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At least 1,387 records · Page 77

Fuel containment and damage tolerance in large composite primary aircraft structures

Technical problems related to fuel containment and damage tolerance of composite material wings for transport aircraft was investigated. The major tasks are the following: (1) the preliminary design of damage tolerant wing surface using composite materials; (2) the evaluation of fuel sealing and lightning protection methods for a composite material wing; and (3) an experimental investigation of the damage tolerant characteristics of toughened resin graphite/epoxy materials. The design concepts investigated for the upper and lower surfaces of a composite wing for a transport aircraft are presented and the relationship between weight savings and the design allowable strain used within the analysis is discussed. Experiments which compare the fuel sealing characteristics of bolt-bonded joints and bolted joints sealed with a polysulphide sealant are reviewed. Data from lightning strike tests on stiffened and unstiffened graphite/epoxy panels are presented. A wide variety of coupon tests were conducted to evaluate the relative damage tolerance of toughened resin graphite/epoxies. Data from these tests are presented and their relevance to the wing surface design concepts are discussed.

Griffin, C. F.↗

Determining interface properties limiting open-circuit voltage in heterojunction solar cells

The development of new thin-film photovoltaic (PV) absorbers is often hindered by the search for an optimal heterojunction contact; an unoptimized contact may be mistaken for poor quality of the underlying absorber, making it difficult to assess the reasons for poor performance. Therefore, quantifying the loss in device efficiency and open-circuit voltage (V OC ) as a result of the interface is a critical step in evaluating a new material. In this work, we fabricate thin-film PV devices using cuprous oxide (Cu 2 O), with several different n-type heterojunction contacts. Their current-voltage characteristics are measured over a range of temperatures and illumination intensties ( JVTi ). We quantify the loss in V OC due to the interface and determine the effective energy gap at the interface. The effective interface gap measured by JVTi matches the gap measured by X-ray photoelectron spectroscopy, albeit with higher energy resolution and an order of magnitude faster. We discuss potential artifacts in JVTi measurements and areas where analytical models are insufficient. Applying JVTi to complete devices, rather than incomplete material stacks, suggests that it can be a quick, accurate method to assess the loss due to unoptimized interface band offsets in thin-film PV devices.

14 SOLAR ENERGY↗

Evaluating cascaded and tunable phase change materials for enhanced thermal energy storage utilization and effectiveness in building envelopes

The incorporation of phase change materials (PCMs) in envelope is considered an effective thermal energy storage (TES) method for energy savings and load flexibility in buildings. However, an important limitation of PCMs is their fixed and narrow transition temperature range. Because the interior temperature setpoints are typically different in summer versus winter, and the exterior temperature varies substantially above and below the setpoints during the year, PCMs with a fixed transition temperature are utilized only during part of the year. In this paper, we provide an extensive numerical analysis of the performance of a lightweight building envelope containing three different types of PCMs: traditional single-layer PCM with a fixed transition temperature, novel cascaded two-layer PCM with different transition temperatures, and a "futuristic" tunable PCM whose transition temperature can be varied in-situ using external excitation. We compare their performances by evaluating the relationship between the PCM utilization and parameters such as latent heat, transition temperature range, PCM thickness, and PCM location. While traditional PCMs are mostly active during one season, properly designed cascaded and tunable PCMs can be active much longer, thereby allowing load shift and energy savings in both heating and cooling seasons. Under the operating conditions considered in this study, tunable PCMs performed best, providing the highest utilization (about 2 times the traditional PCMs) and enhanced effectiveness (up to 99% peak load reduction in cooling season and 34% peak load reduction in heating season) with the same amount of material as the traditional PCMs; however, cascaded PCMs can be a good alternative while tunable PCMs are unavailable.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials (Second Annual Progress Report)

Additive manufacturing (AM) is an emerging method for cost-efficient fabrication of nuclear reactor parts. AM of metallic structures for nuclear energy applications is currently based on laser powder bed fusion (LPBF) process, which can introduce internal material flaws, such as pores and anisotropy. Integrity of AM structures needs to be evaluated nondestructively because material flaws could lead to premature failures due to exposure to high temperature, radiation and corrosive environment in a nuclear reactor. Thermal tomography (TT) provides a capability for non-destructive evaluation of sub-surface defects in arbitrary size structures. Thermal tomography is a computational method for heat diffusion-based imaging of solids, which provides 3D visualization of data from flash thermography measurements. We investigate thermal tomography imaging and nondestructive evaluation of stainless steel and nickel super alloy metallic structures produced with laser powder bed fusion (LPBF) additive manufacturing (AM) process. Metallic structures produced with LPBF contain defects, and there are limited capabilities to evaluate these structures non-destructively. Thermal tomography reconstruction of 3D apparent spatial effusivity provides information about AM structure geometry and internal material flaws. We study performance of thermal tomography in imaging of metallic structures through COMSOL computer simulations of transient heat transfer, and through reconstruction of data obtained from experimental measurements. Reconstruction of internal defects is investigated using a stainless steel 316L specimen with flat bottom hole (FBH) indentations, and Inconel 718 plate produced with laser powder bed fusion (LPBF) method, which contains imprinted hemispherical shape low density regions containing non-sintered metallic powder. The FBH’s have the same sizes as the imprinted defects in the LPBF specimens, but offer better imaging contrast. Thermal tomography reconstructions provide visualizations of internal defects, and allow for estimation of their sizes and locations. Detection sensitivity of TT is limited by noises. We investigate separation of signal from noise in thermography images using several machine learning (ML) methods, including new spatio-temporal blind source separation (STBSS) and spatio-temporal sparse dictionary learning (STSDL) methods. Performance of the ML methods is benchmarked using thermography data obtained from imaging stainless steel 316L and Inconel 718 specimens produced LPBF method with imprinted calibrated porosity defects. The ML methods are ranked by F-score and execution runtime. Finally, we investigate TT of AM stainless steel 316L specimen with imprinted internal porosity defects using relatively low-cost, small form factor infrared (IR) camera based on uncooled micro bolometer detector. Sparse coding related K-means singular value decomposition (SVD) machine learning, image processing algorithms are developed to improve quality of TT images through removal of Additive white Gaussian noise without blurring the images. Following initial qualification of an AM component for deployment in a nuclear reactor, a compact TT can also be used for in-service nondestructive evaluation (NDE). With capability to perform in-service NDE of the AM component lifecycle, TT data can be used for development of a component digital twin.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Additive Manufacturing of Advanced High Temperature Masking Fixtures for EBPVD TBC Coating

The purpose of this Manufacturing Demonstration Facility (MDF) technical collaboration project between Praxair Surface Technologies, Inc. (PST) and Oak Ridge National Laboratory (ORNL) was to develop an additive manufacturing process to fabricate next generation high temperature masking fixtures for coating of turbine airfoils with ceramic Thermal Barrier Coatings (TBC) by the Electron Beam Physical Vapor Deposition (EBPVD) process. Typical masking fixtures are sophisticated designs and require complex part manipulation in order to achieve the desired coating distribution. Fixtures are typically fabricated from high temperature nickel (Ni) based superalloys. The fixtures are fabricated from conventional processes by welding of thin sheet material into a complex geometry, to decrease the weight load for the manipulator and to reduce the thermal mass of the fixture. Recent attempts have been made in order to fabricate the fixtures through casting, but thin walled sections are difficult to cast and have high scrap rates. This project focused on understanding the potential for fabricating high temperature Ni based superalloy fixtures through additive manufacturing. Two different deposition processes; electron beam melting (EBM) and laser powder bed fusion were evaluated to determine the ideal processing route of these materials. Two different high temperature materials were evaluated. The high temperature materials evaluated were Inconel 718 and another Ni base alloy, designated throughout the remainder of this document as Alloy X, as the alloy composition is sensitive. Inconel 718 is a more widely utilized material for additive manufacturing although it is not currently the material utilized for current fixtures. Alloy X is the alloy currently used for the fixtures, but is not a commercially available alloy for additive manufacturing. Praxair determined it was possible to build the fixture using laser powder bed technology from Inconel 718. ORNL fabricated the fixture geometry using the EBM technology in order to compare deposition features such as surface roughness, geometric accuracy, deposition rate, surface and subsurface porosity, and material quality. It was determined that the laser powder bed technology was ideal for the geometry and requirements of the fixture set by Praxair, and Praxair moved forward with the purchase of a laser powder bed system. The subsequent portion of the project focused on determining the ideal processing parameters for alloy X for the laser powder bed system using ORNL’s Renishaw laser powder bed system. Praxair supplied gas atomized powders of alloy X material with properties specified by ORNL. ORNL printed text cube arrays in order to determine the ideal combination of laser powder and laser travel speed in order to maximize material density, improve surface quality, and maintain geometric accuracy. Additional powder supplied by Praxair was used to fabricate a full-scale fixture component.

42 ENGINEERING↗

Evaluation of performance indicators applied to a material recovery facility fed by mixed packaging waste

Highlights: • Material Flows assessment of a Material Recovery Facility has been realized. • Performance Indicators for a generic MRF have been proposed. • A Dashboard has been utilized to measure the facility performance. • Experimental values of incoming waste and output products composition are reported. - Abstract: Most of the integrated systems for municipal solid waste management aim to increase the recycling of secondary materials by means of physical processes including sorting, shredding and reprocessing. Several restrictions prevent from reaching a very high material recycling efficiency: the variability of the composition of new-marketed materials used for packaging production and its shape and complexity are critical issues. The packaging goods are in fact made of different materials (aluminium, polymers, paper, etc.), possibly assembled, having different shape (flat, cylindrical, one-dimensional, etc.), density, colours, optical properties and so on. These aspects limit the effectiveness and efficiency of the sorting and reprocessing plants. The scope of this study was to evaluate the performance of a large scale Material Recovery Facility (MRF) by utilizing data collected during a long period of monitoring. The database resulted from the measured data has been organized in four sections: (1) data related to the amount and type of inlet waste; (2) amount and composition of output products and waste; (3) operating data (such as worked hours for shift, planned and unscheduled maintenance time, setting parameters of the equipment, and energy consumption for shift); (4) economic data (value of each product, disposal price for the produced waste, penalty for non-compliance of products and waste, etc.). A part of this database has been utilized to build an executive dashboard composed by a set of performance indicators suitable to measure the effectiveness and the efficiency of the MRF operations. The dashboard revealed itself as a powerful tool to support managers and engineers in their decisions in respect to the market demand or compliance regulation variation as well as in the designing of the lay-out improvements. The results indicated that the 40% of the input waste was recovered as valuable products and that a large part of these (88%) complied with the standards of the recycling companies. The evaluation of the indicators led to the decision to modify the layout to improve the interception of some polymers for which the performance indicators were poor. In particular, two additional optical sorters have to be inserted to increase the yield indicator and to the overall performance of the facility. Definitely, the results of the work allowed to: increase the yield and purity of products’ flows; ensure the compliance of waste flows; increase the workability.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Development and fabrication of large vented nickel-zinc cells

A preliminary cell design for a 300AH vented nickel-zinc cell was established based on volume requirements and cell component materials selected by NASA Lewis Research Center. A 100AH cell configuration was derived from the 300AH cell design utilizing the same size electrodes, separators, and cell terminal hardware. The first cells fabricated were four groups of three cells each in the 100AH size. These 100AH experimental nickel-zinc cells had as common components the nickel positive electrodes (GFM), flexible inorganic separator (GFM) bags on the negative electrodes, pressed powder zinc oxide electrodes, and cell containers with hardware. The variations introduced were four differing electrolyte absorber (interseparator) systems used to encase the nickel positive electrodes of each cell group. The four groups of 100AH experimental vented nickel-zinc cells were tested to determine, based on cell performance, the best two interseparator systems. Using the two interseparator systems, two groups of experimental 300AH cells were fabricated. Each group of three cells differed only in the interseparator material used. The six cells were filled, formed and tested to evaluate the interseparator materials and investigate the performance characteristics of the 300AH cell configuration and its components.

Donnel, C. P., III↗

Fuel containment and damage tolerance for large composite primary aircraft structures. Phase 1: Testing

Technical problems associated with fuel containment and damage tolerance of composite material wings for transport aircraft were identified. The major tasks are the following: (1) the preliminary design of damage tolerant wing surface using composite materials; (2) the evaluation of fuel sealing and lightning protection methods for a composite material wing; and (3) an experimental investigation of the damage tolerant characteristics of toughened resin graphite/epoxy materials. The test results, the test techniques, and the test data are presented.

Sandifer, J. P.↗

Space resources. Volume 3: Materials

Space Resources addresses the issues of using space resources to support life on the Moon and for exploration of Mars. This volume - Materials - covers a number of technical and policy issues regarding the materials in space (mainly lunar and asteroidal) which can be used to support space operations. In part 1, nature and location of these materials, exploration strategy, evaluation criteria, and the technical means to collect or mine these materials is discussed. A baseline lunar mine and the basics of asteroid mining are presented and critiqued. In part 2, the beneficiation of ores and the extraction of such materials as oxygen, metals, and the makings of concrete are discussed. In part 3, the manufacturing and fabrication of nonterrestrial products are discussed. The economic tradeoffs between bringing needed products from Earth and making these products on location in space is considered.

Mckay, Mary Fae↗

Arc Jet Flow Properties Determined from Laser- Induced Fluorescence of Atomic Species

Flow property measurements that were recently acquired in the Ames Research Center Aerodynamic Heating Facility (AHF) arc jet using two-photon Laser-Induced Fluorescence (LIF) of atomic nitrogen and oxygen are reported. The measured properties, which include velocity, translational temperature, and species concentration, cover a wide range of facility operation for the 30 cm nozzle. During the tests, the arc jet pressure and input stream composition were maintained at fixed values and the arc current was varied to vary the flow enthalpy. As part of this ongoing effort, a measurement of the two-photon absorption coefficient for the 3p4D(left arrow)2p4S transition of atomic nitrogen was performed, and the measured value is used to convert the relative concentration measurements to absolute values. A flow reactor is used to provide a known temperature line shape profile to deconvolve the laser line width contribution to the translational temperature measurements. Results from the current experiments are compared with previous results obtained using NO-beta line profiles at room temperature and the problem of multimode laser oscillation and its impact on the two-photon excitation line shape are discussed. One figure is attached, and this figure show relative N atom concentration measurements as a function of the arc power. Other measurements have already been acquired and analyzed. The arc jet flow facilities are heavily used in thermal protection material development and evaluation. All hypersonic flight and planetary atmospheric entry vehicles will use materials tested in these arc jet facilities. This poster represents an application of laser-spectroscopic measurements in an important test facility.

Fletcher, Douglas G.↗

Arcjet Flow Properties Determined from Laser-Induced Fluorescence of Atomic Species

Flow property measurements that were recently acquired in the Ames Research Center Aerodynamic Heating Facility (AHF) arc jet using two-photon Laser-Induced Fluorescence (LIF) of atomic nitrogen and oxygen are reported. The measured properties, which include velocity, translational temperature, and species concentration, cover a wide range of facility operation for the 30 cm nozzle. During the tests, the arc jet pressure and input stream composition were maintained at fixed values and the arc current was varied to vary the flow enthalpy. As part of this ongoing effort, a measurement of the two-photon absorption coefficient for the 3p4D<-2p4S transition of atomic nitrogen was performed, and the measured value is used to convert the relative concentration measurements to absolute values. A flow reactor is used to provide a known temperature line shape profile to deconvolve the laser line width contribution to the translational temperature measurements. Results from the current experiments are compared with previous results obtained using NO-Beta line profiles at room temperature and the problem of multimode laser oscillation and its impact on the two-photon excitation line shape are discussed. One figure is attached, and this figure shows relative N atom concentration measurements as a function of the arc power. Other measurements have already been acquired and analyzed. This poster represents an application of laser-spectroscopic measurements in an important test facility. The arc jet flow facilities are heavily used in thermal protection material development and evaluation. All hypersonic flight and planetary atmospheric entry vehicles will use materials tested in these arc jet facilities.

Fletcher, Douglas G.↗

Process Qualification Concepts in NASA-STD-6030

- Terminology - Definition and role of QMP in the NASA-STD-6030 framework - Qualification checklist for evaluating a candidate AM material process - Types of data needed to evaluate the metrics for a QMP - Advocacy for a singular, contained data entity that enables QMP evaluation and other aspects of the AM ecosystem - Material Engineering Equivalence Baseline - Discussion of Material Engineering Equivalence concepts - Summary

Doug Wells↗

Development of X-43A Mach 10 Leading Edges

The nose leading edge of the Hyper-X Mach 10 vehicle was orginally anticipated to reach temperatures near 4000 F at the leading-edge stagnation line. A SiC coated carbon/carbon (C/C) leading-edge material will not survive that extreme temperature for even a short duration single flight. To identify a suitable leading edge for the Mach 10 vehicle, arc-jet testing was performed on thirteen leading-edge segments fabricated from different material systems to evaluate their performance in a simulated flight environment. Hf, Zr, Si, and Ir based materials, in most cases as a coating on C/C, were included in the evaluation. Afterwards, MER, Tucson, AZ was selected as the supplier of the flight vehicle leading edges. The nose and the vertical and horizontal tail leading edges were fabricated out of a 3:1 biased high thermal conductivity C/C. The leading edges were coated with a three layer coating comprised of a SiC conversion of the top surface of the C/C, followed by a chemical vapor deposited layer of SiC, followed by a thin chemical vapor deposited layer of HfC. This paper will describe the fabrication of the Mach 10 C/C leading edges and the testing performed to validate performance.

Ohlhorst, Craig W.↗

Post-closure Nuclear Criticality Safety Evaluations for Disposition of Criticality Control Overpacks at the Waste Isolation Pilot Plant

The Waste Isolation Pilot Plant (WIPP) is a geological repository in southern New Mexico that provides for disposal of transuranic (TRU) wastes from atomic energy defense activities. The Sandia National Laboratories (Sandia) Report, Consideration of Nuclear Criticality When Disposing of Transuranic Waste at the Waste Isolation Pilot Plant, addresses nuclear criticality safety based on the projected inventory characteristics for the initial compliance certification application of WIPP in 1996. As the inventory, waste forms, and disposal package designs change, revised or new analyses are necessary to demonstrate acceptability for these configurations within the WIPP safety basis and compliance with 10,000-year post-closure standards of the US Environmental Protection Agency (EPA). Saylor and Scaglione evaluated criticality control overpacks (CCOs) in 2017 based on conservative assumptions for post-closure repository structural conditions with resulting effects on containers and container spacing, The Saylor and Scaglione evaluation of CCOs addressed a single waste configuration that represents the Surplus Plutonium Disposition Program’s dilute and dispose waste form and composition. This initial CCO study demonstrated that 50 grams of boron carbide (B 4 C) per CCO is sufficient to ensure post-closure criticality safety based on a well-mixed waste composition, and Oak Ridge National Laboratory (ORNL) subsequently determined that this amount of B 4 C does not require constraints on moisture or plastic present as moderator. The Saylor and Scaglione analysis conservatively assumes repository room closure that eliminates all space between fissile gram equivalent (FGE) 239 Pu masses. The close-packed array was selected based on limited availability of repository salt creep modeling results at that time. In 2019, Brickner provided additional evaluations for pipe overpack containers (POCs), building on the conservative basis provided by Saylor and Scaglione. Brickner’s 2019 analysis made use of new geomechanical data for post-closure spacing that rely on advances in repository modeling as documented in the work by Reedlunn and Bean. This current CCO evaluation for generic waste materials expands on earlier work performed at ORNL and includes evaluation of CCOs across a much broader range of possible waste compositions and geometries. This evaluation is intended to provide input for the required feature, event and process (FEP) screening to determine if post-closure criticality must be included as an event in the 10,000-year regulatory evaluation. As such, the approach to modeling post-closure criticality presented in this report has been coordinated with the Sandia team responsible for FEP screening. The resulting analysis supports disposition of fissile materials in the CCO containing up to 380 FGE 239 Pu and expands conditions acceptable for disposal of fissile material in CCOs. This evaluation builds on the methodology of Saylor and Scaglione and Brickner, using the most recently available geomechanical data for CCO spacing under salt creep compaction scenarios provided by Reedlunn and Bean. The broad range of fissile material configurations analyzed in this report are intended to account for configurations that may occur during the post-closure disposal time period, and it also includes waste configurations that are not physically possible to support analysis of conditions that influence neutron fluence.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Structural FEM analysis of the strut-to-fuselage joint of a two-seat composite aircraft

An analysis of a strut-to-fuselage joint is realized in order to evaluate the zones with a high probability of failure by means of a safety factor. The whole section is analyzed using the Finite Element Method (FEM) so as to estimate static resistance behavior, therefore it is necessary a numerical mock-up of the section, the mechanical properties of the Carbon-Epoxy (C-Ep) material, and to evaluate the applied loads. Results of the analysis show that the zones with higher probability of failure are found around the wing strut and the fuselage joint, with a safety factor lower than expected in comparison with the average safety factor used on aircrafts built mostly with metals.

42 ENGINEERING↗

Characterization of elastomeric materials with application to design

Redesign of the Space Shuttle Solid Booster has necessitated re-evaluation of the material used in the field joint O-ring seals. The viscoelastic characteristics of five candidate materials were determined. The five materials are: two fluorocarbon compounds, two nitrile compounds, and a silicon compound. The materials were tested in a uniaxial compression test to determine the characteristic relaxation functions. These tests were performed at five different temperatures. A master material curve was developed for each material from the experimental data. The results are compared to tensile relaxation tests. Application of these results to the design analysis is discussed in detail.

Bower, Mark V.↗

Ultrasonic Nondestructive Evaluation Techniques Applied to the Quantitative Characterization of Textile Composite Materials

In this Progress Report, we describe our further development of advanced ultrasonic nondestructive evaluation methods applied to the characterization of anisotropic materials. We present images obtained from experimental measurements of ultrasonic diffraction patterns transmitted through water only and transmitted through water and a thin woven composite. All images of diffraction patterns have been included on the accompanying CD-ROM in the JPEG format and Adobe TM Portable Document Format (PDF), in addition to the inclusion of hardcopies of the images contained in this report. In our previous semi-annual Progress Report (NAG 1-1848, December, 1996), we proposed a simple model to simulate the effect of a thin woven composite on an insonifying ultrasonic pressure field. This initial approach provided an avenue to begin development of a robust measurement method for nondestructive evaluation of anisotropic materials. In this Progress Report, we extend that work by performing experimental measurements on a single layer of a five-harness biaxial woven composite to investigate how a thin, yet architecturally complex, material interacts with the insonifying ultrasonic field. In Section 2 of this Progress Report we describe the experimental arrangement and methods for data acquisition of the ultrasonic diffraction patterns upon transmission through a thin woven composite. We also briefly describe the thin composite specimen investigated. Section 3 details the analysis of the experimental data followed by the experimental results in Section 4. Finally, a discussion of the observations and conclusions is found in Section 5.

Miller, James G.↗

Technical Evaluation of Accelerated Basin De-Inventory Material Addition to Sludge Batch 11

Savannah River Nuclear Solutions has a need to discard spent nuclear fuel (SNF), currently stored in L Basin, to the Defense Waste Processing Facility (DWPF) for vitrification. The Department of Energy (DOE) has approved the Accelerated Basin De-inventory (ABD) Program for discarding SNF via transfers from H-Canyon to the Savannah River Site (SRS) Liquid Waste (LW) system. The first ABD discards will occur during the preparation of Sludge Batch (SB) 11. An initial impact evaluation of the LW flowsheet was performed by the Savannah River National Laboratory (SRNL) prior to the approval of the ABD Program. This evaluation addressed the LW downstream facilities based on the current H-Canyon flowsheet sequence for the average ABD discard. The flowsheet evaluation only included aluminum-clad SNF, specifically Materials Test Reactor (MTR) fuel and High Flux Isotope Reactor (HFIR) fuel similar to the planned SB11 discard. Following this evaluation, the flowsheet has been slightly altered to address (i) new nuclear criticality safety controls for DWPF that credit a higher amount of gadolinium as a neutron poison for all of the enriched uranium contained in a SB and (ii) potential additions of the H-Canyon neutralized fuel stream prior to the Low Temperature Aluminum Dissolution (LTAD) process in Tank 51. The early introduction of ABD material into the SB assembly process is being investigated to provide flexibility regarding transfer opportunities for H-Canyon to Tank 51 for SB11 and future sludge batches.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗