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Topics of the presentation include: MQXFA magnets; Fabrication and test status; Analysis of magnets with limited performance; Lessons learned and corrective actions; MQXFA endurance and toughness; and, conclusions.
Results from a study to identify and characterize discrepancies between validation tests and high-fidelity analyses of compression-loaded panels are presented. First, potential sources of the discrepancies in both the experimental method and corresponding high-fidelity analysis models were identified. Then, a series of laboratory tests and numerical simulations were conducted to quantify the discrepancies and develop test and analysis methods to account for the discrepancies. The results indicate that the discrepancies between the validation tests and high-fidelity analyses can be attributed to imperfections in the test fixture and specimen geometry; test-fixture-induced changes in specimen geometry; and test-fixture-induced friction on the loaded edges of the test specimen. The results also show that accurate predictions of the panel response can be obtained when these specimen imperfections and edge conditions are accounted for in the analysis. The errors in the tests and analyses, and the methods used to characterize these errors are presented.
Several lessons are presented with specific recommendations for considerations for new projects to aid in the planning of cost effective temperature design, test, and analysis.
NASA’s Europa Clipper mission – which is planned to launch in the mid-2020s – is designed to investigate the habitability of the jovian moon Europa with a state-of-the-art suite of over 10 sensors and instruments. Now past its project critical design review, Europa Clipper is starting the execution of its verification and validation (V&V) program. The payload V&V function in particular is responsible for designing and coordinating a thorough test and analysis program that will confirm the proper functioning and performance of our payload instruments. Given the large number of instruments to manage, we have developed a suite of standardized tests and analyses that are designed to cover all of the common interfaces across instruments, while allowing for flexibility to support the unique needs of individual instruments. This suite of activities, coordinated and/or performed by the payload team, forms the bulk of our payload verification and validation campaign. This paper provides a detailed summary of the full set of V&V activities in that suite, covering the four categories of activities: analysis of lower-level evidence, analysis via simulation, testing in the system testbeds, and testing in assembly, test, and launch operations (ATLO). We will describe the purpose of each activity type, how the activities are developed, and the review process for each type of activity. We then define the complete list of activities written for each instrument and how subtleties specific to certain instruments are managed. The discussion will provide a comprehensive understanding of the activities in the payload V&V purview and how various interfaces with different levels of the project are managed. This paper also describes key metrics the payload team uses to track V&V progress and some insights into the teaming design and division of labor we use to ensure consistency and completeness across the entire payload suite. Finally, the paper will offer a snapshot of the status of the Payload V&V program prior to instrument delivery and offer insights into the upcoming phase of instrument delivery and the start of ATLO.
A limitation has been identified in the existing test standards used for making controlled, two-body abrasion scratch measurements based solely on the width of the resultant score on the surface of the material. A new, more robust method is proposed for analyzing a surface scratch that takes into account the full three-dimensional profile of the displaced material. To accomplish this, a set of four volume- displacement metrics was systematically defined by normalizing the overall surface profile to denote statistically the area of relevance, termed the Zone of Interaction. From this baseline, depth of the trough and height of the plowed material are factored into the overall deformation assessment. Proof-of-concept data were collected and analyzed to demonstrate the performance of this proposed methodology. This technique takes advantage of advanced imaging capabilities that allow resolution of the scratched surface to be quantified in greater detail than was previously achievable. When reviewing existing data analysis techniques for conducting two-body abrasive scratch tests, it was found that the ASTM International Standard G 171 specified a generic metric based only on visually determined scratch width as a way to compare abraded materials. A limitation to this method was identified in that the scratch width is based on optical surface measurements, manually defined by approximating the boundaries, but does not consider the three-dimensional volume of material that was displaced. With large, potentially irregular deformations occurring on softer materials, it becomes unclear where to systematically determine the scratch width. Specifically, surface scratches on different samples may look the same from a top view, resulting in an identical scratch width measurement, but may vary in actual penetration depth and/or plowing deformation. Therefore, two different scratch profiles would be measured as having identical abrasion properties, although they differ significantly.
By the end of October 2022, the US HL-LHC Accelerator Upgrade Project (AUP) had completed fabrication of ten MQXFA magnets and tested eight of them. The MQXFA magnets are the low-beta quadrupole magnets to be used in the Q1 and Q3 Inner Triplet elements of the High Luminosity LHC. This AUP effort is shared by BNL, Fermilab, and LBNL, with strand verification tests at NHMFL. An important step of the AUP QA plan is the testing of MQXFA magnets in a vertical cryostat at BNL. The acceptance criteria that could be tested at BNL were all met by the first four production magnets (MQXFA03-MQXFA06). Subsequently, two magnets (MQXFA07 and MQXFA08) did not meet some of the criteria and were disassembled. Furthermore, lessons learned during the disassembly of MQXFA07 caused a revision to the assembly specifications that were used for MQXFA10 and subsequent magnets. In this article, we present a summary of 1) the fabrication and test data for all the MQXFA magnets; 2) the analysis of MQXFA07/A08 test results with characterization of the limiting mechanism; 3) the outcome of the investigation, including the lessons learned during MQXFA07 disassembly; and 4) the finite element analysis correlating observations with test performance.
By the end of October 2022, the US HL-LHC Accelerator Upgrade Project (AUP) had completed fabrication of ten MQXFA magnets and tested eight of them. The MQXFA magnets are the low beta quadrupole magnets to be used in the Q1 and Q3 Inner Triplet elements of the High Luminosity LHC. This AUP effort is shared by BNL, Fermilab, and LBNL, with strand verification tests at NHMFL. An important step of the AUP QA plan is the testing of MQXFA magnets in a vertical cryostat at BNL. The acceptance criteria that could be tested at BNL were all met by the first four production magnets (MQXFA03-MQXFA06). Subsequently, two magnets (MQXFA07 and MQXFA08) did not meet some criteria and were disassembled. Lessons learned during the disassembly of MQXFA07 caused a revision to the assembly specifications that were used for MQXFA10 and subsequent magnets. In this paper, we present a summary of: 1) the fabrication and test data of all the MQXFA magnets; 2) the analysis of MQXFA07/A08 test results with characterization of the limiting mechanism; 3) the outcome of the investigation, including the lessons learned during MQXFA07 disassembly; and 4) the finite element analysis correlating observations with test performance.
The Gear Test Assembly (GTA) is an experimental test apparatus built and installed in the Mechanisms and Engineering Test Loop (METL) at Argonne National Laboratory (ANL). While designed to accommodate a variety of components intended for use in advanced compact in-vessel transfer machine, the focus of GTA been the testing of large radial spur gears. The performance of the components used in GTA motivates the choices made in the design, components, and material choices for the forthcoming METL test articles; the Gripper Test Assembly (GrTA), and the Bearing Test Assembly (BTA). To date, GTA has completed nine experimental testing campaigns and achieved over 21 million revolutions under prototypic sodium fast reactor loads and operating conditions. This report provides an overview and results for the two most recent experiments Campaign #8 and Campaign #9. `Campaign #8 was the first campaign to make use of a set of nickel alloy radial spur gears, made from Hastelloy C-22HS, and combined with heat-treated tapered roller bearings. The bearings and torque profile used allowed Campaign #8 to be directly compared with Campaign #1 where Inconel 718 gears were used instead. Campaign #8 attained 1,058,880 shaft revolutions within 23% of the 1,314,855 revolutions achieved in Campaign #1. These results demonstrate that the heat-treated tapered roller bearings show consistent increased lifetimes, approximately three times longer than for non heat-treated taper rollers, and that the particular material of the gear does not play a substantial role in performance. Similar to Campaign #7 where bearing failure resulted in fragmentation and transport of bearing material into the gear teeth led to tooth damage in the Inconel gears, a similar process led to the damage of the Hastelloy gears. Subsequent NDE analysis showed that the damage was only limited to the tooth surface and does not extend into the gear interiors. Based on the NDE reports, the Hastelloy gears can be reconditioned and put back into service for future campaigns as was done for the Inconel gears. Reconditioned Inconel 718 gears damaged in Campaign #7 were returned to service in Campaign #9 and paired with non heat-treated tapered roller bearings. In Campaign #9 a novel set of operating conditions were implemented whereby the gears and bearings were cycled between hot, submerged refueling conditions where fuel handling operations occurred and cold, dry, and inert conditions where the sodium was drained and the vessel was allowed to cool simulating long, ex-vessel storage of the fuel handling machine. A total of eight of these operating cycles were achieved before a bearing failure occurred after the accumulation of 475,692 shaft revolutions were achieved. During Campaign #9, one of the drive motors was damaged and over the course of a 240 day standby period, the entire GTA drive system was upgraded from a 480VAC system to a 240VAC system that provided the opportunity to consolidate wall-space in the METL facility and provide more space for additional test articles being installed in the coming year. The over 475,000 shaft revolutions achieved in Campaign #9 eclipses the previous record for lifetime of non heat-treated tapered roller bearings held by Campaign #3 of 392,000 shaft revolutions. Further analysis and future campaigns hope to shed light on the cause of this approximately 17% increase in lifetime.
Modular program with a small main program and several specialized subroutines provides a general purpose computer program to simulate the design, test and analysis phases of sensitivity experiments. This program allows a wide range of design-response function combinations and the addition, deletion, or modification of subroutines.
The Gear Test Assembly (GTA) is an experimental test apparatus built and installed in the Mechanisms Engineering Test Loop (METL) at Argonne National Laboratory (ANL). The focus of GTA has been to test larger radial spur gears sets machined from Inconel 718 along with a variety of bearing components that are to be used in the fuel handling machines built for use in pool-type sodium fast reactors. The testing in GTA also informs the design and material choices for the full-scale Gripper Test Assembly (GrTA) being developed by Argonne. To date, the Inconel 718 gears used in all six GTA experimental campaigns have completed over 23.2 million revolutions under various loads equivalent to approximately 37,156 simulated fuel assembly maneuvers (removal from and reinsertion to core) using a conventional height of a core assembly. While the heat treated and untreated tapered roller bearings and cylindrical pin thrust bearings used in the first five experimental campaigns have experienced mechanical or material failure after completing a range of fuel assembly maneuvers ranging from as early as 575 operations in Campaign #5 to 9800 operations in Campaign #1, Campaign #6 was the most successful campaign, achieving 22,563 maneuvers and was concluded before any catastrophic failure occurred. In this report we will present the results from the most recent campaigns, #5 and #6. The longevity of Campaign #6 was likely aided by a variety of adjustments made to the materials and components used and to the experimental testing procedures employed. In terms of materials and components, new gearboxes were fabricated, as opposed to using the old gear boxes which had been impacted by the previous bearing failures, and ball bearings were replaced with tapered roller bearings. The adjustments to the experimental procedure focused on a lowering of the maximum torque applied to the gears and bearings and the increase of the duration of each simulated fuel assembly maneuver conducted. This report will present and discuss the changes made to the materials, components, and procedures and the subsequent results for Campaign #5 and Campaign #6.
The Gear Test Assembly (GTA) is an experimental test apparatus built and installed in the Mechanisms Engineering Test Loop (METL) at Argonne National Laboratory (ANL). The focus of GTA has been to test larger radial spur gear sets machined from Inconel 718 along with a variety of bearing components that are to be used in the fuel handling machines built for use in pool-type sodium fast reactors. The testing in GTA also informs the design and material choices for the full-scale Gripper Test Assembly (GrTA) being developed by Argonne.
Test program to verify theory used in calculating axial thrust uses turbopump instrumented with /a/ proximity transducers for measuring shaft position, /b/ a strain gage thrust bearing carrier to measure axial thrust, and /c/ internal pressure taps to define component pressure gradients used in thrust calculations.
Test results at design speed show fan total pressure ratio, weight flow, and adiabatic efficiency to be 2.2, 2.9, and 1.8% lower than design goal values. The hybrid acoustic inlet (which utilizes a high throat Mach number and acoustic wall treatment for noise suppression) demonstrated total pressure recoveries of 98.9% and 98.2% at takeoff and approach. Exhaust duct pressure losses differed between the hardwall duct and treated duct with splitter by about 0.6% to 2.0% in terms of fan exit average total pressure (depending on operating condition). When the measured results were used to estimate pressure losses, a cruise sfc penalty of 0.68%, due to the acoustically treated duct, was projected.
Tests indicate performance very close to theoretical predictions. Major objectives were to verify system installation techniques, operation, and performance; to verify performance of individual subsystems; and to provide general test data base comparison with field data.
The purpose of these tests was to determine the connectivity range and associated data rates for connection between the flat panel antennas on the Federal Building and the dipole and L-3 tracking antennas on the Neah Bay.
The verification process for a major software subsystem was partially automated as part of a feasibility demonstration. The methods employed are generally useful and applicable to other types of subsystems. The effort resulted in substantial savings in test engineer analysis time and offers a method for inclusion of automatic verification as a part of regression testing.
Results are provided of a series of tests performed to identify the relationship between gas leakage rates across a seal at various internal to external pressure ratios. The results complement and provide insight into the analysis technique used to obtain the results presented in MSFC SSF/DEV/EL91-008, 'Space Station Freedom (S.S. Freedom) Seal Flaw Study with Delta Pressure Leak Rate Comparison Test Report.'
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