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DOE OSTI2017

Numerical Simulation with Experimental Validation of the Draping Behavior of Woven Fabrics

Woven fabric composites are extensively used in molding complex geometrical shapes due to their high conformability compared to other fabrics. Preforming is an important step in the overall process. In this step, the two-dimensional fabric is draped to become the three-dimensional shape of the part prior to resin injection. During preforming, the orientation of the tows may change significantly compared to the initial orientations. Accurate prediction of the tow orientations after molding is important for evaluating the structural performance of the final part. This paper investigates the fiber angle changes for carbon fiber woven fabrics during draping over a truncated pyramid tool designed and fabricated at the General Motors Research Labs. This aspect of study is a subset of the broad study conducted under the purview of a Department of Energy project funded to GM in developing state of the art computational tools for integrated manufacturing and structural performance prediction of carbon fiber composites. Fabric bending, picture frame testing, and bias-extension evaluations were carried out to determine the material parameters for these fabrics. The PAM-FORM computer program was used to model the draping behavior of these fabrics. Following deformation, fiber angle changes at different locations on the truncated pyramid were measured experimentally. The predicted angles matched the experimental results well as measured along the centerline and at several different locations on the deformed fabric. Details of the test methods used as well as the numerical results with various simulation parameters will be provided.

42 ENGINEERING↗

DOE OSTI2023

CI/CD Pipeline and DevSecOps Integration for Security and Load Testing

Dominic D’Onofrio is currently a Junior studying Information and Technology at New Mexico Institute of Mining and Technology. He recently secured an Internship with NMCCoE, where he is involved with the TracerFIRE 12 project. Additionally, he is contributing to the load and security testing team by researching ways to implement pipelining and DevSecOps; this is his main project while he is at part time capacity for TracerFIRE 12. He is doing these projects to enhance his knowledge as a system administrator and gain a deeper understating of cybersecurity practices within national labs.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Acoustic Tomography System (CRADA Final Report)

NREL will install the CU/CIRES acoustic tomography array at the National Wind Technology Center (NWTC). The system consists of 9 freestanding towers of 9.1m height that are currently located at the NWTC. On these towers are installed a series of microphones and speakers. One center tower holds a sonic anemometer and temperature probe. The purpose of the acoustic tomography system is to measure complex flow fields surrounding wind turbine arrays that influence wind farm energy production and reliability. There is currently no funding to test and research the system (just install it), but NREL and CU researchers will write proposals that will fund the actual research with this unique measurement technology.

17 WIND ENERGY↗

DOE OSTI2025

Field Validation of Dynamic Mechanical Torque Measurements for Geared Wind Turbines

Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory's Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors' successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.

17 WIND ENERGY↗

DOE OSTI2025

Fatigue Performance of an Improved Creep Strength 10%Cr Steel

The deployment of 9-12% Cr steels for elevated temperature applications up to 650 °C presents a cost-effective alternative to more expensive nickel-based alloys in steam turbine power generation. To enhance creep resistance at this temperature range, a novel ferritic-martensitic steel, designated CPJ7, was developed and fabricated at the National Energy Technology Laboratory. The alloy design aimed to mitigate the transformation of strengthening carbides into deleterious phases that degrade creep performance. Results have demonstrated that CPJ7 exhibits favorable creep and oxidation resistance at 650 °C. However, its fatigue performance remains unexplored. This study builds upon prior research by evaluating the low cycle fatigue behavior of CPJ7 and verifying that modifications beneficial to creep performance were not detrimental to the fatigue performance. The alloy was tested at both 650 °C and ambient temperature under fully reversed bending conditions (R = − 1) and a load ratio of 0.05. Furthermore, the alloy exhibits cyclic softening, a behavior consistent with other 9-10 wt.% Cr steels. Analysis of the microstructure and hysteresis loops further corroborate cyclic softening mechanisms typical of ferritic-martensitic steels. Overall, the fatigue performance of CPJ7 meets or exceeds that of P91 steel, demonstrating its potential for high-temperature structural applications.

9% Cr ferritic-martensitic steel↗

DOE OSTI2021

Battery Lifecycle Framework

The Battery Lifecycle (BLC) Framework is an open-source platform that provides tools to visualize and share battery data from material characterization, cell testing, manufacturing, and field testing through the technology development cycle. BLC has three components: data importers, a front-end for querying the data and creating visualizations, and an application programming interface to provide access to the data from Python. BLC has been deployed for tracking the development of a battery from the lab to a manufacturing line and systems installed in the field and for comparing studies of multiple cells of the same battery chemistry and configuration. The code was developed around Redash, a robust open-source extract-transform-load engine. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525. SAND2021-4546 O

De Angelis, Valerio↗

DOE OSTI2019

Precision Measurement of the Proton Magnetic Form Factor at High Q2

Elastic electromagnetic form factors characterize the distribution of electric charge and magnetization current inside the nucleon and reflect the internal structure determined by Quantum Chromodynamics. Existing data on the proton magnetic form factor at high Q2 (the 4-momentum transfer squared) have large statistical and systematic uncertainties. The GMp experiment E12-07-108 was one of the first set of experiments to run in Hall A at Jefferson Lab after the 12 GeV upgrade with the goal of this experiment to precisely measure the electron-proton elastic cross section for Q2 up to 17 GeV2 with an accuracy of better than 2% - several times better than existing data in this Q2 range. This will allow further tests of form factor scaling predicted by pQCD and, additionally, will be an important benchmark for many other experiments where elastic electron-proton scattering is used for normalization. Since, GMp data were taken at lower ?(virtual photon polarization) than SLAC data, the measured cross sections recieve a smaller contribution from the electric form factor. This dissertation analyzed the GMp experiment data for five different kinematic settings determining the form factor with total uncertainties nearly two times smaller than the existing data at these Q2. This dissertation also presents the results of all Fall 2016 and Spring 2016 GMp experiment data. The proton magnetic form factors were extracted using both the Rosenbluth separation method and a parameterization of the form factor ratio (?pGpE=GpM) obtained from a fit to the existing cross section data. At the end of this thesis, the extracted GMp form factor data is compared to the existing data. The results for ?pGpE=GpM from Rosenbluth separations are found to be consistent with previous extractions, but with significantly reduced uncertainties, further highlighting the discrepancy with the polarization transfer technique. This data set can provide significant additional constraints on contributions from two-photon exchange.

Narayan Gautam, Thir↗

DOE OSTI2022

Extraction of Proton and Deuteron F2 Structure Function from Inclusive Electron-Nucleon Scattering at Large Bjorken-X

The E12-10-002 experiment measured the inclusive electron-nucleon cross section at Jeferson Lab at large Q2 (up to 16 GeV2) and a large range of x (up to 0.99). The data is analyzed and the cross sections are extracted for hydrogen and deuterium. Then the F2 structure function is extracted for hydrogen and deuterium. Finally the quark-hadron duality is tested for the proton F2 structure function for the previous world data and this experiment.

Biswas, Debaditya↗

DOE OSTI2020

Novel Ionomers and electrode structures for improved PEMFC electrode performance at low PGM loadings (Final Report)

In this project, the objective is to develop new ORR electrocatalysts on optimized supports which can exceed all of the Department of Energy (DOE) 2020 targets listed in DE-FOA-0001412 directly relevant to the subtopic. This project’s approach is to develop novel, electrode-specific ionomers, and integrate them with state-of-the-art NSTF electrocatalyst powder to develop a cathode electrode achieving >= 044 A/mg PGM mass activity, <=30% mass activity loss during metal cycling, and <=0.125 g PGM /kW performance under DOE testing protocols. Ionomer O 2 permeability and proton conductivity will be increased by up to 1.5X over the baseline 3M800 perfluorosulfonate (PFSA) ionomer to enhance cathode electrode performance. Integration of cathode NSTF powder into an ionomer-containing electrode will increase the surface enhancement factor (SEF) to >=40 cm 2 PGM /cm 2 GEO allowing NSTF containing cathodes to exceed DOE MEA robustness targets. This report summarizes this project’s progress towards meeting the stated objectives and includes a summary of significant findings, conclusions, and developments over the entire project period from Oct. 1 st 2016 – Jan. 31 st 2020. This work has overcome key operation robustness issues with classic NSTF electrodes, identified pathways to improved dispersed and dispersed NSTF cathode performance, developed novel ionomers with high bulk conductivity and oxygen permeability, demonstrated exceptional support-independent electrode activity, and significantly increased metal and support stability through ionomer development. At this point, Tufts, MTU and all 5 FCPAD national labs have been involved, and contributed to, the improvements, learning and achievements of this work. Over the course of this project, more than 50 grams of dispersed NSTF powder in 15 different configurations have been generated, paving the way for scaleup within 3M. These whiskers have been processed in multiple ways, including acid leaching, powder-annealed, and sonicated by various means. For Task 2, 27 different types of ionomers were tested, 19 of which were made for the first time during the course of this project. 377 electrode inks with both NSTF and metal-on-carbon catalysts with I/C ratios from 0.2 to 1.2 were generated and mostly coated on a 3M pilot manufacturing line resulting in more than 700 different electrode types.

08 HYDROGEN↗

DOE OSTI2025

Static characterization of a highly optimized streak tube design incorporating a steering slot anode and an aberration-corrected Einzel lens

The BHx streak tube, under development at the Laboratory for Laser Energetics, incorporates a series of novel electron-optics elements to enable high fidelity measurements for high-energy-density physics experiments. The system is engineered to support a 25-mm active photocathode region compatible with sub-picosecond temporal resolution and with 70% internal photoelectron throughput. It exhibits negligible geometric distortion on a flat output screen, making it well suited for variety of measurements, such as ultrafast x-ray spectroscopy. Here, this paper presents characterization data from a prototype unit tested with an ultraviolet laser in a static deflection (non-swept) mode and shows good agreement with the predictions from numerical modeling, including focusing performance and geometric distortion measurements. Key design elements have been demonstrated and de-risked, laying the foundation for dynamic deflection testing. The anticipated improvements in data fidelity are expected to impact the fields as diverse as inertial confinement fusion, laboratory astrophysics, and materials science.

High energy density physics↗

DOE OSTI2025

Investigation of warm dense matter by combining static and dynamic compression

Shock-compressing material samples that are precompressed with diamond-anvil cells (DACs) enables benchmarking equation of state measurements over a wide range of high-pressure conditions, in particular, warm dense matter relevant to planetary science, astrophysics, and inertial confinement fusion. These targets provide optical access to the shocked sample, so optical velocity interferometry and pyrometry are typical diagnostics. We present a scaling for the coupling of the laser drive to the shock pressure in DACs based on over 150 prior experiments that can be used to design future experiments. For initial static pressures ≤ 5 GPa, using a sapphire window mitigates the effect of photoionization compared to diamond windows and allows the measurement of shock pressures up to 1 TPa with optical diagnostics.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2016

Carbon Flux Explorers

42 ENGINEERING↗

DOE OSTI2016

Aboard the R/V Oceanus: Carbon Flux Explorers

Jim Bishop, senior scientist at Berkeley Lab and professor at UC Berkeley, is leading a project to deploy robotic floats that provide data on how microorganisms sequester carbon in the ocean. He recently led a research team on a 10-day voyage, funded by the National Science Foundation, to put the Carbon Flux Explorers to the test. Read more at http://oceanbots.lbl.gov (Video edited by Roxanne Makasdjian and Stephen McNally/UC Berkeley. Video shot by Jessica Kendall-Bar. Drone footage provided by Mark Booher.)

47 OTHER INSTRUMENTATION↗

DOE OSTI2017

Determination of He and D permeability of neutron-irradiated SiC tubes to examine the potential for release due to micro-cracking

Driven by the need to enlarge the safety margins of light water reactors in both design-basis and beyond-design-basis accident scenarios, the research and development of accident-tolerant fuel (ATF) has become an importance topic in the nuclear engineering and materials community. Continuous SiC fiber-reinforced SiC matrix ceramic composites are under consideration as a replacement for traditional zirconium alloy cladding owing to their high-temperature stability, chemical inertness, and exceptional irradiation resistance. Among the key technical feasibility issues, potential failure of the fission product containment due to probabilistic penetrating cracking has been identified as one of the two most critical feasibility issues, together with the radiolysisassisted hydrothermal corrosion of SiC. The experimental capability to evaluate the hermeticity of SiC-based claddings is an urgent need. In this report, we present the development of a comprehensive permeation testing station established in the Low Activation Materials Development and Analysis laboratory at Oak Ridge National Laboratory. Preliminary results for the hermeticity evaluation of un-irradiated monolithic SiC tubes, uncoated and coated SiC/SiC composite tubes, and neutron-irradiated monolithic SiC tubes at room temperature are exhibited. The results indicate that this new permeation testing station is capable of evaluating the hermeticity of SiC-based tubes by determining the helium and deuterium permeation flux as a function of gas pressure at a high resolution of 8.07 x 10 -12 atm-cc/s for helium and 2.83 x 10 -12 atm-cc/s for deuterium, respectively. The detection limit of this system is sufficient to evaluate the maximum allowable helium leakage rate of lab-scale tubular samples, which is linearly extrapolated from the evaluation standard used for a commercial as-manufactured light water reactor fuel rod at room temperature. The un-irradiated monolithic SiC tube is hermetic, as is manifested by the un-detectable deuterium permeation flux at various feeding gas pressures. A large helium leakage rate was detected for the uncoated SiC/SiC composite tube exposed to atmosphere, indicating it is inherently not hermetic. The hermeticity of coated SiC/SiC composite tubes is strongly dependent on the coating materials and the preparation of the substrate SiC/SiC composite samples. To simulate the practical application environment, monolithic CVD SiC tubes were exposed to neutron irradiation at the High Flux Isotope Reactor under high heat flux from the internal surface to the external surface. Although finite element analysis and resonant ultrasound spectroscopy measurement indicated that the combined neutron irradiation and high heat flux gave rise to a high probability of cracking within the sample, the hermeticity evaluation of the tested sample still exhibited gas tightness, emphasizing that SiC cracking is inherently a statistical phenomenon. The developed permeation testing station is capable of measuring the gas permeation flux in the range of interest with full confidence based on the presented results. It is considered a critical pre- /post-irradiation examination technique to characterize SiC-based cladding materials in asreceived and irradiated states to aid the research and development of ATF.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Federated Access from DOE Labs to Distributed Storage in the EIC Era of Computing

The Electron Ion Collider (EIC) collaboration and future experiment is a unique scientific ecosystem within Nuclear Physics as the experiment starts right off as a crosscollaboration between Brookhaven National Lab (BNL) & Jefferson Lab (JLab). As a result, this muti-lab computing model tries at best to provide services accessible from anywhere by anyone who is part of the collaboration. While the computing model for the EIC is not finalized, it is anticipated that the computational and storage resources will be made accessible to a wide range of collaborators across the world. The use of federated ID seems to be a critical element to the strategy of providing such services, allowing seamless access to each lab site computing resources. However, providing Federated access to a Federated storage is not a trivial matter and has its share of technical challenges. In this contribution, we focus on the steps we took towards the deployment of a distributed object storage system that integrates with Amazon S3 and Federated ID. We will first cover for and explain the first stage storage solutions provided to the EIC during the detector design phase. Our initial test deployment consisted of Lustre storage using MinIO, hence providing an S3 interface. High Availability load balancers were added later to provide the initial scalability it lacked. Performance of that system will be shown. While this embryonic solution worked well, it had many limitations. Looking ahead, the Ceph object storage is considered a top-of-the-line solution in the storage community - since the Ceph Object Gateway is compatible with the Amazon S3 API out of the box, our next phase will use a native S3 storage. Our Ceph deployment will consist of erasure coded storage nodes to maximize storage potential along with multiple Ceph Object Gateways for redundant access. We will compare performance of our next stage implementations. Finally, we will present how to leverage OpenID Connect with the Ceph Object Gateway’s to enable Federated ID access. We hope this contribution will serve the community needs as we move forward with cross-lab collaborations and the need for Federated ID access to distributed compute facilities.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2017

Superconducting Magnet Power Supply and Hard-Wired Quench Protection at Jefferson Lab for 12 GeV Upgrade

The superconducting magnet system in Hall B being designed and built as part of the Jefferson Lab 12 GeV upgrade requires powering two conduction cooled superconducting magnets - a torus and a solenoid. The torus magnet is designed to operate at 3770 A and solenoid at 2416 A. Failure Modes and Effects Analysis (FMEA) determined that voltage level thresholds and dump switch operation for magnet protection should be tested and analyzed before incorporation into the system. The designs of the quench protection and voltage tap sub-systems were driven by the requirement to use a primary hard-wired quench detection sub-system together with a secondary PLC-based protection. Parallel path voltage taps feed both the primary and secondary quench protection sub-systems. The PLC based secondary protection is deployed as a backup for the hard-wired quench detection sub-system and also acts directly on the dump switch. Here, we describe a series of tests and modifications carried out on the magnet power supply and quench protection system to ensure that the superconducting magnet is protected for all fault scenarios.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2024

Progress on the Autonomous Event Detection System For the Laser Particulate Counter

Field emission is one of the most important issues that limits the performance of the superconducting radio frequency (SRF) systems and leads to SRF cavity trips at the Continuous Electron Beam Accelerator Facility at Jefferson Lab. Studies have confirmed that particulates are the dominant source of field emitters and the particulates can be transported into a cavity from other parts of the accelerator. To monitor the transportation of the particulates, a prototype of a novel, non-invasive laser particulate counter (LPC) has been developed and tested. Experiments have been done to validate the capability of the LPC. We are developing autonomous event detection system to continuously monitor the readout from the LPC and to recognize real events generated by particulates from noises using machine learning model. In this report, we will present how the data are prepared and how the model is trained. We will also discuss the performance of the model.

Zhang, H.↗

DOE OSTI2025

LDRD for a high-current polarized-beam photogun

The electron accelerator driving the Ce+BAF conversion target requires a spin-polarized photogun capable of delivering a CW beam current of at least 1 mA. As the high beam current limits the useful operating time of the gun between photocathode reactivations due to ion back-bombardment, it is critical to increase the charge lifetime. A Jefferson Lab LDRD project aims to calibrate the simulation models needed to predict photocathode lifetime as a function of electrostatic optics and drive laser parameters in order to design a gun providing at least 1000 C charge lifetime. A prototype gun demonstrating the validity of the scaling predictions will be built and tested at the Gun Test Stand. I will describe the background and progress of this project and give an outlook on the expected performance.

Bruker, Max [Thomas Jefferson National Accelerator↗