Search NASA⌕ Search

SEARCH · Search NASA

Results for “ELECTRIC WIRING”

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.

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

At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

High-speed imaging of transition from fluid breakup to phase explosion in electric explosion of tungsten wires in air

High-speed visible imaging of sub-microsecond electric explosion of wires at the low specific energy deposition threshold reveals three distinct modes of wire failure as capacitor charge voltage and energy deposition are increased. For 100 micron diameter gold-plated tungsten wires of 2 cm length, deposited energies of 1.9 eV/atom produces a liquid column that undergoes hydrodynamic breakup into droplets with radii of order of wire diameter on timescales of 200 μs. Instability growth, column breakup, and droplet coalescence follow classic Rayleigh-Plateau predictions for instability of viscous fluid column. Above 3.2 eV/atom of deposited energy, wires are seen to abruptly transition to an expanding mixture of micron scale liquid-droplets and vapor within one frame (less than 3.33 μs), which has been termed ‘phase explosion’ in literature. Between these two limits, at 2.5 eV/atom of deposited energy, wire radius is unchanged for the first 10 μs before the onset of a rapid expansion and disintegration that resembles homogenous nucleation of mechanically unstable bubbles. Here, thermodynamic calculations are presented that separate cases by temperature obtained during heating: below boiling point, near boiling point, and exceeding boiling point.

42 ENGINEERING↗
DOE OSTI2020

Frequency-domain hot-wire sensor and 3D model for thermal conductivity measurements of reactive and corrosive materials at high temperatures

High temperature solids and liquids are becoming increasingly important in next-generation energy and manufacturing systems that seek higher efficiencies and lower emissions. Accurate measurements of thermal conductivity at high temperatures are required for the modeling and design of these systems, but commonly employed time-domain measurements can have errors from convection, corrosion, and ambient temperature fluctuations. Here, we describe the development of a frequency-domain hot-wire technique capable of accurately measuring the thermal conductivity of solid and molten compounds from room temperature up to 800 °C. Therefore, by operating in the frequency-domain, we can lock into the harmonic thermal response of the material and reject the influence of ambient temperature fluctuations, and we can keep the probed volume below 1 µl to minimize convection. The design of the microfabricated hot-wire sensor, electrical systems, and insulating wire coating to protect against corrosion is covered in detail. Furthermore, we discuss the development of a full three-dimensional multilayer thermal model that accounts for both radial conduction into the sample and axial conduction along the wire and the effect of wire coatings. The 3D, multilayer model facilitates the measurement of small sample volumes important for material development. A sensitivity analysis and an error propagation calculation of the frequency-domain thermal model are performed to demonstrate what factors are most important for thermal conductivity measurements. Finally, we show thermal conductivity measurements including model data fitting on gas (argon), solid (sulfur), and molten substances over a range of temperatures.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Advanced Manufacturing of High-Performance Superconductor Wires for Next Generation Electric Machines

While the transition of RE-Ba-Cu-O (REBCO, RE = rare earth) wires from lab-scale to initial manufacturing demonstrations has been accomplished, the high manufacturing cost is a major impediment to a commercial market. At the onset of this project, commercial REBCO wires exhibiting a critical current of ~ 340 A/cm at 65 K, 1.5T (operating condition of superconducting rotating machines targeted in this project) costed about $\$$300/kA-m which is well above the cost of copper wire. In this project, the UH-led team employed multiple innovative techniques to meet the aggressive performance and cost targets established. The key technology that was developed in this project was advanced metal organic chemical vapor deposition (MOCVD) to fabricate REBCO wires with films as thick as 5 µm and with excellent critical current performance at 65 K, 1.5 T. In addition to excellent performance in short samples, a major accomplishment of this project was to scale up the Advanced MOCVD technology to lengths of 50 meters while maintaining the superior critical current. Multiple 50-m-long tapes were demonstrated in the project with uniform critical current, that confirmed the viability of our technology for industrial manufacturing. Beyond scaling up our technology to long lengths, we worked with our industrial partners to design a REBCO-based motor coil, constructed one such coil and fabricated it using long tapes made in this project. This motor coil was successfully tested at 77 K and 65 K which affirmed the viability of high-performance REBCO wires made in this work for industrial applications. In addition to high critical current, we also demonstrated >4x precursor-to-film conversion efficiency in the advanced MOCVD process which has a first order impact on wire cost.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Wire rivet

A rivet assembly for securing a wire in electrical communication with a substrate having a hollow cylindrical body with a first opening at a proximal end and a second opening at a distal end. The rivet assembly further includes a wire with a portion in electrical communication with the cylindrical body. The rivet assembly yet further includes a compression mechanism configured for use selectively compressing the cylindrical body along an axial direction. Compression of the cylindrical body can cause diametric expansion of an outer diameter of the cylindrical body to retain the cylindrical body within a substrate. The rivet assembly additionally includes wire retention structure configured for holding the wire in electrical contact with the compressed cylindrical body.

Briggs, Timothy↗
DOE OSTI2022

Beam–beam effects and mitigation in a future proton–proton collider

The beam–beam effects in a hadron collider with an unprecedented energy scale were studied. These effects are strongly related to the attainable luminosity of the collider. Long-range interactions were identified as the major factor limiting the dynamic aperture, which is strongly dependent on the crossing angle, β*, and bunch population. Different mitigation methods of the beam–beam effects were addressed, with a focus on the compensation of long-range interactions by electric current wires. The CEPC-SPPC project is a two-stage large circular collider, with a first-stage circular electron–positron collider (CEPC) and a second-stage super proton–proton collider (SPPC). The design of the SPPC aims to achieve a center-of-mass energy of 75 TeV and peak luminosity of approximately 1 × 10$^{35}$ cm$^{-2}$ s$^{-1}$. We studied the beam–beam effects in the SPPC and tested the effectiveness of the mitigation methods. We found that with compensation using electric current wires, the dynamic aperture is at an acceptable level. Moreover, considering the significant emittance damping in this future proton–proton collider, the beam–beam effects and compensation are more complicated and are studied using long-term tracking. It was found that with a smaller emittance, the head-on interactions with a crossing angle become more prominent in reducing the beam stability, and combined head-on and long-range compensation is needed to improve the beam quality. When the reduction in population owing to burn-off was included, it was found that the coupling between the transverse and longitudinal planes at smaller emittance is the main driving source of the instabilities. Thus, crab cavities and emittance control are also necessary than just the compensation of the long-range interactions to improve the beam stability. This study serves as an example for studying the beam–beam effects in future proton–proton colliders.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Assessment of the Electrical Substation-Grid Testbed with Inside/Outside Devices and Distributed Ledger Technology

The electrical substation-grid testbed was created to integrate the GOOSE and/or DNP (Distributed Network Protocol) messages with time synchronized sources and Distributed Ledger Technology (DLT). The objective was to study the impact of faults and cyber-events at an electrical substation with inside (protective relays) and outside (power meters) substation devices. The electrical substation-grid testbed was based on the design of a 34.5/ 12.47 kV electrical substation (sectionalized bus configuration) with two power transformers, connected to radial power lines and load feeders. The electrical substation-grid testbed was installed at 252 lab space (Advanced Power System Protection), Grid Research Integration and Deployment Center (GRID-C), Oak Ridge National Laboratory. This testbed was created for Task 5, DarkNet project. The electrical substation-grid testbed was created to simulate fault and/or cyber events that could potentially result in damage to the electrical infrastructure. In addition, tests were run that are usually not allowed to be performed in an operational electrical power grid, because these test scenarios could trip breakers and/or generate fault situations that could potentially damage equipment. The number of tests performed in the electrical substation-grid testbed were executed in a better way than in a real electrical substation and/or power grid, because multiple tests could be run in a short period of time, and complex permits, and safety/ schedule restrictions like in a real electrical substation environment were not needed. The electrical substation-grid testbed was created using real measurement, communication, and protection devices that are used by electrical utilities, to have same conditions that we could observe in a real power grid or electrical substation. The electrical substation-grid testbed was based on using a real time simulator and expansion box with amplifiers that were wired to electrical substation-grid devices. This hardware-in-the-loop (HIL) was provided by protective relays, power meters, ethernet switches, remote terminal units, synchronized timing network clock, DLT devices, workstations, and servers. This report includes the design, installation, and assessment of the electrical substation-grid testbed that was similar to an operational electrical substation, integrating the power system protection, communication, and control systems. The results for the electrical substation-grid testbed were based on:• verifying the analog signals for protective relays and power meters, • observing the synchronized time source frame at devices, • authenticating the GOOSE (IEC 61850) and DNP messages from power meters and protective relays, and • verifying the trip conditions of protective relays at fault tests with the power system fault event detection, using DLT devices. For future work, the electrical substation-grid testbed with protective relays and power meters, using DLT and synchronized time source from DarkNet, will be used to study the impact of cyber-events at inside and outside substation devices. Advanced algorithms for detecting cyber-events produced by non-desired protective relay settings will be studied, to improve the detection and reliability of protection, control, and communication systems at power grids.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Gate-defined wires in twisted bilayer graphene: From electrical detection of intervalley coherence to internally engineered Majorana modes

Twisted bilayer graphene (TBG) realizes a highly tunable, strongly interacting system featuring superconductivity and various correlated insulating states. We establish gate-defined wires in TBG with proximity-induced spin-orbit coupling as (i) a tool for revealing the nature of correlated insulators and (ii) a platform for Majorana-based topological qubits. We show that the band structure of a gate-defined wire immersed in an intervalley coherent correlated insulator inherits electrically detectable fingerprints of symmetry breaking native to the latter. Surrounding the wire by a superconducting TBG region on one side and an intervalley coherent correlated insulator on the other further enables the formation of Majorana zero modes—possibly even at zero magnetic field depending on the precise symmetry-breaking order present. Our proposal not only introduces a highly gate-tunable topological qubit medium relying on internally generated proximity effects but can also shed light on the Cooper-pairing mechanism in TBG.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Time-resolved nanosecond optical pyrometry of the vapor to plasma transitions in exploding bridgewires

Electrically exploded wires find uses throughout high-energy physics. For example, they are commonly used as high-temperature sources, X-ray generators, and in precision timing detonators. However, the detailed and complete physics that occurs is complex and still poorly understood. A full mechanistic description of these complex phenomena is beyond the scope of a single paper. Instead, we focus on the formation of metal vapor and its transition to plasma. This single transition is commonly assumed to comprise “bridge-burst”. We use a suite of diagnostics including a novel, fiber-based, high-speed, optical pyrometer to better characterize this transition. The primary finding from this project is that peak light output from an exploding wire does not temporally match the peak temperature. Additionally, it is found that peak light does not align with peak bridge-burst voltage and that the peak temperature is not voltage-dependent. These findings are non-intuitive and will allow for the correction of false assumptions previously made about this topic.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Quadrilateral particle arrangement within shocks in a two-dimensional dusty plasma

The microscopic structure within a two-dimensional shock was studied using data from a dusty plasma experiment. A single layer of charged microparticles, levitated in a glow-discharge plasma, was perturbed by an electrically floating wire that was moved at a steady supersonic speed to excite a compressional shock. A rearrangement of particles was observed, from a hexagonal lattice in the preshock into a quadrilateral microstructure on the front side of the shock. This quadrilateral structure would not be stable in a monolayer of identical repulsive particles, under equilibrium conditions. Glaser-Clark polygon analysis of the microstructure helped in identifying quadrilaterals. Voronoi analysis was used to characterize the defect fraction behind the shock, as an indication of shock-induced melting. Published by the American Physical Society 2025

Kananovich, Anton (ORCID:0000000225374952)↗
DOE OSTI2020

Multipole-based cable braid electromagnetic penetration model: magnetic penetration case

The goal of this paper is to present, for the first time, calculations of the magnetic penetration case of a first principles multipole-based cable braid electromagnetic penetration model. As a first test case, a one-dimensional array of perfect electrically conducting wires, for which an analytical solution is known, is investigated: we compare both the self-inductance and the transfer inductance results from our first principles cable braid electromagnetic penetration model to those obtained using the analytical solution. These results are found in good agreement up to a radius to half spacing ratio of about 0.78, demonstrating a robustness needed for many commercial and non-commercial cables. We then analyze a second set of test cases of a square array of wires whose solution is the same as the one-dimensional array result and of a rhomboidal array whose solution can be estimated from Kley's model. As a final test case, we consider two layers of one-dimensional arrays of wires to investigate porpoising effects analytically. We find good agreement with analytical and Kley's results for these geometries, verifying our proposed multipole model. Note that only our multipole model accounts for the full dependence on the actual cable geometry which enables us to model more complicated cable geometries.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

Cathode system for electrodeposition of metals on microspheres

The present disclosure relates to an apparatus for electroplating an element. The apparatus may comprise a cathode cage assembly. The cathode cage assembly may include a cage member and at least one electrically conductive wire extending along at least a portion of the cage member. The wire may be arranged to form at least one volume within the cage member for retaining an element within the cage member. The cage member and the wire permit a degree of movement of the element during an electroplating process while retaining the element within the volume.

Bunn, Thomas L.↗
DOE OSTI2021

Evolving Architectures and Considerations to address Distributed Energy Resources and Non-Wired Alternatives

The electric grid is in the beginning stage of a transformation, driven by a combination of shutdowns of coal-fired plants, commissioning of new natural-gas plants, and tremendous growth in energy supply from renewables such as wind, and solar. As utilities navigate this transformation, their progress is supported by advances in Operational Technologies (OT), and Informational Technologies (IT), such as automation, smart inverters, cloud computing, mobile computing, machine learning, big data analytics, which have the potential to enable advanced capabilities more efficiently and at a lower cost. This white paper focuses on the architectural considerations that will allow the industry to transition in a planned manner. It introduces and formalizes two architectural constructs –the data bus and the control bus. The data bus is responsible for carrying all non-operational models and information necessary to drive utility decisions. In contrast, the control bus is responsible for carrying all operational data and control actions taken at the local level, centralized level, or other levels in-between. The paper reviews those architectural considerations, their requirements and how they will evolve. This paper intends to provide a context for vendors, utilities, and their service providers to review and understand the changes that are coming and get ready for them.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

A Co-Registered In-Situ and Ex-Situ Dataset of Electrical, Acoustic, and CT Characteristics from Wire Arc Additive Manufacturing Process

Recent progress in sensing techniques and data analytics tools have significantly accelerated the development of Wire Arc Additive Manufacturing (WAAM) systems. This data centric approach emphasizes leveraging available data throughout the production process to optimize performance. Integration of extensive data analysis provides the opportunity to improve precision, reduce waste, and enhance the quality of produced parts. This method relies on AI/ML models and optimization techniques, which are developed using the data collected from various sources, including in-situ sensors, ex-situ imaging, and manufacturing process parameters. The quality and diversity of this data, along with the alignment between different data streams (achieved through spatiotemporal registration) are critical for the successful development of AI/ML and optimization models. In this work, we present a spatiotemporally registered dataset generated during the WAAM process of deposition of a rectangular block. The dataset includes the comprehensive description of deposition process, process parameters, in-situ collected welding characteristics, acoustic data, and X-Ray Computed Tomography analysis data for the build. Dataset A Co-Registered In-Situ and Ex-Situ Dataset of Electrical, Acoustic, and CT Characteristics from Wire Arc Additive Manufacturing Process has arisen under UT-Battelle, LLC’s Prime Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy (DOE) to manage and operate the Oak Ridge National Laboratory. UT-Battelle, LLC will not assert any rights under United States law or under the Prime Contract it has in the dataset against any user of the dataset, including any copyrights or patent rights. UT-Battelle, LLC requests that attribution to the dataset is provided as academically appropriate.

42 ENGINEERING↗
DOE OSTI2023

Observations and Lessons Learned in Residential Roofing Integrated Photovoltaics

The data file includes field observations of residential roofing integrated photovoltaics installation that happened between July 2021 and June 2022 in California. There are 21 observations - 2 in the re-roofing category and 19 in the new construction category. The file includes two time and motion forms (Re-Roofing & New Construction) we used to capture the time it takes for each activity in the rooftop solar and electrical installation process. You will see the duration for detailed steps along with activities that are included for total installation time for the paper. There are three parts to the time and motion form - Part 1 has project and crew characteristics, product information, and inspection and permitting data and can be filled before the installation. Part 2 has the actual installation time stamps and related notes. Part 3 has the crew information and can be filled on-site or off-site, but this section is optional. The re-roofing form has pre-solar activities and gutters and vents section in Part 2 of the form, whereas new construction form includes a section for capturing the time it took for rough wiring. The re-roofing form does not include rough wiring but instead includes the final electrical wiring process. These are the key differences in both the forms. Each day/step/installation activity needs to include the crew break time as they happen and there is space available to capture the crew breaks duration. In Table 1 below, the different terms used in the time and motion form are defined and their corresponding unit of measurement stated. We also highlight the optional sections. The data is captured in total mins, total hours, person mins, person hours. You can use this form or make edits to the form to recreate the study or make your own observations. The data herein was reviewed but may not be comprehensive. NREL invites questions and inputs to improve the data, including to: Correct erroneous information Fill in missing/updated information Clarifications on data and variables Updated information may be submitted to Sushmita Jena at sushmita.jena@nlr.gov.

14 SOLAR ENERGY↗
DOE OSTI2020

WIRE SCANNER FOR HIGH INTENSITY BEAM PROFILE DIAGNOSITICS

A control and data acquisition system of a high speed wire scanner is developed for high intensity beam profile diagnostics. The control system of the wire scanner includes two IOCs, a Soft IOC and a VME IOC. The Soft IOC connects with an Aerotech Ensemble motor drive through EPCIS motor record and controls the movement of the wire scanner. An Electrical Input card samples the real-time position of the wire through an incremental encoder, and generates a pulse to synchronize a VME ADC data acquisition card, which digitizes and samples the beam-induced signal after pre-amplification. A VME Relay Output card is installed to control the Brake Solenoid and Actuator Solenoid. All the VME I/O cards are installed on one VME crate and controlled by the VME IOC. The system configuration and software of the wire scanner are under development.

Yan, J.↗
DOE OSTI2025

Characterization and prediction of the electromechanical wear of contact tips during wire arc additive manufacturing of 316L stainless steel

Here, this study seeks to better understand the degradation of the contact tip with respect to WAAM for a 316L wire electrode as well as explore methods of monitoring the contact tip state from process data. The contact tip, a consumable component, positions the wire and serves as the electrical contact surface between the wire electrode and the welding power supply. The wear of the contact tip was characterized in terms of material loss and material contamination for a set of tips worn to discrete levels as measured by the amount of wire fed or arc time. Geometrical characterization found a 49% increase in the bore exit area at 180 meters of wire fed. Machine learning models were developed to predict the relative bore exit area of the contact tip from arc-based process data and a random forest classifier exhibited favorable performance with a cross-validated f1-score of 0.84. The regression architecture implemented a multi-layer perceptron with the ability to predict the relative exit area with an $R^2$ score of 0.75. Key features used in the prediction include the standard deviation of the voltage and the time between shorts.

Contact tip wear↗