA cases. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Length‐Independent Charge Transport in Chimeric Molecular Wires

Abstract Advanced molecular electronic components remain vital for the next generation of miniaturized integrated circuits. Thus, much research effort has been devoted to the discovery of lossless molecular wires, for which the charge transport rate or conductivity is not attenuated with length in the tunneling regime. Herein, we report the synthesis and electrochemical interrogation of DNA‐like molecular wires. We determine that the rate of electron transfer through these constructs is independent of their length and propose a plausible mechanism to explain our findings. The reported approach holds relevance for the development of high‐performance molecular electronic components and the fundamental study of charge transport phenomena in organic semiconductors.

Wardrip, Austin G.↗
DOE OSTI2016

Length‐Independent Charge Transport in Chimeric Molecular Wires

Abstract Advanced molecular electronic components remain vital for the next generation of miniaturized integrated circuits. Thus, much research effort has been devoted to the discovery of lossless molecular wires, for which the charge transport rate or conductivity is not attenuated with length in the tunneling regime. Herein, we report the synthesis and electrochemical interrogation of DNA‐like molecular wires. We determine that the rate of electron transfer through these constructs is independent of their length and propose a plausible mechanism to explain our findings. The reported approach holds relevance for the development of high‐performance molecular electronic components and the fundamental study of charge transport phenomena in organic semiconductors.

Wardrip, Austin G.↗
DOE OSTI2019

The Influence of High Isostatic Pressure on Critical Current Density in C-Doped MgB{sub 2} Wires

This article reports the influence of isostatic pressure (from 0.1 MPa to 1.1 GPa), low annealing temperature of 570 {sup ∘}C, and annealing time for the formation of high-field pinning centers in 2% C-doped MgB{sub 2} wires. Measurements indicate that 1.1 GPa pressure significantly increases the density of high-field pinning centers below 20 K. However, lower pressure (0.6 GPa) slightly increases the density of high-field pinning centers. Increasing the annealing time from 120 to 210 min leads to a reduction of critical temperature (T{sub c}), irreversibility field (B{sub irr}), critical current density (J{sub c}), and upper critical field (B{sub c2}), suggesting that a long annealing time leads to a reduction of high-field pinning center density and the number of connections between superconducting grains. The high pressures and low annealing temperature lead to a high critical current density of 1000 A/mm{sup 2} in 7.2 T and 100 A/mm{sup 2} in 12.5 T at 4.2 K in MgB{sub 2} wires.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

Time-Dependent 600 °C Post-Weld Heat Treatment Response of Laser-Wire-Directed Energy Deposited Austenitic Stainless Steel Claddings on Carbon Steel

Austenitic stainless steel overlay claddings are often used to protect nuclear reactor pressure vessels from corrosion. Arc welding processes are traditionally employed, which require a high heat input to bond the dissimilar metals, creating a large heat-affected zone and high residual stress that demands a lengthy stress-relieving post-weld heat treatment, up to 48 hours. High energy beam (e.g., laser, electron beam) directed energy deposition-based overlay cladding processes show promise for fabricating claddings with superior performance compared to arc welded ones because of their localized heat input; however, their necessity and time of post-weld heat treatment are currently unclear. In this research, we investigate the time dependence of a 600 C stress-relieving post-weld heat treatment of austenitic stainless steel clad on low carbon steel by laser-wire-directed energy deposition, comparing the microstructure and mechanical properties of the as-fabricated condition to 2-, 10-, and 48-hour heat treatment times. Diffusion simulations and microscopy show a gradual carburization of the stainless steel cladding and decarburization of the heat-affected zone/base metal. Nanoindentation testing shows up to a 1.8–2.69 embrittlement in the cladding and a 0.33 to 0.69 softening in the heat-affected zone after the 48-hour post-weld heat treatment. Tensile testing of the cladding composites reveals that increasing post-weld heat treatment time raises clad cracking susceptibility due to intergranular carbide formation and shows that laser-wire-directed energy deposition claddings may not require post-weld heat treatment.

Coating↗
DOE OSTI2017

Correlation of Mechanical Properties with Diameter and Cooling Rate of 1080 Wire-Rod

More than 540 heats of 1080 wire-rod were statistically analyzed by regression analyses to see whether tensile strength and percent reduction in area (%RA) relate to wire-rod diameter and composition. As diameter increases from 5.6 to 12.7 mm, the trend in %RA shows a decrease with negligible effect on the trend of the tensile strength. It was found that the estimated cooling rate at 700 °C during controlled cooling is responsible for the “diameter effect.” The effect of composition on %RA is minor when contrasted to the “diameter effect.” In particular, the effect of the concentrations of the residual elements on %RA within the compositional range studied is negligible.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Influence of Heat Input and Cold Wire Feeding Rate on Pitting Corrosion Resistance of Submerged Arc Welding Duplex Stainless Steel Welds

Welding thermal cycles may severely impair duplex stainless steel (DSS) performance, especially local pitting resistance and toughness. The restricted welding energy between 0.5 and 2.5 kJ mm{sup −1} represents a limiting factor for productivity increase in DSS welding, and the addition of cold wire is an interesting alternative to increase the welding deposition rate without adding extra heat. The aim of this work is to evaluate the influence of the cold wire feeding rate (CW) and heat input (HI) on pitting corrosion behavior of DSS UNS S32304 bead-on-plate welds obtained by submerged arc welding (SAW). Cyclic potentiodynamic polarization was carried out in transverse weld sections using 1 mol L{sup −1} NaCl solution at room temperature. Most pitting corrosion spots were located on the heat-affected zone (HAZ), and the pitting potentials were lower than the base metal due to higher ferrite fractions and the presence of chromium nitrides. Considering the same CW, the HI increasing reduced E{sub pit} for 1.6, 1.9, 2.2 kJ mm{sup −1}, but increased E{sub pit} for 2.7 kJ mm{sup −1}, due to a balance between the HAZ width and the austenite fraction.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effect of N 2 - and CO 2 -containing shielding gases on composition modification and carbonitride precipitation in wire arc additive manufactured grade 91 steel

Additive manufacturing (AM) represents a promising technique to fabricate metallic alloys with greater control of the resulting material features as compared to traditional manufacturing routes. Recently, there is greater interest in AM research on 9 wt% Cr ferritic/martensitic (F/M) steels, which are commonly studied for use in the nuclear energy industry. This work aims to prove that wire arc AM can manufacture F/M steels with adequate mechanical properties in multiple processing atmospheres and aims to study how shielding gas composition can be leveraged during fabrication to induce specific precipitation pathways. The effect of shielding gas composition on MX (M=Nb and/or V, Xdouble bondC and/or N) carbonitride precipitation in a 9 wt% Cr ferritic/martensitic (F/M) steel alloy known as Grade 91 was studied using N 2 and CO 2 gas additions to an inert Ar shielding gas atmosphere during wire arc AM. The N and C atoms present in the processing atmospheres were absorbed into the melt pools during fabrication. Due to their differing affinities for precipitate-forming reactions, the varying levels of C and N between the samples contributed to differences in final carbonitride composition and morphologies. Such precipitate behavior is of interest as carbonitrides have been shown to contribute to increased mechanical performance. This increased performance was studied via electron microscopy and tested for strength, ductility, and fracture properties.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Wire directed energy deposition of steel-aluminum structures using cold metal transfer process

In this study, a sharp transition from 316L stainless steel to 4043 aluminum alloy was fabricated using wire directed energy deposition (DED) via the cold metal transfer (CMT) process. The CMT process with its inherently low heat input, led to a significant reduction in intermetallic thickness at the bi-metallic interface compared to blown powder DED technique reported in the literature resulting in superior properties when compared to those of dissimilar steel-aluminum welds. Thermo-kinetic modeling confirmed that the intermetallic formation is through a classical nucleation and growth mechanism, and the fraction and thickness can be controlled by adjusting CMT process parameters to kinetically arrest or minimize the intermetallic formation. These findings underscore the efficacy of CMT-based wire DED for fabrication of steel-aluminum bi-metallic structures.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructural evolution and mechanical properties of maraging steel produced by wire + arc additive manufacture process

Highlights: • Wire + arc additive manufacture (WAAM) was applied to produce maraging steel structures. • Microstructure evolution of WAAM alloy was characterized and correlated with the layer-by-layer building manner. • Mechanical properties of WAAM alloy were tested and correlated with the aging response of WAAM microstructure. • Retained austenite content was measured and correlated with the tensile strength loss. - Abstract: Wire + arc additive manufacture is developed for producing large-scale metallic components. In this paper, maraging steel parts were produced, and the microstructure and mechanical properties were investigated. The microhardness and tensile strength of the as deposited alloy reduced from the bottom to the top due to the transient thermal cycling, which resulted in partial aging and non-uniform formation of intermetallic compounds along the building direction. Solutionizing, followed by 3 h aging, significantly reduced the microstructural heterogeneity and increased the mechanical properties by 24.7% through the formation of large amounts of finely distributed precipitates. The as deposited alloy possessed superior strength to the wrought alloy in solutionized condition but inferior to the later in aged condition, which was attributed to the less pronounced aging response of the low-angle columnar grains characterized microstructure and the presence of retained and reverted austenite.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Electrochemical properties of Sn-based nanopowders synthesized by a pulsed wire evaporation method and effect of binder coating

Highlights: • Sn-based nanoparticles are fabricated by using the pulsed wire evaporation method. • The electrodes are prepared by mixing the graphene and coating the surface. • Coating the surface of electrode is used with brushing of simple and facile method. • The electrochemical measurements are performed with galvanostatic experiments. • The coating electrode maintains capacity nearly of 501 mAh g{sup −1} up to 100 cycles. - Abstract: Sn-based nanoparticles are prepared with the O{sub 2} concentrations in chamber of Ar atmosphere (by v/v) by using the pulsed wire evaporation (PWE) method. The prepared electrodes are only Sn-based powder electrode, its binder coating electrode and Sn-based powder/graphene nanocomposite electrode. Morphology and structure of the synthesized powders and electrodes are investigated with a field emission scanning electron microscope (FE-SEM) and an X-ray diffraction (XRD) analysis. The electrochemical measurements were performed with galvanostatic cycling experiments using a coin type cell of CR2032 (Ø20, T3.2 mm). The binder coating electrode is superior to others and maintains delithiation capacity nearly of 501 mAh g{sup −1} as 58.3% of first delithiation capacity at 0.2 C-rate up to 100 cycles.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Application of active quenching of second generation wire for current limiting

Superconducting fault current limiters (SFCL's) are increasingly implemented in the power grid as a protection of substation equipment from fault currents. Resistive SFCL's are compact and light, however they are passively triggered and thus may not be sufficiently sensitive to respond to faults in the distribution grid. Here, we explore the prospect of adding an active management feature to a traditional resistive SFCL. A flexible radio-frequency coil, which is an integral part of the switching structure, acts as a triggering device. We show that the application of a short, 10 ms, burst of ac magnetic field during the fault triggers a uniform quench of the wire and significantly reduces the reaction time of the wire at low currents. The ac field burst generates a high density of normal zones, which merge into a continuous resistive region at a rate much faster than that of sparse normal zones created by the transport current alone.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2016

High-energy synchrotron X-ray diffraction measurements of simple bending of pseudoelastic NiTi shape memory alloy wires

Many technological applications of austenitic shape memory alloys (SMAs) involve cyclical mechanical loading and unloading in order to take advantage of pseudoelasticity. In this paper, we investigated the effect of mechanical bending of pseudoelastic NiTi SMA wires using high-energy synchrotron radiation X-ray diffraction (SR-XRD). Differential scanning calorimetry was performed to identify the phase transformation temperatures. Scanning electron microscopy images show that micro-cracks in compressive regions of the wire propagate with increasing bend angle, while tensile regions tend not to exhibit crack propagation. SR-XRD patterns were analyzed to study the phase transformation and investigate micromechanical properties. By observing the various diffraction peaks such as the austenite (200) and the martensite ( ${\bar 1}12$ ), ( ${\bar 1}03$ ), ( ${\bar 1}11$ ), and (101) planes, intensities and residual strain values exhibit strong anisotropy, depending upon whether the sample is in compression or tension during bending.

Zhang, Baozhuo↗
DOE OSTI2019

Probing the Irradiation Defects in Enhanced 2G High Temperature Superconducting Wire

In this paper, we present a detailed investigation of the atomic and chemistry structures of irradiation defects in AMSC’s second generation (2G) HTS coil wire by using aberration-corrected scanning transmission electron microscopy (AC-STEM) coupled with atomic resolution electron energy loss spectroscopy (EELS). A 1.2μm thick Dy-doped YBCO films was deposited onto Ni(5at%)W RABiTS substrate by metal organic deposition (MOD) process [6]. The ion irradiation was carried out at Brookhaven National Laboratory using the tandem Van de Graaff accelerators with 18-MeV Au 5+ ions to a dose of 2×10 11 Au/cm 2 along the c-axis of YBCO film. Prior to the irradiation, the coil wire sample has a 77 K, self-field Ic of around 385 A/cm-w. In comparison, the value decreased to 320 A/cm-w after irradiation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗