SEARCH · Engineering Papers

Results for “Load Frame”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 19 records

All sources NASA NTRS DOE OSTI

DOE OSTI2026

FY26 Progress Report on the Operation of the Activated Materials Laboratory at the Advanced Photon Source as a Nuclear Science User Facilities Partner Facility

The Activated Materials Laboratory (AML), located in the Long Beamline Building of the Advanced Photon Source (APS) at Argonne National Laboratory (ANL), provides a centralized radiological capability for preparing, handling, and supporting synchrotron experiments on activated materials. As a Nuclear Science User Facilities (NSUF) partner facility, the AML enables the receipt of radioactive shipments, open-form sample handling, encapsulation, transport of specimens to and from APS beamlines, and experimentation with dedicated equipment. The partnership includes the APS 1-ID and 20-ID beamlines, which provide high-energy x-ray scattering, tomography, and diffraction microscopy techniques for ex-situ, in-situ, and grainresolved three-dimensional (3D) characterization. All samples supported through the AML and partner beamlines must meet radiological limits of less than 100 mrem/h at 30 cm. This FY26 progress report summarizes the first full year of AML operations as an NSUF partner facility and highlights progress in both user support and capability development. By the end of FY26, the AML had received a total of 10 NSUF-awarded projects, including 2 Consolidated Innovative Nuclear Research (CINR), 7 Rapid Turnaround Experiment (RTE), and 1 Super RTE projects. Beamtime was fully delivered for 3 RTE projects and partially delivered for 1 CINR project, demonstrating successful workflows for receipt, encapsulation, beamline transfer, and radiological experiment execution. These efforts demonstrated safe radiological experiments at APS beamlines for samples with dose rates above the historical 5 mrem/h threshold and now up to 100 mrem/h at 30 cm, marking an important milestone for neutron-irradiated materials research. During FY26, the AML also expanded its experimental capabilities. A Psylotech xTS load frame with in-grip rotation was deployed for room-temperature mechanical testing with threedimensional x-ray characterization during interrupted loading. A Linkam TS1500V vacuum heater was commissioned for thermally driven studies, and temperature calibration experiments were performed to establish specimen-relevant thermal profiles. In parallel, a customized split-tube furnace for high-temperature mechanical testing entered commissioning, and initial work began on robotic sample handling to reduce worker dose and improve operational efficiency. Data workflow and beamline operations continued to mature. Together, these developments demonstrate that the AML is becoming a unique national resource for safe, efficient, and scientifically advanced characterization of activated materials at the APS.

Zhang, Xuan↗

DOE OSTI2025

Ultra-high temperature testing and performance of L-PBF C103

Additive Manufacturing (AM) of refractory alloys is gaining traction as a materials processing route for components subject to extreme temperature environments. Due to the low oxidation resistance of refractory alloys, novel methods for evaluating their elevated temperature performance must be developed. In this work, a Gleeble® 3800 thermomechanical load frame was modified to evaluate the mechanical properties of laser powder bed fusion (L-PBF) consolidated niobium alloy C103 ranging from room temperature (RT) to 1400 °C. The fixturing and sample geometry were designed to accommodate Joule heating and prevent damage to the test chamber. Oxidation of the samples was minimized via testing in vacuum level of 1E-5 Torr. Ultimate tensile strength (UTS), yield strength (YS), elongation, and strain-hardening behavior were determined as a function of temperature. L-PBF C103 presented an average UTS of ∼650 MPa and over 25 % elongation at RT. Above RT, the UTS and YS dropped then leveled off from 500 °C to 1000 °C with values ranging from ∼400 MPa to ∼460 MPa, which is consistent with dynamic strain aging observed in this class of alloys. The strength rapidly declined after 1200 °C to ∼150 MPa at 1400 °C. Fractography indicated ductile fractures for the C103 at all test temperatures, and Electron Backscatter Diffraction (EBSD) analysis revealed a textured microstructure and the presence of dynamic recrystallization within the necked region of the sample tested at 1400 °C.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

Experimental Validation of a Module Cell Cracking Model

The What's Cracking app can predict how changes in crystalline silicon photovoltaic (PV) module materials, design, and mounting affect its susceptibility for cell fracture under uniform loading. This work has experimentally validated the app. A set of commercial crystalline silicon PV modules was obtained for this study. The modules were uniformly loaded at three different mounting points, and their subsequent cell fractures were recorded. A large sample size allowed for the development of an experimental statistical model for cell fracture. Here, the comparison of the experiment to predictions from the app is in excellent agreement. Both experimental and modeling results also elucidate how moving the module mounting points toward the center of the module increases the probability of cell fracture.

14 SOLAR ENERGY↗

DOE OSTI2025

Materials Degradation in Extreme Environments: Novel In-situ Measurements of Cracking in Molten Salt

The safety and reliability of next-gen reactors, i.e. molten salt reactors (MSR), depends on materials performance and longevity in extreme environments, yet no in-situ, validated measurement techniques for environmentally assisted cracking (EAC), one potential degradation mechanism, exist for these conditions. This project combined the use of in-situ direct current potential drop (DCPD) crack growth rate determination applied to a horizontal load frame with high temperature fittings and novel sample geometries to enable evaluation in MSR environments and develop a full in-situ SCC measurement capability for extreme environments (high conductivity and elevated T), necessary to predict materials reliability. A successful demonstration of DCPD measurement in molten NaNO 3 /KNO 3 salts at 340 o C was accomplished and validated through post-test fractography imaging. This is the first ever public example, to the authors knowledge, of an in-situ crack growth rate measurement in a molten salt environment.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

ECAR-8823 Rev 0 Structural Evaluation of the MARVEL Support Frame in Dry Critical Configuration

The purpose of this ECAR is to structurally evaluate the MARVEL reactor support frame during the dry critical (DryCrit) start-up testing. The ECAR includes evaluation of the DryCrit configuration for tip-over of the frame during a seismic event, floor loading of the frame on the MFC-720 (TREAT) operating floor, stress analysis of the adapter ring, and stress analysis of the frame itself for gravity and seismic loads.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

DOE OSTI2025

DROP DURABILITY ASSESSMENT OF ELECTRONIC ASSEMBLIES UNDER OFF-AXIS LOADING WITH SKEWED FIXTURES

This thesis studies drop durability of electronic assemblies when the acceleration vector is oriented at 45° to the out-of-plane direction of the circuit card. The off-axis drop tests are accomplished with a skewed fixture and are conducted as a proxy for multiaxial drop testing. Advanced shock testing and vibration test methods have been developed over the last few decades to better represent real-world field environments during ground-based laboratory testing. However, many of these test methods require expensive and specialized equipment not available in most laboratories. An alternative approach for approximating simultaneous loading along multiple axes on conventional equipment utilizes skewed fixtures which have seen use in off-axis random vibration and drop impact testing. These methods generally rely on the conversion of a uniaxial input load from the test equipment (using a uniaxial drop tower or shaker) into a multiaxial load when resolved in the reference frame of the test article (mounted on a skewed fixture). Skewed fixture design is presented and recommendations for conducting skewed angle drop testing are introduced based on local measurements along the skewed face of the fixture to accurately monitor the impact event. Characterization tests were performed with a skewed fixture, at simultaneous acceleration loads from 500 to 3,000 g in two (in-plane and out-of-plane) directions, while meeting standard time domain tolerances. Upon experimental characterization, drop shock durability tests were conducted on a printed circuit assembly (PCA). Mean drops-to-failure were measured and quantified with Weibull statistics. Dominant solder joint failure modes were identified via failure analysis. Prior work on inclined angle impact testing is limited, and the majority of solder joint interconnect level fatigue studies are conducted considering perpendicular loading normal the circuit card. Low-cycle fatigue curves are generated based on plastic strain and plastic work density within the solder joint. A multiscale nonlinear finite element model is used to relate board-level flexure to solder joint interconnect level plastic strain. A high strain rate solder constitutive model allows for accurate modeling of solder plasticity resulting from high-impact drop shock. Fatigue parameters are computed from the Coffin-Manson relation and Palmgren-Miner damage accumulation. This work serves to apply established low-cycle fatigue methods for conventional drop shock loading (impact normal to circuit card) to non-perpendicular loading with a skewed fixture.

Hower, Jonathan [Kansas City National Security Cam↗

DOE OSTI2025

Model Development for the ACME Lab Modular Wall and A-Frame Assemblies

The structural frame used for conducting large structural tests was replaced by the ACME (Applied Combined Mechanical Environments) Lab in Building 860 of Sandia National Laboratories in Albuquerque, NM. This new design required simulation and analysis to verify maximum loads and corresponding factors of safety. Two major assemblies which are part of the ACME Lab, the Modular Wall and A-Frame, were designed to operate with a multitude of components in various configurations and with varying loads. Simulations of the Modular Wall and A-Frame structures were performed through explicit analysis to determine safety factors for numerous loading scenarios. The Modular Wall had safety factors of 1.1 for the lateral, diagonal, and gusset loading conditions. The A-Frame had safety factors of 2 for all loading conditions simulated.

42 ENGINEERING↗

DOE OSTI2025

Clarifying the trophic state concept to advance macroscale freshwater science and management

For over a century, ecologists have used the concept of trophic state (TS) to characterize an aquatic ecosystem's biological productivity. However, multiple TS classification schemes, each relying on a variety of measurable parameters as proxies for productivity, have emerged to meet use‐specific needs. Frequently, chlorophyll a, phosphorus, and Secchi depth are used to classify TS based on autotrophic production, whereas phosphorus, dissolved organic carbon, and true color are used to classify TS based on both autotrophic and heterotrophic production. Both classification approaches aim to characterize an ecosystem's function broadly, but with varying degrees of autotrophic and heterotrophic processes considered in those characterizations. Moreover, differing classification schemes can create inconsistent interpretations of ecosystem integrity. For example, the US Clean Water Act focuses exclusively on algal threats to water quality, framed in terms of eutrophication in response to nutrient loading. This usage lacks information about non‐algal threats to water quality, such as dystrophication in response to dissolved organic carbon loading. Consequently, the TS classification schemes used to identify eutrophication and dystrophication may refer to ecosystems similarly (e.g., oligotrophic and eutrophic), yet these categories are derived from different proxies. These inconsistencies in TS classification schemes may be compounded when interdisciplinary projects employ varied TS frameworks. Even with these shortcomings, TS can still be used to distill information on complex aquatic ecosystem function into a set of generalizable expectations. The usefulness of distilling complex information into a TS index is substantial such that usage inconsistencies should be explicitly addressed and resolved. To emphasize the consequences of diverging TS classification schemes, we present three case studies for which an improved understanding of the TS concept advances freshwater research, management efforts, and interdisciplinary collaboration. To increase clarity in TS, the aquatic sciences could benefit from including information about the proxy variables, ecosystem type, as well as the spatiotemporal domains used to classify TS. As the field of aquatic sciences expands and climatic irregularity increases, we highlight the importance of re‐evaluating fundamental concepts, such as TS, to ensure their compatibility with evolving science.

classification↗

DOE OSTI2025

A Combined Computational and Mathematical Analysis of Interconnect Fatigue Potential in Photovoltaic Modules

A finite element model of a 60-cell monocrystalline silicon glass-polymer photovoltaic module was simulated with ±1.0 kPa and ±2.4 kPa loads applied to the glass to calculate the deformation under load. Cell-to-cell displacements were used to approximate interconnect strain and stress. A mathematical fatigue cycle life relation was fitted to data for the interconnect material (copper), to generate a life prediction at each interconnect location based on the local stress means, reversal extents, and amplitudes. Interconnect stress was found to be significantly asymmetric about zero despite symmetric positive and negative module loads due to laminate thickness offsets about the neutral plane and the effects of module framing. Cycle life results indicated that interconnect fatigue failure was unlikely to occur over a 30-year lifetime of conservative wind and snow load cycles since the typical cell design feature of leaving some unconstrained length between the cell edge and first solder pad increases the effective gauge length and decreases the stress levels below the material endurance limit. Follow-up analyses found that 3.6 mm and 6.4 mm were the minimum unconstrained lengths required to survive the assumed lifetime of wind and snow cycles, respectively, confirming that typical industrial module constructions with 8–15 mm unconstrained lengths should survive conservatively. Notably, large magnitude, low-cycle snow loading was consistently the limiting factor requiring a longer unconstrained interconnect length. Finally, insights and workflows from this study inform module interconnection design limits for survival against mechanical fatigue in deployment environments.

14 SOLAR ENERGY↗

DOE OSTI2026

Design of a shipping fixture for a compact cryomodule hermetic assembly

In support of the development of a conduction-cooled 915MHz superconducting radio frequency (SRF) cryomodule, this study highlights the design of a shipping fixture for transporting the hermetic assembly 4500 km from Jefferson Lab to General Atomics in San Diego, California. The hermetic assembly consists of a 2-cell 915 MHz SRF cavity, a coaxial fundamental power coupler and warm-to-cold transition beam tubes. The two-part shipping assembly consists of an inner frame, providing direct mounting of the components, and an outer frame mounted to the ground transport vehicle. The inner frame is then connected to the outer frame by way of wire-rope isolators. Accelerometer data from ground transportation of previous projects at Jefferson Lab provides the baseline for the expected frequency and magnitude of vibrational and shock events during transit. Modal analyses were carried out in ANSYS on the inner frame assembly and critical components to identify an appropriate wire-rope isolator configuration such that peak loads are mitigated and the incurred frequencies do not correspond with the fundamental modes of the structures.

Accelerator Physics↗

DOE OSTI2026

A Fast, Accurate Prediction for System-Wide Damage Due to Dynamic Wind Loading

The complex relationship between photovoltaic (PV) hardware configurations, overall system dynamics, and turbulent aerodynamic phenomena generates highly unsteady, non-uniform loads that can lead to damaging instabilities. These effects may result in glass breakage, cell cracking, and structural failures in frames and mounting systems, even under moderate wind conditions. Addressing industry concerns about premature system failures in field conditions deemed survivable, our research aims to develop a fast and accurate predictive model for system damage. This model integrates configurable hardware choices with advanced simulation tools to represent the overall system-specific dynamics effectively. Using this model, we predict responses under varying weather conditions and hardware setups, translating these predictions into pre-trained surrogate models capable of accurately identifying failure risks and rapidly testing new system hardening measures. In this presentation, we will showcase preliminary results in capturing system dynamics through our customizable library of PV hardware configurations. Additionally, we will highlight how these new tools build upon PVade's established wind load modeling capabilities and foster the development of advanced AI/ML surrogates for improving system robustness.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

3D modeling of n = 1 RMP driven heat fluxes on the SPARC tokamak PFCs using HEAT

3D heat flux calculations at the lower outer divertor plate of SPARC using the HEAT code show that 3D fields generated from error field correction coils can lead to enhanced peak heat fluxes up to 15 times larger compared to the axisymmetric case. Previously employed to simulate axisymmetric heat flux on 3D plasma facing components, the HEAT code can now predict 3D heat flux generated by non-axisymmetric plasmas. This is achieved via a new HEAT module which leverages the 3D field line tracing capabilities of MAFOT starting from an M3D-C1 (MHD resistive code) perturbed equilibria. The resulting heat flux is assigned using the magnetic footprint and the heat flux layer model, an extension of the 2D heat flux model also known as the Eich, to 3D non-axisymmetric plasmas. For SPARC, the new capabilities of HEAT are used to calculate the 3D heat loads resulting from n = 1 perturbation fields (with n indicating the toroidal periodicity) applied through a toroidal array of six picture frame coils with different amplitude. The comparison with the unperturbed case shows significant changes in shape and intensity of the heat flux profile. The results show that the application of n = 1 3D field leads to a localized enhancement of the heat flux peak, influenced by the wetted area impacted by the magnetic footprint, and the appearance of a secondary heat flux peak, whose intensity depends on amplitude of the applied 3D field and toroidal location.

3D heat flux↗

DOE OSTI2025

Hybridization Assessment of Trybrid Pumped Storage Hydropower System—Part 1: A Case Study of Corral Summit

This report is a part of the deliverables for technical assistance provided to Cat Creek Energy for the Coral Summit Trybrid (Triple Hybrid-Pumped Storage Hydropower, Battery Energy Storage System, and photovoltaic solar energy) energy project. This report explores the operational benefits and challenges of hybridizing an open loop PSH (200MW) located at Mackay, Custer County, Idaho with solar PV (Ground mount 300MW and floating 40MW) and battery (720MWhr). This document reports two activities performed as a part of the hybridization assessment task 1) optimal resource allocation and energy management strategy, and 2) power quality and reliability assessment. From optimal resource allocation and energy management strategy (activity 1), the following key findings can be observed: • Conventional PSH (CPSH) with two reversible pump turbines and separate penstocks can provide required flexibility equivalent to that from two ternary PSH with separate penstock. With single unit CPSH, upper reservoir head cannot be maintained accurately, the variation of water level is rapid and pump mode flexibility is not available. These disadvantages can be overcome by single unit TPSH. However, using two CPSH units with separate penstocks also overcome these disadvantages with the formation of the hydraulic short circuit between two conventional units. • Flooding of the lower reservoir is a severe concern when considering continuous operation for black start. This limits the duration of continuous operation from PSH alone to around 50 hours. Due to the complementary PV and battery action, the duration of continuous operation and smooth power output can be extended. • An optimization problem is framed that maximizes the power output on an hourly basis while minimizing constraint violations and respecting seasonal variations of solar PV and load profiles . Two value streams, arbitrage and baseload generation are served by this profile. It was uncovered that for smooth power output during regular operation, PV curtailment will be required, or the battery capacity needs to be increased above 90MW to accommodate additional PV. From power quality and reliability assessment (activity 2) the following takeaway points can be observed: • The Trybrid, when integrated at the Lost River bus, and limited to 250MW in generation mode and -150MW in the pump mode, causes no violation of voltage or flow.

13 - HYDRO ENERGY↗

DOE OSTI2025

Design of Transportation Frames for 650 MHz Cavities and High Power Couplers

This work presents the design of a transportation frame system for 650~MHz superconducting radio frequency cavities with high power couplers. Modal analysis identified the coupler antenna as the critical component with a 38~Hz natural frequency, leading to a dual-frame design with wire rope isolators that achieves 82\% vibration attenuation at the critical frequency. The system meets all transportation requirements, fits within standard shipping crates, and maintains structural integrity under 12g shock loads.

42 ENGINEERING↗

DOE OSTI2025

Design of Transportation Frames for 650 MHz Cavities and High Power Couplers

Argento, Marco [Fermilab]↗

DOE OSTI2025

Field Test Report Neutron Scintillator Array Dry Storage Cask Scanner FY2024

During two weeks of Field Testing at the Idaho National Laboratory INTEC Cask Farm in July and August 2024, the LLNL Dry Storage Cask Scanner Array was lifted on top of an MC-10 dry storage fuel cask and operated to acquire neutron and gamma-ray data from the 24 fuel bundle positions. Neutron and gamma-ray data acquisition scans across the top of the cask of varying dwell times were performed July 15-18, 2024 and August 19-22, 2024 to evaluate the ability of the scanner data to reveal asymmetries in the fuel positions that reflect asymmetries in the MC-10 cask fuel bundle loading. The MC-10 cask 24 position fuel bundle loading at the INTEC Cask Farm is well documented, including the locations of six empty fuel bundle positions. This loading presents an opportunity to test the ability of the scanner system to detect diversion of spent fuel bundles as well as to validate the MC-10 cask MCNP modeling. The cask scanner array consists of six Stilbene crystal scintillator detectors and a linear actuator frame that moves the six detectors across the MC-10 dry storage cask to obtain data above each of the 24 fuel bundle positions. The detectors are connected to a pulse-shape discrimination data acquisition system capable of generating separate neutron and gamma-ray spectra for each detector and for each scan position. From the prior single detector Field Test in 2021 and iteration with MCNP modeling, the neutron and gamma-ray data were analyzed in multiple energy regions to identify an analysis method that would provide the strongest and most consistent signature of the asymmetric MC-10 cask fuel loading1 . From both the 2021 Field Test and the current Field Test results, the neutron capture gamma-ray count rate around 2.2 MeV provides the strongest signature of the asymmetric MC-10 cask fuel loading and has qualitative agreement with MCNP calculations. Counting all gamma-rays produces a similar signature. Neutrons emerging from the cask top are moderated and captured by the hydrogen in the polyethylene moderator and scintillator detector, producing a 2.2 MeV gamma ray which is seen in the scintillator gamma-ray spectrum. The count rate in the 2.2 MeV gamma-ray region is ~50 c/s, which is ~1000x higher than the ~0.05 n/s rate in the > 4MeV neutron region, and ~50x greater than the ~1 n/s rate in the neutrons > 500 keV region. Analysis of the 2.2 MeV neutron-capture Compton-scattered gamma-rays produces a statistically significant signature of the INTEC Cask Farm MC-10 asymmetric fuel loading. MCNP simulations indicate that the average neutron energy spectrum offers the potential to detect a large asymmetry from several missing bundles as well as individual missing fuel bundles. Testing this feature will require measurements on a cask with single missing elements.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

Analytic Expressions for Extracting Far Scrape-Off Layer Transport Coefficients from the Plasma-Wall Interaction of Divertor Tokamaks

Magnetic-confinement DT pilot plants and DEMO-class devices will employ thin breeding blanket first walls with substantially lower steady-state power-handling margins than ITER-like thick walls, making reliable prediction of main-chamber particle and heat loads increasingly critical. This report addresses that need by developing analytic tools to interpret far scrape-off layer (far-SOL) plasma–wall interaction measurements in divertor tokamaks, with the goal of extracting effective cross-field transport coefficients from “window-frame” experiments and related diagnostics.

Stangeby, P. C. [Univ. of Toronto, ON (Canada)]↗

DOE OSTI2025

Enabling Grid-Forming Control Under Unbalanced Conditions

Standalone microgrids often experience unbalanced loading and faults, which can cause grid-forming control designed for balanced conditions to produce oscillatory responses. To address this issue, a compact time-domain transformation appropriate for inverter control is proposed, allowing the conversion of unbalanced three-phase signals to positive and negative synchronous reference frames. This transformation supports the development of a grid-forming control with fault ride-through, featuring frequency and voltage droop controllers and nested current and voltage control loops that seamlessly integrate an enhanced current limiter. The effectiveness of the proposed control and transformation is demonstrated through analytical results and electromagnetic transient simulation.

24 - POWER TRANSMISSION AND DISTRIBUTION↗