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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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At least 973 records · Page 54
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Failure Analysis of a New Polyamide-Based Fluoropolymer-Free Backsheet After Combined-Accelerated Stress Testing

The viability of novel coextruded, fluoropolymer-free backsheets for photovoltaic (PV) modules has been questioned as a result of a large number of early-life backsheet failures in PV installations containing one of the earliest co-extruded polyamide (PA)-based backsheet to reach the market, “AAA.” New PV reliability testing protocols have been recently developed and applied to backsheets to reproduce failures observed in the field and evaluate the durability of novel backsheet materials and designs prior to commercialization. A new co-extruded PA-based backsheet was tested using combined-accelerated stress testing (C-AST) and demonstrated a greater lifetime than AAA, and some other fluoropolymer-based backsheets such as polyvinylidene fluoride. The improved PA-based backsheet also eventually failed by through-thickness cracking. Using surface and bulk material characterization techniques, we performed a comprehensive study of material properties before and after the stress testing. Aging of the backsheet resulted in an increase of surface roughness by erosion of the outer PA layer. However the failure is more likely related to an increase in crystallinity of the polyolefin core layer reducing the backsheet tearing energy. The analysis can ultimately inform on the specific weaknesses of the materials so that the manufacturer can improve the backsheet design to extend its lifetime.

14 SOLAR ENERGY↗
DOE OSTI2023

A Testing Framework for Grid-Forming Resources

This paper presents a testing framework for grid-forming (GFM) resources. First, it analytically derives in the frequency domain the active and reactive power response of an ideal voltage source with a reactor. These transfer functions are then used to quantify the voltage source behavior expected from a GFM inverter within subtransient timescales (5-15 cycles) following a grid disturbance. The paper also shows that the testing of a GFM inverter might require a reactor of an appropriate size between the inverter and the grid simulator used for the inverter testing. Finally, the paper presents a systematic approach for developing specifications for GFM resources using active and reactive power response frequency scans. The testing framework and results presented in this paper are demonstrated using EMT-PSCAD simulations of a 1-MW GFM inverter.

frequency scans↗
DOE OSTI2021

Evaluating Non-Fluoropolymer-Based Co-Extruded Backsheets Using Combined-Accelerated Stress Testing and Materials Forensics

Co-extruded, non-fluoropolymer backsheet films for photovoltaic (PV) modules have gained popularity in recent years based on their cost competitiveness. However, their viability has been thrown into question as a result of widespread, early-life field-failures of some materials, particularly the polyamide (PA)-based “AAA” backsheet product. Failure to detect weaknesses in those earlier products could be due, in part, to insufficient quality testing practices. New testing protocols have recently been developed to better evaluate such materials. Here we show the testing results for a non-fluoropolymer, co-extruded PA-based backsheet film, which demonstrates greater durability than AAA and some commercial fluoropolymers. Using material characterization techniques including Fourier-transform infrared spectroscopy (FTIR), wide-angle x-ray scattering (WAXS), differential scanning calorimetry (DSC), X-ray photoelectron spectroscopy (XPS), elongation-to-break (ETB), and optical microscopy we perform a comprehensive failure analysis to better understand the materials weaknesses. This analysis can ultimately inform how best to improve the material and extend its lifetime. This work serves as a demonstration that some materials should not be discounted due to a single poorly designed product and that more appropriate qualification testing with subsequent materials analysis can be used to develop better materials.

41 EE - Solar Energy Technologies Office (EE-4S)↗
DOE OSTI2021

Reassembly and Test of High-Field Nb3Sn Dipole Demonstrator MDPCT1

In the framework of the U.S. Magnet Development Program (MDP), Fermilab has developed and tested a high-field Nb$_3$Sn dipole demonstrator MDPCT1 for a post-LHC Hadron Collider. The magnet was first assembled with a lower coil pre-load to minimize the risk of coil damage during assembly and test. In the first test the magnet reached its test goal producing a world record field of 14.1 T at 4.5 K. Next the magnet was reassembled with nominal pre-load to achieve its design field limit of 15 T. This paper describes the details of MDPCT1 inspection, design modifications and reassembly. The magnet quench performance, including training, ramp rate and temperature dependences in the temperature range of 1.9-4.5 K, is presented and discussed.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Status of the High Field Cable Test Facility at Fermilab

Fermi National Accelerator Laboratory (FNAL) and Lawrence Berkeley National Laboratory (LBNL) are building a new High Field Vertical Magnet Test Facility (HFVMTF) for testing superconducting cables in high magnetic field. The background magnetic field of 15 T in the HFVMTF will be produced by a magnet provided by LBNL. The HFVMTF is jointly funded by the US DOE Offices of Science, High Energy Physics (HEP), and Fusion Energy Sciences (FES), and will serve as a superconducting cable test facility in high magnetic fields and a wide range of temperatures for HEP and FES communities. This facility will also be used to test high-field superconducting magnet models and demonstrators, including hybrid magnets, produced by the US Magnet Development Program (MDP). The paper describes the status of the facility, including construction, cryostat designs, top and lambda plates, and systems for powering, and quench protection and monitoring.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Design and Testing of a Prototype Eddy Current Actuated Valve for the ITER Shattered Pellet Injection System

Reliably mitigating disruptions is essential for ITER to meet its long-term operational research plan without damage to the in-vessel components. Currently, the shattered pellet injection (SPI) technique is the most effective radiator of thermal energy and has been chosen for the baseline disruption mitigation system (DMS) for ITER. The SPI process uses cryogenic temperatures to desublimate material into the barrel of a pipe gun forming a solid cylindrical pellet. Pellets for ITER will initially be hydrogen and hydrogen-neon mixtures. Once formed, pellets are dislodged and accelerated using high-pressure gas (40-60 bar) delivered by a fast-opening valve. The solenoid valves currently used for SPI experiments will not operate in an ITER environment due to the large background magnetic field. An ITER prototype fast-opening valve, called a flyer plate valve (FPV), has been designed and has undergone a wide range of testing. The FPV operates by pulsing current through a pancake coil that is closely coupled with a ``flyer plate.'' The flyer plate is an aluminum plate in which eddy currents are generated creating a repulsive force from the pancake coil. The force generated in the flyer plate rapidly lifts the valve tip off the seat and delivers a pulse of gas to the rear of the pellet, breaking it free from the barrel and accelerating the pellet downstream to its intended target. The design of the valve has been iterated on over the lifetime of this project, as the DMS for ITER shifted from massive gas injection (MGI) to SPI. The most recent design has been tested, and operational ranges have been mapped. The valve must survive 3000+ cycles in an ITER-like magnetic field. The principal functional requirement of this valve is to reliably dislodge and accelerate hydrogen (or H-Ne mixture) pellets into ITER. The valve was mated with an ITER SPI test stand and has been shown to be capable of launching pellets reliably. The valve and power supply design will be discussed in this article, along with the various testing setups used to determine the feasibility of this valve for use on ITER.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Accelerated Creep Test Qualification of Creep-Resistance Using the Wilshire–Cano–Stewart Constitutive Model and Stepped Isostress Method

In this paper, a qualification of accelerated creep-resistance of Inconel 718 is assessed using the novel Wilshire–Cano–Stewart (WCS) model and the stepped isostress method (SSM) and predictions are made to conventional creep data. Conventional creep testing is a long-term continuous process; in fact, the ASME B&PV III requires that 10,000+ h of experiments must be conducted to each heat for materials employed in boilers and/or pressure vessel components. This process is costly and not feasible for rapid development of new materials. As an alternative, accelerated creep testing techniques have been developed to reduce the time needed to characterize the creep resistance of materials. Most techniques are based upon the time-temperature-stress superposition principle that predicts minimum-creep-strain-rate (MCSR) and stress-rupture behaviors but lack the ability to predict creep deformation and consider deformation mechanisms that occur for experiments of longer duration. The SSM has been developed, which enables the prediction of creep deformation response as well as reduce the time needed for qualification of materials. The SSM approach has been successful for polymer, polymeric composites, and recently has been introduced for metals. In this study, the WCS constitutive model, calibrated to SSM test data, qualifies the creep resistance of Inconel 718 at 750 °C and predictions are compared to conventional creep testing data. The WCS model has proven to make long-term predictions for stress-rupture, MCSR, creep deformation, and damage in metallic materials. The SSM varies stress levels after time interval adding damage to the material, which can be tracked by the WCS model. The SSM data is calibrated into the model and the WCS model generates realistic predictions of stress-rupture, MSCR, damage, and creep deformation. The calibrated material constants are used to generate predictions of stress-rupture and are postaudit validated using the National Institute of Material Science database. Similarly, the MCSR predictions are compared from previous studies. Finally, the creep deformation predictions are compared with real data and is determined that the results are well in between the expected boundaries. Material characterization and mechanical properties can be determined at a faster rate and with a more cost-effective method. This is beneficial for multiple applications such as in additive manufacturing, composites, spacecraft, and industrial gas turbines.

42 ENGINEERING↗
DOE OSTI2019

EGS Collab Testbed 1: Second Set Tracer Test Results

The EGS Collab project is developing ~10-20 m-scale field sites where fracture stimulation and flow models can be validated against controlled, small-scale, in-situ experiments. The first multi-well experimental site was established at the 4850 level in the Homestake Mine in Lead, South Dakota, where hydraulic fractures were created at an injection well drilled sub-horizontal from the drift. This file contains the second set of tracer data (also include the data uploaded previously, https://gdr.openei.org/submissions/1128) for the EGS Collab testbed. The tracer tests were conducted during October 2018 - November 2019. Injected tracers include DNA, C-dots (fluorescein nano particles), fluorescein, rhodamine-b, sodium chloride, lithium bromide and cesium iodine. The tracers have been detected in three flowing wells located about 7.5 to 9 meters away from the injection interval. The tracer breakthrough curves from these locations have been adjusted to account for the residence time in the injection and production tubing. The details about the tracer test can be found in Background and Methods of Tracer Tests (Mattson et al. (2019,a,b)) (also included in this package). References Mattson, E.D., Neupane, G., Plummer, M.A., Hawkins, A., Zhang, Y. and the EGS Collab Team 2019a. Preliminary Collab fracture characterization results from flow and tracer testing efforts. In Proceedings 44th Workshop on Geothermal Reservoir Engineering, edited, Stanford University, Stanford, California. Mattson, E.D., Neupane, G., Hawkins, A., Burghardt, J., Ingraham, M., Plummer, M., and the EGS Collab Team, 2019b. Fracture tracer injection response to pressure perturbations at an injection well. GRC Transactions, Vol. 43, 2019. Neupane, Ghanashyam, Earl Mattson, Adam Hawkins, Mitchell Plummer, and Yuran Zhang. EGS Collab Testbed 1: Tracer data sets. No. 1128. DOE Geothermal Data Repository; Idaho National Laboratory, 2019.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

EGS Collab Experiment 3: 4100 Tensile Stimulation and Thermal Circulation Testing

These data and test descriptions are from a set of primarily tensile hydraulic-fracture stimulations in wells E2-TC and E2-TU and a subsequent chilled water circulation test conducted by injecting in well E2-TU on the 4100 level of the Sandford Underground Research Facility (SURF). Stimulations were carried out between April and May of 2022. The thermal circulation test ran semi-continuously from May 19 through August 26, 2022, though chilled water injection began on June 3. More information about the test, rationale, and processing of data is available on the EGS Collab project page, which is linked below.

15 GEOTHERMAL ENERGY↗
DOE OSTI2020

A Section 110 Evaluation of Three Sites Associated with the Grable Test, Area 5, Nevada National Security Site, Nye County, Nevada

This report presents the results of a Section 110 recordation of the 280mm Atomic Gun emplacement and command post (CP) (26NY16244), an associated Flash Observation Point that was used to refine the gun’s firing range (26NY16243), and troop trenches used for Exercise Desert Rock V (26NY16242). All three of these resources are directly associated with the Grable test, a specific test in the Upshot-Knothole series of aboveground nuclear detonations. The Grable test occurred at 8:30 a.m. on May 25, 1953, in Area 5 of the Nevada National Security Site (NNSS). Desert Research Institute (DRI) recommends 26NY16244 and 26NY16242 eligible for listing in the National Register of Historic Places (NRHP) under a combination of the Secretary of the Interior’s Significance Criteria A and D at the national level of significance and related to the era of Nuclear Testing and the Cold War. All three of these resources are recommended as contributing elements to the Frenchman Flat Historic District (SHPO Resource No. D204).

280mm Atomic Gun↗
DOE OSTI2022

Sorbent Based Post-Combustion CO 2 Slipstream Testing

TDA Research, Inc. has developed a low-cost sorbent (alkalized alumina) based technology for post-combustion CO 2 capture. The sorbent runs in an isothermal process for adsorption and regeneration. Neither temperature swing nor pressure swing is needed. TDA designed a system which operated 10 fixed beds to simulate a moving bed process. The flow pattern was optimized to minimize the steam usage for regeneration. An excellent sorbent (Batch 1) was also developed with collaboration with our partner. The sorbent degraded after long term operation. We developed a reprocessing procedure, which can be conducted in situ, to restore the sorbent capture capacity as the fresh sorbent after running for about 1250 hours. The reprocessing extended the sorbent longevity significantly. TDA designed a pilot unit (40’ x 32’ x 11.5’), processing flue gas equivalent to 0.5 MW of power generation. It had 10 beds and each bed could hold 1.75 m 3 of sorbent. We worked with Springs Fabrication, Inc. to complete the construction of the pilot unit. It was then shipped and installed at NCCC. The pilot unit was kept running in 24-hour mode when the flue gas and steam were available. It could run automatically without operator on site. Parametric and long-term (2 months) tests were carried out successfully. The results showed that TDA’s process can achieve 90% capture and 95% CO 2 purity for both coal and NG flue gases. For coal flue gas, the system reached performance target when processing up to 0.62 MW flue gas, 24% higher than the design capacity. Thus, capital cost could be saved on the reactors and sorbent. The strip air flow was designed to be 0.25 of that of the flue gas. The test data showed the strip/flue ratio can be reduced to as little as 0.18, which saves the power consumption for the strip air blower. The pressure drop was found to be lower than what the empirical equation calculated. The sorbent still had 91.7% of original capacity after 3-month test. With the data from the pilot test, we updated the TEA. For a 550-MW e supercritical coal fired power plant with CO 2 capture, the capture cost for TDA’s process is $34.9/tonne CO 2 captured, which meets DOE’s goal of $40/tonne and is 17.1% less than the DOE baseline Case 12. Therefore, TDA’s process has a good potential for commercialization.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Improved Creep Testing Approach for Bentonite EBS

In the United States, the nuclear reactor contributes 18.7 percent of the nation’s total electricity generation and produces a significant amount of spent nuclear fuel (SNF) and high-level waste. Because SNF is being stored for longer periods than initially envisioned, the U.S. Department of Energy Office of Nuclear Energy, Office of Spent Fuel and Waste Science and Technology is assessing the technical performance of the SNF storage systems after extended durations. The concept of a sustainable geologic repository for SNF disposal relies heavily on the safety provided by multiple barriers, such as repository host rock, overlying rock formation, and human-made engineered barrier systems (EBS). One of the major components of EBS is bentonite-based buffer materials that isolate the nuclear-waste canisters from the host rock and fill the void left in the horizontally drilled boreholes. The resaturated bentonite has a swelling characteristic, which is useful for self-sealing the microcracks in the host rock and supporting the canister’s heavy weight. However, factors such as nonuniformity in the saturation, swelling pressure of bentonite, and the high temperature at the canister-bentonite interface may lead to instability of the waste canister inside the borehole. Therefore, evaluating the long-term deformation of bentonite-based material is necessary. RESPEC Company, LLC recently completed a preliminary study for the U.S. Department of Energy (DE SC0022804) that is attempting to understand the time-dependent deformation in the consolidated sand/bentonite (SB) specimens through triaxial creep experiments and improve the understanding of EBS performance under anticipated repository conditions. The project included developing a standard testing procedure for preparing the consolidated core specimen from a mixture of sand and bentonite in a 50:50 ratio by weight, fabricating a new pressure vessel in-house, modifying existing creep equipment to perform triaxial creep experiments on consolidated SB specimens, and performing six long-term triaxial creep experiments under low-deviatoric stress at two different temperature conditions, which is representative of hypothetical conditions that might be encountered in a geologic repository within a reasonable rate of success in completing creep experiments. The consolidated SB specimen was prepared using the novel specimen preparation procedure and had physical characteristics (e.g., moisture content and bulk density) reasonably comparable with the properties of bentonite-based buffer, which is proposed to be used in the EBS in the Swedish KBS-3H design and the Swiss design of SNF disposal in the horizontal drifts. The newly fabricated pressure vessel could withstand the confining pressure of up to 15 megapascals (MPa) while maintaining the test temperature of up to 90 degrees Celsius (°C) for long-term creep experiments. The preliminary results from the triaxial creep experiments suggested that the consolidated SB specimen may experience time-dependent deformation at a low-deviatoric stress state and room temperature condition. Based on the deformation recorded in the SB specimen from axial and radial linear variable differential transformers (LVDTs) and physical characteristic changes, it is apparent that the time-dependent deformation is a combination of consolidation and creep, which is influenced by the level of deviatoric stresses and temperature. The systematic creep testing of bentonite-based specimens helped develop a standard testing procedure applicable for analyzing the similar characteristics of shale or clay-like materials in different geologic conditions outside repository science, including in civil engineering and infrastructure projects, underground and open pit mining, and deep drilling.

58 GEOSCIENCES↗
DOE OSTI2026

Optimizing resource allocation in Miscanthus breeding via sparse testing designs for genomic prediction

Phenotyping high-biomass perennial crops is laborious and the rate of genetic gain in conventional perennial crop breeding programs is typically low. So, it is especially important to identify methods that produce efficiency gains in the breeding process. Miscanthus is a C4 perennial grass with favorable characteristics for producing biomass as a feedstock for biofuels and diverse bio-based products. Increasing biomass yield will increase profitability and environmental benefits, so it is a key target for Miscanthus breeding. In addition, the identification of well-adapted genotypes across a wide range of environmental conditions requires the establishment of multi-environment trials (METs). Sparse testing is a genomic prediction-based strategy that reduces the phenotyping costs in METs by selecting a subset of genotypes to evaluate in a subset of environments and then predicts the performance of the unobserved genotype-environment combinations. A Miscanthus sacchariflorus (MSA) population comprising 336 genotypes observed across three environments was analyzed implementing sparse testing designs. Three prediction models considering main effects (environments, genotypes, genomic) and interaction effects (genotype-by-environment; G×E interaction) were implemented for forecasting dry biomass yield (YDY), total culm (TCM), average internode length (AIL), and culm node number (CNN). Multiple calibration sets based on different compositions and sizes were considered to evaluate performance in terms of the predictive ability (PA) and the mean square error (MSE) for a fixed testing set size. The training set size ranged from 52 to 112 to predict a fixed set of 224 unobserved genotypes across all three environments. The results showed that the model accounting for G×E interaction consistently presented the highest PA and the lowest MSE: for CNN (PA: ~0.77, MSE: ~0.5) and YDY (PA: ~0.70, MSE: ~1.3) while for TCM and AIL these ranged from ~0.28 to 0.41 and ~1.3 to 4.3, respectively. Overall, varying training sets and allocation strategies did not affect PA and MSE, with 52 non-overlapping and 0 overlapping genotypes per environment as the optimal cost-effective allocation framework. This suggests that implementing sparse testing designs could significantly reduce phenotyping costs by fivefold, without compromising PA in breeding programs for perennial crops such as Miscanthus.

Miscanthus sacchariflorus (MSA)↗
DOE OSTI2021

Failure in Confined Brazilian Tests on Sandstone

Strength of rocks in the confined tension region, where the minimum principal stress is tensile, has only infrequently been measured and is not well understood. Quasi-static confined Brazilian tests under a range of confining stresses (2.76 to 27.58 MPa) where used to determine the strength of sandstone in the confined tension region. The test results indicate that the strength in the confined tension region was a strong function of the intermediate principal stress: increasing the intermediate principal stress significantly increased the strength of the sandstone. The strength data were well fit by the Mogi–Coulomb criterion, which accounts for the intermediate principal stress. Unconfined Brazilian strength data were not well fit to the Mogi–Coulomb criterion derived from the confined Brazilian test data, consistent with a transition from tensile to shear processes dominating failure with increasing confining pressure. Observations of post-failure fracture surfaces reveal more indication of shear processes with increasing confining pressure. Numerical simulations from combined finite-discrete element method are compared to the experimental results and reflect similar conditions for failure compared to the experimental tests in the confined tension region.

42 ENGINEERING↗
DOE OSTI2022

Comparison of Microbial Profiling and Tracer Testing for the Characterization of Injector-Producer Interwell Connectivities

Insufficient understanding of the microbial communities and associated microbial processes in geological reservoirs hinders the utilization of this rich data source for improved resource management. In this study, along with four interwell tracer tests at a 1478-m deep fractured crystalline-rock aquifer, we analyzed the microbial communities in the injected and produced water by high-throughput sequencing. The microbial community similarities across boreholes during an interwell flow scenario frequently encountered in reservoir development was explored. Despite the significant tracer recoveries (~30%) in all tracer tests and the cumulatively >100,000 L of exogenous water (carrying exogenous microbes) injected into the 10-m-scale reservoir, the overall structure of produced-fluid microbiome did not increasingly resemble that of the injectate. However, producers with better connectivity with the injector (based on tracer test results) did have more amplicon sequence variants (ASVs) that overlapped with those in the injectate. We identified possible drivers behind our observations and verified the practicality of repeated microbial sampling in the context of reservoir characterization and long-term monitoring. We highlight that injector-producer microbial profiling could provide insights on the relative connectivities across different producers with a given injector, and that the associated logistical needs may be comparable or even less than that of classic tracer tests.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

NREL's Advanced Distribution Management System (ADMS) Test Bed

NREL's advanced distribution management system (ADMS) test bed is a vendor-neutral resource for evaluating existing and future ADMS functionalities in a realistic laboratory setting. The test bed uses Opal-RT's ePHASORsim and eMEGAsim products interfaced with an OpenDSS power system simulation through the HELICS cosimulation platform developed by multiple DOE laboratories; and with power and controller hardware. NREL will present an overview of the test bed and the technologies included within it, and also some examples of how the test bed has been used to address industry challenges.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

PV High Wind User Test Facility

The creation of a PV high wind test facility at the NREL Flatirons Campus that will enable private and public research efforts aimed at storm hardening PV systems. The facility will be instrumented to monitor effects of high wind conditions on modules and other array components. These in-field tests will coordinate with flow models, wind tunnel testing, validation of PV aeroelastic design codes, and post-testing module and system component analysis.

14 SOLAR ENERGY↗
DOE OSTI2020

Combined-Accelerated Stress Testing for Advanced Reliability Assessment of Photovoltaic Modules

New and previously undiscovered degradation mechanisms continue to be identified after field exposure in new photovoltaic module designs or materials oftentimes results in significant losses in investment. This is despite passing certification tests. Testing is insufficient largely due to their single-or double-stress nature. A Combined-Accelerated Stress Test (C-AST) has recently been developed. The test combines multiple stress factors of the natural environment to better replicate conditions experienced by modules in the field and detect mechanisms not a-priori known in new materials and designs.

accelerator factor modeling↗