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DOE OSTI2020

Validation of a Generalized Formulation for Load-Sharing Behavior in Epicyclic Gears for Wind Turbines: Preprint

In an ideal epicyclic gear set every parallel gear path transmits the same amount of torque. However, it is well known that certain manufacturing variations result in unequal load sharing between the parallel gear paths. Previous works have developed and validated a general closed-form analytical model of this phenomenon that describes the load sharing characteristics of epicyclic gear sets from three to six planets at any torque level. More recently, this analytical model has been reformulated to include the effects of gravity, carrier bearing clearance, and external applied moments, all of which are relevant to most gearboxes and their mounting configuration in horizontal-axis wind turbines. In this paper, the reformulated model is compared to load measurements collected from two similar wind turbine gearboxes with three-planet epicyclic gear sets. The resulting load sharing values are also compared to the mesh load factor requirements in the AGMA 6006 and IEC 61400-4 wind turbine gearbox design standards. Load sharing factors as high as 1.16 at extreme rotor moments and 1.08 with no moment were measured for the gearbox with cylindrical roller bearings, but the load sharing factor remained below 1.10 for the gearbox with tapered roller bearings The results show that in the wind turbine application, load sharing is not equal - even for three-planet systems with a floating central member because of the effects of gravity, rotor moments, and the resulting relative motions among the epicyclic gear components within the carrier bearing clearance.

closed-form analytical model↗

DOE OSTI2020

Validation of a Generalized Formulation for Load Sharing Behavior in Epicyclic Gears for Wind Turbines

closed-form analytical model↗

DOE OSTI2025

Hydrodynamic expansion and near-infrared absorption of x-ray heated aluminum plasmas

We use x-ray pulses from dense argon plasmas at the Z Machine (Sandia National Laboratories) to generate hypersonic aluminum plasmas akin to material ejecta during proposed planetary defense missions, fusion reactor wall excursions, and other high-energy density processes. Near-infrared absorption is used to diagnose the controlled expansion of the plasmas through cylindrical cavities following their generation from x-ray heating of solid aluminum 7075 alloy. The data are compared to multidimensional radiation hydrodynamics simulations utilizing the ALEGRA multiphysics code, accounting for the dynamics of radiation scattering, material phase change, plasma expansion, thermal re-irradiation, and interactions with the cavity and with the infrared beams. To allow for accurate simulation, density functional theory is used to apply the Hagen–Rubens relation for the far-infrared and is adjoined with a detailed configuration accounting model using the Propaceos code, producing opacities spanning 10 −1 –10 4 eV photon energy for aluminum 7075 alloy, and in comparison with pure aluminum. The model is found to agree with experimental data in the higher-fluence regime when the Hagen–Rubens relation is applied. The ejected material, which is observed to travel up to 55 km/s, is comprised of a strongly ionized, non-LTE plasma front at ∼10 eV temperature followed by a weakly ionized LTE gas at higher density. The present findings lend some confidence to the broad-range equation of state and infrared opacity models for weakly ionized aluminum plasmas while demonstrating an approach to their future refinement, with potential application to astrophysical plasmas and other extreme processes.

Adiabatic process↗

DOE OSTI2026

Development of a broadband hard x-ray radiography platform for pulsed-power experiments

In this article, we develop and demonstrate a broadband hard x-ray radiography platform at the Zebra Pulsed Power Laboratory that integrates point-projection radiography, bremsstrahlung measurements, and hard x-ray pinhole imaging, designed to diagnose current-driven, cylindrically compressed matter. Initial laser-pulsed-power coupled experiments revealed that intense background radiation generated during 1 MA Zebra current shots overwhelmed laser-produced hard x-rays, obscuring radiographic images. Using combined spectral and spatial diagnostics, we identify energetic electrons accelerated by return currents as the dominant source of background hard x-rays, with electron energies inferred to be 3–4 MeV based on Monte Carlo simulations, and demonstrate mitigation through modifications to the radiation shielding and return-current configuration. The diagnostic platform was validated using a wire-pinch hard x-ray source, allowing radiographs of static 1-mm-diameter aluminum wires to be obtained while simultaneously measuring x-ray source spectra and spatial emission distributions within a single shot. Measured wire transmission profiles were quantitatively reconstructed using radiation transport simulations that incorporate an experimentally inferred two-temperature exponential x-ray spectrum from bremsstrahlung signal analysis and spatially distributed emission sources identified by pinhole imaging. Agreement between measured and simulated transmission profiles demonstrates the validity of the radiographic and x-ray source characterization approach, establishing this diagnostic platform as a promising tool for diagnosing magnetically driven, high-density plasmas relevant to warm dense matter and inertial fusion energy research.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Experimental Investigation of Melting and Solidification Processes of Phase Change Material Heat Exchanger

Rapid development and validation of PCM embedded heat exchangers (PCM-HX) concepts warrant a purpose-built test bench. This paper describes a test facility built for testing various PCM-HX configurations and phase change temperatures that will serve to validate the performance of novel PCM-HX designs. The entire test rig is placed in a temperature-controlled environmental chamber. Inside the PCM-HX containers, up to 48 T-type thermocouples can be spatially distributed on and around the tubes depending on the HX type to capture the phase change process over time. In this paper, a straight tube embedded in PCM having a phase change temperature of 37°C in cylindrical containers is tested. The PCM-HX uses water as an in-tube working fluid. Based on the measured data, the energy balance is analyzed, and its temperature distribution is presented. Here, the maximum deviation between the predicted stored energy and the energy stored calculated from experimental measurements is less than 5%.

36 MATERIALS SCIENCE↗

DOE OSTI2022

The stability of expanding reactive shocks in a van der Waals fluid

Despite the extensive literature accumulated since the pioneering works of D'yakov and Kontorovich in the 1950s, the stability of steady shocks is still an open question when realistic boundary conditions are accounted. The consideration of a supporting mechanism, which is indeed a necessary condition for shock steadiness, modifies the perturbation shock dynamics in the unstable range. The Noh problem is a suitable example to form steady expanding shocks. This configuration is of great interest to the high-energy-density-physics community because of its direct application to inertial confinement fusion and astrophysics, for which the stagnation of a supersonically converging material via an accretion shock front is ubiquitous. Here in this work, we extend the generalized Noh problem, both base-flow solution and linear stability analysis, to conditions where endothermic or exothermic transformations undergo across the shock. Within the spontaneous acoustic emission conditions found for a van der Waals gas, we find that cylindrical and spherical expanding shocks become literally unstable for sufficiently high mode numbers. Counterintuitively, the effect of exothermicity or endothermicity across the shock is found to be stabilizing or destabilizing, respectively.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2023

Post-Shot Report for OMEGA Double Cylinders (CylDRT 22B)

The direct-drive double cylinder experimental platform is a high-energy-density (HED) science platform designed to image an imploding cylindrical target. The target consists of a directly-driven outer cylinder and a shock-and-collision driven inner cylinder. The purpose of this platform is to study hydrodynamic instability growth on the inner cylinder, the outer surface of which is classically Rayleigh-Taylor unstable during the acceleration phase. We present results from recent experiments at the OMEGA laser facility. These experiments were designed as a proof-of-principle for the platform, using the same cylinder exterior dimensions and direct-drive beam configuration as previous single cylinder experiments. In these experiments, three sets of targets were fielded: no machined perturbations (smooth), a sinusoidal mode-10 perturbation on the outer surface of the inner cylinder, and a mode-20 perturbation on the outer surface of the inner cylinder. The primary diagnostic was a gated x-ray framing camera which imaged the backlit inner cylinder on-axis for sixteen frames over a time window of 1 ns for each shot. A second side-lit radiograph captured one image per shot, diagnosing axial uniformity. In this report we include an overview of the results from both the backlighter and the sidelighter diagnostics. We discuss at length the experimental analysis process. Finally, we present the results of the smooth target implosion trajectory and compare them to post-shot simulations. We see favorable agreement between simulation and experiment.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Electrostatic generator/motor electrodes located on the inner surface of an electromechanical battery rotor

A geometric design of E-S generator motor electrodes mounted on the inner surface of a fiber-composite rotor is provided. The electrode configuration is able to sustain very high g levels. The rotor may be funned of carbon-fiber wound on top of an inner E car S-glass fiber composite core. The electrode design provides the needed area to satisfy the power requirements of the storage system and utilizes a stacked wedge-like electrode array that both solves the high-g problem and results in a doubling or tripling of the electrode area, relative to that of electrodes that conform to the inner cylindrical surface of the rotor.

25 ENERGY STORAGE↗

DOE OSTI2020

Microwave Cavity Simulation Using Ansys HFSS

The design of microwave cavity detectors for axion dark matter research is often accomplished using advanced full-wave electromagnetic simulation software tools. These tools provide a cost-effective approach to evaluate a wide variety of cavity configurations, frequency tuning mechanisms, and conductive or dielectric materials and coatings. One simulation software package used for this application is Ansys High Frequency Structure Simulator (HFSS), which is based upon the well-established finite element method. HFSS includes numerous features useful for microwave cavity design such as parametric geometry modeling, adaptive meshing algorithm, curvilinear mesh elements, driven modal and eigenmode matrix solvers, and optimization algorithms. This paper describes the use of the HFSS software to simulate microwave cavities for axion haloscope detectors, with an example tutorial for a cylindrical cavity. Excellent agreement between the simulated and analytical results is shown for the resonant frequency, quality factor, and form factor.

Ansys HFSS, Cavity simulation, finite element mode↗

DOE OSTI2021

Wien filter with integrated vacuum pump

An integral Wien filter and vacuum pump for separating charged particles or for orienting their spin direction while maintaining optimal beamline vacuum. The vacuum pump is an ion pump including one or more cylindrical Penning cells to trap and expel electrons. The Wien filter includes orthogonal electric and magnetic fields to direct particles with the desired speed through the device while deflecting particles at undesired speeds. The Wien filter includes two electrodes, one biased positive and one biased negative, a dipole magnet, and means for reversing polarity of the electrodes to flip the spin of the charged particles. Metal plates on either side of the Penning cells embed gas that is ionized by trapped electrons in the Penning cell thus creating vacuum by turning gas into solid. The two metal plates can be configured to obtain vacuum pumping via chemical gettering and for removal of noble gases.

Poelker, Bernard Matthew↗

DOE OSTI2024

Path-Integrated Stereo X-Ray Digital Image Correlation: Resolving the Violation of Conservation of Intensity

In this study, x-ray imaging addresses many challenges with visible light imaging in extreme environments, where optical diagnostics such as digital image correlation (DIC) and particle image velocimetry (PIV) suffer biases from index of refraction changes and/or cannot penetrate visibly occluded objects. However, conservation of intensity—the fundamental principle of optical image correlation algorithms—may be violated if ancillary components in the X-ray path besides the surface or fluid of interest move during the test. The test series treated in this work sought to characterize the safe use of fiber-epoxy composites in aerospace and aviation industries during fire accident scenarios. Stereo X-ray DIC was employed to measure test unit deformation in an extreme thermal environment involving a visibly occluded test unit, incident surface heating to temperatures above 600°C, and flames and soot from combusting epoxy decomposition gasses. The objective of the current work is to evaluate two solutions to resolve the violation of conservation of intensity that resulted from both the test unit and the thermal chamber deforming during the test. The first solution recovered conservation of intensity by pre-processing the path-integrated X-ray images to isolate the DIC pattern of the test unit from the thermal chamber components. These images were then correlated with standard, optical DIC software. The second solution, called Path-Integrated Digital Image Correlation (PI-DIC), modified the fundamental matching criterion of DIC to account for multiple, independently-moving components contributing to the final image intensity. The PI-DIC algorithm was extended from a 2D framework to a stereo framework and implemented in a custom DIC software. Both solutions accurately measured the cylindrical shape of the undeformed test unit, recovering radii values of R = 76.20±0.12 mm compared to the theoretical radius of R theor = 76.20 mm. During the test, the test unit bulged asymmetrically as decomposition gasses pressurized the interior and eventually burned in a localized jet. Both solutions measured the heterogeneous radius of this bulge, which reached a maximum of approximately R = 91 mm, with a discrepancy of 2–3% between the two solutions. Two solutions that resolve the violation of conservation of intensity for path-integrated X-ray images were developed. Both were successfully employed in a stereo X-ray DIC configuration to measure deformation of an aluminum-skinned, fiber-epoxy composite test unit in a fire accident scenario.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Molecular Dynamics Simulation and Cryo-Electron Microscopy Investigation of AOT Surfactant Structure at the Hydrated Mica Surface

Structural properties of the anionic surfactant dioctyl sodium sulfosuccinate (AOT or Aerosol-OT) adsorbed on the mica surface were investigated by molecular dynamics simulation, including the effect of surface loading in the presence of monovalent and divalent cations. The simulations confirmed recent neutron reflectivity experiments that revealed the binding of anionic surfactant to the negatively charged surface via adsorbed cations. At low loading, cylindrical micelles formed on the surface, with sulfate head groups bound to the surface by water molecules or adsorbed cations. Cation bridging was observed in the presence of weakly hydrating monovalent cations, while sulfate groups interacted with strongly hydrating divalent cations through water bridges. The adsorbed micelle structure was confirmed experimentally with cryogenic electronic microscopy, which revealed micelles approximately 2 nm in diameter at the basal surface. At higher AOT loading, the simulations reveal adsorbed bilayers with similar surface binding mechanisms. Adsorbed micelles were slightly thicker (2.2–3.0 nm) than the corresponding bilayers (2.0–2.4 nm). Upon heating the low loading systems from 300 K to 350 K, the adsorbed micelles transformed to a more planar configuration resembling bilayers. The driving force for this transition is an increase in the number of sulfate head groups interacting directly with adsorbed cations.

58 GEOSCIENCES↗

DOE OSTI2025

An experimental study of the existence regions and non-linear interactions of drift wave and Kelvin–Helmholtz instabilities in a linear magnetized plasma

Experimental observations of the intrinsic excitation and non-linear interactions of drift wave (DW) and Kelvin–Helmholtz (KH) instabilities in a linear magnetized plasma column are presented. The experiments are carried out in the inverse mirror plasma experimental device (IMPED)—a cylindrical, magnetized, linear plasma machine designed to study low-frequency waves and instabilities in plasma. A novel feature of IMPED is the ability to control plasma profiles, such as the density n(r)⁠, electron temperature T e (r)⁠, and plasma potential V p (r) by varying the ratio Rm of the magnetic field in the main chamber to that in the source chamber. At high values of Rm, higher-density gradient scale length promotes the drift wave (DW) instability while lower Rm value results in a higher radial electric field, inducing a sheared poloidal flow that enhances the dominance of the Kelvin–Helmholtz (KH) mode. The background and fluctuating plasma parameters are characterized using various configurations of multiple in situ electric probes at different spatial locations to quantify the local gradients that excite the low-frequency primary instabilities. Statistical, spectral, and bispectral analysis of the density and potential signals help identify these modes in terms of wave number, frequency, phase, and amplitude and also delineate the nature of their non-linear interactions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Epoxy-based infrared filter assembly and associated fabrication devices and method

Epoxy-based inline infrared (IR) filter assembly, and manufacture and use of the same. Co-axial infrared filter assemblies comprise a substantially cylindrical filter body forming a central cavity characterized by opposing holes at each end. The filter body forms an outer conductor, and SMA connectors coupled to the opposing holes at each end of the body are electrically coupled to form an inner conductor positioned along a long axis of the filter body. An infrared absorbing material (such as castable epoxy resin) fills the central cavity of the filter body. Methods for producing the co-axial infrared filter include pressing SMA connectors into the respective ends of the filter body, electrically coupling the SMA connectors, and filling the filter body with epoxy. Electronic systems for operating a dark matter detector include a feedline comprising a coaxial filter configured to advantageously block infrared noise.

Spahn, Gabriel↗

DOE OSTI2022

Optimization of the moderators in the STS preliminary design

This report details the results for an optimization of the dimensions of the moderators in the preliminary design of the Spallation Neutron Source Second Target Station (STS). This study uses the optimization algorithms of Dakota and an unstructured mesh model for the moderators in MCNP. More details on the unstructured mesh model and the automated mesh generation can be found in [3]. Parallel to this effort, the same moderator geometries have been optimized using a constructive solid geometry (CSG) MCNP model. More details on this model and its results can be found in [4]. Three optimal designs are selected for each moderator: one that is optimized for maximum peak brightness, one for maximum time-integrated brightness, and one for a combination of peak and time-integrated brightness. The backbone of the optimization work flow is provided by Dakota. For each set of design parameters requested by Dakota, a new solid geometry is automatically built in Creo and SpaceClaim, and subsequently exported to Attila4MC to generate an unstructured mesh geometry for MCNP. After the MCNP calculation is finished, the objective function (e.g., brightness metric) is returned to Dakota. After the new design has been evaluated, a result-file is written, and Dakota proposes the next set of design parameters to be evaluated. The loop continues until a specified convergence criterion has been met. The design parameters of the cylindrical (upper) moderator include the hydrogen radius, the premoderator thickness (top, bottom, radial), the beryllium radius and the horizontal position of the moderator. The crucial design choice is the hydrogen radius. A radius of 62 mm is shown to provide the maximum time-integrated brightness. The maximum peak brightness occurs with a radius of 40 mm. A combined (middle) design, which balances peak and time-integrated brightnesses, is obtained with a hydrogen radius of 50 mm. The premoderator thicknesses and the beryllium radius are slightly larger in the design optimized for time-integrated brightness than in the design optimized for peak brightness. The sensitivity to these two parameters is relatively small close to the optimal configurations. The hydrogen vessel and vacuum vessel wall thicknesses are dependent on the radius of the liquid hydrogen due to structural integrity requirements. The increased wall thicknesses for larger vessels significantly penalize the time-integrated brightness, with the maximum obtainable value reduced by more than 10% relative to earlier studies which used fixed vessel wall thicknesses. The impact of the variable wall thicknesses is much less for the peak brightness and combined brightness designs. The design parameters of the tube (lower) moderator selected for the optimization are the tube length, the annular premoderator thickness, the beryllium radius and the horizontal position of the moderator. The tube length is the crucial parameter and is chosen large (210 mm) and small (125 mm) in the designs optimized for time-integrated and peak brightness respectively. A combined optimal design has a tube length of 170 mm. The premoderator thickness and the beryllium radius are chosen larger in the design optimized for time-integrated brightness.

42 ENGINEERING↗

DOE OSTI2023

A conservative Galerkin solver for the quasilinear diffusion model in magnetized plasmas

We propose a conservative Galerkin scheme for the quasilinear model in three-dimensional momentum space and three-dimensional spectral space, with cylindrical symmetry. We construct an unconditionally conservative weak form and use a discretization that preserves conservation properties independent of the wave emission probability. The discrete operators, combined with a consistent quadrature rule, preserve all the conservation laws rigorously. The proposed scheme is quite general: it works for both relativistic and non-relativistic systems, for both magnetized and unmagnetized plasmas, and even for problems with time-dependent dispersion relations. We represent the particle distribution by continuous basis functions and use discontinuous basis functions for the wave spectral energy density, which enables the application of a positivity-preserving technique. We adopt the marching simplex algorithm, designed initially for computer graphics, for numerical integration on the resonance manifold. Furthermore, the numerical examples with a bump-on-tail initial configuration show how the unstable waves produce strong momentum space diffusion.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Tomographic optical emission spectroscopy of an atmospheric pressure plasma jet and surface ionization waves on planar and structured surfaces

Here in this paper, an approach for 3D plasma structure diagnostics using tomographic optical emission spectroscopy (Tomo-OES) of a nanosecond pulsed atmospheric pressure plasma jet (APPJ) is presented. In contrast to the well-known Abel inversion, Tomo-OES does not require cylindrical symmetry to recover 3D distributions of plasma light emission. Instead, many 2D angular projections are measured with intensified cameras and the multiplicative algebraic reconstruction technique is used to recover the 3D distribution of light emission. This approach solves the line-of-sight integration problem inherent to optical diagnostics, allowing recovery of localized OES information within the plasma that can be used to better infer plasma parameters within complex plasma structures. Here, Tomo-OES was applied to investigate an APPJ operated with helium in ambient air and impinging on planar and structured dielectric surfaces. Surface charging caused the guided streamer from the APPJ to transition to a surface ionization wave (SIW) that propagated along the surface. The SIW experienced variable geometrical and electrical material properties as it propagated, leading to 3D configurations that were non-symmetric and spatially complex. Light emission from He, N$_2^+$, and N2 were imaged at ten angular projections and the respective time-resolved 3D emission distributions in the plasma were then reconstructed. The spatial resolution of each tomographic reconstruction was 7.4 µm and the temporal resolution was 5 ns, sufficient to observe the guided streamer and the effects of the structured surface on the SIW. Emission from He showed the core of the jet and emission from N$_2^+$ and N2 indicated effects of entrainment of ambient air. Penning ionization of N2 created a ring or outer layer of N$_2^+$ that spatially converged to form the 'plasma bullet' or spatially diverged across a surface as part of a SIW. The SIW entered trenches of size 150 µm, leading to decreases in plasma light emission in regions above the trenches. The plasma light emission was higher in some regions with trenches, possibly due to effects of field enhancement.

plasma interactions with complex surfaces↗

DOE OSTI2025

Directed Self-Assembly of the Organic Semiconductor C8-BTBT-C8 in Anodic Aluminum Oxide Nanopores

Controlling the self-assembly of organic semiconductors at the nanoscale is critical for advancing high-performance electronic and photonic devices, yet it remains challenging due to their intrinsic anisotropic crystallization and sensitivity to processing conditions. Here, in this study, we demonstrate that cylindrical nanoconfinement within anodic aluminum oxide membranes provides a versatile platform to precisely tune the molecular orientation and phase behavior of the prototypical organic semiconductor 2,7-dioctyl[1]benzothieno[3,2-b][1]benzothiophene (C8-BTBT-C8). Combining temperature-dependent high-resolution synchrotron X-ray scattering with optical birefringence measurements, we uncover that confinement geometries (pore diameters 25–180 nm) and surface chemistry govern the emergence of distinct smectic A textures, featuring molecular layers either parallel or perpendicular to the pore axis. The competition between axial and radial smectic layering is modulated by pore size, surface hydrophilicity, and thermal history, enabling reversible control over domain orientations and transitions between liquid crystalline and crystalline states. Notably, nanoconfinement stabilizes the smectic phase over an expanded temperature range compared to bulk, while inducing complex multidomain configurations owing to geometric constraints and anchoring conditions. Our results elucidate fundamental mechanisms by which anisotropic nanoscale confinement directs the self-organization of highly conjugated organic molecules, with implications for optimizing directional charge transport and anisotropic optical responses in organic–inorganic hybrid nanoarchitectures. This study establishes nanoconfinement as a powerful strategy to engineer morphology and functional properties in organic semiconducting materials with nanoscale precision.

36 MATERIALS SCIENCE↗