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LT61LEP-40 Phase II, Final Report

LT-40 Phase II evaluates the shear strength of Wilethane 44 (W44) when bonded to plastic bonded explosives (PBXs) as a function of accelerated aging time. These tests involve two PBX formulations, PBX 9502 and PBX 9012 (which is identical to the LX-07 formulation but lacks the orange dye). The LT-40 Phase I and Phase II test series differ from each other in their use of different lots of the two PBX formulations. The earlier LT-40 Phase I reports captured the initial shear strength data aged to 6 months [1] and18 months [2] for LX-07 lot 692 -5 and PBX 9502 lot 891-008. The Phase I final report [2] incorrectly refers to LX -07 as PBX 9012. These materials have the same formulation but, again, LX-07 includes orange dye. This report gives the Phase II data which includes the test results of 3-month and 6-month specimens [3] along with the18-month aged specimens of PBX 9012 Development Lot 1 and PBX 9502 Development Lot 2. The summary of all the LT-40 Phase II results are given and compared with the Phase I work. In a separate study, LT61LEP-21 [4 ], using the same Iosipescu loading configuration, the dependence of W44 shear bond strength as a function of cure time was investigated on the Phase I lots.

36 MATERIALS SCIENCE↗

Improving GCM Predictability of Mixed-Phase Clouds and Aerosol Interactions at High Latitudes with ARM Observations

The overachieving goal of this project is to improve the predictability of mixed-phase clouds and aerosol interactions in the Community Atmosphere Model version 6 (CAM6) through comparison with the ARM observations. There are three main objectives of the proposed study: (1) Improve the representation of ice microphysical processes in mixed-phase clouds; (2) Test the performance of ice microphysics in CESM-CAM6 with the ARM observations in northern and southern high latitudes; and (3) Examine mixed-phase cloud microphysics-aerosol-turbulence-radiation interactions in CESM-CAM6. In this project, we have (1) Improved the representation of ice microphysical processes in mixed-phase clouds in CESM-CAM6 by implementing the marine organic aerosol (MOA) and treating the ice nucleating particles (INPs) from MOA and its impacts on mixed-phase clouds. We improved the treatment of ice depositional growth through the Wegener–Bergeron–Findeisen (WBF) process by considering the subgrid heterogeneous distributions between liquid droplets and ice crystals in mixed-phase clouds; (2) Tested the performance of ice microphysics in CESM-CAM6 with the ARM observations at high latitudes. We compared the simulated INP concentrations with the ARM observations, e.g., from M-PACE, ISDAC, INPOP, and other data (Mace Head, Zeppelin, CAPRICORN). We examined the impact of improved WBF treatment on model simulated Arctic mixed-phase clouds observed in the M-PACE field campaign. Seasonal variations of modeled mixed-phase cloud properties (LWO, IWP) are compared with the ground-based remote sensing retrievals at the ARM’s NSA $Utqia\dot{g}vik$ site; and (3) Examined mixed-phase cloud microphysics-aerosol-dynamics-radiation interactions in CESM-CAM6 that include the impacts of MOA INPs, and impacts of different model parameterizations (CLUBB versus UW turbulence & shallow convection schemes, MG2 versus MG1) on high-latitude mixed-phase cloud properties. Aerosol indirect effects of MOA through the liquid phase (droplet activation) and ice phase processes (e.g., the glaciation indirect effect) were investigated.

54 ENVIRONMENTAL SCIENCES↗

Time-temperature-stress capabilities of composite materials for advanced supersonic technology application

Advanced composites will play a key role in the development of the technology for the design and fabrication of future supersonic vehicles. However, incorporating the material into vehicle usage is contingent on accelerating the demonstration of service capacity and design technology. Because of the added material complexity and lack of extensive data, laboratory replication of the flight service will provide the most rapid method to document the airworthiness of advanced composite systems. Consequently, a laboratory program was conducted to determine the time-temperature-stress capabilities of several high temperature composites. Tests included were thermal aging, environmental aging, fatigue, creep, fracture, tensile, and real-time flight simulation exposure. The program had two phases. The first included all the material property determinations and aging and simulation exposures up through 10,000 hours. The second continued these tests up to 50,000 cumulative hours. This report presents the results of the Phase 1 baseline and 10,000-hr aging and flight simulation studies, the Phase 2 50,000-hr aging studies, and the Phase 2 flight simulation tests, some of which extended to almost 40,000 hours.

Kerr, James R.↗

Design and Testing of a Hard-Fault Protection Circuit for a 1 kV SiC MOSFET Inverter

Due to increasingly high DC link voltages and further advancements in the current density of silicon carbide (SiC) MOSFETs, it has become evident that conventional IGBT protection methods are not sufficient to prevent exceeding the current rating of these devices during low-inductance fault events. This paper explores the use of an air core Rogowski coil topology to mitigate these hard fault events. The design of this circuit resulted in safe shutdown of a low impedance phase-to-phase fault in under one microsecond, tested up to DC link voltages of 1 kV. This paper details the theory, design, simulation, and successful test results of this method.

hard fault protection↗

Final Technical Report

Statement of the problem or situation that is being addressed in your application. The DOE and its national laboratories developed the Home Energy Score™ (HES) to encourage homeowners to improve their energy performance, lower costs and to share energy information through the MLS listing, appraisal, and financing channels. While the HES is an instrumental tool, it is currently underutilized and consists of technical, structural and sector barriers which need to be addressed in order to scale and many energy efficiency contractors are understandably overwhelmed by the added time and effort and lack of incentive to sell and deliver deep retrofit projects while simultaneously meeting the DOE HES program requirements; consequently, contractors may decide to forgo participation. Home Energy Rating System (HERS) Raters have the opportunity to play the critical Assessor role in producing a Home Energy Score (HES); this role has immense potential but currently is unfulfilled. Lastly, while utilities are interested in their customer base achieving greater energy efficiency, especially to help offset growing residential loads in states like California that are accelerating electrification, utilities do not have access to the market actors who are on the front line of influence to homeowners or review and approve their permits: HERS Raters, assessors, contractors and building departments. General statement of how this problem is being addressed: ConSol will integrate the Home Energy Score™ (HES) to its State of California, approved home energy rating services (HERS) platform (CHEERS) to develop a single tool for contractors nationwide to assess, record and install recommended cost, energy, and emissions saving measures to the 140 million single-family homes throughout the U.S. and 14 million homes in California (CHEERS+HES). The CHEERS high fidelity energy code permitting data will be integrated with HES for simple, accurate, easy-to-use home energy estimation and analysis and will directly gain access to the retrofit and renovations markets with the same upgraded platform. This innovative project will assist the utilities in supporting existing homes in their jurisdictions with HES and develop measures to improve energy efficiency and reduce emissions. How is this problem being addressed? What is the overall project approach? In effort to expand the Home Energy Score™ (HES) by increasing the use of aggregable home energy asset data, ConSol proposes to integrate the DOE HES via Application Programming Interface (API) to its State of California approved home energy rating services platform (CHEERS). Once the CHEERS platform and HES are integrated (CHEERS+HES), this enhanced platform will be instantly available and actively deployed via Phase 1 pilot to HERS Raters, assessors and contractors in California to market-test the solution, understand the rate of adoption and identify opportunities for improvement prior to scaling nationally. The CHEERS high fidelity energy code permitting data will be integrated with HES for simple, accurate, easy-to-use home energy estimation and analysis and will directly gain access to the retrofit and renovations markets with the same upgraded platform. This innovative project will assist the building industry and homeowners with an easy-to-use assessment if energy and carbon impacts of existing homes, and assist the utilities in supporting existing homes in their jurisdictions with HES to improve energy efficiency and reduce emissions. What is to be done in Phase I? During Phase I of this proposed project, ConSol will (1) design software architecture that links CHEERS to the Home Energy ScoreTM via API, (2) solicit partnership from one or more California utilities for a regional pilot, (3) test the new software with its HERS Raters and contractor network in the partnership utility jurisdiction, (4) launch a pilot version of the newly developed software with HERS Raters and contractors in the utility territory, and (5) explore California’s GoGreen energy efficiency homeowner lending program in parallel with the pilot. Commercial Applications and Other Benefits. Summarize the future applications or public benefits if the project is carried over into Phase II or Phase III and beyond. The CHEERS+HES commercialized product will be ready for national market scale following a successful Phase 1 performance. The CHEERS+HES adoption is estimated to reach a 5% adoption growth rate versus the 110,000 baseline, starting in Year 1 after Phase I completion, and continuing each year. As a direct benefit to the DOE, CHEERS will set a goal of 100,000 Home Energy Score assessments for existing home alterations within the first 10 years following Phase 1 performance. The technical benefits of this proposed project include the harmonized, automated, and seamless integration of the DOE HES into the widely used and market leading California energy registry, CHEERS. The social benefits include the aggregate energy, cost and GHG savings by allowing the broader public streamlined access to the CHEERS+HES measurement and the energy efficiency recommended measures that may result. Key Words: Home Energy ScoreTM (HES); Application Programming Interface (API); Home Energy Rating Services (HERS); HERS Raters; contractors; assessors; existing homes, energy asset data; cost, energy, and emissions saving measures; energy code (Title 24) compliance; document repository; utilities; pilot; newly developed software; energy efficiency; homeowner. Summary for Members of Congress: The DOE Home Energy Score™ (HES) is a tool to encourage homeowners to improve their energy performance, lower costs and share energy information but is underutilized and consists of barriers which need to be addressed in order to scale. In effort to expand the HES, CHEERS, Inc. will integrate the HES to its State of California, approved home energy rating services (HERS) platform (CHEERS) to develop a single tool for contractors nationwide to assess, record and install recommended cost, energy, and emissions saving measures to the 140 million single-family homes throughout the U.S. and 14 million homes in California.

Application Programming Interface (API)↗

External Payload Carrier (XPC) A Suborbital Research Platform

This slide presentation details the concept of an External Payload Carrier (XPC), that can fly on ann unused Solid Rocket Booster (SRB) location on the Atlas V rocket to suborbital environment. The XPC can be used anytime there is sufficient excess lift capability available. The dimensions and possible uses of the XPC are reviewed. The completed Phase 1 study reviewed 57 variations, and arrived at three viable configurations, identified design baselines, subsystems and preliminary testing requirements. Phase II effort is planned to produce the preliminary design (i.e., PDR level), Systems Requirements Document (SRD), identify flight candidates, develop schedule and funding profiles, and identify the risk-reduction activities.

Schallhorn, Paul↗

Unmanned Aircraft Systems (UAS) Integration in the National Airspace System (NAS) Project: Terminal Operations HITL 1: Primary Results

This presentation covers the primary results of the Unmanned Aircraft Systems (UAS) Integration in the National Airspace System (NAS) Project Terminal Operations Foundational Human-in-the-Loop (HITL) simulation. The study tasked 16 pilots (half with manned piloting experience, and the other half with unmanned piloting experience) with maintaining "well clear" from other traffic while performing three different types of approaches into the Santa Rosa airport. A detect and avoid (DAA) system was provided to pilots to assist their ability to manage separation. The DAA system used in this test conformed to the criteria defined by RTCA Special Committee 228 (SC-228) in their Phase 1 Minimum Operational Performance Standards (MOPS) for UAS intending to operate in the NAS. The Phase 1 system was not designed to account for terminal operations, focusing instead on en route operations. To account for this, three different alerting and guidance configurations were presently tested in order to determine their effect on pilots operating the system in the terminal area. Results indicated that pilots with the alerting and guidance condition that provided the least amount of assistance (fewer alert levels and guidance types) experienced slightly increased pilot response times and rates of losses of separation. Additional data is presented on the effects of approach type and descriptive data on pilot maneuver preferences and ATC interoperability.

terminal environmen↗

Changes in the MJO under Greenhouse Gas–Induced Warming in CMIP5 Models

This study investigates changes to the Madden–Julian oscillation (MJO) in response to greenhouse gas–induced warming during the twenty-first century. Changes in the MJO’s amplitude, phase speed, and zonal scale are examined in five models from phase 5 of the Coupled Model Intercomparison Project (CMIP5) that demonstrate superior MJO characteristics. Under warming, the CMIP5 models exhibit a robust increase in the spectral power of planetary-scale, intraseasonal, eastward-propagating (MJO) precipitation anomalies (~10.9% K −1 ). The amplification of MJO variability is accompanied by an increase of the spectral power of the corresponding westward-traveling waves at a similar rate. This suggests that enhanced MJO variability in a warmer climate is likely caused by enhanced background tropical precipitation variability, not by changes in the MJO’s stability. All models examined show an increase in the MJO’s phase speed (1.8% K –1 –4.5% K −1 ) and a decrease in the MJO’s zonal wavenumber (1.0% K –1 –3.8% K −1 ). Using a linear moisture mode framework, this study tests the theory-predicted phase speed changes against the simulated phase speed changes. It is found that the MJO’s acceleration in a warmer climate is a result of enhanced horizontal moisture advection by the steepening of the mean meridional moisture gradient and the decrease in zonal wavenumber, which is partially offset by the lengthening of the convective moisture adjustment time scale and the increase in gross dry stability. While the ability of the linear moisture mode framework to explain MJO phase speed changes is model dependent, the theory can accurately predict the phase speed changes in the model ensemble.

54 ENVIRONMENTAL SCIENCES↗

Antenna evaluation study for the shuttle multispectral radar, phase 2

The results of the second phase of the Antenna Evaluation Study for the Shuttle Imaging Radar are presented. The objectives of Phase II were (1) to complete the specifications for the subarray test panels, (2) to begin a study of the effects of electrical and mechanical tolerance variations on overall SIRA performance, (3) to initiate the development of a mathematical model which adequately described the array performance and (4) to begin the development of a comprehensive computer program which will eventually simulate the performance characteristics of the antenna in a spaceborne environment. Items (2), (3), and (4) were begun in Phase I (ahead of schedule), and because of this, it has been possible to accelerate the Phase II modeling/simulation objectives to the point where simulations of expected mechanical/electrical errors have already been produced.

Coffey, E. L., III↗

Placement and Sizing of Inverter-Based Renewable Systems in Multi-Phase Distribution Networks

This study develops a tractable formulation for optimal placement and sizing of inverter-based renewable systems in multi-phase distribution networks. The goal of the formulation is to minimize the cost of inverter installation, average power import, and average distributed generation curtailment. Threephase and single-phase inverter models are presented that preserve the underlying mappings between renewable uncertainty to power injection. The uncertainty of distributed generators (DGs) and loads are characterized by a finite set of scenarios. Linear multi-phase power flow approximations are used in conjunction with scenario reduction techniques to arrive at a tractable twostage stochastic formulation for optimal DG placement and sizing. First-stage decisions are locations for DG deployment and capacity sizes, and second-stage decisions include DG real power curtailment, reactive power support, as well as feeder voltage profile. The resulting formulation is a mixed-integer second-order cone program and can be solved efficiently either by existing optimization solvers or by relaxing the binary variables to the [0,1] interval. Simulation studies on standard multi-phase IEEE test feeders promise that optimal stochastic planning of DGs reduces costs during validation, compared to a scheme where uncertainty is only represented by its average value.

24 POWER TRANSMISSION AND DISTRIBUTION↗

ATF Benchmark Problems

The events at Fukushima Daiichi Nuclear Power Plant on March 2011 propelled the research and development of accident-tolerant fuel (ATF) for use in nuclear power plants. After these events, the United States Senate Appropriations Committee requested a report from the United States Department of Energy (DOE) regarding DOE’s plan for developing ATF. In DOE’s development plan, a 10-year effort beginning in 2012 was outlined from Phase 1 feasibility studies through Phase 3 commercialization with a lead test assembly (LTA) or a lead fuel rod (LFR) to be ready for insertion into a reactor by 2022. In fiscal year 2018, the US Nuclear Regulatory Commission (NRC) expressed an interest in using the DOE Office of Nuclear Energy (NE) advanced modeling and simulation (M&S) tools to evaluate advanced fuel concepts such as ATF. This interest evolved into a formal cooperation between DOE and NRC to ensure that an effective M&S capability is available for NRC analyses of ATF concepts. Over the last 10 years, the DOE-funded Energy Innovation Hub, also known as the Consortium for Advanced Simulation of Light Water Reactors (CASL), has developed, applied and deployed advanced M&S capabilities to enhance the operational performance, efficiency, and safety of light water reactors (LWRs). Due to the aging US nuclear fleet, CASL was initiated to improve the efficiency of nuclear power production, lower costs by enhancing the understanding of fuel performance and residence time in the nuclear reactor, enhance safety by studying new fuels that can endure severe conditions, and extend the life of existing reactors by predicting the lifetimes of key structural components

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Experimental clean combustor program, phase 1

A program of screening three low emission combustors for conventional takeoff and landing, by testing and analyzing thirty-two configurations is presented. Configurations were tested that met the emission goals at idle operating conditions for carbon monoxide and for unburned hydrocarbons (emission index values of 20 and 4, respectively). Configurations were also tested that met a smoke number goal of 15 at sea-level take-off conditions. None of the configurations met the goal for oxides of nitrogen emissions at sea-level take-off conditions. The best configurations demonstrated oxide of nitrogen emission levels that were approximately 61 percent lower than those produced by the JT9D-7 engine, but these levels were still approximately 24 percent above the goal of an emission index level of 10. Additional combustor performance characteristics, including lean blowout, exit temperature pattern factor and radial profile, pressure loss, altitude stability, and altitude relight characteristics were documented. The results indicate the need for significant improvement in the altitude stability and relight characteristics. In addition to the basic program for current aircraft engine combustors, seventeen combustor configurations were evaluated for advanced supersonic technology applications. The configurations were tested at cruise conditions, and a conceptual design was evolved.

Roberts, R.↗

Novel oxygen atom source for material degradation studies

Physical Sciences Inc. (PSI) has developed a high flux pulsed source of energetic (8 km/s) atomic oxygen to bombard specimens in experiments on the aging and degradation of materials in a low earth orbit environment. The proof-of-concept of the PSI approach was demonstrated in a Phase 1 effort. In Phase 2 a large O-atom testing device (FAST-2) has been developed and characterized. Quantitative erosion testing of materials, components, and even small assemblies (such as solar cell arrays) can be performed with this source to determine which materials and/or components are most vulnerable to atomic oxygen degradation. The source is conservatively rated to irradiate a 100 sq cm area sample at greater than 10(exp 17) atoms/s, at a 10 Hz pulse rate. Samples can be exposed to an atomic oxygen fluence equivalent to the on-orbit ram direction exposure levels incident on Shuttle surfaces at 250 km during a week-long mission in a few hours.

Krech, R. H.↗

An integrated optical CO2 sensor. Phase 0: Design and fabrication of critical elements

Significant progress has been made toward all of the goals for the first phase of the project short of actual fabrication of a light path. Two alternative approaches to fabricating gold mirrors using the basic LIGA process were developed, one using electroplated solid gold mirrors and the second using gold plated over a nickel base. A new method of fabrication, the transfer mask process, was developed and demonstrated. Analysis of the projected surface roughness and beam divergence effects was completed. With gold surface with low surface roughness scattering losses are expected to be insignificant. Beam divergence due to diffraction will require a modification of the original design, but should be eliminated by fabricating mirrors 1000 mu m in height by 1000 mu m in width and using a source with an initial beam radius greater than 300 mu m. This may eliminate any need for focusing optics. Since the modified design does not affect the mask layout, ordering of the mask and fabrication of the test structures can begin immediately at the start of Phase 1.

Murphy, Michael C.↗

A Microfabricated Involute-Foil Regenerator for Stirling Engines

A segmented involute-foil regenerator has been designed, microfabricated and tested in an oscillating-flow rig with excellent results. During the Phase I effort, several approximations of parallel-plate regenerator geometry were chosen as potential candidates for a new microfabrication concept. Potential manufacturers and processes were surveyed. The selected concept consisted of stacked segmented-involute-foil disks (or annular portions of disks), originally to be microfabricated from stainless-steel via the LiGA (lithography, electroplating, and molding) process and EDM (electric discharge machining). During Phase II, re-planning of the effort led to test plans based on nickel disks, microfabricated via the LiGA process, only. A stack of nickel segmented-involute-foil disks was tested in an oscillating-flow test rig. These test results yielded a performance figure of merit (roughly the ratio of heat transfer to pressure drop) of about twice that of the 90% random fiber currently used in small ~ 100 W Stirling space-power convertors in the Reynolds Number range of interest (50-100). A Phase III effort is now underway to fabricate and test a segmented-involute-foil regenerator in a Stirling convertor. Though funding limitations prevent optimization of the Stirling engine geometry for use with this regenerator, the Sage computer code will be used to help evaluate the engine test results. Previous Sage Stirling model projections have indicated that a segmented-involute-foil regenerator is capable of improving the performance of an optimized involute-foil engine by 6-9%; it is also anticipated that such involute-foil geometries will be more reliable and easier to manufacture with tight-tolerance characteristics, than random-fiber or wire-screen regenerators. Beyond the near-term Phase III regenerator fabrication and engine testing, other goals are (1) fabrication from a material suitable for high temperature Stirling operation (up to 850 C for current engines; up to 1200 C for a potential engine-cooler for a Venus mission), and (2) reduction of the cost of the fabrication process to make it more suitable for terrestrial applications of segmented involute foils. Past attempts have been made to use wrapped foils to approximate the large theoretical figures of merit projected for parallel plates. Such metal wrapped foils have never proved very successful, apparently due to the difficulties of fabricating wrapped-foils with uniform gaps and maintaining the gaps under the stress of time-varying temperature gradients during start-up and shut-down, and relatively-steady temperature gradients during normal operation. In contrast, stacks of involute-foil disks, with each disk consisting of multiple involute-foil segments held between concentric circular ribs, have relatively robust structures. The oscillating-flow rig tests of the segmented-involute-foil regenerator have demonstrated a shift in regenerator performance strongly in the direction of the theoretical performance of ideal parallel-plate regenerators.

Tew, Roy↗

A Microfabricated Involute-Foil Regenerator for Stirling Engines

A segmented involute-foil regenerator has been designed, microfabricated and tested in an oscillating-flow rig with excellent results. During the Phase I effort, several approximations of parallel-plate regenerator geometry were chosen as potential candidates for a new microfabrication concept. Potential manufacturers and processes were surveyed. The selected concept consisted of stacked segmented-involute-foil disks (or annular portions of disks), originally to be microfabricated from stainless-steel via the LiGA (lithography, electroplating, and molding) process and EDM. During Phase II, re-planning of the effort led to test plans based on nickel disks, microfabricated via the LiGA process, only. A stack of nickel segmented-involute-foil disks was tested in an oscillating-flow test rig. These test results yielded a performance figure of merit (roughly the ratio of heat transfer to pressure drop) of about twice that of the 90 percent random fiber currently used in small approx.100 W Stirling space-power convertors-in the Reynolds Number range of interest (50 to 100). A Phase III effort is now underway to fabricate and test a segmented-involute-foil regenerator in a Stirling convertor. Though funding limitations prevent optimization of the Stirling engine geometry for use with this regenerator, the Sage computer code will be used to help evaluate the engine test results. Previous Sage Stirling model projections have indicated that a segmented-involute-foil regenerator is capable of improving the performance of an optimized involute-foil engine by 6 to 9 percent; it is also anticipated that such involute-foil geometries will be more reliable and easier to manufacture with tight-tolerance characteristics, than random-fiber or wire-screen regenerators. Beyond the near-term Phase III regenerator fabrication and engine testing, other goals are (1) fabrication from a material suitable for high temperature Stirling operation (up to 850 C for current engines; up to 1200 C for a potential engine-cooler for a Venus mission), and (2) reduction of the cost of the fabrication process to make it more suitable for terrestrial applications of segmented involute foils. Past attempts have been made to use wrapped foils to approximate the large theoretical figures of merit projected for parallel plates. Such metal wrapped foils have never proved very successful, apparently due to the difficulties of fabricating wrapped-foils with uniform gaps and maintaining the gaps under the stress of time-varying temperature gradients during start-up and shut-down, and relatively-steady temperature gradients during normal operation. In contrast, stacks of involute-foil disks, with each disk consisting of multiple involute-foil segments held between concentric circular ribs, have relatively robust structures. The oscillating-flow rig tests of the segmented-involute-foil regenerator have demonstrated a shift in regenerator performance strongly in the direction of the theoretical performance of ideal parallel-plate regenerators.

Tew, Roy↗

Hard Fault Protection for a Silicon Carbide-Based Aerospace Motor Drive

Due to increasingly high DC link voltages and further advancements in the current density of silicon carbide (SiC) MOSFETs, it has become evident that conventional IGBT protection methods are not sufficient to protect these devices from overcurrent during low-inductance fault events. The use of an air core Rogowski coil topology was explored to see if it could mitigate these hard fault events. The design of this circuit resulted in safe shutdown of a low impedance phase-tophase fault, tested up to DC link voltages of 1 kV.

High Voltage↗