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.

SourceResearch connectionFrom yearThrough year

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

At least 775 records · Page 43

All sources NASA NTRS DOE OSTI

DOE OSTI2021

Test of Superconducting Wires and Rutherford Cables With High Specific Heat

High-field accelerator magnets made of state-of-the-art Nb 3 Sn Rutherford cables demonstrate relatively long trainings due to sudden heat depositions originated by thermo-mechanical perturbations in the magnet coils. Coil sensitivity to these perturbations can be reduced by increasing the specific heat, Cp, of major coil components - strands, or whole cable, or epoxy. The R&D on all these three approaches is in progress. This paper studies feasibility of increasing the Cp of Rutherford-type cables by using a thin composite Cu/Gd 2 O 3 tape. The tape can be either wrapped around the cable, placed on the cable wide faces under the insulation, and/or inserted as a core. In this work, Cu/Gd 2 O 3 ribbons with ~30% of Gd 2 O 3 powder and two different thicknesses were produced by Hyper Tech Research, Inc. Wire and cable samples outfitted with these high-Cp ribbons, or tapes, were prepared and tested at FNAL for the Minimum Quench Energy (MQE). At 80%Ic, the MQE gain average over the tested magnetic field range of the NbTi cable with high-Cp tape on both sides was ~1.3. The MQE gain average of the NbTi wire wrapped with the high-Cp ribbon was 3.1.

43 PARTICLE ACCELERATORS↗

DOE OSTI2022

Minimum Quench Energy of Nb 3 Sn Wires With High Specific Heat Tape

A major problem of state-of-the-art Nb3Snaccelerator magnets is their long training due to thermo-mechanical perturbations. Increasing the specific heat, Cp, of the Rutherford cable would reduce and/or eliminate training by limiting the coils temperature rise. This paper studies feasibility of increasing the Cp of Rutherford-type cables by using thin composite Cu/Gd 2 O 3 and Cu/Gd 2 O 2 S tapes produced by HyperTech Research, Inc. The tape can be either wrapped around the cable, placed on the cable wide faces under the insulation, and/or inserted as a core. Wire samples outfitted with these high-Cp ribbons, or tapes, were prepared and tested at FNAL for their Minimum Quench Energy (MQE). At 90%Ic and 15 T, the average gain of MQE of the Nb 3 Sn wire soldered to the Cu/Gd 2 O 2 S 55 μm thick ribbon was 2.5, and further increased at larger transport currents.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2026

Fabrication of 8-Strand Rutherford Cables Using Roped Strands Made from Ultrafine Wires

Conventional Rutherford cables are typically made from solid round wire. While multi-stage cables have been made elsewhere, the purpose was usually to achieve a higher strand count and therefore a higher current carrying capability. In this work, we attempt to use two-stage roped strands made from ultrafine wires to fabricate Rutherford cables. The ultimate goal of this work is to obtain a very flexible cable that can wind accelerator magnet coils with a very tight bend radius in both the “easy way” (along the broad face of the cable) and the “hard way” (along the edge of the cable) in the wind-and-react manner, or wind coils with a radius typically used today but in the react and-wind manner with a much reduced degradation in critical current. We report our experience fabricating such Rutherford cables at the Lawrence Berkeley National Laboratory, and the initial findings from the analysis of the experimental cables made. We will discuss how the conventional wisdom and some rules of thumb for making Rutherford cables are no longer applicable or relevant, and the new thinking required in designing these cables.

Pong, Ian↗

DOE OSTI2017

Pressure Measurements in a Wire-Wrapped 61-Pin Hexagonal Fuel Bundle

To achieve longer-life liquid-metal fast reactor cores, designers are considering to increase the wall gap of the wire-wrapped hexagonal fuel bundles to account for volumetric void swelling and radiation creep. A new wire-wrapped hexagonal test bundle has been constructed, with a wall gap larger than prior experiments, and experimental pressure drop data have been generated under laminar, transition, and turbulent flow regimes (corresponding to Re of 250–19,000), to complement the existing database of small wall gap experimental bundles. The comparison of the experimental data set with the predictions of four existing correlations (Baxi and Dalle Donne, Cheng and Todreas detailed (CTD), Kirillov, and Rehme) showed general agreement between data and the selected correlations. However, the CTD correlation most accurately predicted the experimental trend and the transition between flow regimes. The analysis of the experimental data also revealed that the larger wall gap size caused a lower bundle pressure drop due to the increased bypass flow area.

42 ENGINEERING↗

DOE OSTI2021

IoT Devices and Applications for Wire-Based Hybrid Manufacturing Machine Tools

Hybrid manufacturing machine tools have the potential to be a disruptive technology as they can leverage the benefits of both additive and subtractive manufacturing by incorporating both processes on the same machine while limiting the downsides of the individual processes. Since these machines use two very disparate manufacturing processes and hybrid manufacturing is an emerging technology, it will be useful to monitor data coming from the machine and apply it to improve the manufacturing process, the operation of the machine, and to integrate the machine into the larger digital framework of Industrial Internet of Things (IoT). The present work discusses IoT devices that would be beneficial to add to a hybrid machine tool as well as applications for those devices. The proposed methods discussed in this work have not been experimentally implemented on a hybrid machine tool and so there are no performance data available yet. The hybrid machine tool used as a basis to generate these IoT applications is the Mazak VC-500A/5x AM Hot Wire Deposition, which is a 5-axis machine tool incorporated with a wire feedstock 4kW laser deposition system. Methodologies and applications will be outlined for machine health and process monitoring. Other areas covered include process benchmarking, secure networking options for the proposed IoT framework, and hybrid process improvement. Limitations of these methods and future work for new sensor devices and application areas is also discussed.

Thien, Austen↗

DOE OSTI2015

SU-E-T-786: Utility of Gold Wires to Optimize Intensity Modulation Capacity of a Novel Directional Modulated Brachytherapy Tandem Applicator for Image Guided Cervical Cancer Brachytherapy

Purpose: To evaluate the impact of using gold wires to differentially fill various channels on plan quality compared with conventional T&R applicator, inside a novel directional modulated brachytherapy (DMBT) tandem applicator for cervical cancer brachytherapy. Materials and Methods: The novel DMBT tandem applicator has a 5.4-mm diameter MR-compatible tungsten alloy enclosed in a 0.3-mm thick plastic tubing that wraps around the tandem. To modulate the radiation intensity, 6 symmetric peripheral holes of 1.3-mm diameter are grooved along the tungsten alloy rod. These grooved holes are differentially filled with gold wires to generate various degrees of directional beams. For example, three different fill patterns of 1) all void, 2) all filled except the hole containing the 192-Ir source, and 3) two adjacent holes to the 192-Ir source filled were Monte Carlo simulated. The resulting 3D dose distributions were imported into an in-house-coded inverse optimization planning system to generate HDR brachytherapy clinical plans for 19 patient cases. All plans generated were normalized to the same D90 as the clinical plans and D2cc doses of OARs were evaluated. Prescription ranged between 15 and 17.5Gy. Results: In general, the plans in case 1) resulted in the highest D2cc doses for the OARs with 11.65±2.30Gy, 7.47±3.05Gy, and 9.84±2.48Gy for bladder, rectum, and sigmoid, respectively, although the differences were small. For the case 2), D2cc doses were 11.61±2.29Gy, 7.41±3.07Gy, and 9.75±2.45Gy, respectively. And, for the case 3), D2cc doses were 11.60±2.28Gy, 7.41±3.05Gy, and 9.74±2.45Gy, respectively. Difference between 1) and 2) cases were small with the average D2cc difference of <0.64%. Difference between 1) and 3) cases were even smaller with the average D2cc difference of <0.1%. Conclusions: There is a minimal clinical benefit by differentially filling grooved holes in the novel DMBT tandem applicator for image guided cervical cancer brachytherapy.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2015

Photodetectors on the basis of Ge/Si(001) heterostructures grown by the hot-wire CVD technique

The fabrication of photodetectors for the wavelength range of communications λ = 1.3–1.55 µm on the basis of Ge/Si(001) heterostructures with thick (∼0.5 µm) Ge layers grown by the hot-wire technique at reduced growth temperatures (350°C) is reported. The single-crystal Ga layers are distinguished by a low density of threading dislocations (∼10{sup 5} cm{sup –2}). The photodetectors exhibit a rather high quantum efficiency (∼0.05 at λ = 1.5 µm and 300 K) at moderate reverse saturation current densities (∼10{sup –2} A cm{sup –2}). Thus, it is shown that the hot-wire technique offers promise for the formation of integrated photodetectors for the wavelength range of communications, especially in the case of limitations on the conditions of heat treatments.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Calorimetric wire detector for measurement of atomic hydrogen beams

A calorimetric detector for minimally disruptive measurements of atomic hydrogen beams is described. The calorimeter measures heat released by the recombination of hydrogen atoms into molecules on a thin wire. As a demonstration, the angular distribution of a beam with a peak intensity of ≈ 10 16 atoms/(cm 2 s) is measured by translating the wire across the beam. The data agree well with an analytic model of the beam from the thermal hydrogen atom source. Using the beam shape model, the relative intensity of the beam can be determined to 5% precision or better at any angle.

Astaschov, M. [Johannes Gutenberg Univ., Mainz (Ge↗

DOE OSTI2024

A Co-Registered In-Situ and Ex-Situ Dataset of Electrical, Acoustic, and CT Characteristics from Wire Arc Additive Manufacturing Process

Recent progress in sensing techniques and data analytics tools have significantly accelerated the development of Wire Arc Additive Manufacturing (WAAM) systems. This data centric approach emphasizes leveraging available data throughout the production process to optimize performance. Integration of extensive data analysis provides the opportunity to improve precision, reduce waste, and enhance the quality of produced parts. This method relies on AI/ML models and optimization techniques, which are developed using the data collected from various sources, including in-situ sensors, ex-situ imaging, and manufacturing process parameters. The quality and diversity of this data, along with the alignment between different data streams (achieved through spatiotemporal registration) are critical for the successful development of AI/ML and optimization models. In this work, we present a spatiotemporally registered dataset generated during the WAAM process of deposition of a rectangular block. The dataset includes the comprehensive description of deposition process, process parameters, in-situ collected welding characteristics, acoustic data, and X-Ray Computed Tomography analysis data for the build. Dataset A Co-Registered In-Situ and Ex-Situ Dataset of Electrical, Acoustic, and CT Characteristics from Wire Arc Additive Manufacturing Process has arisen under UT-Battelle, LLC’s Prime Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy (DOE) to manage and operate the Oak Ridge National Laboratory. UT-Battelle, LLC will not assert any rights under United States law or under the Prime Contract it has in the dataset against any user of the dataset, including any copyrights or patent rights. UT-Battelle, LLC requests that attribution to the dataset is provided as academically appropriate.

42 ENGINEERING↗

DOE OSTI2019

First results of the compensation of the beam-beam effect with DC wires in the LHC

The compensation of the long-range beam-beam interactions using DC wires is presently under study as an option for enhancing the machine performance in the framework of the High-Luminosity LHC Project (HL-LHC). The original idea dates back more than 15 years ago. After the installation of four wire prototypes in the LHC in 2018, a successful experimental campaign was performed. The experimental setup and the main results are reported in this paper.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Geant4 Simulations on Faraday Cup Design for PIP-II Laser Wire Scanner System

The Proton Improvement Plan-II (PIP-II) accelerator upgrade at Fermilab represents a groundbreaking leap forward in high-energy physics research. This ambitious initiative involves enhancing Fermilab's accelerator complexby replacing the current linear accelerator (linac) with awarm front end (WFE) capable of accelerating H- beamsup to 2.1 MeV. Subsequently, a superconducting linac further accelerates these beams up to 800 MeV. To preciselymeasure the transverse beam profile, a combination of traditional wire scanners at the WFE section and Laser wirescanners along the superconducting linac are planned forimplementation. This investigation is centered on refiningthe Faraday cup design for the PIP-II Laser wire scannersby utilizing GEANT4, a Monte Carlo simulation toolkit.Leveraging this method enables a comprehensive analysisof particle trajectories, energy deposition, secondary particle emission, backscattering, etc., facilitating optimizationthrough adjustments to cup geometries, materials, andplacement to maximize its efficacy in beam diagnostics.

43 PARTICLE ACCELERATORS↗

DOE OSTI2013

Humidity effects on wire insulation breakdown strength.

Methods for the testing of the dielectric breakdown strength of insulation on metal wires under variable humidity conditions were developed. Two methods, an ASTM method and the twisted pair method, were compared to determine if the twisted pair method could be used for determination of breakdown strength under variable humidity conditions. It was concluded that, although there were small differences in outcomes between the two testing methods, the non-standard method (twisted pair) would be appropriate to use for further testing of the effects of humidity on breakdown performance. The dielectric breakdown strength of 34G copper wire insulated with double layer Poly-Thermaleze/Polyamide-imide insulation was measured using the twisted pair method under a variety of relative humidity (RH) conditions and exposure times. Humidity at 50% RH and below was not found to affect the dielectric breakdown strength. At 80% RH the dielectric breakdown strength was significantly diminished. No effect for exposure time up to 140 hours was observed at 50 or 80%RH.

Appelhans, Leah↗

DOE OSTI2013

Electron Lens as Beam-Beam Wire Compensator in HL-LHC

Current wires are considered for compensation of long-range beam-beam interactions for the High Luminosity upgrade (HL-LHC) of the Large Hadron Collider at CERN. In this note, we demonstrate the advantage of using Electron Lens for this purpose instead of a conventional current-bearing wire.

Valishev, A.↗

DOE OSTI2016

Improving RF Characteristics of Wire: CRADA Final Report

Los Alamos National Laboratory (LANL) and the partner investigated microwave loss characteristics of coated wire made at LANL. The characterization of the coatings was performed using a microwave cavity. The loss characteristics of the coatings was compared to those of bare Cu and Ag wires of the same diameter.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Developing Light Collection Enhancements and Wire Tensioning Methods for LArTPC Neutrino Detectors

Liquid argon Time Projection Chambers (LArTPCs) are becoming widely used as neutrino detectors because of their image-like event reconstruction which enables precision neutrino measurements. They primarily use ionisation charge to reconstruct neutrino events. It has been shown, however, that the scintillation light emitted by liquid argon could be exploited to improve their performance. As the neutrino measurements planned in the near future require large-scale experiments, their construction presents challenges in terms of both charge and light collection. In this dissertation we present solutions developed to improve the performance in both aspects of these detectors. We present a new wire tensioning measurement method that allows a remote measurement of the tension of the large number wires that constitute the TPC anode. We also discuss the development and installation of WLS-compound covered foils for the SBND neutrino detector at Fermilab, which is a technique proposed t o augment light collection in LArTPCs. This included preparing a SBND-like mesh cathode and testing it in the Run III of LArIAT, a test beam detector also located at Fermilab. Finally, we present a study aimed at understanding late scintillation light emitted by recombining positive argon ions using LArIAT data, which could affect large scale surface detectors.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2017

Description of CBETA magnet tuning wire holders

A non-magnetic insert will be placed directly inside the permanent magnet blocks in every CBETA Halbach magnet in order to hold a set of iron “tuning wires”. These wires have various lengths around the perimeter of the aperture in order to cancel multipole field errors from the permanent magnet blocks.

43 PARTICLE ACCELERATORS↗

DOE OSTI2018

Wire Arc Additive Manufacturing

Project highlight. This project designs and implements a new additive manufacturing capability at Savannah River National Laboratory. Wire Arc Additive Manufacturing is an Advanced Manufacturing technology that enables materials and energy savings by producing materials that are in near net shapes to minimize material losses compared to conventional forging and machining techniques. Wire arc additive manufacturing is an evolving technology that can be used to fabricate large components with significantly less materials waste than conventional processing. This project includes an engineering model, an aspect that is largely overlooked in the Additive Manufacturing modeling work where the emphasis has been on mechanistic and microscopic modeling, to estimate the residual stresses and distortions. The Abaqus Weld Interface software coupled with user subroutines in Fortran enable the local cooling rates to be estimated to provide a coarse scale model for the secondary dendrite arm spacing, a parameter useful to estimate mechanical properties.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Bridge-bursting and the action-integral in exploding bridge-wire (EBW) detonators

Methods of simulating the electrical characteristics of exploding bridge-wire detonators using only inert materials are reported. Specifically, it is found that both pressed finely powdered sucrose (confectioners sugar) and 3 µm aluminum oxide powder match the signals measured in a real EBW detonator with PETN fill. The exact pressing density of the inert powder is found not to affect to the measured electrical signals. Additionally, the action-integral (the time integral of bridge current squared) and energy-to-burst are measured for the same gold bridge design with several capacitor discharge units at different charge voltages and inductances as well as pseudo-constant current fireset made from charged coaxial-cables. It is found that in contrast to some reports, the action-integral to burst is not a constant for a specific bridge geometry and material, but instead is a function of the rate of current change in the bridge around the time of burst. This is explained by the confining effects of bridge-wire inertia affecting the rapid expansion of the bridge around burst time and hence the dynamic resistance.

36 MATERIALS SCIENCE↗