Special Session on Cutting Edge Approaches in Data Analytics for Nonproliferation.
Abstract not provided.
Anderson, Dylan↗
SEARCH · Engineering Papers
Results for “CUTTING”
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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Cross-Cutting Capability in MOOSE for Advanced Reactor Simulation
This presentation highlights NEAMS multiphysics work conducted by the MOOSE team in fiscal year 2022.
97 MATHEMATICS AND COMPUTING↗
A Stress Constrained Level Set Topology Optimization Method with the Cut Finite Element Method
Explore the source record for details and available documents.
Mathematics and Computing↗
TOWARD A NEW APPROACH FOR VITAL AREA IDENTIFICATION FOR CUTTING-EDGE NUCLEAR FACILITIES
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Williams, Adam David↗
Core-Cutoff Tool
A tool makes a cut perpendicular to the cylindrical axis of a core hole at a predetermined depth to free the core at that depth. The tool does not damage the surrounding material from which the core was cut, and it operates within the core-hole kerf. Coring usually begins with use of a hole saw or a hollow cylindrical abrasive cutting tool to make an annular hole that leaves the core (sometimes called the plug ) in place. In this approach to coring as practiced heretofore, the core is removed forcibly in a manner chosen to shear the core, preferably at or near the greatest depth of the core hole. Unfortunately, such forcible removal often damages both the core and the surrounding material (see Figure 1). In an alternative prior approach, especially applicable to toxic or fragile material, a core is formed and freed by means of milling operations that generate much material waste. In contrast, the present tool eliminates the damage associated with the hole-saw approach and reduces the extent of milling operations (and, hence, reduces the waste) associated with the milling approach. The present tool (see Figure 2) includes an inner sleeve and an outer sleeve and resembles the hollow cylindrical tool used to cut the core hole. The sleeves are thin enough that this tool fits within the kerf of the core hole. The inner sleeve is attached to a shaft that, in turn, can be attached to a drill motor or handle for turning the tool. This tool also includes a cutting wire attached to the distal ends of both sleeves. The cutting wire is long enough that with sufficient relative rotation of the inner and outer sleeves, the wire can cut all the way to the center of the core. The tool is inserted in the kerf until its distal end is seated at the full depth. The inner sleeve is then turned. During turning, frictional drag on the outer core pulls the cutting wire into contact with the core. The cutting force of the wire against the core increases with the tension in the wire and, hence, with the frictional drag acting on the outer sleeve. As the wire cuts toward the center of the core, the inner sleeve rotates farther with respect to the outer sleeve. Once the wire has cut to the center of the core, the tool and the core can be removed from the hole. The proper choice of cutting wire depends on the properties of the core material. For a sufficiently soft core material, a nonmetallic monofilament can be used. For a rubber-like core material, a metal wire can be used. For a harder core material, it is necessary to use an abrasive wire, and the efficiency of the tool can be increased greatly by vacuuming away the particles generated during cutting. For a core material that can readily be melted or otherwise cut by use of heat, it could be preferable to use an electrically heated cutting wire. In such a case, electric current can be supplied to the cutting wire, from an electrically isolated source, via rotating contact rings mounted on the sleeves.
Gheen, Darrell↗
TRIDENT Drill Validation at Mars and Lunar Analog Field Sites
Drilling on Earth is typically a human-intensive activity. Drilling on other planets is further complicated by the lack of prior local field surveys of their target area, hence blindly drilling into uncertain target rocks. Field conditions on the Moon or Mars are also different than for shallow drilling on Earth: lower temperatures and pressures, less power available, low masses (hence less weight-on-bit). Given the cost of transport from Earth, no drilling muds or working fluids are likely to be available to carry away cuttings. And impact-gardened regolith and dust vary mechanically and texturally from most terrestrial soils. The Regolith and Ice Drill for Exploration of New Terrains (TRIDENT) is a rotary-percussive 1m-class drill from Honeybee Robotics. It is low-power (rotary and percussive actuators are 200 W each) and lightweight (<20 kg) with the maximum weight on bit limited to 200 N. TRIDENT has been manifested for the Volatiles Investigating Polar Exploration Rover (VIPER) and PRIME-1 lunar south pole missions in 2024, has previously been field tested at a hot, dry analog site in the Atacama Desert, and in lunar conditions in thermal vacuum chamber tests. TRIDENT was also part of the 2019 Icebreaker Mars Discovery proposal, as well as in the Mars Life Explorer concept. During ARADS tests, drill control and fault recovery automation software enabled hands-off operations of a rover-mounted TRIDENT drill. TRIDENT Drill Analog Site Validation: Past TRIDENT tests in thermal vacuum (TVAC) chambers targeted containers of manufactured lunar simulants with added volatiles. 2022 TRIDENT ambient testing at NASA Ames drilled into cemented lunar simulant materials. Low cuttings-permeability led to cuttings buildup, and drill choking and binding was observed. The Atacama analog site in ARADS had desiccated unconsolidated sediments that did not challenge the TRIDENT design. However, lunar polar regolith is expected to be diverse and heterogeneous with varying clast sizes, with abundant impactites and perhaps subsurface ice deposits. Neither the simulants nor Atacama testing had completely covered the TRIDENT-targeted field characteristics, motivating further analog tests prior to the planned lunar missions. To gain more insight into the behavior of the TRIDENT hardware in diverse impactites and subsurface ice, and to verify the software automation in that environment, in August 2023 TRIDENT was brought to Haughton Crater, a field analog site in the Canadian Arctic. In September 2023 the same drill was brought to the Bishop Tuff in southern California to verify whether drilling binding behaviors previously seen in lunar simulant testing would be observed in naturally occurring fine-grained massive layers. The ~22 Ma Haughton Crater impact structure is located at 75 ̊22’ N, 89 ̊41’ W, on northwestern Devon Island, Nunavut, Canada. Numerous deposits of pale-grey crater-fill polymictic impact-melt breccia are found within the crater with a typical thickness reaching ~125 m or greater and covering ~60 km -2 . An approximately 600m-thick permafrost layer is also present with ice typically found within 0.5-0.6m of the surface. The volcanic tableland north of Bishop, CA exposes densely welded tuff laid down during the eruption that created the Long Valley Caldera at approximately 0.76 Ma. Extensional faults and the Owens River gorge expose cross-sections across the plateau. The area is viewed as an analog site for Mars features believed to be of pyroclastic origin. Results: Haughton Crater.Drilling tests were conducted 8-13 August 2023 at a previously undisturbed area separated 5-10 m from past years’ Drill Hill test sites (75.4208, -089.7613). In six days, TRIDENT drilled 8 holes to nearly 1 m depth each, totaling 7.80 m. The active layer/ice boundary was at ~67 cm depth, with a total of approximately 2.4 m drilled into ice or ice-cemented impact breccia. During drilling, five drill fault states were observed and successfully recovered. Holes 23-1, 4 and 7 were drilled under manual control, using Honeybee’s Thorax user interface. Holes 23-5, 6, and 8 were drilled with the Ames IBexec automated drilling control software. TRIDENT was observed to have little difficulty in the thawed uncemented impact breccia above the active layer boundary, but required percussion to make slower headway in the ice-cemented breccia. In Hole 23-7 (Fig.1), drilling slowed down in a massive unit just above the active-layer boundary (perhaps a large rock extending into the ice-cementation?), with only 7cm progress made in 27 minutes of high auger torque and constant percussion, leading to a choking fault and then a binding fault. A similar pattern had been observed in TRIDENT Rio Tinto test data from 2017 [6] as well as in the 2022laboratory tests.Bishop Tuff.A team from NASA Ames and the US Geological Survey deployed the same TRIDENT drill to Bishop Sites 1B and 1C (37.4203, -118.4289; 37.4265, -118.4215) on 13-16 September 2023, on the Bishop Tuff plateau. A third drill site was used 17-18 September 2023(37.4598, -118.3667) in an abandoned pumice mine. Four holes (totaling 2.5m depth) were drilled into the fine-grained, meters-thick tuff units at Sites 1B and 1C, and a further two boreholes (totaling 1.98m depth) were made at the pumice site. Drill behavior in the tuff below 10 cm depth was similar to that seen at 65-74 cm depth in Haughton Hole 23-7 (Fig. 1) and that seen in the 2022 lab simulant drilling. Drill safety torque limits were exceeded multiple times resulting in drill stops downhole. These freezes then required external added torques (with a pipe wrench) to resume rotation, to unstick the drill for withdrawal. To prevent this choking and binding behavior we found that more-frequent cuttings removal was necessary, e.g., reducing the “drill bite” size from the nominal 10 cm to 2 cm per bite --bringing the auger up to the surface more frequently, as seen in Bishop Site 1C Hole 2 (Fig.2). This permitted slow progress without drill binding and without external interventions. Conversely, TRIDENT drilling in the more porous pumice target material showed no cuttings buildup issue, and single bites as large as 40 cm were demonstrated. Discussion: We observed that TRIDENT easily penetrated unconsolidated heterogeneous soils (both above the active layer boundary at Haughton and previously in the Atacama). Cemented or consolidated targets that were cuttings-permeable (icy impact breccia, pumice) required more energy applied and percussion. However, in non-cuttings-permeable targets (welded microporous tuff, cemented simulants, boulder) TRIDENT was observed to be prone to excessive cuttings accumulation leading to choking/binding faults and stalling. The wedge cutting bit, used by TRIDENT in field tests and in its flight versions, pulverizes the target rock and creates fine cuttings that ideally are transported up the auger spirals for removal. In porous, fractured or vesicular target materials (such as at the Bishop pumice site) a significant portion of the cuttings are pushed aside, but for non-fractured, microporous targets the cuttings remain in the borehole and accumulate. Rock powder is relatively incompressible as a working fluid at only 100-200N downward force (TRIDENT limits) and hence eventual drilling progress slows or stops. Our recommended strategy for improving TRIDENT cuttings removal in massive target units with low cuttings-permeability is to reduce TRIDENT bite sizes when encountering these units, from 10cm to as little as 1-2cm, to effectively bail the accumulating cuttings. This approach was demonstrated to reduce choking and allowed slow progress to continue in cuttings-impermeable microporous target units (viz. the Bishop tuff in our September 2023 tests or cemented simulants in 2022 ambient tests).
robotic drilling↗
Decommissioning Experience at Rokkasho; Standing Type Manipulator: A1000S for Dismantling Tasks - 16434
Decommissioning is a technical process which includes various steps and processes from the clean-up of radioactive materials to the progressive demolition of the plant. One of these steps is the cutting of subassemblies, like tanks, pipes or walls in small pieces suitable for the sorting and disposal. Different solutions are offered for this cutting work and can be grouped as following: - Chip forming - sawing, drilling, milling, turning etc. - Shearing - punching, stamping, scissoring. - Abrading - Grinding, lapping, polishing; water-jet. - Heat - flame cutting, plasma cutting, laser cutting. - Electro-Chemical - Etching, Electrical discharge machining (EDM). Each method has its limitations in accuracy, cost, and effect on the material. In 2013, Waelischmiller Engineering won a contract for two remote handling systems dedicated to the dismantling cell at Rokkasho Nuclear Fuel Reprocessing Facility in Japan. For this project, Inconel and other metals needed to be cut. One of the main cutting methods was decided to use of an angle grinder handled by a robotic arm. Because the use of the overhead systems (bridges and cranes) was difficult for this installation, it was determined, that the best alternative was a power manipulator A1000 installed on the floor with a pre-positioning system. The project proceeded to go forward with the adaptation of the standard A1000 with integration of a control system in a Cartesian coordinate frame; resulting in a heavy duty arm; A1000S with 6 degrees of freedom. The heavy duty power arm A1000S was developed and designed for mechanical cutting with an angle grinder, especially for thick and hard material for example stainless steel and Inconel. Cutting a thick material with an angle grinder requires repeatable precise linear motion, in order not to damage the disc. The angle grinder should be handled with a manipulator which can cut in all directions in a linear motion, since the objects which should be cut are usually very large and fixed in any direction For these requirements, the Cartesian control function was added to our standard power manipulator type A1000. In some cases, the decommissioning work includes repeated access routes or fixed access points that the manipulator arm has to pass repeatedly. For example a fixed point where the waste materials are collected, or repeated transport route that the arm has to go along for each step. For this requirement, the A1000S has been equipped with the 'Go To-Mode'. It is a 'teach and playback mode' which has been developed especially for remote operating manipulators. Quick direct teach, quick play function and an intuitive touch-panel layout are some of the features. With the Go To-Mode high working efficiency was achieved. After rigorous testing at Waelischmiller premises; the manipulator was delivered to JNFL in Rokkasho. It was found that the obtained functionality and precision can be applicable not only for the cutting with a disc grinder, but also the laser cutting method, which requires precise trajectory control. This paper will provide: - A project description, - Presentation of solution process, - Technical description of the A1000S, - Future Applications of the robotic Arm A1000S. (authors)
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Impact of specimen preparation method on photovoltaic backsheet degradation during accelerated aging test
In this study, we highlight some important factors in the specimen preparation methods for evaluating photovoltaic backsheet properties after accelerated aging. Two different sequences are considered: Method (I) cut-then-age: cut into 1-cm wide strips and then expose to stress, and Method (II) age-then-cut: expose a larger sheet to stress and then cut into 1-cm widths for mechanical property measurements. We also compare the effect of three cutting methods, (a) tensile specimen punch, (b) paper cutter, and (c) fresh razor blade. Several commercial backsheets were evaluated, with stress exposures including (a) pressure cooker test (PCT), (b) dry ultraviolet (UV) radiation exposure, and (c) UV combined damp heat tests. Fourier transform infrared spectrometer (FTIR) and intrinsic viscosity (IV) were used to analyze the materials on unstressed materials and samples exposed to PCT. The results show that both the cutting method and the time of cutting have an impact on the backsheet mechanical properties. Additionally, under UV exposure, Method II, age-then-cut, generally resulted in a higher average value, with more variation than Method I; however, if the side strips from Method II were excluded, the variation dropped to the same level. This is because the specimens at the sides of the sheet get additional damage from UV light from the exposed sides of the sample. In contrast to UV exposure, PCT specimens prepared by Method II result in lower average values and higher variability. This is attributed to embrittlement through the bulk of the sample where the cutting of embrittled specimens appears to result in more edge defects which can then initiate a break at smaller strains. The data suggest that for UV exposures, the specimens should be cut after aging and the exposed side specimens discarded, and that for PCT exposures, the specimens should be cut before the exposure.
14 SOLAR ENERGY↗
Remote Dismantling and Packaging of the RPV and Thermal Shield at the Obrigheim NPP - 16073
The Obrigheim Nuclear Power Plant (KWO) is located in the Federal State of Baden- Wuerttemberg in Germany and was operated by the EnKK-KWO. The Nuclear Power Plant - a light water pressurized water reactor with 357 MW of electrical power - was operated from 1968 to 2005. In June 2009 the Energiewerke Nord GmbH (EWN) was charged with the dismantling planning and dismantling of the reactor. According to the German nuclear and radiation protection law, several licenses will be required for the realisation of this task. This also applies to the disposal of the waste produced by dismantling, which must finally be stored in the German final repository for low and medium-radioactive waste (underground repository 'Konrad'). In spring 2010 EWN completed all application documents for the dismantling of the reactor pressure vessel (RPV) and the RPV internals and EnKK-KWO delivered them to the responsible Environmental Ministry of Baden-Wuerttemberg. Since then it has been worked intensively on the design, construction and manufacturing of the facilities for dismantling. With a separate notification of amendment, it was applied for the license to install and commission the facilities for the dismantling of the RPV and the RPV internals at the Environmental Ministry of Baden-Wuerttemberg in October 2010. This notification of amendment was confirmed in summer 2012. In September 2011 the work process and test plan and the technical information about the campaign for the removal of the radioactive waste resulting from the RPV with internals, peripheral components and secondary waste with the aim of final disposal in the Federal Repository 'Konrad' was submitted to the Federal Office for Radiation Protection. The evaluation and assessment of the work process and test plan was concluded in August 2013, when it was audited by TUV Nord EnSys without any further measures and indications. On September 10 the work process and test plan was released by the Federal Office for radiation protection. The dismantling of the RPV internals upper core and lower core structure started in September 2013 in the wet cutting area in room 01.106/306 and were finished in October 2014. In the presentation 'Dismantling of the Obrigheim NPP Reactor and Waste Management' held on the WM Symposia in Phoenix, 2014, an overview about the remote cutting and packaging of the upper and lower core structure was given. In today's presentation the subsequent dismantling activities will be outlined and evaluated. The presentation will start with the short description of the basic frame conditions for the nuclear licensing procedure, important procedural principles, and necessary plant-specific conditions. After the remote cutting and packing of the reactor internals of the upper and lower core structure was completed, the wet cutting area 'reactor room 01.106/306' was cleaned and the reactor room rebuilt into a cutting area for peripheral components. After the peripheral components were dismantled, all preconditions were set to lift the RPV from its mounting position and to arrange it in the upper reactor room 01.306. After these activities were completed, the lifting of the RPV was prepared and the cutting area 'Dismantling of the RPV insulation in the reactor room 01.106/306' was set up. To carry out this task, a strand jack unit with connection block was installed on the bridge of the reactor building crane. The opening created by the dismantling of the pool plate was closed with a flap door. The manipulators used for the wet cutting of the RPV internals were also used for the remote dismantling of the RPV insulation and mounted in the cutting area. The remote facilities were handled from a control centre and/or control stand. The air-technical housing which has already been used for the remote dismantling of the RPV internals was designed for the dismantling of the RPV insulation and was extended for this dismantling scope with appropriate ventilation systems. A special feature is the fixation of the RPV insulation at the RPV corpus. The RPV insulation consists of insulation wool, wire mesh and metal-sheet insulation. This 'Sandwich Construction' is detached with a steel corset at the RPV corpus and partly tightened. The insulation of the RPV bottom dome is tightened at the supporting frame. Due to the activation of the material in the core area and the resulting high ambient dose rate the RPV insulation can only be dismantled remotely. Additionally, as asbestos fibers are expected to be found in the insulation the dismantling has to be performed according to the Technical Rules for hazardous substances. The demolition, restoration or maintenance works have to be performed remotely according to the Technical Rules for hazardous substances when the RPV is located in the cutting area. But in case of dismantling of a power reactor no such experience can be found. Beginning with the explanation of the technical, radiological and substantial boundary conditions this presentation will not only impart knowledge about the dismantling of the RPV insulation but also about the remote controlled packaging of the metal sheet insulation and the manual conditioning of the RPV insulation. Subsequently, reports on the remotely controlled cutting and packaging of the RDB are given. Here is particularly interesting that cutting methods have been used and how the activity determination of the segments was carried out. On the basis of the evaluation of the realisation the subsequent dismantling activities will be lined out. In parallel to the dismantling tasks, the waste package documentation for the final repository was issued, checked and confirmed for the containers loaded with parts of the RDB internals. The most important stages are exemplified in this presentation. (authors)
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Control of machining-induced residual stress via tool geometry and process parameter modification
Distortion generated in machined, monolithic, thin-walled aerospace components due to residual stresses leads to significant material and economic waste in the manufacturing industry. Inherent residual stress (IRS) present in stock materials combines with machining-induced residual stress (MIRS) to influence the final machined part distortion. It is hypothesized that MIRS can be controlled, based on the part geometry, through deliberate cutting tool geometry and process parameter modifications to negate the effect of IRS on distortion, consequently resulting in distortion-free parts. A finite element (FE) orthogonal cutting model is developed to study how tool geometry and process parameters influence machining-induced residual stress (MIRS). Orthogonal cutting experiments are performed on Al 7075-T651 samples to measure cutting forces and MIRS. A cutting force dynamometer is used to measure forces during cutting and a novel digital image correlation (DIC) based hole drilling technique is employed to measure the near-surface residual stress (RS) in the cut samples. These data are subsequently utilized to validate the FE prediction model. Various cases of cutting simulations involving different depths of cut, tool tip radii, and rake angles are performed to study their effects on RS. Similar to prior literature, increasing the depth of cut, tool tip radius, or rake angle is found to promote the formation of near-surface tensile stresses. The competing effects of material plowing and temperature are shown to determine the type of RS at the end of the cut. Moreover, a window of variation of RS (up to ± 400 MPa) is estimated within the given range of conditions, allowing for the control of MIRS through tool and process modification.
Mathews, Ritin [ORNL] (ORCID:0000000301440828)↗
E-Area Low Level Waste Generator Inventory Uncertainty Estimation
This report describes the method used to estimate the uncertainty and bias in the low-level waste inventory, as reported by Waste Generators, for waste disposed in the E-Area Low-Level Waste Facility at SRS. The waste cut uncertainty and bias is summed to calculate the current total uncertainty and bias in each disposal unit in the E-Area Low-Level Waste Facility. This information is used to estimate the future uncertainty and bias when all disposal units are closed. For most waste cuts, there are two areas of inventory uncertainty and bias: in the isotopic characterization of the waste stream and in the measurement of total waste cut activity. Waste stream characterization is accomplished through a combination of process knowledge and analytical measurements. This characterization is documented by a technical baseline that describes the relative quantity of each isotope present in the waste stream. The total activity of each individual waste cut is usually measured directly or is calculated through a ratio of activity per weight or activity per volume. The waste cut total activity is multiplied by the waste stream isotopic fraction to calculate the total isotopic activity present in the waste cut. The waste cut uncertainty and bias is calculated by analyzing the uncertainties and biases in the waste stream characterization and waste cut measurements and adding the uncertainties in quadrature and multiplying the reported isotopic activities by the bias factors. The current isotopic inventory, uncertainty, and bias of a disposal unit is the sum of the currently disposed individual waste cut isotopic activities, uncertainties, and biases. The future uncertainty and bias is estimated based on the average “worst-case” (largest) uncertainties and biases of currently closed and operational disposal units. This report details the method, data sources, and calculation techniques used to calculate these values. It also presents some of the difficulties in working with the reported data and gives examples of the calculations and analysis. The software used to carryout the analysis is included and the location of the complete individual analyses is given. After discussion with waste generators, examination of multiple waste characterization documents, and a review of SRS Manual 1S, the reported ELLWF radionuclide activities are clearly conservative and likely represent reasonable upper bounds for the true activities. However, quantifying the bias and uncertainty in each waste cut requires detailed analysis of the documentation for each waste cut measurement and waste stream characterization.
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Landsat near-infrared (NIR) band and ELM-FATES sensitivity to forest disturbances and regrowth in the Central Amazon
Forest disturbance and regrowth are key processes in forest dynamics, but detailed information on these processes is difficult to obtain in remote forests such as the Amazon. We used chronosequences of Landsat satellite imagery (Landsat 5 Thematic Mapper and Landsat 7 Enhanced Thematic Mapper Plus) to determine the sensitivity of surface reflectance from all spectral bands to windthrow, clear-cut, and clear-cut and burned (cut + burn) and their successional pathways of forest regrowth in the Central Amazon. We also assessed whether the forest demography model Functionally Assembled Terrestrial Ecosystem Simulator (FATES) implemented in the Energy Exascale Earth System Model (E3SM) Land Model (ELM), ELM-FATES, accurately represents the changes for windthrow and clear-cut. The results show that all spectral bands from the Landsat satellites were sensitive to the disturbances but after 3 to 6 years only the near-infrared (NIR) band had significant changes associated with the successional pathways of forest regrowth for all the disturbances considered. In general, the NIR values decreased immediately after disturbance, increased to maximum values with the establishment of pioneers and early successional tree species, and then decreased slowly and almost linearly to pre-disturbance conditions with the dynamics of forest succession. Statistical methods predict that NIR values will return to pre-disturbance values in about 39, 36, and 56 years for windthrow, clear-cut, and cut + burn disturbances, respectively. The NIR band captured the observed, and different, successional pathways of forest regrowth after windthrow, clear-cut, and cut + burn. Consistent with inferences from the NIR observations, ELM-FATES predicted higher peaks of biomass and stem density after clear-cuts than after windthrows. ELM-FATES also predicted recovery of forest structure and canopy coverage back to pre-disturbance conditions in 38 years after windthrows and 41 years after clear-cut. The similarity of ELM-FATES predictions of regrowth patterns after windthrow and clear-cut to those of the NIR results suggests the NIR band can be used to benchmark forest regrowth in ecosystem models. Our results show the potential of Landsat imagery data for mapping forest regrowth from different types of disturbances, benchmarking, and the improvement of forest regrowth models.
54 ENVIRONMENTAL SCIENCES↗
Dividing the Concentrator Target From the Genesis Mission
The Genesis spacecraft, launched in 2001, traveled to a Lagrangian point between the Earth and Sun to collect particles from the solar wind and return them to Earth. However, during the return of the spacecraft in 2004, the parachute failed to open during descent, and the Genesis spacecraft crashed into the Utah desert. Many of the solar wind collectors were broken into smaller pieces, and the field team rapidly collected the capsule and collector pieces for later assessment. On each of the next few days, the team discovered that various collectors had survived intact, including three of four concentrator targets. Within a month, the team had imaged more than 10,000 fragments and packed them for transport to the Astromaterials Acquisition and Curation Office within the ARES Directorate at JSC. Currently, the Genesis samples are curated along with the other extraterrestrial sample collections within ARES. Although they were broken and dirty, the Genesis solar wind collectors still offered the science community the opportunity to better understand our Sun and the solar system as a whole. One of the more highly prized concentrator collectors survived the crash almost completely intact. The Genesis Concentrator was designed to concentrate the solar wind by a factor of at least 20 so that solar oxygen and nitrogen isotopes could be measured. One of these materials was the Diamond-on-Silicon (DoS) concentrator target. Unfortunately, the DoS concentrator broke on impact. Nevertheless, the scientific value of the DoS concentrator target was high. The Genesis Allocation Committee received a request for approximately 1 cm(sup 2) of the DoS specimen taken near the focal point of the concentrator for the analysis of solar wind nitrogen isotopes. The largest fragment, Genesis sample 60000, was designated for this allocation and needed to be precisely cut. The requirement was to subdivide the designated sample in a manner that prevented contamination of the sample and minimized the risk of losing or breaking the precious requested sample fragment. The Genesis curator determined that the use of laser scribing techniques to "cut" a precise line and subsequently cleave the sample (in a controlled break of the sample along that line) was the best method for accomplishing the sample subdivision. However, there were risks, including excess heating of the sample, that could cause some of the implanted solar wind to be lost via thermal diffusion. Accidentally breaking the sample during the handling and cleaving process was an additional risk. Early in fiscal year 2013, to address this delicate, complicated task, the ARES Directorate assembled its top scientists to develop a cutting plan that would ensure success when applied to the actual concentrator target wafer; i.e., to produce an approximately 1 cm(sup 2) piece from the requested area of the wafer. The team, subsequently referred to as the JSC Genesis Tiger Team, spent months researching and testing parameters and techniques related to scribing, cleaving, transporting, handling, and holding (i.e., mounting) the specimen. The investigation required considerable "thinking outside the box," and many, many trials using nonflight wafer analogs. After all preliminary testing, the following method was adopted as the final cutting plan. It was used in two final end-to-end practice runs before being used on the actual flight target wafer. The wafer was oriented on the laser cutting stage with the 100 and 010 directions of the wafer parallel to the corresponding X and Y directions of the cutting stage. The laser was programed to scribe 31 lines of the appropriate length along the Y stage direction. The programed scribe lines were separated by 5 micron in the X direction. The laser parameters were set as follows: (1) The laser power was 0.5 watts; (2) each line consisted of 50 passes, with the Z position being advanced 5 micron per pass; and (3) 30 s would elapse before the next line was scribed to allow for wafer cool down from any possible heating via the laser. The ablated material that "stuck" in the "scribe-cut" was removed from the "cut" using an ultrasonic micro-tool. After all the ablated silicon was removed from the wafer, the wafer was repositioned in exactly the same orientation on the laser stage. The laser was focused using the bottom of the wafer channel, and the 31-line scribing pattern described above was reprogrammed using the Z position of the groove bottom as the starting Z value instead of the top wafer surface, which was used previously. Upon completion of the second set of scribes, the ultrasonic micro-tool was again used to clean out the cut. The wafer was remounted on the stage in exactly the same orientation as before. The laser was again focused on the bottom of the groove. This time, however, the laser was.programed to scribe only one line down the exact center of the channel. The final scribe line consisted of 100 passes with a Z advance of 5 micron per pass and with the laser power set at 0.5 watts. As mentioned above, the final cutting plan was practiced in two end-to-end trials using non-flight, triangular-shaped silicon wafers similar in size and orientation to the actual DOS 60000 target sample. The actual scribing of the triangular-shaped wafers required scribing two lines and cleaving (i.e. scribe-cleave, then scribe-cleave) to obtain the piece requested for allocation. Early in December 2012, after many months of experiments and practicing and perfecting the techniques and procedures, the team successfully subdivided the Genesis DoS 60000 target sample, one of the most scientifically important samples from the Genesis mission (figure 2). On December 17, 2012, the allocated piece of concentrator target sample was delivered to the requesting principal investigator.The cutting plan developed for the subdivision of this sample will be used as the model for subdividing future requested Genesis flight wafers (appropriately modified for different wafer types).
Lauer, H. V., Jr.↗
An integrated equipment for massive segmentation and packaging of control Rod Guide Tubes - 15161
Over time, some utilities have decided to undergo safety upgrades that include replacement of some ageing components like control rod guide tubes (GT's). GT's are safety related components because they control the path of the control rods into and out of the core. These components are usually stored underwater in interim storage pools to decay their radioactivity. When the interim storage facility reaches saturation, treatment and final disposal of the retired Guide Tubes needs to be performed. Based on more than 30 years of experience and lessons learned in the development of segmentation and packaging technologies for nuclear components, Westinghouse has designed, commissioned and will operate a dedicated system for cutting and packaging retired GT's from 900 MW plants, currently stored in a EDF maintenance facility located in the south of France. The first main technical challenge was the waste volume optimization. Two separate waste streams had to be considered for coping with the highly irradiated portion of the GT's (lower part) and the very low level waste sections (upper part). The segmentation plan has been designed to minimize the waste volume of the highly irradiated waste and therefore develop a process which could be adapted to the container size specified by EDF. Metallic baskets have been designed to optimize the packaging and storage density in the containers. All cutting techniques previously used by Westinghouse in similar applications were assessed and underwater mechanical cutting with a band saw was selected as the preferred method. A turning stand positions the GT in front of the band saw. When the cut is completed, the remnant GT is inserted into the next turning stand for the next cut. Each cell of the turning stand positions the GT at the pre-defined cutting height. An integrated water filtration system is used to ensure good visibility during the cutting operations and to minimize water volume and limit the final liquid effluents. The whole process of GT insertion, cutting, packaging and waste conditioning is carried out in a hot cell and controlled remotely. The operator can therefore follow the packaging plan accurately and safely by using a four axis pick and place unit, while keeping personal radiation exposure low. This innovative process allows cutting and packaging large quantities of GT's in a safe and efficient manner. The pilot project covers the segmentation of 93 GT's but it can be further used for cutting larger quantities of retired GT's resulting from the upcoming GT replacement campaigns. (authors)
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Complementary Measurements of Residual Stresses Before and After Base Plate Removal in an Intricate Additively-Manufactured Stainless-Steel Valve Housing
Residual stress measurements using neutron diffraction and the contour method were performed on a valve housing made from 316 L stainless steel powder with intricate three-dimensional internal features using laser powder-bed fusion additive manufacturing. The measurements captured the evolution of the residual stress fields from a state where the valve housing was attached to the base plate to a state where the housing was cut free from the base plate. Making use of this cut, thus making it a non-destructive measurement in this application, the contour method mapped the residual stress component normal to the cut plane (this stress field is completely relieved by cutting) over the whole cut plane, as well as the change in all stresses in the entire housing due to the cut. The non-destructive nature of the neutron diffraction measurements enabled measurements of residual stress at various points in the build prior to cutting and again after cutting. Good agreement was observed between the two measurement techniques, which showed large, tensile build-direction residual stresses in the outer regions of the housing. The contour results showed large changes in multiple stress components upon removal of the build from the base plate in two distinct regions: near the plane where the build was cut free from the base plate and near the internal features that act as stress concentrators. These observations should be useful in understanding the driving mechanisms for builds cracking near the base plate and to identify regions of concern for structural integrity. Neutron diffraction measurements were also used to show the shear stresses near the base plate were significantly lower than normal stresses, an important assumption for the contour method because of the asymmetric cut.
36 MATERIALS SCIENCE↗
Developing Lathing Parameters for PBX 9501
This thesis presents the work performed on lathing PBX 9501 to gather and analyze cutting force and temperature data during the machining process. This data will be used to decrease federal-regulation-constrained machining time of the high explosive PBX 9501. The effects of machining parameters depth of cut, surface feet per minute, and inches per revolution on cutting force and cutting interface were evaluated. Cutting tools of tip radius 0.005 -inches and 0.05 -inches were tested to determine what effect the tool shape had on the machining process as well. A consistently repeatable relationship of temperature to changing depth of cut and surface feet per minute is found, while only a weak dependence was found to changing inches per revolution. Results also show the relation of cutting force to depth of cut and inches per revolution, while weak dependence on SFM is found. Conclusions suggest rapid, shallow cuts optimize machining time for a billet of PBX 9501, while minimizing temperature increase and cutting force.
42 ENGINEERING↗
The design of a mechanical referencing system for the rear drum of the Longwall Shearer Coal Miner
The design of two systems which reference the position of a longwall shearer coal miner to the mine roof of the present cut and of the last cut are presented. This system is part of an automation system that will guide the rear cutting drum in such a manner that the total depth of cut remains constant even though the front drum may be following an undulating roof profile. The rear drum referencing mechanism continually monitors the distance from the mine roof to the floor for the present cut. This system provides a signal to control a constant depth of cut. The last cut follower mechanism continually monitors the distance from the mine roof of the prior cut to the cutting drum. This latter system provides a signal to minimize the step height in the roof between cuts. The dynamic response of this hydraulic-pneumatic and mechanical system is analyzed to determine accumulator size and precharge pressure.
Jones, E. W.↗
An Assessment of Molten Metal Detachment Hazards During Electron Beam Welding in the Space Shuttle Bay at LEO for the International Space Welding Experiment
In 1997, the United States [NASA] and the Paton Electric Welding Institute are scheduled to cooperate in a flight demonstration on the U.S. Space Shuttle to demonstrate the feasibility of welding in space for a possible repair option for the International Space Station Alpha. This endeavor, known as the International Space Welding Experiment (ISWE), will involve astronauts performing various welding exercises such as brazing, cutting, welding, and coating using an electron beam space welding system that was developed by the E.O. Paton Electric Welding Institute (PWI), Kiev Ukraine. This electron beam welding system known as the "Universal Weld System" consists of hand tools capable of brazing, cutting, autogeneous welding, and coating using an 8 kV (8000 volts) electron beam. The electron beam hand tools have also been developed by the Paton Welding Institute with greater capabilities than the original hand tool, including filler wire feeding, to be used with the Universal Weld System on the U.S. Space Shuttle Bay as part of ISWE. The hand tool(s) known as the Ukrainian Universal Hand [Electron Beam Welding] Tool (UHT) will be utilized for the ISWE Space Shuttle flight welding exercises to perform welding on various metal alloy samples. A total of 61 metal alloy samples, which include 304 stainless steel, Ti-6AI-4V, 2219 aluminum, and 5456 aluminum alloys, have been provided by NASA for the ISWE electron beam welding exercises using the UHT. These samples were chosen to replicate both the U.S. and Russian module materials. The ISWE requires extravehicular activity (EVA) of two astronauts to perform the space shuttle electron beam welding operations of the 61 alloy samples. This study was undertaken to determine if a hazard could exist with ISWE during the electron beam welding exercises in the Space Shuttle Bay using the Ukrainian Universal Weld System with the UHT. The safety issue has been raised with regard to molten metal detachments as a result of several possible causes such as welder procedural error, externally applied impulsive forces(s), filler wire entrainment and snap-out, cutting expulsion, and puddle expulsion. Molten metal detachment from either the weld/cut substrate or weld wire could present harm to a astronaut in the space environment it the detachment was ti burn through the fabric of the astronaut Extravehicular Mobility Unit (EMC). In this paper an experimental test was performed in a 4 ft. x 4 ft. vacuum chamber at MSFC enabling protective garment to be exposed to the molten metal drop detachments to over 12 inches. The chamber was evacuated to vacuum levels of at least 1 x 10(exp -5) torr (50 micro-torr) during operation of the 1.0 kW Universal Hand Tool (UHT). The UHT was manually operated at the power mode appropriate for each material and thickness. The space suit protective welding garment, made of Teflon fabric (10 oz. per yard) with a plain weave, was placed on the floor of the vacuum chamber to catch the molten metal drop detachments. A pendulum release mechanism consisting of four hammers, each weighing approximately 3.65 lbs, was used to apply an impact forces to the weld sample/plate during both the electron beam welding and cutting exercises. Measurements were made of the horizontal fling distances of the detached molten metal drops. The volume of a molten metal drop can also be estimated from the size of the cut. Utilizing equations, calculations were made to determine chande in surafec area (Delat a(surface)) for 304 stainless steel for cutting based on measurements of metal drop sizes at the cut edges. For the cut sample of 304 stainless steel based on measurement of the drop size at the edge, Delta-a(surface) was determined to be 0.0054 2 in . Calculations have indicated only a small amount of energy is required to detach a liquid metal drop. For example, approximately only 0.000005 ft-lb of energy is necessary to detach a liquid metal steel drop based on the above theoretical analysis. However, some of the energy will be absorbed by the plate before it reaches the metal drop. Based on the theoretical calculations, it was determined that during a weld cutting exercise, the titanium alloy would be the most difficult to detach molten metal droplets followed by stainless steel and then by aluminum. The results of the experimental effort have shown that molten metal will detach if large enough of a hammer blow is applied to the weld sample plate during the full penetration welding and cutting exercises. However, no molten metal detachments occurred as a result of the filler wire snap-out tests from the weld puddle since it was too difficult to cause the metal to flick-out from the pool. Molten metal detachments, though not large in size, did result from the direct application of the electron beam on the end of the filler weld wire.
Fragomeni, James M.↗