Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “prototyping and performance testing”

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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Purity monitoring for ProtoDUNE

The next-generation neutrino experiment, DUNE, will utilize a high-intensity neutrino beam produced to measure electron-neutrino appearance and muon-neutrino disappearance with its 40 kilotons (fiducial mass) liquid argon far detector. Liquid argon purity is crucial to use liquid argon time projection chambers (LArTPC) in DUNE’s large detectors. A purity monitor is a miniature TPC that measures the lifetime of photoelectrons generated by its UV-illuminated gold photocathode to measure the purity of liquid argon. ProtoDUNEs are full-scale DUNE prototype LArTPCs built at CERNand perform beam tests. The following will discuss the design, implementation, and results of liquid argon purity monitors deployed in ProtoDUNE.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Final Design and Current Status of the Mu2e Crystal Calorimeter

The Mu2e experiment at Fermi National Accelerator Laboratory will search for the CLFV neutrino-less conversion of a negative muon into an electron in the field of an aluminum nucleus. The Mu2e design has been studied to improve the single event sensitivity of four orders of magnitude with respect to the previous experiments and provide an indirect probe for New Physics energy scales up to thousands TeV. Mu2e is composed of a tracker, an electromagnetic calorimeter, and an external veto for cosmic rays. The calorimeter provides a powerful particle identification and an online trigger while operating in a harsh environment. We report on the status of the calorimeter components production, the quality assurance tests, and the tests performed with a reduced-scale prototype.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

High Level Gap Analysis for Accident Tolerant and Advanced Fuels for Storage and Transportation

This initial gap analysis considers proposed accident tolerant fuel (ATF) options currently being irradiated in commercial reactors, since these are most likely for future batch implementation. Also, advanced fuel (AF) options that may be likely for use in advanced reactors are considered. The cladding technologies considered were chromium-coated zirconium-based alloys, FeCrAl, and both monolithic and matrix composite Silicide carbide (SiC). The fuel technologies considered were chromium-doped uranium dioxide fuel, uranium alloys, uranium nitride, and uranium silicide. Numerous national labs, industry, and countries are performing significant testing and modeling on these proposed technologies to establish performance, but at this time none of the prototypes being irradiated have achieved end-of-life (EOL) burnup. There are some testing results after one burnup cycle to verify in-reactor performance, but little data beyond that. As the ATF prototypes acquire more burnup, data will be produced that is relevant to storage and transportation. The DOE:NE Spent Fuel and Waste Science and Technology (SWFST) Storage and Transportation (ST) Control Account will evaluate the performance data as it becomes available for application to the identified gaps for ST.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Development and Performance of RFD Crab Cavity Prototypes for HL-LHC AUP

The US will be contributing to the HL-LHC upgrade at CERN with the fabrication and qualification of RFD crabbing cavities in the framework of the HL-LHC Accelerator Upgrade Project (AUP) managed by Fermilab. AUP received Critical Decision 3 (CD-3) approval by DOE in December 2020 launching the project into the production phase. The electro-magnetic design of the cavity was inherited from the LHC Accelerator Research Program (LARP) but needed to be revised to meet new project requirements and to prevent issues encountered during beam tests performed at CERN in the R&D phase. Two prototype cavities were manufactured in industry and cold tested. Challenges specific to the RFD cavity were the stringent interface tolerances, the pole symmetry, and the higher-order-mode impedance spectrum. Chemical processing and heat treatments were performed initially at FNAL/ANL and are now being transferred to industry for the production phase. HOM dampers are manufactured and validated by JLAB. A summary of cold test results with and without HOM dampers is presented.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Development and Performance of RFD Crab Cavity Prototypes for HL-LHC AUP

The US will be contributing to the HL-LHC upgrade at CERN with the fabrication and qualification of RFD crabbing cavities in the framework of the HL-LHC Accelerator Upgrade Project (AUP) managed by Fermilab. AUP received Critical Decision 3 (CD-3) approval by DOE in December 2020 launching the project into the production phase. The electro-magnetic design of the cavity was inherited from the LHC Accelerator Research Program (LARP) but needed to be revised to meet new project requirements and to prevent issues encountered during beam tests performed at CERN in the R&D phase. Two prototype cavities were manufactured in industry and cold tested. Challenges specific to the RFD cavity were the stringent interface tolerances, the pole symmetry, and the higher-order-mode impedance spectrum. Chemical pro-cessing and heat treatments were performed initially at FNAL/ANL and are now being transferred to industry for the production phase. HOM dampers are manufactured and validated by JLAB. A summary of cold test results with and without HOM dampers is presented.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2021

Fabrication and Preliminary Demonstration of Microwave Resonant Cavity Transducer Performance

We are investigating a microwave cavity-based transducer for in-core high-temperature fluid flow sensing in molten salt cooled reactors (MSCR) and sodium fast reactors (SFR). This sensor is a hollow metallic cylindrical cavity, which can be fabricated from stainless steel, and as such is expected to be resilient to radiation, high temperature and corrosive environment of MSCR and SFR. The principle of sensing consists of making one wall of the cylindrical cavity flexible enough so that dynamic pressure, which is proportional to fluid velocity, will cause membrane deflection. Membrane deflection causes cavity volume change, which leads to a shift in the resonant frequency. We have developed an initial design for proof-of-principle testing of the flow sensor performance in microwave K-band. A cylindrical resonator prototype was fabricated from brass for initial tests in water. The cavity size is matched to the flange of a standard WR-42 waveguide. Microwave field is coupled into the resonant cavity through a subwavelength-size aperture. A test article was developed, consisting of a piping Tee with bulkhead WR-42 microwave waveguide installed in leak-proof design. In the test article, the cylindrical cavity is positioned in the center of the pipe. A microwave waveguide circulator was installed in the setup to suppress microwave reflections at the cavity entrance. Preliminary spectral characterization of cavity spectral response was performed with microwave VNA. Applying mechanical pressure to cavity membrane showed a measurable shift in the microwave resonant frequency. We also investigate mechanical integrity of the flowmeter’s membrane through computer simulations. By calculating the stress on the plate due to deflection and, comparing the stress to the material ultimate tensile strength and yield strength, it can be estimated if the plate will fail. The stress on the plate was calculated with an analytic closed form solution model, and with COMSOL Structural Mechanics Module which does not involve any approximations. Both the analytic model and COMSOL model showed that maximum stresses on the plate, which are at the radial boundary of the plate, are three orders of magnitude smaller than the yield strength and ultimate tensile strength. This indicates that the sensor is at a low risk of mechanical failure.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Feasibility of Power Ramp Testing in the Advanced Test Reactor

For decades, the Halden Boiling Water Reactor (HBWR) in Norway was an international resource for assessing nuclear fuels and materials behavior and its unexpected shutdown in 2018 represented a significant loss in experimental capability for prototypical irradiation testing. In the aftermath of the closure, a study was performed to assess capability gaps related to the Accident Tolerant Fuels (ATF) program. It was concluded that the primary capability gaps left by the closure of the HBWR were the loss of prototypic in-pile Light Water Reactor (LWR) loops that provide operational transient testing and in-pile Loss-of-Coolant Accident (LOCA) testing capabilities. The study also concluded that the Advanced Test Reactor (ATR) and Transient Reactor Test Facility (TREAT) likely have the necessary key capabilities to absorb the breadth of the HBWR mission gaps related to the ATF program, but additional investments in experimental infrastructure were needed. One such investment is the design and installation of additional pressurized water loops in the medium-I positions of the ATR, hereafter referred to as I-Loops, to support power ramp testing and testing in Boiling Water Reactor (BWR) conditions. This paper gives an overview of the planned ATR I-Loops and assesses the feasibility of performing power ramp testing inside such a loop.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2022

Preliminary conceptual design of fast neutron spectrum nuclear thermal rocket cores using monolithic uranium nitride fuel

This paper presents a few nuclear thermal rocket (NTR) reactor core preliminary conceptual designs based on the use of monolithic uranium nitride (UN) fuel plates or pins clad with tungsten (W), alloyed or unalloyed as needed. High-assay low-enriched uranium (HALEU) as well as high-enriched uranium (HEU) are considered. Nominal core thermal powers are between 300 and 1100 MW corresponding to thrusts between 66 kN and 240 kN. The estimated thrust-to-reactor-weight ratios (T/WRx) achievable with the HEU plate and pin configurations are between 3.8 and 10.9. The T/WRx achievable with the HALEU plate and pin configurations are lower, 1.9–4.0, than those achievable with HEU. It is noteworthy that even a relatively modest increase in fuel enrichment above the HALEU limit enables a significant increase in T/WRx. It must be emphasized that these results do not yet account for uncertainties and that the appropriateness of the assumed fuel thermal design limits for normal operation (i.e., peak centerline temperature of 3100 K) will need to be confirmed. Finally, just like for the other UN-based fuels currently considered for NTR applications (i.e., CERMET and CERCER), the proposed UN fuel systems need significant testing in prototypic conditions to confirm the appropriate performance for safe NTR applications. However, the monolithic fuel systems may have, overall, a higher technology readiness level (TRL), and, consequently, shorter fuel development and validation time may result.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Test beam performance of a CBC3-based mini-module for the Phase-2 CMS Outer Tracker before and after neutron irradiation

The Large Hadron Collider (LHC) at CERN will undergo majorupgrades to increase the instantaneous luminosity up to5–7.5×10$^{34}$ cm$^{-2}$s$^{-1}$. This High Luminosityupgrade of the LHC (HL-LHC) will deliver a total of3000–4000 fb$^{-1}$ of proton-proton collisions at acenter-of-mass energy of 13–14 TeV. To cope with thesechallenging environmental conditions, the strip tracker of the CMSexperiment will be upgraded using modules with two closely-spacedsilicon sensors to provide information to include tracking in theLevel-1 trigger selection. This paper describes the performance, ina test beam experiment, of the first prototype module based on thefinal version of the CMS Binary Chip front-end ASIC before and afterthe module was irradiated with neutrons. Results demonstrate thatthe prototype module satisfies the requirements, providing efficienttracking information, after being irradiated with a total fluencecomparable to the one expected through the lifetime of theexperiment.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

A Field Enhancement Integration Design Featuring Misalignment Tolerance for Wireless EV Charging Using LCL Topology

This article proposes a magnetic integration design for EV wireless power transfer (WPT) systems, where the compensation and transmitting coils overlap one on top of the other to share the ferrite layer without any decoupling consideration. The magnetic field generated by both the compensation and transmitting coils are exploited to transfer power. To this end, a compensation method is proposed to enable magnetic field enhancement without any reactive power flow between the compensation and the transmitting coils, and to achieve input zero phase angle and constant current output. In addition, an efficient finite element analysis-based coil optimization algorithm is proposed to improve the coil misalignment tolerance on the horizontal plane, in which a reversely connected inner coil is used to stabilize the system output under misalignment conditions. Analytical and simulation results confirm transmission flux density enhancement and reduced leakage field characteristics of the proposed coil design. Finally, a scaled-down WPT prototype is built and tested to verify the performance and effectiveness of the design. The proposed design achieves 91.17% efficiency and misalignment tolerance up to 200 mm in any XY-direction while maintaining the power transfer and its efficiency. The results of this work provide insights into magnetic integration design of high-order compensation topologies featuring higher compactness, less ferrite usage, magnetic field enhancement, and misalignment tolerance for WPT systems.

42 ENGINEERING↗
DOE OSTI2020

Performance of prototype GE1/1 chambers for the CMS muon spectrometer upgrade

The high-luminosity phase of the Large Hadron Collider (HL-LHC) will result in ten times higher particle background than measured during the first phase of LHC operation. In order to fully exploit the highly-demanding operating conditions during HL-LHC, the Compact Muon Solenoid (CMS) Collaboration will use Gas Electron Multiplier (GEM) detector technology. The technology will be integrated into the innermost region of the forward muon spectrometer of CMS as an additional muon station called GE1/1. The primary purpose of this auxiliary station is to help in muon reconstruction and to control level-1 muon trigger rates in the pseudo-rapidity region 1.6 ≤ |η| ≤ 2.2. The new station will contain trapezoidal-shaped GEM detectors called GE1/1 chambers. The design of these chambers is finalized, and the installation is in progress during the Long Shutdown phase two (LS-2) that started in 2019. Several full-size prototypes were built and operated successfully in various test beams at CERN. Here, we describe performance measurements such as gain, efficiency, and time resolution of these prototype chambers, developed after years of R&D, and summarize their behavior in different gas compositions as a function of the applied voltage.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Prototype SSR2 Tuner Procurement and Testing at IJCLab for PIP-II Project

IJCLab is involved in the PIP-II project on the design and development of accelerator components for the SSR2 (Single Spoke Resonator type 2) section of the superconducting linac. Five prototype tuners have been built and are being tested at IJCLab. After a short description of the tuner, this paper reports on the procurement strategy and the performance observed at both room and low temperatures in vertical cryostat test with SSR2 prototype cavities. This paper will also share results on accelerated lifetime tests performed in a dedicated nitrogen-cooled cryostat.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

The DAQ system of the 12,000 channel CMS high granularity calorimeter prototype

The CMS experiment at the CERN LHC will be upgraded to accommodate the 5-fold increase in the instantaneous luminosity expected at the High-Luminosity LHC (HL-LHC). Concomitant with this increase will be an increase in the number of interactions in each bunch crossing and a significant increase in the total ionising dose and fluence. One part of this upgrade is the replacement of the current endcap calorimeters with a high granularity sampling calorimeter equipped with silicon sensors, designed to manage the high collision rates. As part of the development of this calorimeter, a series of beam tests have been conducted with different sampling configurations using prototype segmented silicon detectors. In the most recent of these tests, conducted in late 2018 at the CERN SPS, the performance of a prototype calorimeter equipped with ≈12,000 channels of silicon sensors was studied with beams of high-energy electrons, pions and muons. This paper describes the custom-built scalable data acquisition system that was built with readily available FPGA mezzanines and low-cost Raspberry Pi computers.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Bench testing of an early prototype pitch resonator WEC

This report describes a series of tests performed on a "pitch resonator'" concept for a wave energy converter. The overall testing campaign goals centered on risk reduction for the pitch resonator wave energy converter concept and model validation. Two modes of testing are captured in this report: one using a single degree of freedom test rig and one in which a six degree of freedom Stewart platform was employed.

16 TIDAL AND WAVE POWER↗
DOE OSTI2022

A compact design for an electric driven hydraulic gear machine capable of multiple quadrant operation

This paper presents an innovative design of an integrated electro-hydraulic (EH) flow generation unit able to operate in multiple quadrants. The proposed unit is composed of a hydraulic machine which can operate in either pumping or motoring mode, and an electric machine, which can operate as electric motor or generator. The adopted morphological integration of the two unit fulfills the goals of maximizing compactness, power to weight ratio, energy efficiency and quietness. Furthermore, the design results from a numerical optimization procedure that includes detailed simulation of both the electric machine and the hydraulic machine, using simulation tools previously developed by the authors, but combined for the first time in this work. After describing the optimization procedure, the paper focuses on the design integration aspects of the novel unit. A 9 kW prototype of the integrated unit was also fabricated and tested to verify its performance. Tests results show a measured overall energy efficiency up to 69%, demonstrating the potentials of the proposed concept, despite some limitations present in the first prototypes which could be addressed in future design refinements.

42 ENGINEERING↗
DOE OSTI2021

Destructive Examination of a FeCrAl-UO 2 Irradiation Test

Several destructive postirradiation examinations were performed on an irradiation specimen that coupled an early iron-chromium-aluminum (FeCrAl) candidate alloy cladding with UO2 pellets. This irradiation test was designed to investigate the early life performance and compatibility of the FeCrAl-UO 2 cladding-fuel system under prototypic light water reactor neutronic conditions. Additionally, these tests were expected to provide neutron irradiated samples for severe accident testing of this fuel system. The irradiation studied in this work was part of the ATF-1 series of drop-in style irradiations performed in the Idaho National Laboratory Advanced Test Reactor. The rodlet studied in this work is one of three similar rodlets irradiated in ATF-1 that had approximately 7.6 cm of cladding machined from a wrought FeCrAl alloy and fueled with a 6.1 cm stack of UO 2 pellets. The outer diameter of the cladding was ~0.94 cm and the inner diameter was ~0.83 cm. After irradiation and non-destructive examination in Idaho this rodlet was shipped to the Oak Ridge National Laboratory hot-cells for further examination. The irradiated rodlet was sectioned into several samples for microstructural, micromechanical, and severe accident testing. During sectioning, it was noted that the fuel was not firmly bonded to the cladding and could be readily removed from small cladding slices. Microstructural characterization of fuel cross sections also revealed no significant interaction between the fuel and the cladding. Samples were also prepared for microhardness testing. To prepare for high temperature oxidation testing, the fuel was dissolved from segments of the cladding. High temperature oxidation testing of cladding segments was performed at 1200°C and 1300°C in a steam environment. Comparisons between the oxidation of this FeCrAl alloy in its neutron irradiated state, as-fabricated state, and the oxidation of Zircaloy-2 are made. The oxidation testing will be followed by ring compression testing to evaluate ductility. The microstructure of the samples after oxidation and ring compression testing will also be analyzed.

Harp, Jason↗
DOE OSTI2024

Boiling-Water Reactor Testing Capability in the Advanced Test Reactor

I-Loop is an irradiation facility that is currently being installed at the Advanced Test Reactor. It is a two-loop test facility capable of performing Light Water Reactor (LWR) irradiations in prototypic coolant conditions. The two loops are being installed to be capable of both Boiling Water Reactor (BWR) and Pressurized Water Reactor (PWR) pressure, temperature, and chemistry environments. Each loop is nominally dedicated as a BWR or PWR for simplicity of operations. In-reactor water loop testing that an I-Loop provides is key to the deployment of new accident tolerant fuel technologies and other advanced LWR fuel concepts. Currently, pressurized water loops are the only testing facilities available to test BWR fuel concepts. Their test environments are non-prototypic at higher pressure/temperature and at single-phase fluid flow conditions. This void in the LWR test bed capabilities is one that the I-Loop is uniquely situated to provide. This report discusses the mechanical design, thermal hydraulic calculations, and neutronic calculations of a proposed standard experiment of accident tolerant BWR fuel concepts. Mechanical design examines the geometry and features of the main components. Thermal hydraulic calculations examine the modeling and results of the two-phase flow options available. Lastly, neutronic calculations examine the Monte Carlo analysis of enrichment, heat rates, and flux spectrum.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Micro-Environmental Control System (Final Report)

This project developed an innovative micro-environmental control system (µX) that enables office buildings to reduce energy used for heating and cooling by 15% or more. The µX is a compact, quiet, and ergonomic device that is designed to be installed under an office workstation; it is designed to maintain occupant comfort when room thermostat setpoints are incremented by 4°F or more (warmer in the summer and cooler in the winter) to save energy. When ambient room temperatures are outside of the usual comfort range, the µX maintains occupant comfort by delivering personalized cooling or heating locally to each office worker. The µX provides personalized cooling using a micro vapor compression system that includes a new high-performance micro-scroll compressor and a novel thermal storage unit. The vapor compression system operates at night to freeze a phase-change material (PCM). During the workday, the cooling stored in the PCM is released as a cool breeze of air to make occupants more comfortable. The micro-scroll compressor was developed specifically for this application; it is smaller than any of its type, minimizing the amount of power needed. In heating mode, the µX maintains occupant comfort using a foot heating mat with an infrared reflective box. The µX R&D project was conducted by Syracuse University in collaboration with United Technologies Research Center, Air Innovations, Bush Technical, and Cornell University. Over the course of the initial three-year project, the team developed and evaluated four versions of the unit, advancing the concept to Technology Readiness Level 6. The capabilities of individual proof-of-concept prototypes were verified in tests that were conducted with: 1) units in psychrometric chambers, 2) an instrumented manikin in a laboratory, and 3) human subjects in laboratories that simulate office environments. The tests verified that the µX prototypes met or exceeded all performance targets required to enable office buildings to reduce energy used for heating and cooling by 15% or more by maintaining occupant comfort when thermostat setpoints are incremented by 4°F or more.

25 ENERGY STORAGE↗