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Oak Ridge National Laboratory (ORNL) worked with Whirlpool Corporation to demonstrate additive manufacturing (AM) of stamping dies for the appliance industry using a large-scale wire arc metal additive manufacturing system jointly developed between Lincoln Electric and ORNL. An appliance stamping die was successfully printed, machined, nitrided, and demonstrated in the last quarter of 2019.
Improvised explosive devices (IEDs) have injured and killed numerous soldiers and civilians as a consequence of military operations in the Middle East. With gaps in existing technologies, the US military required devices for quickly addressing deadly IEDs without harming military personnel or inflicting severe damage to the environment. In response to this need, Sandia developed Stingray, a clear, plastic handheld device to quickly and safely disable threatening IEDs. Stingray is designed to be used in two configurations: a coherent water blade for cutting operations and as a water slug for general device disruption. Prior to disabling an IED, Explosive Ordnance Disposal (EOD) technicians will x-ray the target using tools such as Sandia's X-ray Toolkit (XTK) to determine which function operators should use to dismantle the IED. For example, if the operator knows exactly which wires to cut, they can use the precision water blade. If the operator wants to create a general disruption, they can use the water slug function.
This report contains a figure and caption. Left: Compton radiographs of a 3-shock HDC THD layered implosion recorded 10ps before and 160ps after bang-time (BT) at the NIF, using >50keV point projection backlighters generated by irradiating a 25μm-diameter Au wire with 30ps-long ARC pulses. Right: Reconstructed density distributions of fuel and remaining ablator showing significant 3D structure and top-down asymmetry.
This report covers the work performed in support of the ASC Integrated Codes FY20 Milestone 7179. For the Milestone, Sandia's Xyce analog circuit simulator was enhanced to enable a loose coupling to Sandia's EIGER electromagnetic (EM) simulation tool. A device was added to Xyce that takes as its input network parameters (representing the impedance response) and short-circuit current induced in a wire or other element, as calculated by an EM simulator such as EIGER. Simulations were performed in EIGER and in Xyce (using Harmonic Balance analysis) for a variety of linear and nonlinear circuit problems, including various op amp circuits. Results of those simulations are presented and future work is also discussed.
Detrimental beam dynamics effects limit performance of high intensity rapid cycling synchrotrons (RCS) such as the 8 GeV Fermilab Booster. Here we report the results of comprehensive studies of various beam intensity dependent effects in the Booster. In the previous publication we presented the dependencies of the Booster beam intensity losses on the total number of protons per pulse and on key operational parameters such as the machine tunes and chromaticities. Here we discuss two methods of the Booster beam emittance measurements (the multi-wires proportional chambers and the ionization profile monitors), analyze the intensity dependent emittance growth effects and discuss the ultimate performance of the machine now and after foreseen and proposed upgrades.
Detrimental beam dynamics effects limit performance of high intensity rapid cycling synchrotrons (RCS) such as the 8 GeV Fermilab Booster. Here we report the results of comprehensive studies of various beam intensity dependent effects in the Booster. Part I covers the dependencies of the Booster beam intensity losses on the total number of protons per pulse and on key operational parameters such as the machine tunes and chromaticities. In Part II we cross-check two methods of the beam emittance measurements (the multi-wires proportional chambers and the ionization profile monitors), analyze the intensity dependent emittance growth effects and discuss the ultimate performance of the machine now and after foreseen and proposed upgrades.
In CSP systems using solid particles for heat transfer, erosion from the falling particles can damage the system components upon impact, and from sliding against the component walls. Furthermore, the resulting attrition of particles can change the thermal performance due to alterations in particle morphology. The research on these issues has been limited to industrial applications, and don’t necessarily coincide with the operating conditions in CSP systems. In this work, we investigated the durability of the particles selected as the heat transfer media, as well as special substrate materials that are of interest as lining materials to the particle storage tanks and hoppers. Three different erosion phenomena were studied: impact, abrasion, and attrition erosion. The low-temperature experiments revealed negligible losses from attrition and abrasion erosion. Although the substrates indicated visible surface damage from impact erosion, the actual material mass loss was small even after a throughput of 500kg of particles 63 days of 1MW CSP plant operation assuming 14 hours per day of operation. Erosion is typically classified as impact, abrasion, or attrition erosion. For example, the CSP systems utilizing solid particles as heat transfer media will likely experience impact erosion on the receiver hopper and heat exchanger walls as the solid particles fall from the reservoir. Additionally, there will be sliding erosion along the receiver walls as particles move through the hopper, and lastly, there will also be attrition erosion as the particles rub against each other. The extent of erosion depends on many factors including but not limited to particle shape and size, material hardness/brittleness and ductility, and particle impact speed and angle. Mechanistic erosion equations that are available in the literature are mostly derived from data pertaining to specific experiments and therefore can’t be applied to all applications without suitable adjustments. Survey of the literature relating to particle-based receivers revealed that the most prevalent approach has been to choose low velocities to limit erosion, but to our knowledge, little effort has been put in to fully characterize erosion at the expected operating conditions. A relatively recent work investigated the erosion of wire mesh proposed for use in a particle receiver, where the results actually showed an increase in mass as oxidation occurred on the mesh surface but the work did not investigate the particle attrition rate, and the erosion rate of a solid substrate. The end goal of this work is to develop a comprehensive particle and substrate durability model that will allow a comprehensive understanding of particle-based CSP operating conditions on component durability.
InAs Quantum Dots (QDs) embedded into GaAs semiconductor waveguide have unique scintillation properties, valuable for nuclear security, medical imaging, and high energy physics. In this work, we developed thick (~25um) epitaxial heterostructres with high luminescence efficiency composed of self-assembled nano-engineered InAs QDs grown by molecular beam epitaxy. In this type of detector, the GaAs matrix acts as a stopping material for charged particles or photons generating electrons captured by the QDs acting as luminescence centers. The QD medium is designed to provide fast capture of electrons into QDs (few ps), high QD luminescence efficiency at room temperature (>50%), and strong red-shift of photoluminescence (PL) from the GaAs absorption edge (>250nm). Typical devices consist of a 10-25um thick GaAs layer with embedded sheets of modulation p-type doped InAs QDs and an InGaAs photodetector tuned to the QD emission wavelength. The thick GaAs layer acts also as a waveguide when layer-transferred onto a low-index substrate. Waveguiding and self-absorption (~1cm -1 ) were studied using photoluminescence with scanning laser excitation and modeled with ray optics approximation and geometrical coupling of high-index waveguide to a collection fiber. Scintillating signals from α-particles were analyzed with both an external photodiode (PD) and an integrated PD which provided an improved optical coupling. In the former case, the external InGaAs PD was air-coupled to the scintillator and had the light collection efficiency of about 1% corresponding to limited light extraction through a planar interface with air due to total internal reflection. The mean charge collected by the integrated PD was in the range of (3÷5)×10 4 photoelectrons per 1 MeV of deposited energy, or ~13-20% of the theoretically achievable light yield. Timing of the integrated device was measured by wire-bonding it to the input of an 8 GHz IC. The scintillation response shows an extremely fast 0.3-0.6 ns decay constant and about 40-70 ps time resolution, limited by the system noise. The combined light yield and decay time makes the InAs/GaAs QD heterostructures the fastest high yield scintillation material reported making it valuable for high energy physics and medical imaging applications.
The present work investigates high initial pressure detonations of a stoichiometric mixture of ethylene and nitrous oxide (C2H4 + 6N2O) as a method of fracturing rock beneath the ground surface. These tests were conducted at a test site operated by the Energetic Materials Research and Testing Center (EMRTC), Socorro, New Mexico. The volume under the surface used for testing (called the Down Hole Assembly) consists of a 0.438 in. ID x 50 ft. long stainless-steel tube running down from the test site to a well bore which is 3 in. ID x 10 ft. long and the rock in the well bore is exposed to the propagating combustion wave. The testing carried out at Zucrow Laboratories in the smaller, alloy steel combustion vessel provided a scaling of pressures expected in the well bore. The combustion is initiated by energizing an EBW (Exploding Bridge Wire) above the ground surface. The experimental setup accommodates one high pressure (100,000 psia) transducer to measure the pressure peak and is placed approximately 5 ft. above the ground surface and 5 ft. downstream of the EBW. The focus of this series of experiments is to investigate the dependence of fracture to the rock beneath the surface on initial pressures of the mixture of ethylene and nitrous oxide. Experiments were carried out at initial pressures varying between 125 psia and 300 psi. The transducer recorded elevated pressures, which were 2.3 to 2.6 times in excess of the CJ values. The experimental results are discussed and explained in this report.
This report focuses on potential DER benefits for distribution systems, primarily in their role as non-wires alternatives to defer, mitigate, or eliminate the need for some traditional system investments at locations where distribution capacity is insufficient to meet expected future needs. It describes approaches and tools to estimate the locational value of DERs. The report includes 24 case studies to illustrate how states and utilities are considering the locational value of DERs.
This report provides an overview of principles, practices, and emerging issues in all-source competitive solicitations. It reviews the history of electric utility all-source solicitations and recent results; provides an overview of goals, design tradeoffs, and stages; and examines solicitation design and implementation options and issues, including methodological issues around bid evaluation. The report draws on a review of regulatory documents, resource plans, solicitation materials, independent evaluator reports, and scholarly literature. While the report focuses on solicitations by investor-owned utilities for bulk power system needs, it also briefly discusses solicitations for non-wires alternatives for distribution system needs, as well as nascent practices for integrating both types of procurements.
The irradiation testing of sensors in reactors is a crucial step towards calibrating and qualifying sensors prior to their deployment in experiments. This report details the process toward qualifying and calibrating custom-designed rhodium-based self-power neutron detectors (Rh-SPNDs) for steady-state reactor irradiations. This process serves to both demonstrate the performance capabilities of Rh-SPNDs as well as to provide experimental data for development of a sensor sensitivity model. Two designs of Rh-SPNDs were tested in various reactors to demonstrate: detection resolution in a low neutron flux environment, a delayed-response compensation technique, output linearity in a large range of neutron flux, and measurement accuracy verified with dosimetry. The detection resolution and compensation technique was demonstrated in the AGN-201m reactor at Idaho State University. The irradiation confirmed the sensors’ capability to perform steady-state operations in a low neutron flux of ~2E8 n/cm 2 -sec. Sensor output linearity coupled with the delayed-response compensation was investigated at the neutron radiography reactor at Idaho National Laboratory. A Rh-SPND was irradiated to neutron fluxes ranging from 2E8 to 2E13 n/cm2-sec range. The measured data demonstrated a wide and linear range of operation with a measured linear sensitivity of 1.0129 ×10 -13 A/W with a correlation-squared value of r 2 =0.9927. The measurement accuracy was investigated at the Advanced Test Reactor Critical reactor. The SPNDs were inserted into a test vehicle with collocated flux wires. Two irradiations with different flux levels were performed, and the SPNDs relative measurement between the two irradiations was calculated to be 1.2613 ± 0.0153 for the small SPND design and 1.1809 ± 0.0108 for the large SPND design. Both SPND measurements fell between the co-axial dosimetry result, which reported 1.218 ± 0.047. Additionally, the preliminary MCNP model for calculating SPND sensitivity was developed in parallel to this work. Modeled neutron spectrum with measured magnitude was used for inputs to determine the simulated SPND output. The results showed an overestimation of signal strength by a factor of 5, which was expected because of model simplification. This leads to future modeling work to account for signal losses from additional physical properties, including high temperature environments for FY-21.
The Ducted Assembly Steady-State Heat transfer software (DASSH) is being developed at Argonne National Laboratory to obtain a steady-state thermal fluids result for the coolant flow and temperature distribution in a hexagonally gridded reactor core with ducted assemblies. In DASSH, each assembly is assumed to contain a hexagonal bundle of wire-wrapped pins. DASSH divides the coolant in the pin bundle into subchannels on which it applies energy balances to determine coolant and duct temperatures. DASSH offers multiple models for inter assembly heat transfer and features the ability to calculate pin temperatures. This document describes the models and equations implemented in DASSH. It includes a description of the geometric system to which the models are applied and a derivation of the subchannel energy balance formulation is presented. It also reviews the available correlations and provides an overview of the process by which power distributions are generated. Finally, it covers the code execution procedure, discussing the main code objects and their interactions.
Efficient modeling of low magnetic Reynolds number (low-Rm) magnetohydrodynamics is often challenging and requires the implementation of innovative techniques to avoid key barriers experienced with prior approaches. We detail a new paradigm for first-principles simulation of the solution to the low-Rm governing equations in complex geometries. As a result of a number of innovative numerical advances, the next-generation GPU (graphics processing unit) accelerated physics code LGR has been successfully applied to the modeling of exploding wire problems.
Work in the project was spread across 4 main themes:1) Improved Understanding of Why Cracks Form and Cause Degradation in Solar Cells: We developed a finite element model which correlated well with experimental determined deflection vs load profiles and which predicted stress profiles vs load level and temperature. These profiles helped to guide brace designs and showed the high stress levels seen in the silicon near the interconnect wire locations as the temperature is cooled below -30C, likely forming "invisible" microcracks. Experiments showed how for polymer backsheet modules, a brief exposure to such low temperatures made modules extremely sensitive to propagation of these microcracks at relatively low load levels, and how thicker and softer encapsulant helped to reduce this crack sensitivity. We showed for some modules that most cracks that are seen under loading had their origin at short, hard to see, V-cracks from soldering damage, and how the shunting from cells with high densities of cracks reduces energy delivery more than Pmax. 2) Improved Durability Testing Methods With Respect to Cracked Cells: We lobbied the PV community throughout the project that IEC 61215 was insufficient to probe the sensitivity of module Pmax degradation due to cracks in that in did not have a test leg that included a crack creation step (static loading) followed by a crack opening step (cyclic loading and/or thermal cycling). We published extensively on how pre- existing cracks opened up with cyclic loading. The new IEC TS 63209-1 ED1 test sequence now include our recommendations, and this should lead to improved module designs and reduced risk for investors. We also published recommendations for a new "Cold Climate Test" sequence to probe the sensitivity of modules to degradation from short microcracks formed when modules see temperatures below -30C followed by front side loading. We participated in several USTAG meetings related to cracked cells, EL testing, and mechanical load testing and provided input to the group to improve new standards under consideration. We also showed how the act of performing an EL test can affect the test results due to heating from the injected current. 3) New Module Designs and Related Manufacturing Methods & Equipment: We demonstrated reduced crack sensitivity on encapsulated cell coupons the benefits of building protective compressive stress into the cells by laminating them in a bent state and then allowing the coupon to flatten out after lamination. Our attempts to scale this to the module level with a more manufacturable sequence did not demonstrate the same positive effects, but we hope that others will follow up with other variations on this bent lamination or bent cooling concept to make more durable modules. 4) New Module Mounting Designs: We explored a range of bracing concepts which pressed on the backsheet to slightly bow the glass outward and place cells in a state of protective compressive stress and to reduce the deflection under front side loads. These successfully reduced cell cracking and crack opening, but high static loads permanently deformed cost-effective braces, after which they provided little benefit. We settled on an elegant & effective solution – the RailPad, where lightweight bracing elements are placed between the mounting rail(s) and the backsheet, and the existing strength of the rails is used to prevent module deflection under load. New construction and retrofit designs were made, and test sites were implemented in FL and MA. We applied for RailPad patent protection.
Increasing penetration levels of inverter-based distributed energy resources (DERs) in distribution systems are creating challenges in system operation. Currently, wired or proprietary wireless communications are used by advanced distribution management systems (ADMS) to detect the state of the system and control the DERs for optimal operation. Wireless communications are an alternative solution that can enable connectivity between the dispersed assets used in distribution system applications. As demand for the seamless integration of distributed energy resources (DERs) continues to increase, proper networking and communications systems are becoming important to support the DER infrastructure. This report summarizes validation of a private wireless LTE network in a laboratory environment. The purpose of this work is to 1) demonstrate the effectiveness of private wireless LTE communication for grid applications and 2) provide a means of evaluating latency and overall performance of wireless communication in grid applications. First, private wireless LTE communication was validated in a direct transfer trip relaying scenario as an example of one-way communications using grid equipment. This study provided a baseline understanding of the variation in latency for seven different kinds of wireless scenarios shown in Figure A below. As expected, weak (attenuated) wireless signal-based communication yielded the widest ranges in latency. When higher priority was set for the trip signal communication, this resulted in lower latency in communication timing. In the final phase of this project, the private wireless LTE network was validated using two-way communications in an advanced distribution management system (ADMS) testbed which was developed in the ESIF at NREL. The purpose of this was to study the impact of wireless communication on grid performance.
Hybrid-CMOS (hCMOS) nanosecond x-ray imagers are a powerful timeresolved HED (high-energy-density) diagnostic due to their sensitivity to visible light, x-rays, and charged particles. However, significant pseudosinusoidal background oscillations have been observed in these sensors when exposed to an early incident excitation, a phenomenon that has been experimentally linked the sensor’s bond wire inductance. We analyze the oscillations both in the time domain and spatially to account for variations on the pixel level. Both theoretical techniques and analysis of experimental data have shown that the oscillations are a global sensor phenomenon. In addition, we effectively describe the oscillations with a physics-based model, giving further insight into the processes affecting them. This technique allows the hCMOS user to subtract out the oscillations from their measurements and improve accuracy.
Alloy 709 is a candidate construction material for the Sodium Fast Reactor (SFR). As part of the Alloy 709 ASME Code Case development team under the Advanced Reactor Technologies (ART) Program, this work covers the development of the technical basis for weld fabrication and weld qualification of Alloy 709. This report summarizes the research conducted in FY 2021 and relevant results from previous reporting periods, aimed at welding commercial heat of Alloy 709 plates of relatively high phosphorous (P) level in support of ASME code case data package. Welding, code qualification tests, and associated microstructure characterization were carried out in determining the effect of P levels of weld wire on the weldability of the high P commercial heat of Alloy 709. The Alloy 709 weld creep strength was evaluated though preliminary creep testing.