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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.

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DOE OSTI2024

Vehicle Position Detection Based on Machine Learning Algorithms in Dynamic Wireless Charging

Dynamic wireless charging (DWC) has emerged as a viable approach to mitigate range anxiety by ensuring continuous and uninterrupted charging for electric vehicles in motion. DWC systems rely on the length of the transmitter, which can be categorized into long-track transmitters and segmented coil arrays. The segmented coil array, favored for its heightened efficiency and reduced electromagnetic interference, stands out as the preferred option. However, in such DWC systems, the need arises to detect the vehicle’s position, specifically to activate the transmitter coils aligned with the receiver pad and de-energize uncoupled transmitter coils. This paper introduces various machine learning algorithms for precise vehicle position determination, accommodating diverse ground clearances of electric vehicles and various speeds. Through testing eight different machine learning algorithms and comparing the results, the random forest algorithm emerged as superior, displaying the lowest error in predicting the actual position.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

EMP Testing of NAE Magnetic Motor Starters

Sandia National Laboratories (SNL) performed a high-altitude nuclear electromagnetic pulse (HEMP) critical generation station component vulnerability test campaign with a focus on high-frequency, conducted early-time (E1) HEMP for the Department of Energy (DOE) Office of Cybersecurity, Energy Security, and Emergency Response (CESER). This report provides vulnerability test results to investigate component response and/or damage thresholds to reasonable HEMP threat levels that will help to inform site vulnerability assessments, mitigation planning, and modeling calibrations. This work details testing of North American Electric (NAE) magnetic motor starters to determine the effects of conducted HEMP environments. Motor starters are the control elements that provide power to motors throughout a generating plant; a starter going offline would cause loss of power to critical pumps and compressors, which could lead to component damage or unplanned plant outages. Additionally, failed starters would be unable to support plant startup. Six industrial motor starters were tested: two 2 horsepower (HP) starters with breaker disconnects and typical protection equipment, two 20 HP starters with breaker disconnects, and two 20 HP starters with fused disconnects. Each starter was placed in a circuit with a generator and inductive motor matching the starter rating. The conducted EMP insult was injected on the power cables passing through the motor starter, with separate tests for the generator and motor sides of the starter.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Characteristics of Ultralow Aspect Ratio Toroidal Plasmas and Non-Solenoidal Startup and Edge Stability Studies at Near-Unity Aspect Ratio (Final Report)

This grant supported a long-term research and development program to explore the physics and technology of spherical tokamak (ST) plasma behavior at near-unity aspect ratio ( A ). The PEGASUS Toroidal Experiment is a university-scale ( R ) ~ 0.40 m, α ~ .35 m, I p ≤ 0.3 MA, B T ≤ 0.15 T) experiment that accesses A → 1, to provide large values of the normalized plasma current, I N = I p /α B T , or equivalently the toroidal field utilization factor I p / I TF . The research activities focused on: 1) developing the technique of Local Helicity Injection (LHI) as a viable means of initiating and growing an ST plasma without the use of a central solenoid; 2) exploring the equilibrium and stability properties of spherical tokamak plasmas at extremely low aspect ratio; and 3) obtaining new insights in the properties of the enhanced confinement H-mode regime at A ~ 1. The initial (Phase I) facility employed a unique high-stress central solenoid Ohmic for current drive and heating with simple magnet current waveforms. A subsequent major upgrade (Phase II) offered more flexible control of the plasma evolution along with a powerful LHI system for plasma initiation, heating and sustainment. The LHI technique consists of injection of high-density current streams into vacuum toroidal and vertical magnetic fields. These streams become unstable and support magnetic reconnection to allow the system to relax into a tokamak-like magnetic configuration. This program focused on: 1) development of electron current sources that provide sufficiently high injection currents in the challenging edge plasma region; 2) validation of theoretical limits to achievable I p arising from magnetic helicity and energy conservation plus absolute limits arising from relaxation to a minimal energy states; 3) tests of a power balance model to describe the evolution of the plasma current I p (t); and 4) study of magnetic fluctuations and their role in the I p evolution. This culminated in the production of toroidal currents of I p ≥ 0.2 MA with only ~8 kA of injected current. Operation with Ohmic induction alone in Phase I created plasmas with soft limits on the achievable I p and field utilization ( I p / I TF ~ 1) due to the onset of large low-order (2/1 or 3/2) internal resonant tearing modes. With the expanded capabilities in Phase II operation, methods employed to mitigate those modes and achieve I p / I TF > 1 were: 1) I TF ramp-downs; 2) non-solenoidal startup via LHI; and 3) extremely low I TF Ohmic operations assisted by LHI current injector pre-ionization. Extensive use of LHI-driven startup and drive for non-solenoidal operation produced favorable current profiles to stably operate tokamak plasmas with unprecedentedly high I N = I p / aB T ~ 15 and I p / I TF > 2. With strong reconnection-driven anomalous ion heating, this in turn provided access to tokamak plasmas with B t up to 100%, a world record 2 times higher than that previously achieved in advanced or spherical tokamaks. This high B t regime had a large fraction (~50%) of the plasma volume in a region of an absolute minimum- B configuration. The MHD stability limit in this regime was the ideal external kink mode without a stabilizing wall. These results provided the first demonstration of access to tokamak plasmas with very high B t , high i N , high elongation κ, and low internal inductance ℓ i , and as such served as a proof-ofprinciple for access to this long-sought ST regime. The naturally low B T needed for stability at A ≤ 1.2 reduces the L-H mode power threshold, P LH , so that H-mode plasmas were achieved with Ohmic heating alone. The power threshold for the transition to the H-mode regime was found to be 10× the accepted values from the ITER international scaling, confirming initial trends indicated by experiments on MAST and NSTX, and suggesting that the physics behind this transition is not yet fully understood. The density dependence of the transition and the observed insensitivity to whether the plasma is bounded by a limiter or magnetic divertor are consistent with the recent FM 3 model. Multiple unstable toroidal magnetic modes were measured during ELM (Edge Localized Mode) crashes, with generally lower toroidal mode numbers than seen at higher A , which was attributed to the larger peeling mode instability drive at low A . First-ever edge current profile measurements through an ELM crash showed current-carrying filaments were generated, as seen in ELM simulations and in electromagnetic blob transport theory.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Optical leakage mitigation in ortho-mode transducer detectors for microwave applications

Ortho-mode transducers (OMT) are a commonly used method of coupling opti-cal signals between waveguides and on-chip circuitry and detectors. While the ideal OMT-waveguide coupling requires minimal disturbance to the waveguide, when used for mm-wave applications the waveguide is often slide though and the OMT probes inserted on a thin support membrane. This interface is a potential source of signal leakage and can lead to signal loss and experimental systematics (e.g. in CMB polarization experiments where lost signal can result in temperature to polarization leakage). Here we report on the development of new OMT- waveguide coupling structures with the goal of reducing leakage at the horn-to-detector-wafer interface. The pixel to pixel optical leakage due to the gap be-tween the coupling waveguide and the backshort is reduced by means of a protrusion that passes through the OMT membrane and connects the waveguide sections on each side of the wafer. High frequency electromagnetic simulations indicate that these protrusions can reduce optical leakage in the gap by ~80% percent, with a ~60% filling factor, respect to an ordinary OMT coupling without protrusion, using designs that are compatible with current fabrication processes. We describe the design of the new coupling structure including the impact of varying two key parameters: wafer to optical coupling gap and protrusion fill factor. Prototype devices have been designed that will characterize the performance of the new design using a relative measurement with varying filling factors. We describe the simulation setup and results, and present a chip layout and sample box designed to perform an initial measurement.

Detectors↗
NASA NTRS2022

Calculation of Transformer Leakage Inductance by Simplified Flux Path Geometries

Series inductance is a critical energy storage element in isolated power converters. Many have explored methods of estimating the total leakage inductance of transformers as an integrated series inductance without external inductors. However, this poses challenges with medium frequency converters and magnetic ribbon-based cores, e.g., metal amorphous nanocrystalline. The material’s relatively high conductivity allows eddy currents to develop when magnetic flux intersects wide surfaces. These eddy currents result in significant additional losses that increase with increasing power flow. This paper presents a simplified and accurate method of estimating leakage flux while identifying separate leakage flux paths that correlate with the magnetic material surfaces. This enables an understanding the proportion of leakage flux that will contribute to extra losses. The methods presented are applicable to both leakage and fringing (around heterogeneous material interfaces) fluxes. This paper includes detailed FEA studies and 3D flux vector measurements matching the presented analytical models.

transformer↗
DOE OSTI2021

Linear gyrokinetic stability of a high β non-inductive spherical tokamak

Spherical tokamaks (STs) have been shown to possess properties desirable for a fusion power plant such as achieving high plasma β and having increased vertical stability. To understand the confinement properties that might be expected in the conceptual design for a high β ST fusion reactor, a 1 GW ST plasma equilibrium was analyzed using local linear gyrokinetics to determine the type of micro-instabilities that arise. Kinetic ballooning modes and micro-tearing modes are found to be the dominant instabilities. The parametric dependence of these linear modes was determined and, from the insights gained, the equilibrium was tuned to find a regime marginally stable to all micro-instabilities at θ 0 = 0.0. This work identifies the most important micro-instabilities expected to generate turbulent transport in high β STs. The impact of such modes must be faithfully captured in first-principles-based reduced models of anomalous transport that are needed for predictive simulations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2003

Development of Numerical Codes for Modeling Electromagnetic Behavior at High Frequencies Near Large Objects

A study into the problem of determining electromagnetic solutions at high frequencies for problems involving complex geometries, large sizes and multiple sources (e.g. antennas) has been initiated. Typical applications include the behavior of antennas (and radiators) installed on complex conducting structures (e.g. ships, aircrafts, etc..) with strong interactions between antennas, the radiation patterns, and electromagnetic signals is of great interest for electromagnetic compatibility control. This includes the overall performance evaluation and control of all on-board radiating systems, electromagnetic interference, and personnel radiation hazards. Electromagnetic computational capability exists at NASA LaRC, and many of the codes developed are based on the Moment Method (MM). However, the MM is computationally intensive, and this places a limit on the size of objects and structures that can be modeled. Here, two approaches are proposed: (i) a current-based hybrid scheme that combines the MM with Physical optics, and (ii) an Alternating Direction Implicit-Finite Difference Time Domain (ADI-FDTD) method. The essence of a hybrid technique is to split the overall scattering surface(s) into two regions: (a) a MM zone (MMZ) which can be used over any part of the given geometry, but is most essential over irregular and "non-smooth" geometries, and (b) a PO sub-region (POSR). Currents induced on the scattering and reflecting surfaces can then be computed in two ways depending on whether the region belonged to the MMZ or was part of the POSR. For the MMZ, the current calculations proceed in terms of basis functions with undetermined coefficients (as in the usual MM method), and the answer obtained by solving a system of linear equations. Over the POSR, conduction is obtained as a superposition of two contributions: (i) currents due to the incident magnetic field, and (ii) currents produced by the mutual induction from conduction within the MMZ. This effectively leads to a reduction in the size of linear equations from N to N - Npo with N being the total number of segments for the entire surface and Npo the number of segments over the POSR. The scheme would be appropriate for relatively large, flat surfaces, and at high frequencies. The ADI-FDTD scheme provides for both transient and steady state analyses. The restrictive Courant-Friedrich-Levy (CFL) condition on the time-step is removed, and so large time steps can be chosen even though the spatial grids are small. This report includes the problem definition, a detailed discussion of both the numerical techniques, and numerical implementations for simple surface geometries. Numerical solutions have been derived for a few simple situations.

Joshi, R. P.↗
NASA NTRS2002

Magnetohydrodynamic MACH Code Used to Simulate Magnetoplasmadynamic Thrusters

The On-Board Propulsion program at the NASA Glenn Research Center is utilizing a state of-the-art numerical simulation to model the performance of high-power electromagnetic plasma thrusters. Such thrusters are envisioned for use in lunar and Mars cargo transport, piloted interplanetary expeditions, and deep-space robotic exploration of the solar system. The experimental portion of this program is described in reference 1. This article describes the numerical modeling program used to guide the experimental research. The synergistic use of numerical simulations and experimental research has spurred the rapid advancement of high-power thruster technologies for a variety of bold new NASA missions. From its inception as a U.S. Department of Defense code in the mid-1980's, the Multiblock Arbitrary Coordinate Hydromagnetic (MACH) simulation tool has been used by the plasma physics community to model a diverse range of plasma problems--including plasma opening switches, inertial confinement fusion concepts, compact toroid formation and acceleration, z-pinch implosion physics, laser-target interactions, and a variety of plasma thrusters. The MACH2 code used at Glenn is a time-dependent, two-dimensional, axisymmetric, multimaterial code with a multiblock structure. MACH3, a more recent three-dimensional version of the code, is currently undergoing beta tests. The MACH computational mesh moves in an arbitrary Lagrangian-Eulerian (ALE) fashion that allows the simulation of diffusive-dominated and dispersive-dominated problems, and the mesh can be refined via a variety of adaptive schemes to capture regions of varying characteristic scale. The mass continuity and momentum equations model a compressible viscous fluid, and three energy equations are used to simulate nonthermal equilibrium between electrons, ions, and the radiation field. Magnetic fields are modeled by an induction equation that includes resistive diffusion, the Hall effect, and a thermal source for magnetic fields. Various models of plasma resistivity are included, along with ablation models and multiport circuit solvers. The set of equations is closed using either an ideal gas or real equation of state.

Mikellides, Pavlos G.↗
NASA NTRS2008

Making Superconducting Welds between Superconducting Wires

A technique for making superconducting joints between wires made of dissimilar superconducting metals has been devised. The technique is especially suitable for fabrication of superconducting circuits needed to support persistent electric currents in electromagnets in diverse cryogenic applications. Examples of such electromagnets include those in nuclear magnetic resonance (NMR) and magnetic resonance imaging (MRI) systems and in superconducting quantum interference devices (SQUIDs). Sometimes, it is desirable to fabricate different parts of a persistent-current-supporting superconducting loop from different metals. For example, a sensory coil in a SQUID might be made of Pb, a Pb/Sn alloy, or a Cu wire plated with Pb/Sn, while the connections to the sensory coil might be made via Nb or Nb/Ti wires. Conventional wire-bonding techniques, including resistance spot welding and pressed contact, are not workable because of large differences between the hardnesses and melting temperatures of the different metals. The present technique is not subject to this limitation. The present technique involves the use (1) of a cheap, miniature, easy-to-operate, capacitor-discharging welding apparatus that has an Nb or Nb/Ti tip and operates with a continuous local flow of gaseous helium and (2) preparation of a joint in a special spark-discharge welding geometry. In a typical application, a piece of Nb foil about 25 m thick is rolled to form a tube, into which is inserted a wire that one seeks to weld to the tube (see figure). The tube can be slightly crimped for mechanical stability. Then a spark weld is made by use of the aforementioned apparatus with energy and time settings chosen to melt a small section of the niobium foil. The energy setting corresponds to the setting of a voltage to which the capacitor is charged. In an experiment, the technique was used to weld an Nb foil to a copper wire coated with a Pb/Sn soft solder, which is superconducting. The joint was evaluated as part of a persistent-current circuit having an inductance of 1 mH. A current was induced in a loop, and no attenuation of the current after a time interval 1,000 s was discernible in a measurement having a fractional accuracy of 10(exp -4): This observation supports the conclusion that the weld had an electrical resistance <10(exp -10) omega.

Penanen, Konstantin I.↗
NASA NTRSDate not supplied

Hall Magnetohydrodynamic Power Generation and Drag Augmentation Using A Coaxial-Electrode Configuration During Hypersonic Entry

For interplanetary missions, a spacecraft must reduce its relative velocity from orbital speeds of multiple kilometers per second to zero in order to safely land on the surface of a planetary body. During this phase known as planetary reentry, the spacecraft undergoes high speed above Mach 5 up to Mach 30. This hyper-sonic flight regime imposes a strong bow shock in front of the vehicle that imparts extreme aerodynamic and thermal effects. In addition, during portions of this regime, a plasma is formed in the post-shock flow-field around the vehicle due to these high temperatures. Interaction between an applied magnetic field with this electrically conductive fluid, or magnetohydrodynamic (MHD) interaction, can be utilized to convert kinetic energy from the flow into storable electrical energy. Onboard MHD energy generation can benefit the spacecraft by increasing the power of active thermal control components and vehicle control systems during reentry. MHD interaction also exerts a Lorentz body force on the plasma flow that can be manipulated to act as an additional drag force through the vehicle body. MHD drag augmentation can benefit the spacecraft with an additional control mechanism that operates without moving parts. This can be utilized at higher altitudes and subsequently reduce convective heat transfer to the vehicle. MHD interaction with plasma flow suggests that both power generation and drag augmentation can be integrated together in one design. Modern numerical studies have only demonstrated the viability and potential of MHD energy generation and drag modulation separately for implementation into future spacecraft designs [1] [2] [3]. Steeves et. al. presented one possible generator design specifically for reentry vehicles that utilized a modular panel with two embedded electromagnets and two extruding electrodes for air plasma to flow between. Fujino et. al. presented results that indicated increased total drag with a permanent magnet embedded in the blunt body of the Orbital Reentry Experiment (OREX) trajectory. Furthermore, experimental investigations of these two MHD applications have been limited and separate due to the difficult technical nature of experimental de-sign and analysis. For MHD energy generation, there have been two designs which used a cylindrical fore-body with two embedded permanent magnets and two outward facing curved electrodes for tangency to an artificially ionized plasma that flowed along the body length [4] [5]. The first design was studied using an air microwave (MW) ionized supersonic plasma wind tunnel and the second design used radio frequency (RF) ionization of Argon, but both physically demonstrated the feasibility of MHD energy generation in reentry plasma conditions. For MHD drag modulation, one study involved a small-scale cylindrical blunt body embedded with permanent magnets immersed in plasma flow in an arcjet tunnel [6], and another utilized a spherical permanent magnet enclosed with a spherical forebody that was evaluated in a shock expansion tunnel [7]. Both experimental studies provided physical evidence of drag augmentation due to MHD interactions. Therefore, because of the multi-faceted effects of MHD along with both applications having been deemed feasible and beneficial during reentry, this indicates that a coupled power generation and drag modulation design could be achievable. The axi-symmetric nature of blunt bodies for reentry suggests that a spherical set of two ring electrodes near the nose along the body axis. Based on first principles, flow along the walls of the spherical body can then produce MHD interactions between the electrodes. As a result, two currents are generated: a Hall current that produces power and a primary inductive current that augments the drag force. The goal of this work is to provide a simulated design of a coaxial-electrode con-figuration for power generation and drag modulation for experimental testing.

E. Leong↗
DOE OSTI2025

Simulations of plasma current induced by toroidal field ramping down on tokamaks

In tokamak experiments, the BT ramping down can drive off-axis and parallel inductive current. This approach leads to a decrease in q95 and an increase in normalized beta, βN. The off-axis inductive current also broadens the current profile. Typically, the 1.5D transport code is used to simulate the time evolution of the plasma current profile, which is based on the flux-surface-averaged Faraday’s law. The ONETWO code is one of those transport codes. However, this code cannot simulate the situation of the evolving toroidal field BT. This article proposes a new time-dependent model to take into account the BT ramping down situation. A modified formula of flux-surface-averaged Faraday’s law was derived to consider the effect of the BT ramping rate on the current evolution, and it was implemented in the ONETWO code. Then, the modified ONETWO code was used to simulate the BT ramping down experiment on DIII-D. The simulation result of the plasma current evolution with BT ramping down shows a broader current profile with smaller ohmic current induced by the poloidal field, compared to that without BT ramping down.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

MAGNETICALLY SUSPENDED CANNED ROTOR PUMPS FOR THE INTEGRAL MOLTEN SALT REACTOR

This project developed a molten salt pump design for small modular reactors, concentrated solar, and Gen IV nuclear reactors with a magnetically levitated rotor that can operate at temperatures of up to 700 °C. This eliminates the need for rotating seals and roller element bearings which require maintenance and are prone to failure. The pump design is also more compact than existing molten salt pump designs which require long shafts to thermally isolate the electric motor. The aims of the project are to: 1) design and test the molten salt pump, 2) develop and test a high temperature position sensor needed for magnetic bearing control, and 3) develop and test high temperature coil fabrication methods for electric motor and magnetic bearing fabrication. To develop the high temperature coils, conductor materials were analyzed for oxidation, diffusion, cladding, and resistivity. Of the candidate conductor materials that met the requirements, silver was chosen. The long-term impact of radiation on silver resistivity was analyzed by developing a model of a generic molten salt fast reactor to model the conductor irradiation in worst case scenarios. The analysis showed that increased resistivity due to transmutation of silver decreases exponentially with the reactor reflector thickness. Different electrical insulation materials were tested and the final high temperature coils developed were able to withstand conductor to ground voltages up to 1800 V before insulation breakdown. Magnetic bearings require high-precision high-speed measurements of the rotor position to operate. Current commercial position sensors can only operate up to 550 °C so a novel position sensor was developed that can operate up to 800 °C. These sensors were also designed to measure the position of the metallic rotor through a thin metallic corrosion barrier that protects that coils, insulation, and magnetic cores so that the salt containment barrier does not have any penetrations. The high-temperature sensor was tested and had comparable performance to commercially available inductive position sensors. The sensor design and signal processing has led to several invention disclosures. The magnetically levitated molten salt pump design was completed and analyzed. The chloride salt test loop at Oak Ridge National Laboratory was chosen to test the pump and the pump hydraulics and power were designed for the test loop flow and pressure requirements. Classes of motor designs that do not utilize permanent magnetic were considered for the high-temperature motor. After extensive analysis of their performance, a synchronous reluctance motor was chosen for the pump. The design was refined and analyzed to optimize performance. The magnetic bearings were designed to meet the force and frequency requirements necessary to levitate the rotor and reject disturbances from rotor imbalance, motor forces, and hydraulic forces. Compliant mounts for the position sensors were designed that would not damage the ceramic sensor components and maintain sensor alignment over a wide temperature range. A thermal hydraulic analysis of the molten salt coolant flow used to cool the rotor and stator was performed to ensure that the maximum temperature in the rotor and stator will not exceed 725 °C. The corrosion barrier and casing were designed to maintain the salt fluid boundary by using compliant features to absorb large expansion mismatches due to different coefficients of thermal expansion (CTE). Finally, the salt drain and fill systems were designed along with the pump support structure, integration with the test loop, and thermal insulation and heating. Corrosion barrier fabrication experiments were performed to assess using laser cladding to apply a sub-millimeter corrosion barrier to the surface of a Fe-Co-V magnetic core material. The cladding method showed minimal mixing between materials at their interface and withstood temperature cycling without damage to the cladding. The technology commercialization is focused on the high-temperature position sensors and there has been significant interest from the nuclear industry in utilizing these sensors along with some interest from the aerospace industry. The project also led to a research collaboration with a fusion energy industrial partner to study barriers to scaling the pump design from the kW size to the MW size. This research collaboration will also study methods to create high-temperature coils that have conductor to ground breakdown voltages above 5 kV. The successful development of high-temperature electromagnetic coils and high-temperature position sensors greatly increases the temperature limits for electromagnetic devices that don’t rely on permanent magnets. This includes electric motors, magnetic bearings, linear actuators, rotary position and velocity sensing, actuated valves, and generators to name a few. This will fill a current need in molten salt reactors, concentrated solar, and fusion energy for these critical peripheral devices needed for practical reactor designs that do not currently have commercial solutions.

Hines, J Wesley↗
NASA NTRSDate not supplied

Modeling and Analysis of Stirling Power Convertors

Modeling and Analysis of Stirling Power Convertors Luis A. Rodriguez1 Steven M. Geng, Terry V. Reid, Scott D. Wilson NASA Glenn Research Center, Cleveland, OH, 44135, USA NASA Glenn’s Thermal Energy Conversion Branch is supporting the development of the next generation free-piston Stirling power convertors. American Superconductor (AMSC) and Sunpower Inc. are the two firms under contract to develop the Flexure Isotope Stirling Convertor (FISC) and the Sunpower Robust Stirling Convertor (SRSC), respectively. To comprehend and forecast convertor performance, Sage, ANSYS® Maxwell, and ANSYS® Fluent were used to model the Stirling thermodynamic cycle, alternator electromagnetics, and piston and displacer dynamics. I. Introduction Stirling convertors are being developed by NASA as a potential steady source of electrical power for NASA’s future scientific space missions. Currently, NASA Glenn Research Center has two corporations under contract, American Superconductor (AMSC) and Sunpower Inc., for the development of the next generation of free-piston Stirling convertors for dynamic radioisotope power systems. AMSC is developing the Flexure Isotope Stirling Convertor (FISC), which uses flexures to prevent side motion and rubbing of the piston. Similarly, Sunpower Inc, is developing the Sunpower Robust Stirling Convertor (SRSC). The SRSC uses gas bearings to prevent radial contact of the moving piston. As convertor development continues, it is increasingly important to understand and predict the interactions of components in the system, how they respond to one another, and how they perform as a response to changes in operating conditions. A suitable and enlightening way to demonstrate and foresee these interactions is with the use of accurate modeling software. Sage, ANSYS® Maxwell, and ANSYS® Fluent are the current modeling tools used by NASA to analytically determine convertor performance. Sage is a one-dimensional object-oriented commercial software package used for modeling and optimizing Stirling convertors for Dynamic Radioisotope Power Systems (DRPS) and it is one of the most accurate Stirling convertor codes in use by NASA. This code is the successor to GLIMPS (Globally-Implicit Stirling Cycle Simulation) and GLOP (GLIMPS Optimization) software created by Gedeon Associates [1]. Model input parameters are typically material/gas type, component physical dimensions, temperatures, frequency, charge pressure, and number of time/space nodes. Sage is used to model both the FISC’s and SRSC’s Stirling cycle thermodynamics and piston/displacer dynamics. Performance maps were created and analyzed for both power systems to better understand the relationship between the following conditions: cold-end temperature, hot-end temperature, piston/displacer amplitudes, pressure drop, and thermal input power. The synergy between these conditions will help determine parameter sensitivity. ANSYS® Maxwell was used to create a three-dimensional (3-D) axisymmetric model for both FISC and SRSC alternators. The significant physical components included in each model are the magnets, magnet carrier, outer/inner laminations, and the coil. Inputs to the model are piston amplitude, piston frequency, alternator load, coil resistance, tuning capacitance, and specific material properties. The alternator models calculate terminal voltage, current, piston/current phase, voltage/current phase, coil inductance, terminal power and efficiency. The RI2 losses, core (hysteresis and eddy) losses, and magnet/can eddy losses are also a part of the final results. ANSYS® Fluent is used to build 3-D computational fluid dynamic (CFD) models to examine the Stirling cycle thermodynamics for both the FISC and SRSC systems. Three-dimensional Computer Aided Design (CAD) models were used to create the physical components of each convertor. Steady-state simulations were conducted for hardware testing, prediction of environmental losses during testing, and generation of radiation look-up tables. The model inputs to the aforementioned analysis are the material properties and boundary thermal conditions. The steady-state model calculates temperature and heat flow distributions. Transient 3-D calculations were also part of the CFD analysis. In this study a physically reduced version of the FISC is used to obtain a prediction of available engine power. For the gas bearing SRSC, the transient effort is used to obtain a prediction of bearing pad performance and its sensitivity to micro-channel geometric variation. The model inputs to the transient simulations are the piston amplitude, displacer amplitude, frequency, displacer/piston phase angle, dynamic deforming CFD grid, temperature boundary conditions, and user defined files describing motion profile of piston/displacer. The results of the model are temperature distributions, heat distributions, and PV power produced at pre-determined conditions.

Luis A Rodriguez↗
DOE OSTI2020

Charge collection and electrical characterization of neutron irradiated silicon pad detectors for the CMS High Granularity Calorimeter

The replacement of the existing endcap calorimeter in the Compact Muon Solenoid (CMS) detector for the high-luminosity LHC (HL-LHC), scheduled for 2027, will be a high granularity calorimeter. It will provide detailed position, energy, and timing information on electromagnetic and hadronic showers in the immense pileup of the HL-LHC. The High Granularity Calorimeter (HGCAL) will use 120-, 200-, and 300-$\mu\textrm{m}$ thick silicon (Si) pad sensors as the main active material and will sustain 1-MeV neutron equivalent fluences up to about $10^{16}~\textrm{n}_\textrm{eq}\textrm{cm}^{-2}$. In order to address the performance degradation of the Si detectors caused by the intense radiation environment, irradiation campaigns of test diode samples from 8-inch and 6-inch wafers were performed in two reactors. Characterization of the electrical and charge collection properties after irradiation involved both bulk polarities for the three sensor thicknesses. Since the Si sensors will be operated at -30 $^\circ$C to reduce increasing bulk leakage current with fluence, the charge collection investigation of 30 irradiated samples was carried out with the infrared-TCT setup at -30 $^\circ$C. TCAD simulation results at the lower fluences are in close agreement with the experimental results and provide predictions of sensor performance for the lower fluence regions not covered by the experimental study. All investigated sensors display 60$\%$ or higher charge collection efficiency at their respective highest lifetime fluences when operated at 800 V, and display above 90$\%$ at the lowest fluence, at 600 V. The collected charge close to the fluence of $10^{16}~\textrm{n}_\textrm{eq}\textrm{cm}^{-2}$ exceeds 1 fC at voltages beyond 800 V.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Development of NDE/NDT Tools for High-Volume & High-Speed Inspection of CFRP Structures in Automotive Manufacturing

Main advantages of the air-coupled ultrasound testing (ACUT) and electromagnetic testing (EMT) techniques for NDE of CFRP composites were non-contact sensing, scalability for high-speed inspection, cost-effectiveness, and non-hazardous operation. Despite these advantages, no systems that would satisfy the project requirements were commercially available. Hence, one of the major efforts of the Michigan State University (MSU) team at the initial stage of the project was to close this technological gap by developing, optimizing, and validating array sensors that would provide sufficient sensitivity, spatial coverage, and resolution for robust defect detection. Optimization of the ACUT and EMT sensor designs was performed using experimentally validated finite element models. Initial experiments using array probes were conducted on relatively flat CFRP samples. In parallel, the MSU team designed and assembled a portable platform with two robotic arms. The robots were equipped with newly designed sensors that enabled high-speed NDE of curved CFRP parts. Presently, the developed robotic platform can be used as a demo/template NDE system, which is easily adaptable to manufacturing environments and in-line NDE. The ACUT NDE system developed by the MSU team used a high-power 4-channel pulser receiver for parallel data acquisition. The array probes were designed by stacking commercially available ACUT transducers, which operated in the frequency range between 100 kHz and 500 kHz. MSU optimized the excitation procedure and developed wave focusing cones so as to reduce the crosstalk between the transducers and to provide higher pulse repletion frequency (PRF). The through-transmission (TT) and single-side access (SSA) inspection modes were successfully implemented. In the TT-ACUT, structural defects in CFRP were detected by passing ultrasonic waves through the test part. Hence, the ACUT transmitters and receivers needed to be placed on the opposite sides of the test part. In the SSA-ACUT, guided waves (GW) were excited in the test part using the transmitters and were sensed by the receivers from the same side. Multi-channel TT-ACUT and SSA-ACUT provided high-speed NDE, and were successfully validated on CFRP test samples with interlaminar delaminations and other embedded defects The EM techniques developed by the MSU team included: 1) eddy current testing (ECT), 2) capacitive imaging (CI) and hybrid dual-mode imaging. In ECT, structural damage was detected in CFRP using coils sensor arrays. In ECT, the excitation magnetic field is generated by passing an alternating current through a coil, which is placed above the test sample. The excitation field penetrates the conductive sample and induces the eddy currents in its transect. In turn, the eddy currents generate the reaction field, which affects the total field sensed by a coil. Hence, the presence of structural flaws will alter the eddy current flow and the picked-up signal. ECT is mostly sensitive to local changes of the electric conductivity of the test sample, and CFRPs are mostly conductive in the direction of carbon fibers. Hence, ECT was well suited for the detection of fiber damage/fiber irregularities. The MSU team developed printed circuit boards (PCB) with coil sensor arrays optimized for NDE of CFRP. Unlike most commercial probes designed for ECT of metallic structures, the MSU array probes were designed for operation in [1-10] MHz frequency range, which was optimal for low-conductive CFRP. Multiple sensing topologies (coil groups excitation/sensing arrangements) were implemented and successfully validated. Capacitive Imaging (CI) technique developed by MSU was complementary to ECT. In contrast to ECT, which was sensitive to local changes of the electrical conductivity, the CI was sensitive to local changes of the dielectric constant. Therefore, CI could provide information about matrix damage/matrix irregularities in CFRP. The MSU CI sensor arrays were made of multiple circular or rectangular open-plate capacitors printed on PCB. Sensors of this type are not commercially available. In addition to ECT and CI, the MSU team developed a hybrid (dual-mode) inductive/capacitive measurement technique that synergistically combined the benefits of inductive and capacitive sensing for rapid NDE of fiber reinforced polymer (FRP) composite structures. Fiber damage and fiber irregularities in FRPs were detected by configuring hybrid sensors as coil sensors. Similarly, matrix damage, matrix irregularities and interlaminar delaminations were detected by configuring hybrid sensors as capacitive sensors. ECT and CI were performed sequentially by means of electronic switching. Hence, eliminating the need for mounting two separate sensor arrays on the probe. Portable robotic platform was developed by MSU for multi-technique high-speed NDE of CFRP test parts. The platform had two 6-axis robots, which enabled inspection of curved parts in approximately a 6×6×6 ft 3 active scan area. On the software side, the MSU team integrated scripts for NDE hardware control with scripts for robot motion control. MSU also implemented automated path planning for the robots, reconstruction of part’s surfaces via stereovision, 3D rendering of inspection data, and image processing algorithms for enhanced defect detection. Automotive composite parts manufactured by Plasan Composites from Phase I were used to validate the ACUT and EMT techniques on representative testbeds. Among those parts were three X-braces for a Dodge Viper, one composite calibration plaque with known defects at known locations, and four other test sections, including sections from a front splitter, a corner section from a composite hood, and a high-pressure RTM panel made using non crimp fabric. Other test samples included CFRP and GFRP calibration plates with fiber/matrix defects fabricated at MSU/CVRC.

36 MATERIALS SCIENCE↗