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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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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

US HL-LHC cryo-assemblies at FNAL - testing and lessons learned

The U.S. High-Luminosity LHC Accelerator Upgrade Project (AUP) is fabricating ten cryogenic assemblies for the HL-LHC Q1/Q3 quadrupole optics at CERN, each integrating two Nb_{3}Sn-based magnets. Fermilab has tested three assemblies (LQXFA/B01–03) at its upgraded horizontal test stand under 1.9 K conditions. Overview of the test stand and the cryo-assembly tests is given along with main results. Challenges met and lessons learned are discussed. Successful testing validates the design and integration of U.S.-produced cryo-assemblies, keeping the project on track for timely delivery to CERN.

Stoynev, Stoyan [Fermilab] (ORCID:0000000345637702↗
DOE OSTI2025

Noble Liquid Test Facility at Fermilab

The Noble Liquid Test Facility (NLTF) at Fermilab is a liquid argon detector R\&D facility open to the national and international HEP community. The facility consists of 4 permanent cryostats, ranging from 250L up to 3000L, open space for small open dewar testing, and an optical test stand facility capable of measuring the optical properties of materials and characterizing photon detectors. NLTF’s strongest advantage is its capability to provide ultra-pure LAr in a reliable manner. Its inline filters are capable of filtering all of the three biggest contaminants for standard LAr detectors, O$_2$ and H$_2$O down to $< 1$ppb and N$_2$ $< 1$ppm. This is critical for the users of the test stands as small levels of impurities can dramatically change the efficiency of LArTPCs for the collection of charge and light. The smallest cryostat is mainly used for material testing, a service provided to the international HEP community interested in understanding how the introduction of a specific material might affect the electron lifetime in LAr. The test stands can be equipped with a purity monitor, which allows measuring the electron lifetime in real time, as well as gas sampling and analyzing, and in the near future, local recirculation and filtering. The facility has hosted many successful R\&D projects, which have published their results in well-known journals and talks. A few examples of such projects are: NIR light production in LAr and GAr, the characterization of VUV metalenses, the testing of new filter media capable of filtering N$_2$ from LAr, high voltage studies and direct charge amplification in LAr, and various doping studies.

Blaszczyk, Flor María [Fermilab]↗
DOE OSTI2025

Evaluation of a 5kW Solid Oxide Electrolysis Cell Stack

Solid oxide electrolysis cells (SOECs) are a developing technology for hydrogen production. They are promising due to their utilization of thermal energy to reduce their electricity consumption. The Department of Energy (DOE) has set goals to reduce the price per kilogram of hydrogen, and Idaho National Laboratory (INL) is conducting research to develop and demonstrate advanced methods and technologies to achieve making hydrogen a more affordable, efficient, and sustainable energy source. In this project, INL is collaborating with a vendor to evaluate and validate the design of a 5kW SOEC stack. The test aims to demonstrate a safe startup, operation, and shutdown on INL’s 5kW test stand, providing third-party validation in a different environment. A successful 50-hour test with stable hydrogen production will pave the way for a subsequent 1000-hour test. This project emphasized learning about electrolysis and the various support systems, referred to as balance of plant (BOP) equipment. These systems required modification while swapping to the vendor 5kW SOEC stack, most prominently the furnace door design and the controls system. It also included gaining skills in creating computer-aided design (CAD) drawings for the new door while using available materials and ensuring it met high-temperature requirements. Upon completion of modifications to the test stand, the SOEC will be test-fitted with respective wiring and piping. Instrumentation and piping will be checked for leaks and quality. This must be completed before the vendor’s engineers arrive to observe the test plan, startup, and a collection of 50 hours of data. The vendor’s engineers will ensure their stack performed sufficiently in the 50-hour test to enable the progression to a 1000-hour test.

08 - HYDROGEN↗
DOE OSTI2024

In‐operando thermal transport characterization of moving particle bed heat exchanger

The project aimed to develop modulated photothermal radiometry (MPR) for conducting in-operando measurements of thermal transport in moving particle bed heat exchangers (MPBE) located at Sandia National Laboratory (SNL). The plan was to initially conduct lab-scale measurements on a 1-meter-long particle channel at UCSD, followed by in- operando measurements at SNL on a 20 kWth MPBE prototype built for this project, and if time permitting, potential final deployment on SNL’s 1 MWth G3P3 MPBE. The first two goals were successfully achieved but due to changes with commissioning timeline of the G3P3 MPBE, in-operando measurements on the G3P3 MPBE could not be conducted. The measurement campaigns have resulted in some promising results and the MPR tool has been handed over to trained SNL personnel for future use. MPR measurements on UCSD’s 1-meter-long particle channel showed a peculiar length dependence of the particle bed thermal conductivity and near-wall thermal resistance. The bed thermal conductivity increased, and the near-wall thermal resistance decreased, with increasing distance from the channel inlet, both eventually reaching a plateau. This was found to be due to hydrostatic pressure screening by the channel walls, known as the “Janssen effect”, and is the first experimental study on its role in granular heat transfer. A 20 kWth small-scale MPBE prototype, the first of its kind with 3 mm particle channels and 2 mm sCO2 plates, was designed and manufactured by Vacuum Process Engineering (VPE) for this project. This MPBE prototype was installed in SNL’s HEX test stand and the MPR tool was integrated into the test stand for in-operando measurements. Several modifications have been made to the MPR setup for facile installation and easy operation at SNL. Measurements with Carbo HSP40/70 particles were conducted with various particle and sCO2 temperatures and flow rates. Further, apart from regular MPBE operation, fault scenarios such as plate warping, particle stagnation, and choking were also detected and MPR showed excellent sensitivity to the detection of such conditions. Through the course of this project, MPR has evolved from a sensitive laboratory technique to a rugged industrial tool with various applications in high temperature measurements and diagnostics.

14 SOLAR ENERGY↗
DOE OSTI2024

Conceptual Design of the Moderator Test Station at the Spallation Neutron Source

We describe the Moderator Test Station (MTS), under construction at the Spallation Neutron Source. We will leverage the Beam Test Facility (BTF) at the Spallation Neutron Source to provide a moderator neutronics test stand with which we will verify the anticipated performance gains expected and required from the innovative moderator concepts central to the SNS Second Target Station (STS) and the future of the First Target Station (FTS). These concepts include large-volume para-hydrogen moderators and high-brightness tube moderators. The MTS will add to the existing BTF a proton beam chopper similar to that already used in the SNS at the RFQ exit (the so-called MEBT chopper), various proton beam transport components, a neutron-producing target, a cryogenic moderator test stand, a reflector-shielding assembly, and a performance assessment neutron beamline. The MTS will provide the ability to test a wide variety of moderators in a prototypic configuration, simultaneously measuring the neutronic performance of the moderator concept central to the anticipated STS gains and developing the instrumentation necessary to provide that performance in a production environment. The presentation will describe the MTS, its progress, and the way we optimize the prototypic nature of the moderators we will test.

Iverson, Erik B↗
DOE OSTI2025

Design and Analysis of a Mutual Inductance Level Sensor for Liquid Metals

Here, this article describes the design and analysis of an electromagnetic level sensor for use in high-temperature liquid metal systems. The mutual inductance level sensor (MILS) described in this work was fabricated using two single-conductor mineral insulated cables wrapped in a bifilar fashion around a stainless steel tube core and was housed in an isolating thimble that preserved the pressure boundary of the test vessel. Two sensor variations were fabricated that differ only in active length, 1016 and 1778 mm. Experimental data were collected using the 1016-mm sensor (MILS-MKII-040) that demonstrated a sensitivity of 9.2 μ V/mm in a room temperature testing stand that used solid aluminum as a surrogate for liquid metal. Experimental data were collected using the 1778-mm sensor (MILS-MKII-070) that demonstrated a sensitivity of 6.9 μ V/mm in the high-temperature (300 ° C) liquid sodium environment at the mechanisms engineering test loop (METL) of Argonne National Laboratory. The sensor performance was found to be repeatable over the course of several months, with roughly ±1% deviation from nominal output. Finite element models were developed in COMSOL Multiphysics that fully describe each test setup, and the models were validated using experimental data. The validated COMSOL models were used to perform an array of analyses that examined the performance of the sensor in differing environments. Maximizing the coil diameter inside the isolating thimble was found to maximize the signal and sensitivity of the sensor. An optimal operating frequency was found near 1000 Hz using both experimental data and COMSOL. The influence of a metallic thimble surrounding the sensor and a metallic sensor core was quantified and found to be negligible at the optimal operating frequency. The sensitivity of the sensor was quantified when monitoring the level of additional liquid metals. These include lead, lead-bismuth eutectic (LBE), sodium-potassium alloy (NaK), and lithium (in addition to sodium). The sensitivities were quantified using liquid metal properties at 350 ° C and 650 ° C. The geometry of the test stand model, all material properties used in the model, and the results are presented in a manner that allows the reader can replicate the model and perform additional analyses.

COMSOL↗
DOE OSTI2026

Operando X-Ray Diffraction During High Temperature Electrolysis

This work presents the design, development, and deployment of an operando X-ray diffraction (XRD) system for high-temperature electrolysis (HTE), enabling real-time characterization of solid oxide electrolysis cells (SOECs) under true operational conditions. The integration of an HTE test stand within a synchrotron radiation environment, mimicking the conditions of a laboratory setup, aims to enhance our understanding of the degradation processes affecting the performance and longevity of SOECs. Utilizing a custom furnace and a high precision motor stack assembly at the Stanford Synchrotron Radiation Lightsource (SSRL), the system revealed unparalleled insights into the structural evolution of SOEC components through various operational stages, including initial heat ramp, cell reduction, fuel ramp, and wet electrolysis. Initial results demonstrate the significant impact of the initial heating and cooling on secondary phase formation within the SOEC, highlighting the utility of operando XRD for developing more efficient and durable hydrogen production technologies.

08 HYDROGEN↗
DOE OSTI2025

Cryogenic Testing of HL-LHC Q1/Q3 Cryo-Assemblies at Fermilab

Fermilab is conducting horizontal cryogenic testing of Q1/Q3 Cryo-Assemblies for the high-luminosity LHC upgrade (HL-LHC). Cryo-Assemblies are installed on the upgraded Fermilab horizontal test stand previously used for testing the LHC inner triplet quadrupoles. The cryogenic process requirements of these tests include controlled cool-down and warm-up with a 100 K maximum temperature differential between the two ends of the cold mass, operation of a 1.3 bar, 1.9 K bath of subcooled superfluid helium during power testing and magnetic measurements, and operation at pressures up to 18 bar with full helium recovery after a quench. This paper presents the operational experience gained from the first tests as well as improvements for subsequent tests.

Rabehl, R. [Fermilab]↗
DOE OSTI2025

Cryogenic testing of HL-LHC Q1/Q3 cryo-assemblies at Fermilab

Fermilab is conducting horizontal cryogenic testing of Q1/Q3 cryo-assemblies for the high-luminosity LHC upgrade (HL-LHC). Cryo-assemblies are installed on the upgraded Fermilab horizontal test stand previously used for testing the LHC inner triplet quadrupoles. The cryogenic process requirements of these tests include controlled cool-down and warm-up with a 100 K maximum temperature differential between the two ends of the cold mass, operation of a 1.3 bar, 1.9 K bath of subcooled superfluid helium during power testing and magnetic measurements, and operation at pressure up to 18 bar with full helium recovery after a quench. This paper presents the operational experience gained from the first tests as well as improvement for subsequent tests.

Rabehl, R. [Fermilab] (ORCID:0000000311130030)↗
DOE OSTI2025

Self-Lubricating Bushing Testing for John Day Dam Ka plan Turbine Replacement

The goal of this testing program is to find suitable self-lubricated alternatives to replace the in use oil lubricated grooved-bronze bushing in Kaplan runner hubs that are currently being utilized at John Day Dam operated by the U.S. Army Corps of Engineers (USACE). Scaled bushing testing utilizing a Pacific Northwest National Laboratory designed, fabricated, and operated Bushing Test Stand under the direction and funding from USACE determined that self-lubricated bushings tested appear capable of outperforming the current oil-lubricated bronze bushings. Performance tests are focused on durability which includes cyclic load bearing properties and articulations under various loading scenarios. This testing was performed at nominally 1/5 th scale. A scaling sensitivity analysis determined that scaled testing results apply to prototypic size. This report shows the direct comparison between the current baseline bronze bushing to self-lubricated bushings from various manufacturers. Bushing data like coefficient of friction and bushing material loss (associated with bushing wear) was determined. Self-lubricated bushings tested include products manufactured specifically for hydropower applications by the following companies: Trelleborg, Kamatics, Anonymous, and Tenneco/Deva.

42 ENGINEERING↗
DOE OSTI2025

Characterization of the X-ARAPUCA Systems' Response for SBND's Light Detection

X-ARAPUCA waveform data, collected at a test stand at the Noble Liquid Test Facility (NLTF) and the Short Baseline Near Detector (SBND), were analyzed via python scripts. For the ARARA system, various distributions and correlations were studied, including the area and amplitude distributions of the waveform peaks for identifying single photoelectron peaks, as well as characterizing the behavior of the baseline artifact. The ARARA system is being studied in order to be implemented into SBND, just as the APSAIA X-ARAPUCAs have been.

Novotny, Andrew [U. Illinois, Chicago]↗
DOE OSTI2025

Characterization of the X-ARAPUCA systems' response for SBND's light detection

X-ARAPUCA waveform data, collected at a test stand at the Noble Liquid Test Facility (NLTF) and the Short Baseline Near Detector (SBND), were analyzed via python scripts. For the ARARA system, various distributions and correlations were studied, including the area and amplitude distributions of the waveform peaks for identifying single photoelectron peaks, which was able to be accomplished. The behavior of the baseline artifact was also characterized, which appeared only at high voltages/bright events, and separates further from the prompt peak as the voltage/brightness increases. The ARARA system is being studied in order to be implemented into SBND, just as the APSAIA X-ARAPUCAs have been.

Novotny, Andrew [Fermilab]↗
DOE OSTI2025

First Results from a Nb3Sn-Coated 1.5-Cell 650 MHz SRF Cavity for Cryogen-Free Industrial Accelerators

First Results from a Nb3Sn-Coated 1.5-Cell 650 MHz SRF Cavity for Cryogen-Free Industrial Accelerators ABSTRACT = Fermilab is advancing the development of a compact, high-power electron beam accelerator using superconducting radio frequency (SRF) technology as a non-radioactive alternative to traditional radiological sources. The current design targets continuous-wave (CW) operation at \SI{1.6}{MeV} and \SI{20}{kW}. To ensure suitability for industrial environments, the system is being designed for cryogen-free operation, driving the adoption of a novel Nb$_3$Sn-coated 1.5-cell SRF cavity operating at \SI{650}{MHz}. This contribution reports on the fabrication, surface preparation, and Nb$_3$Sn coating process of the cavity, as well as first results from vertical test stand (VTS) measurements performed in a liquid helium bath. These initial tests mark a key milestone toward demonstrating the viability of conduction-cooled Nb$_3$Sn SRF cavities for industrial-scale deployment.

Tagdulang, N. [Fermilab]↗
DOE OSTI2025

First Results from A $Nb_3Sn$-Coated 1.5-Cell 650MHZ SRF Cavity for Cryogen-Free Industrial Accelerators

Fermilab is advancing the development of a compact, high-power electron beam accelerator using superconducting radio frequency (SRF) technology as a non-radioactive alternative to traditional radiological sources. The current design targets continuous-wave (CW) operation at \SI{1.6}{MeV} and \SI{20}{kW}. To ensure suitability for industrial environments, the system is being designed for cryogen-free operation, driving the adoption of a novel Nb$_3$Sn-coated 1.5-cell SRF cavity operating at \SI{650}{MHz}. This contribution reports on the fabrication, surface preparation, and Nb$_3$Sn coating process of the cavity, as well as first results from vertical test stand (VTS) measurements performed in a liquid helium bath. These initial tests mark a key milestone toward demonstrating the viability of conduction-cooled Nb$_3$Sn SRF cavities for industrial-scale deployment.

Tagdulang, Nikki Diala [Fermilab]↗
DOE OSTI2025

In-Field Testing of Components for Feedback and Control of the ITER Disruption Mitigation System

Here, the shattered pellet injection (SPI) method has been chosen as the disruption mitigation system (DMS) for ITER. To protect the device from plasma disruptions that cause damaging heat and electromagnetic loads, SPI is used to inject high-Z material into the plasma. The process of SPI utilizes cryogenic cooling to form solid pellets. Pellets are accelerated down a barrel and into an angled surface, causing the pellet to shatter prior to entering the tokamak chamber. For the DMS to function reliably, the 27 separate shattered pellet injectors planned for ITER must rely on many components to provide accurate feedback data and for control functions. Each component in the DMS is exposed to an elevated background magnetic field depending on its placement and proximity to the plasma chamber. A Helmholtz coil test stand that is operated at Oak Ridge National Laboratory was utilized to test the components in relevant background field levels to assess component performance. This paper details the test design and results for in-field component operation for a variety of components. This list includes the following components: two different network switches for camera connectivity, a VAT fast shutter valve intended to reduce the flow of SPI propellant gas into the torus, a solenoid control valve intended for use in the pellet formation process, pressure/vacuum switches to be used for feedback and control, a printed circuit board piezo pressure sensor to be used to measure breech pressure, and various relays for the high-voltage pulsed power supply used to drive the SPI propellant valve.

Disruption mitigation↗
DOE OSTI2024

VTS Dynamic Model and Experimental Validation for Vibration Suppression

High Q-factor superconducting radio-frequency (SRF) cavities are extremely sensitive to mechanical vibrations, which can cause an uncontrolled shift of the electromagnetic resonance frequency, with detrimental effects on the cavity performance. To avoid this phenomenon (i.e. microphonics) the dynamic behavior of the assembly must be studied, to design vibration suppression systems. In this paper, the numerical model of the Vertical Test Stand (VTS) insert adopted at the Fermi National Accelerator Laboratory for cold tests was studied, in the framework of the experimental characterization of Dark SRF cavities conducted by the SQMS (Superconducting Quantum Materials and Systems) center. Due to the complexity of the assembly, experimental activity is of utmost importance to validate the model. Thus, vibration testing was performed on the actual system, and a good correlation between numerical and experimental results was found. Additionally, two different setups were compared, with and without implementing a preliminary passive vibration suppression system, to assess its effectiveness in reducing the microphonics phenomenon. The obtained results allowed for the design of an improved isolation system, which will be the subject of future experimental testing.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Accelerated Lifetime Testing of Main Shaft Seals for Tidal Turbine Rotors

This document will briefly discuss the observations and results from an NREL conducted accelerated lifetime testing of the main shaft seal for the Verdant Power fifth generation Gen5 underwater Tidal Energy Converter (TEC) turbine, which successfully performed at the RITE project in 2020-2021. In order to evaluate a 5-year Service Interval ( SI) for this component, testing at NREL operated the main shaft seal nearly continuously for over 135 (text says 130 days on page 5 and 125 days on page 7 and 137 days on page 11) days at a rotational velocity of 160 rpm while the test stand recorded water pressure, barrier fluid pressure, temperature, and number of cycles., representing ~ 40% of the SI. An additional separate test was conducted to measure the aging behavior of the rubber drive rings. The water pressure reservoir was held constant as 29 psi. Barrier fluid pressure remained relatively constant throughout the duration of the test but was seen to sink to as low as 10.1 psi. No barrier fluid leakage was observed throughout the test. A sudden failure occurred within the seal after the power to test machine was interrupted for a scheduled building maintenance procedure. Upon restarting, the main shaft seal lost all ability to prevent water ingress. The exact cause is not known but is believed to be either a seal assembly issue or a change in the alignment of the seal components during or following the power outage. Following seal disassembly, significant wear was seen on one of the graphite sealing rings. Based on these results it is recommended that a follow-on TEAMER be conducted to rectify protocol and assembly issues to further evaluate SI of this component. The support and participation of Verdant Power Inc, Dovetail Solutions LLC and Garlock Manufacturing Inc were instrumental in understanding the results. NREL thanks them for their significant effort.

13 HYDRO ENERGY↗
DOE OSTI2025

Flat TBPS Integration Testing for the CMS Outer Tracker Upgrade

The upcoming High-Luminosity (HL) LHC will significantly increase luminosity, introducing more demanding operating conditions for the CMS detector. To meet these challenges, CMS is undergoing major upgrades, including a complete replacement of its tracking detector. This poster presents recent integration testing efforts conducted at Fermilab on the Flat Tracker Barrel with pixel-strip (PS) modules integration test stand, a subcomponent of the outer tracker located in the central barrel region. In this region, PS modules are mounted on structures that provide mechanical support and cooling, called planks. The testing focuses on validating the integrated system’s thermal and electrical performance. Results from these tests will be discussed, highlighting their importance for ensuring reliable tracker operation in the HL-LHC era.

Salazar Segovia, Itzelli [UC, Davis]↗