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All sources NASA NTRS DOE OSTI

DOE OSTI2023

ac susceptibility studies of intra- and intergrain properties of high-$J_c$ Bi-2212 wires

Bi 2 Sr 2 CaCu 2 O x (Bi-2212) is the only high-$T_c$ superconductor (HTS) available as a multifilamentary round wire with multiple architectures and it is a very promising conductor for the realization of high-field applications. Despite their relatively simple wire fabrication by the powder-in-tube technique, Bi-2212 wires require a tightly controlled overpressure heat treatment (HT) with a multi-parameter time-temperature schedule to achieve high critical current density, $J_c$. Further, the variation of these HT parameters, changes in the wire design, wire diameter and powder quality can lead to variations in both the microstructure and the superconducting performance. Particularly noticeable are variations in $J_c$ performance and degree of filament bridging. In this work, we focus on the use of different magnetic characterization techniques to estimate the bridging level and assess the balance of INTER-grain and intra-grain superconducting properties including the irreversibility field ($H_{\text{irr}}$) and the pinning energy ($U_0$) in differently processed wires. Regardless of the actual bridging level, we find that the supercurrent flows at the filament bundle level, not just at the individual filament level. Moreover, using AC susceptibility we identify two distinct supercurrent contributions, one related to the intra-grain and one to the INTER-grain properties, whose irreversibility fields are different but without large sample-to-sample variation. Moreover, an additional component of intra-grain pinning mechanism becomes effective at low temperatures with positive effects also on the INTER-grain performance. The work clearly shows that detailed magnetic characterizations can become valuable tools to investigate the performance of differently processed Bi-2212 wires, correlating their microstructure and overall transport $J_c$, to obtain a deeper understanding of the causes of performance variation and paths to achieve further improvement.

2212↗

DOE OSTI2025

Voltage-Current Behavior of a Superconducting STAR ® Wire in a 6-Around-1 Cable Configuration

A 6-around-1 transposed cable using superconducting STAR® wires can be useful for future circular collider applications. We made three cable samples using single STAR® wires with a diameter of 1.3 mm. The first two samples, made with a cabling machine, used STAR® wires consisting of a 0.7 mm diameter Nb-Ti core. The third cable sample was manually wound and used a STAR® wire made with a 0.81 mm diameter Cu core. The first sample showed severe degradation after the cable was bent to a 75 mm radius. The current-carrying capability of the innermost and outermost REBCO tapes in the STAR® wire degraded by 42% to 98% and the middle REBCO tapes remained intact. This was also the case for the second and straight cable sample. After fabrication of the third cable sample, we observed only about 5% reduction in the current along the wire, measured at different locations inside the terminations. Finally, the results indicate that the differences in architecture or fabrication of the STAR® wires could have caused differences in critical current retention after cabling.

6-around-1 cable↗

DOE OSTI2025

Analysis Background & Noise in Stretched Wire Alignment Technique Measurements

The Stretched-Wire Alignment Technique (SWAT) is one method of magnet alignment for linear induction accelerators. The applications of SWAT have been implemented for aligning solenoid magnets on the Scorpius linear induction accelerator which will be sited at the Nevada National Security Site and the Flash X-Ray (FXR) linear induction accelerator at Lawrence Livermore National Laboratory’s Contained Firing Facility. This article describes both systematic (repeatable) and random sources of background and noise as well as practical ways to eliminate or reduce them to acceptable levels. Systematic sources include reflections from wire ends, rapid sag due to ohmic heating of the wire, magnetic materials, and shot rate. Random sources include air currents, vibration of nearby equipment, mechanical stability of test equipment, and the instruments used to measure the wire motion. Mitigations include curve fitting and adaptive noise signal cancellation, and mechanical damping. Finite Element Analysis (FEA) was used to identify and resolve a repeatable wire vibration frequency interfering with the signal resolution. Two stretched wire alignment technique set ups from Sandia National Labs and Lawrence Livermore National Lab have shown background noise sources and ways of mitigating them by either analysis methods or change of mechanical configuration. Conclusions that were drawn included the severe sensitivity of the deflection to even small external interferences of the SWAT wire such that it requires attention to detail in mechanical set up and analysis.

Linear Inductive Accelerator↗

DOE OSTI2020

EVALUATION OF PRESSURE DROP CORRELATIONS FOR THE WIRE-WRAPPED ROD BUNDLES

The accurate prediction of pressure drop in the fuel rod bundle is of importance for the design and thermal-hydraulic analysis of nuclear reactor system. Due to very complex geometry of wire-wrapped fuel rod bundle geometry for the Sodium Fast Reactor (SFR), a simple method using hydraulic (equivalent) diameter is not sufficient to predict the pressure drop of rod bundle accurately. For several decades, many experimental works have been performed to develop an accurate correlation for wire-wrapped fuel bundle friction factor. In these works, the friction factor correlation of wire-wrapped fuel bundle has been developed as a function of Reynolds number of the flow and the design parameters such as fuel pin diameter, wire diameter, rod pitch, and wire lead length. The Cheng and Todreas correlations are well-known and used in many subchannel analysis code, such as CADET, TRIO-U, MATRA-LMW, SE2-ANL, etc. Novendstern model, Rehme model, Baxi and Dalle Donne model are also well-known and widely referred. Computational Fluid Dynamics is another typical approach to predict the pressure drop of wire-wrapped fuel rod bundle, but it requires the model validation because the accuracy of pressure drop prediction by the CFD simulation depends on what turbulence model is employed. The present work aims at evaluating the existing pressure drop correlations for the wire-wrapped fuel rod bundle and evaluating the pressure drop of 217-pin rod bundle by the CFD analysis.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Investigating Electron Conductivity Regimes in the Bacterial Cytochrome Wire OmcS

The anaerobic bacterium Geobacter sulfurreducens produces extracellular, electronically conductive cytochrome polymer wires that are conductive over micron length scales. Structure models from cryo-electron microscopy data show OmcS wires form a linear chain of hemes along the protein wire axis, which is proposed as the structural basis supporting their electronic properties. However, the mechanism by which this heme arrangement supports long-range electronic conduction remains unknown. Structure models from cryo-electron microscopy data show these wires form a linear chain of hemes along the protein wire axis, which is proposed as the structural basis supporting their electronic properties. Existing computational models using static heme redox potentials and coupling energies fail to explain experimental observations, predicting conductances 10,000 to 100,000 times lower than measured values. Here, we investigate how dynamic disorder affects site energies, interheme coupling, and long-range electronic conductivity within these cytochrome wires. We introduce an approach to extract charge carrier site information directly from Kohn–Sham density functional theory, without employing projector schemes, and show that site and coupling energies are highly sensitive to changes in interheme geometry and the surrounding electrostatic environment. Unlike models that incorporate dynamic disorder as a thermally averaged quantity, our quantum charge carrier model incorporates proxies for dynamic disorder through decoherence corrections, yielding predicted diffusion coefficient closer to what is expected from experiment and comparable with other organic-based electronic materials. Based on these simulations, we propose that the instantaneous fluctuations of the local electrostatic environment can transiently lift energy degeneracies and delocalize charge carriers. Furthermore, these studies reveal how incorporating dynamic fluctuations associated with the environment resolves the discrepancy between theory and experiment in microbial cytochrome wires and highlight design principles for bioinspired, heme-based conductive materials.

Bioinorganic chemistry↗

DOE OSTI2023

The Simons Observatory: A fully remote controlled calibration system with a sparse wire grid for cosmic microwave background telescopes

For cosmic microwave background (CMB) polarization observations, calibration of detector polarization angles is essential. We have developed a fully remote controlled calibration system with a sparse wire grid that reflects linearly polarized light along the wire direction. The new feature is a remote-controlled system for regular calibration, which has not been possible in sparse wire grid calibrators in past experiments. The remote control can be achieved by two electric linear actuators that load or unload the sparse wire grid into a position centered on the optical axis of a telescope between the calibration time and CMB observation. Furthermore, the sparse wire grid can be rotated by using a motor. A rotary encoder and a gravity sensor are installed on the sparse wire grid to monitor the wire direction. They allow us to achieve detector polarization angle calibration with an expected systematic error of 0.08°. The calibration system will be installed in small-aperture telescopes at Simons Observatory.

47 OTHER INSTRUMENTATION↗

DOE OSTI2020

Etching sharp tips from thin metallic wires for tuning-fork-based scanning probe microscopy

Sharp tips are critical for obtaining high resolution images in scanning probe microscopy (SPM), particularly in samples with large variations in topography. For tuning-fork-based SPM, such tips are commonly obtained by electrochemical etching of metallic wires (e.g., tungsten). Electrochemical etching of metallic wires is the preferred means of preparing tips for scanning tunneling microscopy (STM), and techniques for obtaining sharp tips have been investigated extensively. However, the requirements for STM and tuning-fork-based SPM are different. In particular, the wires used in STM are typically 250-500 μ m in diameter, while the wires used for tuning-fork-based SPM are usually an order of magnitude narrower in order to minimize loading of the tuning fork: 25-50 μ m and sometimes down to a few micrometers in diameter. Consequently, many of the recipes developed for etching thicker metallic wires for STM tips do not give optimal results for smaller diameter wires. The authors describe here a modification of the etching circuit of Ibe et al . that significantly improves the reproducibility and reliability of the etching process for thin wires, and discuss the parameters that affect the aspect ratio of produced tips.

42 ENGINEERING↗

DOE OSTI2022

WIRE-21 Sensor Irradiation Experiment Ready for HFIR Insertion

The ability to deploy new nuclear fuels for current or future reactor concepts requires a wealth of data regarding fuel performance during normal operation, anticipated operational occurrences, and design-basis accidents. Most of these data have historically been collected during experiments in materials test reactors, ideally with online instrumentation to collect as much data as possible. However, advanced instrumentation could also allow for in situ monitoring of fuel operating conditions during commercial reactor operation to maximize fuel utilization, reduce unnecessary conservativism in design margins, and improve operator understanding of limiting peaking factors. The latter approach would complicate fuel handling, particularly during refueling, unless the instrumentation could be placed inside the fuel rods and transmitted wirelessly to a receiver located outside the fuel’s primary pressure boundary. To this end, Westinghouse Electric Company (WEC) developed wireless sensors based on inductive coupling that can transmit information regarding fuel centerline temperatures and rod internal pressures wirelessly from within a fuel rod to a nearby instrument thimble. After testing these sensors in lower-power university research reactors, the next step is to perform high neutron fluence testing to characterize the performance of these wireless sensors under conditions that are more representative of the intended application—in this case, light-water reactors (LWRs). The removable Be (RB) positions of the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL) provide the neutron flux, experiment volume, and access to instrument leads required to achieve these sensor testing goals. This report summarizes the design, analysis, and assembly of the Wireless Instrumented RB Experiment 2021 (WIRE-21). This is the most highly instrumented irradiation experiment ever performed in HFIR. The experiment will use seven different sensing techniques to measure temperature, pressure, neutron flux, and neutron fluence during reactor operation. In addition to WEC’s wireless temperature and pressure sensors, WIRE-21 includes an array of thermocouples, self-powered neutron detectors, spatially distributed fiber optic temperature sensors, passive SiC temperature monitors, and flux wires. The design of WIRE-21 and the cabling that was installed in HFIR also provide the infrastructure to enable accelerated, economical testing of advanced sensor technologies while leveraging the extremely high neutron flux that is available in HFIR. The containment for WIRE-21 is similar to previous RB irradiation vehicles but includes a few modifications, most notably the use of integrated compression seals to pass a larger number of sensor leads through the experiment’s pressure boundary. In addition to the sensor leads, inert gas lines are passed into the experiment to enable active temperature control and the ability to pneumatically actuate a bellows-driven pressure sensor. WIRE-21 is targeting component temperatures (300–350°C) and neutron fluence levels (~10 22 n/cm 2 ) that would be expected in the plenum region of LWR fuels, except for the active sensing region of the wireless temperature sensor, which is targeting LWR fuel centerline temperatures (~800–1,100°C). WIRE-21 was successfully assembled, passed all nondestructive examination, and was delivered to HFIR for insertion during upcoming cycle 498 (April 2022).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1972

Development of explosively bonded TZM wire reinforced Columbian sheet composites

Methods of producing TZM molybdenum wire reinforced C129Y columbium alloy composites by explosive welding were studied. Layers of TZM molybdenum wire were wound on frames with alternate layers of C129Y columbium alloy foil between the wire layers. The frames held both the wire and foils in place for the explosive bonding process. A goal of 33 volume percent molybdenum wire was achieved for some of the composites. Variables included wire diameter, foil thickness, wire separation, standoff distance between foils and types and amounts of explosive. The program was divided into two phases: (1) development of basic welding parameters using 5 x 10-inch composites, and (2) scaleup to 10 x 20-inch composites.

Otto, H. E.↗

NASA NTRS1976

Impact tensile testing of wires

The test consists of fixing one end of a wire specimen and allowing a threaded falling weight to strike the other. Assuming the dynamic stress in the wire to be a function only of its strain, energy considerations show for negligible wire inertia effects that the governing dynamic stress-strain law can be determined directly from impact energy vs. wire elongation data. Theoretical calculations are presented which show negligible wire inertia effects for ratios of wire mass to striking mass of the order of .01 or less. The test method is applied to soft copper wires and the dynamic stress-strain curve so determined is found to be about 30 percent higher than the corresponding static curve.

Dawson, T. H.↗

NASA NTRS1978

Wire stripper

An insulation stripper is described which is especially useful for shielded wire, the stripper including a first pair of jaws with blades extending substantially perpendicular to the axis of the wire, and a second pair of jaws with blades extending substantially parallel to the axis of the wire. The first pair of jaws is pressed against the wire so the blades cut into the insulation, and the device is turned to form circumferential cuts in the insulation. Then the second pair of jaws is pressed against the wire so the blades cut into the insulation, and the wire is moved through the device to form longitudinal cuts that permit easy removal of the insulation. Each of the blades is located within the concave face of a V-block, to center the blades on the wire and to limit the depth of blade penetration.

Economu, M. A.↗

NASA NTRS1995

Hot-wire calibration in subsonic/transonic flow regimes

A different approach for calibrating hot-wires, which simplifies the calibration procedure and reduces the tunnel run-time by an order of magnitude was sought. In general, it is accepted that the directly measurable quantities in any flow are velocity, density, and total temperature. Very few facilities have the capability of varying the total temperature over an adequate range. However, if the overheat temperature parameter, a(sub w), is used to calibrate the hot-wire then the directly measurable quantity, voltage, will be a function of the flow variables and the overheat parameter i.e., E = f(u,p,a(sub w), T(sub w)) where a(sub w) will contain the needed total temperature information. In this report, various methods of evaluating sensitivities with different dependent and independent variables to calibrate a 3-Wire hot-wire probe using a constant temperature anemometer (CTA) in subsonic/transonic flow regimes is presented. The advantage of using a(sub w) as the independent variable instead of total temperature, t(sub o), or overheat temperature parameter, tau, is that while running a calibration test it is not necessary to know the recovery factor, the coefficients in a wire resistance to temperature relationship for a given probe. It was deduced that the method employing the relationship E = f (u,p,a(sub w)) should result in the most accurate calibration of hot wire probes. Any other method would require additional measurements. Also this method will allow calibration and determination of accurate temperature fluctuation information even in atmospheric wind tunnels where there is no ability to obtain any temperature sensitivity information at present. This technique greatly simplifies the calibration process for hot-wires, provides the required calibration information needed in obtaining temperature fluctuations, and reduces both the tunnel run-time and the test matrix required to calibrate hotwires. Some of the results using the above techniques are presented in an appendix.

Nagabushana, K. A.↗

NASA NTRS1995

NASA wiring for space applications program

An overview of the NASA Wiring for Space Applications Program and its relationship to NASA's space technology enterprise is given in viewgraph format. The mission of the space technology enterprise is to pioneer, with industry, the development and use of space technology to secure national economic competitiveness, promote industrial growth, and to support space missions. The objectives of the NASA Wiring for Space Applications Program is to improve the safety, performance, and reliability of wiring systems for space applications and to develop improved wiring technologies for NASA flight programs and commercial applications. Wiring system failures in space and commercial applications have shown the need for arc track resistant wiring constructions. A matrix of tests performed versus wiring constructions is presented. Preliminary data indicate the performance of the Tensolite and Filotex hybrid constructions are the best of the various candidates.

Schulze, Norman↗

NASA NTRS1999

Autonomous Command Operations of the WIRE Spacecraft

This paper presents operational innovations which will be introduced on NASA's Wide Field Infrared Explorer (WIRE) mission. These innovations include an end-to-end design architecture for an autonomous commanding capability for the uplink of command loads during unattended station contacts. The WIRE mission is the fifth and final mission of NASA's Goddard Space Flight Center Small Explorer (SMEX) series to be launched in March of 1999. Its primary mission is the targeting of deep space fields using an ultra-cooled infrared telescope. Due to its mission design WIRE command loads are large (approximately 40 Kbytes per 24 hours) and must be performed daily. To reduce the cost of mission operations support that would be required in order to uplink command loads, the WIRE Flight Operations Team has implemented all autonomous command loading capability. This capability allows completely unattended operations over a typical two-day weekend period. The key factors driving design and implementation of this capability were: 1) integration with already existing ground system autonomous capabilities and systems, 2) the desire to evolve autonomous operations capabilities based upon previous SMEX operations experience - specifically the TRACE mission, 3) integration with ground station operations - both autonomous and man-tended, 4) low cost and quick implementation, and 5) end-to-end system robustness. A trade-off study was performed to examine these factors in light of the low-cost, higher-risk SMEX mission philosophy. The study concluded that a STOL (Spacecraft Test and Operations Language) based script, highly integrated with other scripts used to perform autonomous operations, was best suited given the budget and goals of the mission. Each of these factors is discussed in addition to use of the TRACE mission as a testbed for autonomous commanding prior to implementation on WIRE. The capabilities implemented on the WIRE mission are an example of a low-cost, robust, and efficient method for autonomous command loading when implemented with other autonomous features of the ground system. They call be used as a design and implementation template by other missions interested in evolving toward autonomous and lower cost operations. Additionally, the WIRE spacecraft will be used as an operational testbed upon completion of its nominal mission later in 1999. One idea being studied is advanced on-board modeling. Advanced on-board modeling techniques will be used to more efficiently display the spacecraft state. This health and safety information could be used by engineers on the ground or could be used by tile spacecraft for its own assessments. Additionally, this same state information could also be input into the event-driven scheduling system, as the scheduling system will need to assess the spacecraft state before undertaking a new activity. Advanced modeling techniques are being evaluated for a number of NASA missions including The Next Generation Space Telescope (NGST), which is scheduled to launch in 2007.

Walyus, Keith↗

NASA NTRS2003

Aging Wire Insulation Assessment by Phase Spectrum Examination of Ultrasonic Guided Waves

Wire integrity has become an area of concern to the aerospace community including DoD, NASA, FAA, and Industry. Over time and changing environmental conditions, wire insulation can become brittle and crack. The cracks expose the wire conductor and can be a source of equipment failure, short circuits, smoke, and fire. The technique of using the ultrasonic phase spectrum to extract material properties of the insulation is being examined. Ultrasonic guided waves will propagate in both the wire conductor and insulation. Assuming the condition of the conductor remains constant then the stiffness of the insulator can be determined by measuring the ultrasonic guided wave velocity. In the phase spectrum method the guided wave velocity is obtained by transforming the time base waveform to the frequency domain and taking the phase difference between two waveforms. The result can then be correlated with a database, derived by numerical model calculations, to extract material properties of the wire insulator. Initial laboratory tests were performed on a simple model consisting of a solid cylinder and then a solid cylinder with a polymer coating. For each sample the flexural mode waveform was identified. That waveform was then transformed to the frequency domain and a phase spectrum was calculated from a pair of waveforms. Experimental results on the simple model compared well to numerical calculations. Further tests were conducted on aircraft or mil-spec wire samples, to see if changes in wire insulation stiffness can be extracted using the phase spectrum technique.

Anastasi, Robert F.↗

NASA NTRS2004

Non-Destructive Evaluation of Wire Insulation and Coatings

The present invention uses the generation and detection of acoustic guided waves to evaluate the condition of the insulation on electrical wiring. Low order axisymmetric and flexural acoustic modes are generated in the insulated wire and travel partially in the center conductor and partially in the outer insulation. The stiffness of the insulation and the insulation's condition affect the overall wave speed and amplitude of the guided wave. Analysis of the received signal provides information about the age or useful life of the wire insulation. In accordance with the present invention, signal transmission occurs at one location on the electrical wire to be evaluated, and detection occurs at one or more locations along the electrical wire. Additional receivers can be used to improve measurement accuracy. Either the transmission transducer or one or more receiver transducers may be angled at other than 90 degrees to the wire. Generation of the guided waves can be accomplished by imparting a pressure pulse on the wire. Alternative embodiments include generation via a laser, such as a Q-switched laser or a laser diode.

Eric I Madaras↗

NASA NTRS2007

Wire Crimp Termination Verification Using Ultrasonic Inspection

The development of a new ultrasonic measurement technique to quantitatively assess wire crimp terminations is discussed. The amplitude change of a compressional ultrasonic wave propagating through the junction of a crimp termination and wire is shown to correlate with the results of a destructive pull test, which is a standard for assessing crimp wire junction quality. Various crimp junction pathologies such as undercrimping, missing wire strands, incomplete wire insertion, partial insulation removal, and incorrect wire gauge are ultrasonically tested, and their results are correlated with pull tests. Results show that the nondestructive ultrasonic measurement technique consistently (as evidenced with destructive testing) predicts good crimps when ultrasonic transmission is above a certain threshold amplitude level. A physics-based model, solved by finite element analysis, describes the compressional ultrasonic wave propagation through the junction during the crimping process. This model is in agreement within 6% of the ultrasonic measurements. A prototype instrument for applying this technique while wire crimps are installed is also presented. The instrument is based on a two-jaw type crimp tool suitable for butt-splice type connections. Finally, an approach for application to multipin indenter type crimps will be discussed.

Perey, Daniel F.↗

NASA NTRS2007

Fabrication of a Thermally Isolated and Pre-amplified Transistor Module with Polyimide Micro-wires for Cryogenic Detectors

For use in cryogenic applications such as bolometer and x-ray microcalorimeter arrays, pre-amplifying Junction Field Effect Transistors (JFETs) are often required for the readout electronics. The optimum operating temperature of the JFETs is 130 Kelvin while the cryogenic detectors operate in the milli-Kelvin range. Thus, the JFETs must be heated up but thermally isolated from the surrounding cryogenic instruments. In the past, the thermal isolation was accomplished by suspending the JFETs with low conductance wires such as manganium or stainless steel on a Kevlar support platform [I]. This also achieved electrical connections. However, this assembly required manual soldering work, which could raise a reliability issue for the cryogenic applications. In order to eliminate the manual work, polyimide micro-wires were developed [2]. The wires must be of sufficient length to decrease the heat load and in tension to prevent microphonic noise from vibration of the wires: the polyimide wires were patterned into llS"shaped curves over a thin metal wires such as aluminum, titanium, or niobium. The bilayer of the films were then suspended by etching silicon substrate thus to make freestanding air bridges (enough explanation?). In this paper, we present a method to fabricate micromachined JFET mechanical modules suspended by polyimide Pyraline micro-wires and heated up with built-in aluminum micro-heaters.

Oh, L. H.↗