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DOE OSTI2021

Hermetic edge-connect headers and corresponding connectors

A hermetically-sealed edge-connect header that can withstand high temperatures, high pressures (or high vacuum levels), and high vibration environments, along with two corresponding connectors are disclosed. After brazing the edge-connect header components, the assembly is machined to form a slot with a portion of each of a plurality of electrical conductors removed in the machining process, resulting in a header with a high pin density. During the process of mating the first connector design to the edge-connect header, a plurality of wipers in the connector deflect, thereby causing the wipers to extend from the connector and contact the corresponding electrical conductors in the header. During the process of mating the second connector design to the edge-connect header, each of a plurality of wipers formed of low-mass, compliant metal wool, forms multiple contact points with a corresponding electrical conductor in the header.

Kellogg, Rick A.↗

DOE OSTI2022

Hermetic edge-connect headers and corresponding connectors

Kellogg, Rick A.↗

DOE OSTI2022

Hermetic edge-connect headers and corresponding connectors

Kellogg, Rick A.↗

DOE OSTI2020

Evaluating the Effect of Vane Trailing Edge Flow on Turbine Rim Sealing

Abstract Modern gas turbine development continues to move toward increased overall efficiency, driven in part by higher firing temperatures that point to a need for more cooling air to prevent catastrophic component failure. However, using additional cooling flow bled from the upstream compressor causes a corresponding detriment to overall efficiency. A primary candidate for cooling flow optimization is purge flow, which contributes to sealing the stator–rotor cavity and prevents ingestion of hot main gas path (MGP) flow into the wheelspace. Previous research has identified that the external main gas path flow physics play a significant role in driving rim seal ingestion. However, the potential impact of other cooling flow features on ingestion behavior, such as vane trailing edge (VTE) flow, is absent in the open literature. This paper presents experimental measurements of rim cavity cooling effectiveness collected from a one-stage turbine operating at engine-representative Reynolds and Mach numbers. Carbon dioxide (CO2) was used as a tracer gas in both the purge flow and vane trailing edge flow to investigate flow migration into and out of the wheelspace. Results show that the vane trailing edge flow does in fact migrate into the rim seal and that there is a superposition relationship between individual cooling flow contributions. Computational fluid dynamics (CFD) simulations using unsteady Reynolds-averaged Navier–Stokes (URANS) were used to confirm VTE flow ingestion into the rim seal cavity. Radial and circumferential traverse surveys were performed to quantify cooling flow radial migration through the main gas path with and without vane trailing edge flow. The surveys confirmed that vane trailing edge flow is entrained into the wheelspace as purge flow is reduced. Local CO2 measurements also confirmed the presence of VTE flow deep in the wheelspace cavity.

Engineering↗

DOE OSTI2022

Use of Multiple Tracer Gases to Quantify Vane Trailing Edge Flow Into Turbine Rim Seals

Abstract Overlapping features are commonly used as rim seals between stationary and rotating components in a turbine stage. These rim seals are used to prevent main gas path ingestion to the wheelspace cavity, which reduces the lifespan of critical engine components such as the turbine disk. In addition to the overlapping features, purge flow, diverted from the compressor, is injected into the rim cavity to act as an airflow sealing mechanism. Previous research identified that in addition to the purge flow in the rim cavity, cooling flow from the vane trailing edge (VTE) is ingested into the rim seal cavity carrying the potential to cool components in the wheelspace. These previous findings, however, were not able to distinctly separate purge from VTE cooling flows, which is the contribution of this paper based on uniquely using two different tracer gases. A one-stage test turbine operating at engine-relevant conditions and consisting of real engine hardware was used to validate and quantify the ingestion of the VTE flow by independently seeding the purge and VTE flows with two different tracer gases. Experimental results show the presence of VTE flow in the rim seal throughout all purge flowrates evaluated. Circumferential variation of VTE flow was also studied both experimentally and computationally using a computational fluid dynamics model. Results showed that ingested VTE flow can reduce the detrimental effect of hot gas ingestion particularly at higher purge flowrates.

Engineering↗

DOE OSTI2024

Interpreting accelerated tests on perovskite modules using photooxidation of MAPbI 3 as an example

Solar panels (modules) based on metal halide perovskites are following a fast track to commercialization. Unlike more established solar cell materials, there are not yet decades-long field observations to increase consumer confidence. The "physics and chemistry of failure" approach is used in other industries and estimates product degradation based on laboratory accelerated tests integrated with an understanding of degradation mechanisms. This work uses that approach to quantify the relationship between accelerated tests and projected product behavior for metal halide perovskite modules. Degradation involving photooxidation of methylammonium lead iodide is used to illustrate the method. Acceleration factors in common accelerated tests are found to be low. Conclusions emphasize that the accelerated tests on photovoltaics should not be interpreted as equivalent across module types or as a green light for commercialization unless supported by the appropriate field data or physics and chemistry of failure analysis.

14 SOLAR ENERGY↗

DOE OSTI2026

NREL Validation of S3.2 and S3.3 (CRADA Final Report)

The scope of work for S3.2 and S3.3 validation includes cooperative planning, execution, and analysis of all recommended and agreed-upon test protocols to determine the suitability of the product for long-term deployment of the photovoltaic modules to a broad range of climates. The test plan will be established within two months of project initiation, and NREL will write monthly reports for the duration of the work.

14 SOLAR ENERGY↗

DOE OSTI2020

Using Meteorological Data to Evaluate Worldwide PV Degradation Rates

Here we automate the process to enable the creation of world maps for specific PV durability metrics. The end goal is to create a tool for the creation of world maps predicting the sensitivity of modules to degradation to inform the development and utilization of module testing standards and to provide information to module designers. TMY (Typical Meteorological Year) Data was aggregated from sites around the world to render insight into factors contributing to the degradation of solar modules. The focus of aggregating data was to create a single dataset to work with utilizing Solar Irradiance values combined with Ambient Temperature, Relative Humidity, Wind Speed and Dew-Point Temperature.

14 SOLAR ENERGY↗

DOE OSTI2021

Design of Sample Holder for Plutonium Coupon Studies

In order to gain better understanding of the plutonium (Pu) corrosion behaviors and reaction kinetics, it is imperative that coupon experiments must be performed on well-defined surfaces. The reactions at the samples’ surfaces have to be properly monitored in terms of reactive gaseous pressures and temperatures. The pressure can be measured by using a pressure gauge, the temperature can be detected with calibrated thermal couples and/or pyrometric camera. These devices do not interfere with the chemistry of the surface reaction. However, to obtain information from the surface reaction, the aggressively machined edge and the back side of the Pu coupons need to be shielded from the applied gases. The coupons are typically made to 5/8 inch in diameter and 0.065 inch in thickness. To this end, a sample holder was designed which can seal the machined edge and the back side of coupons from the exposed gases, thus allowing proper surface reaction. The holder design was fabricated and had been tested with several coupon samples. We have achieved perfect sealing of the machined edge and the back side of the coupons, even when the coupons’ thicknesses are vastly different than the nominal thickness for which the sample holders were fabricated for. This write-up is to document the design of the holder and provide a description of the procedures to properly put the components together.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2024

Beyond the Surface: Non-Invasive Low-Field NMR Analysis of Microbially-Induced Calcium Carbonate Precipitation in Shale Fractures

Microbially-induced calcium carbonate precipitation (MICP) is a biological process in which microbially-produced urease enzymes convert urea and calcium into solid calcium carbonate (CaCO 3 ) deposits. MICP has been demonstrated to reduce permeability in shale fractures under elevated pressures, raising the possibility of applying this technology to enhance shale reservoir storage safety. For this and other applications to become a reality, non-invasive tools are needed to determine how effectively MICP seals shale fractures at subsurface temperatures. In this study, two different MICP strategies were tested on 2.54 cm diameter and 5.08 cm long shale cores with a single fracture at 60 °C. Flow-through, pulsed-flow MICP-treatment was repeatedly applied to Marcellus shale fractures with and without sand (“proppant”) until reaching approximately four orders of magnitude reduction in apparent permeability, while a single application of polymer-based “immersion” MICP-treatment was applied to an Eagle Ford shale fracture with proppant. Low-field nuclear magnetic resonance (LF-NMR) and X-Ray computed microtomography (micro-CT) techniques were used to assess the degree of biomineralization. With the flow-through approach, these tools revealed that while CaCO 3 precipitation occurred throughout the fracture, there was preferential precipitation around proppant. Without proppant, the same approach led to premature sealing at the inlet side of the core. In contrast, immersion MICP-treatment sealed off the fracture edges and showed less mineral precipitation overall. This study highlights the use of LF-NMR relaxometry in characterizing fracture sealing and can help guide NMR logging tools in subsurface remediation efforts.

MICP↗

DOE OSTI2022

Influence of Vane Trailing Edge Flow on the Formation of Cavity Cells and Rim Sealing

Abstract Hot gas ingestion into the turbine rim seal cavity is an important concern for engine designers. To prevent ingestion, rim seals use high-pressure purge flow; however, the penalty is that excessive use of the purge flow decreases engine thermal efficiency. In this paper, a one-stage turbine operating at engine-representative conditions was used to study the effect of steady and time-resolved under-platform cavity temperatures and pressures across a range of coolant flowrates in the presence of vane trailing edge (VTE) flow. This study correlates time-resolved pressure with time-resolved temperature to identify primary frequencies driving ingestion. At certain flowrates, the time-resolved pressures are out of phase with the temperatures, indicating ingestion. Measurements from high-frequency response pressure sensors in the rim seal and vane platform were also used to determine rotational speed and quantity of large-scale structures (cells). In a parallel effort, a computational model using Unsteady Reynolds-averaged Navier–Stokes (URANS) was applied to determine swirl ratio in the rim seal cavity and time-resolved rim sealing effectiveness. The experimental results confirm that at low purge flowrates, the VTE flow influences the unsteady flow field by decreasing pressure unsteadiness in the rim seal cavity. Results show an increase in purge flow increases the number of unsteady large-scale structures in the rim seal and decreases their rotational speed. However, VTE flow was shown to not significantly change the cell speed and count in the rim seal. Simulations point to the importance of the large-scale cell structures in influencing rim sealing unsteadiness, which is not captured in current rim sealing predictive models.

Engineering↗

DOE OSTI2020

PDRD Project 19039 - All metal vacuum scroll pump development for tritium

Currently the United States relies on a single source, foreign company, Eumeca (formerly Normetex) for the supply of an all metal vacuum scroll pump to process tritium. This “one of a kind”, all metal, vacuum scroll pump utilizes no “wetted”, polymeric materials that degrade prematurely when exposed to tritium. U.S. based vacuum scroll pump suppliers typically utilize a polymer, Teflon®, as a tip seal material at the edge of the scroll impellers for proper pump function. Teflon® is known to degrade within a relatively short time frame (approximately 1 year) when continually exposed to tritium gas. This degradation results in “flaking” of the Teflon® material which results in particulate contamination of the process gas stream. While filtration of the particulate is possible, doing so requires additional maintenance which is costly in a glovebox environment. In addition, filtration can degrade pumping system performance as particulate collects in the filter media over time. To date, all of the well established U.S and European based vacuum scroll pump manufacturers have been uninterested in developing an all metal vacuum scroll pump that does not use a polymeric scroll tip seal. This position is taken as the vacuum scroll pump manufacturers do not see a large enough market to make it profitable for them to develop and market an all metal vacuum scroll pump. In the mid 2000s, one company, Air Squared, Inc., a small Original Equipment Manufacturer (OEM) specializing in design and fabrication of custom scroll vacuum pumps and compressors, was willing to pursue the effort. The first design effort incorporated Vespel® as a polymeric tip seal material. Results of this effort led to realizing the affect that the Met-Bel MB-601 metal bellows pump has on performance when used as a backing pump for an all metal vacuum scroll pump without a scroll tip seal. As a result, Air Squared subsequently designed an all metal vacuum scroll pump without a tip seal material for evaluation. Although the initial, all metal version of the Air Squared pump was found deficient in regard to scroll impeller stiffness, which resulted in scroll contact, general design and pump performance was verified to be adequate. SRS PDRD Project 19039 was launched in 2019 as a 3rd attempt with Air Squared, Inc. in regard to development of an all metal vacuum scroll pump for consideration as an equivalent to the Eumeca/ Normetex pump. The effort specified 300 series stainless steel for the scroll impellers, all metal sealing, and design to meet tritium throughput and ultimate vacuum requirements. In addition, a 60 psig design pressure rating requirement was specified for the pump containment boundary. The 3rd generation Air Squared pump has been designed, fabricated, and has received preliminary testing. Preliminary testing has indicated proper leak tightness and pump performance. However, work continues regarding development of a pumping chamber containment bellows that can be subjected to 66 psig without damage to the bellows. Work will continue in 2020 and 2021 to pursue a pumping chamber containment bellows that meets the pressure rating requirement.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

High-power ultraviolet (UV) and vacuum ultraviolet (VUV) lamps with micro-cavity plasma arrays

A plasma lamp includes plates that are approximately parallel, with at least one array of microcavities formed in a surface of at least one plate. When desirable, the plates are separated a fixed distance by spacers with at least one spacer being placed near the plate's edge to form a hermetic seal therewith. A gas makes contact with the microcavity array. Electrodes capable of delivering a time-varying voltage are located on the surface of each plate. At least one electrode is located on an exterior surface of at least one interior plate. Optionally, protective windows may be placed over the electrodes. The application of the time-varying voltage interacts with the gas to form a glow discharge plasma in the microcavities and the fixed volume between the plates (when present). The glow discharge plasma efficiently and uniformly emits UV/VUV radiation over the entire surface of the lamp.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

High-power ultraviolet (UV) and vacuum ultraviolet (VUV) lamps with micro-cavity plasma arrays

A product having at least one plasma lamp that includes plates that are approximately parallel, with at least one array of microcavities formed in a surface of at least one plate. When desirable, the plates are separated a fixed distance by spacers with at least one spacer being placed near the plate's edge to form a hermetic seal therewith. A gas makes contact with the microcavity array. Electrodes capable of delivering a time-varying voltage are located such that the application of the time-varying voltage interacts with the gas to form a glow discharge plasma in the microcavities and the fixed volume between the plates. The glow discharge plasma efficiently and uniformly emits radiation that is predominantly in the UV/VUV spectral range with at least a portion of the radiation being emitted from the plasma lamp.

Park, Sung-Jin↗

DOE OSTI2022

LiMo 8 O 10 : Polar Crystal Structure with Infinite Edge-Sharing Molybdenum Octahedra

Here, polycrystalline LiMo 8 O 10 was prepared in a sealed Mo crucible at 1380 °C for 48 h using the conventional high-temperature solid-state method. The polar tetragonal crystal structure (space group I4 1 md) is confirmed based on the Rietveld refinement of powder neutron diffraction and 7 Li/ 6 Li solid-state NMR. The crystal structure features infinite chains of Mo 4 O 5 (i.e., Mo 2 Mo 4/2 O 6/2 O 6/3 ) as a repeat unit containing edge-sharing Mo 6 octahedra with strong Mo–Mo metal bonding along the chain. X-ray absorption near-edge spectroscopy of the Mo-L 3 edge is consistent with the formal Mo valence/configuration. Magnetic measurements reveal that LiMo 8 O 10 is paramagnetic down to 1.8 K. Temperature-dependent resistivity [ρ(T)] measurement indicates a semiconducting behavior that can be fitted with Mott’s variable range hopping conduction mechanism in the temperature range of 215 and 45 K. The ρ(T) curve exhibits an exponential increase below 5 K with a large ratio of ρ 1.8 /ρ 300 = 435. LiMo 8 O 10 shows a negative field-dependent magnetoresistance between 2 and 25 K. Heat capacity measurement fitted with the modified Debye model yields the Debye temperature of 365 K.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Debris tolerant valve

A valve includes a valve body, a sleeve within the valve body and a rotatable valve element that has one portion within the sleeve to control flow of media through the valve and another portion extending from the valve body and coupled to an actuator that rotates the valve element. The valve element is rotatable to a first position to flow media to one port and to a second position to flow media to another port. The sleeve has a pair of side openings. Each side opening has an angled perimetrical edge and is aligned with a corresponding port member. A half dovetail shaped groove is formed by the angled perimetrical edge of each side opening, the corresponding port and the valve body. A seal is lodged within each groove to form a seal that exhibits reduced unswept volume and which wipes debris off the valve element as it rotates.

42 ENGINEERING↗

DOE OSTI2022

Design, Construction, and Field Validation of a Blown-In Fiberglass Wall System in a Cold, Wet, and Windy Climate

In the Native Village of Tununak, located on Nelson Island in Southwest Alaska,buildings are exposed to wind-driven rain and snow throughout the year. The Cold Climate Housing Research Center (CCHRC) and Knauf Insulation partnered with the community in 2018 to design a residence for a public safety officer. Construction began in fall 2021 and is scheduled to conclude in summer 2022. The house will use integrated trusses with floor, attic, and wall cavities filled with blown-in fiberglass insulation. Hygrothermal models of the building envelope system demonstrate that the high ambient moisture load will wet the outer edges of the insulation annually regardless of the extent and integrity of exterior weather sealing measures; blown-in fiberglass is expected to be more resilient to this wetting than blown-in cellulose. To verify this, researchers will embed temperature, relative humidity, and moisture sensors in the two windward walls of the house to monitor the ability of the blown-in fiberglass insulation to dry out after wetting events that may have occurred during the transport of the insulation to the building site, storage of the insulation on site, construction process, or after installation in the wall. Sensors will remain in place for two years,documenting the wall's performance over time and verifying the design's potential for use in buildings located in climates where the chance for moisture damage is high. Here, we describe the wall system , design criteria, and the results from the hygrothermal modeling. We share details on the monitoring system's components and the planned management and analysis of data. Finally, we explain how the experiences and data from this project will inform future builds in similar locations.

building design↗

DOE OSTI2022

Multi-cell, triple pane, vacuum insulated glazing

A novel Triple Pane Vacuum Insulated Glazing (TPVIG) architecture consisting of three panes of glass separated by two offset grids is described. The grids are made of frit-coated fibers fused with the glass panes in a vacuum to create many independent hermetic cells. Unlike traditional VIGs, which are separated by support pillars, these cells significantly increase the redundancy in sealing, and the additional bonds formed by the grid lines reduce the stresses on the edge bonds thereby increasing VIG reliability. A numerical thermal analysis was conducted to determine the thermal performance of the VIG and suggested U-values below 0.5 W/m 2 -K (greater than R=11.4 hr-ft 2 -°F/Btu) can be obtained. A prototype of the VIG unit consisting of three glass panes (5.7 mm, 1.1 mm and 5.7 mm thick with low-e coating on two surfaces) was fabricated and tested for thermal performance using the hot box method. The experimental center of glass U-value for the VIG was found to be 0.42 W/m 2 K (R=13.2 hr-ft 2 -°F/Btu). Furthermore, this U-value is about four times lower than a typical Argon filled double pane window.

14 SOLAR ENERGY↗