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At least 19 records

IROS 2023 Workshop Report: Draft Guidelines on Manufacturing Procedures, Test Methods and Reporting for Soft Robotics

Soft roboticists are facing challenges with reproducibility, which prevents researchers from making holistic comparisons to prior work, impedes full understanding of results, and forces the need to “reinvent the wheel,” delaying fundamental advances. Reproducibility of results is key to advancing science as well as achieving technology transfer from research laboratories to industrial applications. Recently, a discussion-based workshop dedicated to the topic, “Developing Standard Testing and Reporting Guidelines for Soft Robotics,” was held at IROS 2023 in Detroit, MI. The purpose of this document is to record a set of recommendations and voluntary draft guidelines for soft roboticists concerning fabrication/manufacturing, test procedures, and reporting, which were collectively developed at the workshop. Together as a community, we hope to improve the reporting standards of soft robotics and drive the field as a whole toward more rigorous research practices.

43 PARTICLE ACCELERATORS↗

DC Fast Charging Test Procedures

This report has been drafted as an initial effort to develop a standardized test procedure for DCFC for LD EVs. The proposed test procedures are designed to be time-efficient, aligned with EV discharge tests, and practical to implement, thereby minimizing the testing and computational efforts required by OEMs and testing authorities.

33 ADVANCED PROPULSION SYSTEMS↗

Module Testing Procedures and Results for the CMS Phase-2 Outer Tracker Upgrade at Fermilab

The High-Luminosity LHC (HL-LHC) will operate at significantly increased luminosities and is expected to deliver about 3000 $fb^{-1}$ of proton-proton collision data at $\sqrt{s}=14$ TeV over a decade of operation. To maintain efficient tracking and triggering performance under high pileup and radiation conditions, the CMS experiment is upgrading its tracking detector for Phase-2 operations. The upgraded Outer Tracker (OT) will consist of Pixel-Strip (PS) and Strip-Strip (2S) silicon modules capable of providing tracking information to the Level-1 trigger at 40 MHz. Production and qualification of OT modules have been ongoing for about one year across several assembly and testing centers in the US, Europe, India, and Pakistan, requiring extensive testing to ensure stable operation in the HL-LHC environment. Fermilab is responsible for the production and testing of a significant fraction of the OT modules. The testing activities include IV characterization of silicon sensors, noise and pedestal measurements, verification of communication between module components, and burn-in studies using cold-box systems operated under controlled thermal conditions. Results from module testing and qualification studies performed during production will be presented.

Baradia, Sweta [UC, Davis (main)]↗

Review of supplementary cementitious materials with implications for age-dependent concrete properties affecting precast concrete

Here, this paper presents a comprehensive review of existing research examining the effects of supplementary cementitious materials on age-dependent concrete properties with the most profound implications for precast concrete production. The review covers the physical and chemical properties of selected types of supplementary cementitious materials, concrete mixture proportions, concrete curing methods, testing procedures, and test results related to the fresh properties and strengths of a range of concrete mixtures. Although the use of supplementary cementitious materials in precast concrete products is common, the detailed information provided in this paper may facilitate more widespread use of these materials to enhance concrete properties and comply with sustainability initiatives.

20 FOSSIL-FUELED POWER PLANTS↗

ATLAS ITk strip sensor quality control procedures and testing site qualification

Abstract The high-luminosity upgrade of the Large Hadron Collider, scheduled to become operational in 2029, requires the replacement of the ATLAS Inner Detector with a new all-silicon Inner Tracker. Radiation hard n + -in-p micro-strip silicon sensors were developed by the ATLAS Inner Tracker strip collaboration and are produced by Hamamatsu Photonics K.K. Production of the total amount of 22000 strip sensors has started in 2020 and will continue until 2025. The ATLAS strip sensor collaboration has the responsibility to monitor the quality of the fabricated devices by performing detailed measurements of individual sensor characteristics and by comparing the obtained results with the tests done by the manufacturer. Dedicated Quality Control procedures were developed to check whether the delivered large-format sensors adhere to the ATLAS specifications. The institutes performing the Quality Control testing of the pre-production and production ATLAS ITk strip sensors had to initially be qualified for multiple high-throughput tests by successfully completing the Site Qualification process. The Quality Control procedures and the qualification process are described in this paper.

Instruments & Instrumentation↗

Building a Simplistic Automatic Extruder: Instrument Development Opportunities for the Laboratory

This work presents an automatic extruder as a research experience for undergraduate students. The system offers a user-friendly approach to preparing vesicles, such as liposomes or polymersomes, with a defined size and polydispersity properties crucial for research in biology and macromolecules. It comprises two syringe pumps connected by a membrane filter. The setup is controlled by software. Compared to manual extrusion, this automated system provides advantages, such as precisely controlled variables. The project describes a tool to enhance undergraduate learning in science and engineering laboratories. Building an automatic extruder serves as a simplified model of a complex industrial process. It offers a clear advantage: automating a well-understood manual extrusion process. To make this project accessible, it is broken down into three manageable tasks: software development, hardware assembly, and testing procedures. This breakdown describes the software created, the hardware components used, and the testing procedures conducted for this project. All project data, including software code, testing data, and procedures, are freely available online. This allows undergraduate students to not only begin their own projects but also contribute to this educational instrument’s ongoing development.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

High-Mileage Courier Fleet Vehicle Laboratory Battery Pack Testing

For one of each of the AVTA's plug-in hybrid electric vehicles, battery electric vehicles, and some hybrid electric vehicles tested in high-mileage courier fleets, the high-voltage traction battery packs were removed from the vehicle and tested at the beginning and end of fleet testing. For some vehicles, batteries also were tested at periodic intervals during fleet testing. Standard reference performance tests were conducted to characterize battery degradation over time. This dataset contains results from two or more rounds of battery tests for 21 distinct year/make/model vehicles (see reference ["INL Advanced Vehicle Testing Activity: On-road Logger and Laboratory Battery Pack Testing Vehicle List"](https://avt.inl.gov/sites/default/files/pdf/reports/DatasetVehicleList.pdf) for full list of vehicles). Each round of battery testing included the "Static Capacity Test" and the "Hybrid Pulse Power Characterization (HPPC) Test", conducted according to test procedures published in the United States Advanced Battery Consortium ["Battery Test Manual For Power-Assist Hybrid Electric Vehicles"](https://www.uscar.org/commands/files_download.php?files_id=57), ["Battery Test Manual For Plug-In Hybrid Electric Vehicles"](https://www.uscar.org/commands/files_download.php?files_id=168), and ["Electric Vehicle Battery Test Procedures Manual"](https://www.uscar.org/commands/files_download.php?files_id=5) prior to the time of testing. These tests were performed by Intertek Testing Services, North America. This dataset is shared by API; a small sample of the vehicle battery and test data has been extracted and is also available for download.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Improved Creep Testing Approach for Bentonite EBS

In the United States, the nuclear reactor contributes 18.7 percent of the nation’s total electricity generation and produces a significant amount of spent nuclear fuel (SNF) and high-level waste. Because SNF is being stored for longer periods than initially envisioned, the U.S. Department of Energy Office of Nuclear Energy, Office of Spent Fuel and Waste Science and Technology is assessing the technical performance of the SNF storage systems after extended durations. The concept of a sustainable geologic repository for SNF disposal relies heavily on the safety provided by multiple barriers, such as repository host rock, overlying rock formation, and human-made engineered barrier systems (EBS). One of the major components of EBS is bentonite-based buffer materials that isolate the nuclear-waste canisters from the host rock and fill the void left in the horizontally drilled boreholes. The resaturated bentonite has a swelling characteristic, which is useful for self-sealing the microcracks in the host rock and supporting the canister’s heavy weight. However, factors such as nonuniformity in the saturation, swelling pressure of bentonite, and the high temperature at the canister-bentonite interface may lead to instability of the waste canister inside the borehole. Therefore, evaluating the long-term deformation of bentonite-based material is necessary. RESPEC Company, LLC recently completed a preliminary study for the U.S. Department of Energy (DE SC0022804) that is attempting to understand the time-dependent deformation in the consolidated sand/bentonite (SB) specimens through triaxial creep experiments and improve the understanding of EBS performance under anticipated repository conditions. The project included developing a standard testing procedure for preparing the consolidated core specimen from a mixture of sand and bentonite in a 50:50 ratio by weight, fabricating a new pressure vessel in-house, modifying existing creep equipment to perform triaxial creep experiments on consolidated SB specimens, and performing six long-term triaxial creep experiments under low-deviatoric stress at two different temperature conditions, which is representative of hypothetical conditions that might be encountered in a geologic repository within a reasonable rate of success in completing creep experiments. The consolidated SB specimen was prepared using the novel specimen preparation procedure and had physical characteristics (e.g., moisture content and bulk density) reasonably comparable with the properties of bentonite-based buffer, which is proposed to be used in the EBS in the Swedish KBS-3H design and the Swiss design of SNF disposal in the horizontal drifts. The newly fabricated pressure vessel could withstand the confining pressure of up to 15 megapascals (MPa) while maintaining the test temperature of up to 90 degrees Celsius (°C) for long-term creep experiments. The preliminary results from the triaxial creep experiments suggested that the consolidated SB specimen may experience time-dependent deformation at a low-deviatoric stress state and room temperature condition. Based on the deformation recorded in the SB specimen from axial and radial linear variable differential transformers (LVDTs) and physical characteristic changes, it is apparent that the time-dependent deformation is a combination of consolidation and creep, which is influenced by the level of deviatoric stresses and temperature. The systematic creep testing of bentonite-based specimens helped develop a standard testing procedure applicable for analyzing the similar characteristics of shale or clay-like materials in different geologic conditions outside repository science, including in civil engineering and infrastructure projects, underground and open pit mining, and deep drilling.

58 GEOSCIENCES↗

International Actions to Reduce Miscellaneous Electrical Loads Energy Consumption

Miscellaneous electric loads (MELs) research dates back over thirty years, with the earliest publications on MELs originating in the late 1980s. As the number and types of MELs grew over the subsequent decades, so did the body of minimum energy performance standards (MEPS) and regulations put in place to control what is now an ever-growing source of energy consumption in the residential and commercial sectors. In particular, these MEPS are designed to control off-mode, standby, and connected standby power consumption to prevent energy waste. Research on MELs focuses a great deal on analyzing the characteristics of MELs, approaches for measuring their consumption, and at a higher level what constitutes a MEL. Despite these advances, there has yet to be a comparison of different approaches across regulatory bodies of MELs – both between and within countries – to identify similarities, gaps, and opportunities for crafting common language and testing procedures. This study provides an international analysis of MELs-related voluntary and mandatory MEPS across 12 economies to address this gap. The analysis demonstrates that even while economies may participate in shared commitments to regulated MELs energy consumption, there remains no common language for framing MELs, nor is there a shared understanding of updating aging test procedures used globally for verifying MELs-related MEPS.

Miscellaneous Electric Loads, MELs, Appliance and ↗

Evaluation of liquid metal embrittlement of F82H and 4340 steels in liquid lithium

Here, to evaluate the liquid metal embrittlement (LME) susceptibility of F82H, a reduced activation ferritic-martensitic (RAFM) steel, a testing procedure using hollow cylindrical tensile specimens was used. Tensile tests are compared between specimens filled with argon and lithium at 200 °C. To validate the procedure, initial testing was performed on type 4340 steel, which is well-known to exhibit LME. Compared to 4340 steel, F82H only showed minor effects of Li exposure, including pre-testing exposures with Li at 400 °C for 1 h and 500 °C for 500 h. Furthermore, changing the strain rate or tensile test temperature also did not show significant embrittlement.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Auto Stop-Start Fuel Consumption Benefits

With increasingly stringent regulations mandating the improvement of vehicle fuel economy, automotive manufacturers face growing pressure to develop and implement technologies that improve overall system efficiency. One such technology is an automatic (auto) stop-start feature. Auto stop-start reduces idle time and reduces fuel use by temporarily shutting the engine off when the vehicle comes to a stop and automatically re-starting it when the brake is released, or the accelerator is pressed. As mandated by the U.S. Congress, the U.S. Environmental Protection Agency (EPA) is required to keep the public informed about fuel saving practices. This is done, in partnership with the U.S. Department of Energy (DOE), through the fueleconomy.gov website. The “Fuel-Saving Technologies” and “Gas Mileage Tips” sections of the website are focused on helping the public make informed purchasing decisions and encouraging fuel-saving driving habits. Here, in order to provide users with accurate information about the auto stop-start feature, experiments were conducted to determine its fuel economy effect. Four vehicles were tested both with and without the feature enabled under three test cycles: the Federal Test Procedure (FTP) city fuel economy test, the US06 high acceleration aggressive driving schedule that is often identified as the “Supplemental FTP” driving schedule, and the EPA New York City Cycle (NYCC). The results were compared to measure the fuel economy and consumption effects of using the auto stop-start feature. It was found that the fuel economy improvement varied significantly between drive cycles depending on the amount and percentage of idle time during the test. The largest fuel economy improvements were 7.27% and 26.4% for the FTP and NYCC, respectively.

33 ADVANCED PROPULSION SYSTEMS↗

Utah FORGE: Wells 16A(78)-32 and 16B(78)-32 Extended Circulation Test Data - August and September 2024

The dataset includes data collected during an extended circulation test conducted at the Utah FORGE site between August 8 and September 5, 2024. It provides uncorrected, raw digital data from the test, along with calibration information and a final report detailing the test procedures and corrections. The data is bundled in a single .zip file containing both field calibration and test data. Files include manual calibration data for temperature, pressure, and flow meters, as well as uncorrected, time-stamped measurements recorded in 30-second intervals, such as wellhead pressures, flow rates, and temperatures for wells 16A(78)-32 and 16B(78)-32. Additionally, the final report offers insights into the test methodology and provides guidelines on how to apply field calibrations to correct the raw Pason data.

15 GEOTHERMAL ENERGY↗

Summary of Alloy 617 and Alloy 709 Elevated Temperature Crack Growth Test Results from the Planned FY24 Crack Growth Test Activities

This report covers the results from crack growth rate testing performed at Idaho National Laboratory in the fiscal year 2024. It includes two creep crack growth rate tests and two creep-fatigue crack growth rate tests. Results are shown for each of these tests, included crack growth measured during the test using direct current potential drop, and measurements based off of the fracture surface. Load line displacement, as well as load, were also collected during the tests. Detailed analysis of the results will continue into the next fiscal year, however, a number of potential improvements to the equipment and testing procedures were identified that will increase testing reliability and throughput, as well as decrease complications with the analysis.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Solid oxide electrolysis cell and stack testing best practices

Solid oxide electrolyzer (SOE) technology is an emerging method for hydrogen production, noted for its superior electrical efficiency. Despite the significant progress made in recent years, the broad development of SOE technology is often constrained by the necessary and extensive "skill of the craft" required to successfully test simple single cell test articles. This may be linked to the dearth of practical and pragmatic guidance within the literature for safe, reliable, and performant test equipment and test procedures. Researchers at the Idaho National Laboratory (INL) have been actively testing SOEs ranging from button cells to stacks up to 500 kW, in collaboration with industry and other national laboratories. Based on operational experience, INL has developed system design procedures that ensure safe and reliable operation of SOE systems with the level of support required for each test. This paper presents key aspects of SOE stack and system testing, including safe design procedures, balance of plant components design, and specific implementations at INL. Practical design details of reactants, heat, and power management are presented along with lessons learned from the SOE test facility operations at INL.

08 HYDROGEN↗

Out-of-Pile Testing and Instrumentation Transient Water Irradiation System

Current initiatives to increase the burnup of conventional nuclear fuels past the approximate 62 GWd/t limit have been spurred on by direct savings to refueling and waste storage. The technical justification for a new license limit requires extensive qualification through experimental testing. Unlike beginning-of-life fuels, high-burnup fuels are more susceptible to fuel fragmentation, relocation, and dispersal (FFRD), therefore more data is needed to characterize fuels under key accident scenarios. The Transient Reactor Test Facility (TREAT) located at the Idaho National Laboratory has developed a testing apparatus architecture to test fuels and claddings at prototypic conditions. The Transient Water Irradiation System (TWIST) is the latest iteration of a testing device capable of conducting loss of coolant accidents (LOCAs) in TREAT. The Out-of-Pile Testing and Instrumentation TWIST (OPTI-TWIST) is an electrically heated device that is analogous to TWIST. OPTI-TWIST allows for detailed instrumentation and thermal-hydraulic characterization. TWIST ultimately aims to conduct the most advanced in-situ diagnostics to evaluate FFRD in a prototypic LOCA. Moreover, it will explore the phenomenological bifurcation of a decay-energy heat up driven LOCA and a stored-energy heat up driven LOCA. The instrumentation suite includes conventional thermocouples and pressure transducers in addition to an electro impedance sensor, an acoustic emission sensor, an optical pressure sensor, and an optical pyrometer. Characterizing these instruments in OPTI-TWIST eliminates complications of irradiation effects while preserving extreme thermal-hydraulic conditions. Finally, benchmarking both devices to a thermal-hydraulic code like the Reactor Excursion and Leak Analysis Program (RELAP)5-3D provides a unique opportunity for iteration. Pre-test predictions and post-test interpretations inform the physical designs, operational procedures, test conditions, and instrumentation types and positions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Acceptance criteria for in situ surveillance of MSR materials based on thermally-loaded mechanical test articles

This report describes practices and acceptance test procedures for designing, running, and maintaining a material surveillance program in a future operating molten salt reactor. The programs described here rely on test data from passively actuated mechanical test articles inserted into critical regions of the reactor and periodically removed for out-of-reactor testing. The report defines definite acceptance procedures, based on the results of these tests, to determine whether a component can continue to operate accounting for the accumulation of environmentally-assisted mechanical damage in the component materials to date, and extrapolated out through the next inspection period. Additionally, the report describes work on a software tool implementing many of the surveillance methods and procedures described here and progress on simplified methods for inferring damage accumulation in the test articles, based on out-of-reactor thermal cycling, that do not rely on sophisticated numerical analysis.

36 MATERIALS SCIENCE↗