Search NASA⌕ Search

SEARCH · Search NASA

Results for “fixture”

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 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Impact of lead on an axisymmetric, single bead blown powder DED overhung geometry

Metal additive manufacturing can be utilized for the near net-shape manufacture of components in a layer wise technique. Traditionally, the buildup process is conducted in the direction of gravity or bottom to top in the vertical orientation; however, with the availability of commercial systems with additive heads or fixturing that can index from vertical, and the need to manufacture larger parts without modifying available systems, the limitation of manufacturing from bottom to top is removed enabling the buildup of larger components printed at an angle from vertical. The effect of gravity on the melt pool and as-deposited component quality when printing off vertical is unknown in literature, especially for axisymmetric components. This understanding is critical for the advancement of manufacturing components of increased size in 4 and 5-axis additive systems. This investigation utilizes blown powder directed energy deposition to evaluate the change in as-printed geometry when the start point is altered in relation to gravity while the part rotates to manufacture an axisymmetric component. The objectives of this work are to determine the impact of the deposition location on the geometric variability on axisymmetric components. This investigation tests the hypothesis that differences in layer height exist due to a change in catchment efficiency when the deposition location is moved to a tangent of the round geometry due to a change in the melt pool dynamics. It was found the ideal deposition location when printing at 26.6-degrees from vertical was at −90-degrees from the top center point of the component, along the tangent, where gravity was pushing the melt pool down, but the rotation of the part was pulling the deposited material towards the top center of the component. This work provides an understanding of layer height stability and catchment efficiency to guide print orientation strategy for high-aspect ratio components. It was found the −90-degree lead deposition had the best layer height stability at 0.6 % as compared to the top-center at 6.3 % and +90-degree deposition location at 9.2 % for the nominal programmed layer height. The change in layer height also effected the final diameter the greatest for the top center deposition location where the diameter diverged by 2.5 % during the overbuild condition and converged by 0.6 %. In conclusion, this finding will increase the manufacturing efficiency of axisymmetric components by increasing the passive stability of the printing process for the successful manufacture of parts without the need for perfectly calibrated manufacturing parameters.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Equibiaxial flexural strength determination of UO 2 using a ball-on-ring test

To increase nuclear fuel performance and reliability, their mechanical properties require an accurate and statistically relevant assessment. Biaxial flexural strength tests provide an alternative to bend bar techniques for assessing mechanical behavior; namely, the transverse rupture strength (TRS) of ceramic samples. Biaxial test samples require simple geometries and minimal surface preparation, reducing fabrication costs and handling hazards. This study investigated the TRS of polycrystalline UO 2 fuel forms at room temperature using a ball-on-ring test fixture. Here, pellets were fabricated from UO 2 powder using conventional powder processing and sintering techniques. The TRS and Weibull parameters were obtained through Weibull statistics on over 60 UO 2 samples tested under equibiaxial flexure. The larger sample size in this study enabled a more robust Weibull statistical analysis than alternative test methods, which may not capture the stochastic failure of typical ceramics. Furthermore, two different loading ball diameters were employed to assess the impact of contact damage on fracture strength. While Hertzian contact damage was observed with the smaller loading ball, the fracture strength remained unaffected. A fracture analysis of the tested UO 2 samples indicated a mixture of intergranular and transgranular fracture that transitions to transgranular fracture with increasing distance from the fracture origin. The characteristic strength of the combined data sets was determined to be 148 MPa, and the Weibull modulus was determined to be 9.1. The TRS values and Weibull parameters were close to values found in the literature for alternative testing techniques using samples with similar microstructure and density. The findings in this study validate the ball-on-ring method used to obtain the TRS of UO 2 with a sample geometry more representative of nuclear fuels. Additionally, experimental TRS results from this study can be implemented in modeling codes to predict fuel performance, which is critical to fuel burnup extension and advanced nuclear fuel technologies.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Measuring residual stress in Ti-6Al-4V with HR-EBSD, using reference patterns from annealed material

In this study, elastic strain and residual stress values in an engineering material were determined by high-resolution EBSD (HR-EBSD) using reference patterns from annealed, recrystallized material. Specifically, rolled Ti-6Al-4V sheet was analyzed using HR EBSD in both an as-annealed and a strained state, the latter established via a static two-point bend fixture. The commercial software CrossCourt4 (CC4) was used to evaluate the relative intragranular strain tensor components of the alpha grains mapped by HR-EBSD. The intragranular reference patterns identified in each grain by the software were then replaced with similarly-oriented patterns from scans of the as-annealed, recrystallized material. The CC4 analysis was then repeated to provide calibrated strain and residual stress values. Elastic strains on the order of 10–3 were detected, with corresponding residual stress values on the order of 1 GPa. Subsequent analyses using high energy synchrotron x-ray diffraction showed good correlation with the elastic strains measured by HR-EBSD using the annealed reference patterns. Additionally, the maximum macroscopic stress analytically predicted for two-point bending was in agreement with the residual stress observed. Good repeatability of the methodology and insight into the state of individual grains were also observed. The findings provide encouraging evidence that accurate intragranular and long-range residual stress measurements of engineering significance can be made with HR-EBSD using a physical reference pattern library.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Validation of Manufacturing Process Designs for Stamped Microchannel Recuperators

Microchannel recuperators can achieve high-efficiency power cycles and chemical reactions by recovering waste heat from hot turbine exhaust and chemical reaction streams. However, the industrial application of microchannel recuperators are restricted by the high cost of patterning and bonding. The objective of this study was thus to investigate new methods for producing microchannel recuperators for emerging markets. Based on greenfield cost estimates, process designs based on stamping, laser welding and vacuum brazing of 316L stainless steel laminae were found to be more economical than conventional photochemical machining and diffusion bonding. Subsequently, validation experiments were conducted to produce stamped microchannel components using cost model parameters. At a mass flow rate of 0.99 g/s, the test article made with laser welding was found to provide higher effectiveness than the test article produced using vacuum brazing. Preliminary investigations showed that residual stresses during laser welding of the laminae led to significant warpage, collapsing channels and making lamina-to-lamina fit up challenging. In contrast, the test article produced by vacuum brazing of stamped laminae showed no clogging and 4.6% and 10.5% channel height standard deviation for the cold and hot channels, respectively. Channel variation in the vacuum brazing sample was determined to be caused by misregistration of laminae during brazing. In future work, efforts are needed to choose cheaper, more ductile brazing foils as well as design a brazing fixture to improve lamina-to-lamina registration.

42 ENGINEERING↗
DOE OSTI2022

Stress corrosion cracking mechanism of cold spray coating on a galvanically similar substrate

Here, the chloride-induced stress corrosion cracking (CISCC) mechanism of cold spray (CS) coating on a galvanically similar substrate is investigated. Arc welded 304L stainless steel (SS) specimens are loaded into four-point bend fixtures, cold sprayed with 304L SS, then immersed in boiling MgCl 2 . Interconnected porosity forms through crevice corrosion along CS splat boundaries, allowing corrosive species to penetrate through the CS layer. Nevertheless, the substrate is resistant to CISCC likely because of compressive stress introduced by peening during CS particle impacts. These findings underscore the importance of residual stress in the environmental degradation of CS coatings or repairs of engineering structures.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Deciphering volume changes in Li-S solid-state battery components during cycling: Implication for advanced battery design

Here, in this work, we developed custom fixtures to investigate the mechanical and electrochemical behavior of all-solid-state lithium batteries during cycling under constant pressure and constant volume conditions. We successfully monitored vertical displacements during constant pressure cycling and pressure variations during constant volume cycling, allowing us decouple volume changes in the sulfur, Li 2 S cathodes, LixIn anode, and solid-state electrolyte. Scanning electron microscopy and electrochemical impedance spectroscopy confirmed that two structural changes occur during ASSLB cycling: (1) irreversible fractures in the active material particles, and (2) void formation within the electrode matrix. While the fractures in primary particles are permanent, void formation can be mitigated through stack pressure, which promotes particle rearrangement in the electrode matrix. Our findings emphasize the importance of stack pressure in maintaining the microscale integrity of all-solid-state lithium batteries, preventing void formation and enhance battery performance and durability.

Cell Design↗
DOE OSTI2023

Stabilizing a strongly nonlinear structure through shaker dynamics in fixed frequency voltage control tests

Bifurcations are commonly encountered during force controlled swept and stepped sine testing of nonlinear structures, which generally leads to the so-called jump-down or jump-up phenomena between stable solutions. There are various experimental closed-loop control algorithms, such as control-based continuation and phase-locked loop, to stabilize dynamical systems through these bifurcations, but they generally rely on specialized control algorithms that are not readily available with many commercial data acquisition software packages. A recent method was developed to experimentally apply sequential continuation using the shaker voltage that can be readily deployed using commercially available software. By utilizing the stabilizing effects of electrodynamic shakers and the force dropout phenomena in fixed frequency voltage control sine tests, this approach has been demonstrated to stabilize the unstable branch of a nonlinear system with three branches, allowing for three multivalued solutions to be identified within a specific frequency bandwidth near resonance. Recent testing on a strongly nonlinear system with vibro-impact nonlinearity has revealed jumping behavior when performing sequential continuation along the voltage parameter, like the jump phenomena seen during more traditional force controlled swept and stepped sine testing. Here, this paper investigates the stabilizing effects of an electrodynamic shaker on strongly nonlinear structures in fixed frequency voltage control tests using both numerical and experimental methods. The harmonic balance method is applied to the coupled shaker-structure system with an electromechanical model to simulate the fixed voltage control tests and predict the stabilization for different parameters of the model. The simulated results are leveraged to inform the design of a set of experiments to demonstrate the stabilization characteristics on a fixture-pylon assembly with a vibro-impact nonlinearity. Through numerical simulation and experimental testing on two different strongly nonlinear systems, the various parameters that influence the stability of the coupled shaker-structure are revealed to better understand the performance of fixed frequency voltage control tests.

42 ENGINEERING↗
DOE OSTI2026

Prediction of dynamic behavior of a system undergoing an exchange of components using a transmission simulator method

In systems with modular design, it is of interest to perform component exchanges to upgrade components and explore new system configurations. If the dynamics of the components are known, then dynamic substructuring can be used to obtain a prediction of system performance for the new configuration. The transmission simulator method is a substructuring technique that utilizes an additional fixture to apply an elastic boundary condition to a test article such that an appropriate dynamic response can be obtained for a given substructuring application, and the technique has been used widely for performing coupling and decoupling operations. Here, in this work, a modified transmission simulator method is proposed that allows a direct exchange of components to be performed. In a numerical demonstration, the proposed method is shown to accurately predict the dynamics of an assembly that has undergone a component exchange in which the exchanged components have different material properties and different geometric properties. This approach can be applied to dynamic qualification frameworks in which structures undergo modifications or upgrades rather than complete redesigns.

Component exchange↗
DOE OSTI2023

Cost Estimates of Roll-to-Roll Production of Organic Light Emitting Devices for Lighting

White organic light emitting devices (WOLEDs) offerdistinct advantages as solid state lighting sources, including high energy efficiency, superior color quality,and a flexible, thin profile that can accommodate a vast array of possible fixture designs. Recent advances in device lifetime and high speed deposition suggest that mass production of WOLED panels is approaching an inflection point. To understand the tradeoffs in the volume manufacturing of WOLED lighting panels, in this work, we estimate the cost of white WOLED panel production based on vacuum and vapor phase deposition in a roll-to-roll production line envisioned to yield an annual capacity of at least 6 × 10 6 m 2 . Assuming a WOLED operating luminance at 10 klm/m 2 , we anticipate a $\$12.5$ /klm cost of a WOLED light engine that includes the cost of the current driverand packaging. With incremental reduction in material and driver costs and improved luminance, the costof WOLED lighting can be reduced to $\$6.3$ /klm in thenear term, potentially positioning WOLEDs for use innumerous premium lighting applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Intrinsic quality factor extraction of multi-port cavity with arbitrary coupling

In this work, we derived S-parameter based expressions for the intrinsic quality factor of an arbitrary coupled multiport microwave cavity and a non-ideal test fixture. Practical accuracy limitations of the obtained expressions specifically for superconducting accelerator cavities were evaluated both analytically and with the simulation software. The resulting formulas can be used to extract the intrinsic quality factor of normal-conducting and superconducting cavities directly from the calibrated S-parameter measurements.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Simultaneous determination of electrical conductivity and thickness of nonmagnetic metallic foils using two-sided multifrequency eddy current techniques

Here, in this paper, we describe a simple method for performing multifrequency eddy current characterization of free-standing uniform-thickness metallic foils using a forked inductive coil arrangement. The method involves measuring the mutual inductance between two coils when a foil is present between the coils, and when it is not present; the ratio of these mutual inductances is compared with an analytical solution, and foil conductivity, thickness, and sheet resistance are simultaneously estimated using numerical inversion and least-squares fitting. This method was used to characterize 34 non-ferrous metallic samples with thicknesses between 50 and 640 μm and with conductivities between 0.8 × 10 7 and 5.8 × 10 7 S/m. The estimated thicknesses from eddy current characterization agreed well with those measured using confocal optical techniques; the two approaches agreed to within 1 μm for samples that were thinner than 200 μm, and to within 0.5% for samples that had a thickness of 200 μm or greater. The estimated conductivities from eddy current characterization were in close agreement with expected values, given knowledge of the materials used. A particular strength of this approach is that the instrumentation needed is broadly available in research and development laboratories and the associated fixturing is easy to manufacture and assemble. A calibration procedure is described that can be used to reduce errors from geometric uncertainties. This calibration requires a sample that has only a known conductivity or thickness; both do not need to be known. The method described herein is likely extensible to conductivities and thickness well outside the ranges measured as part of this work.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

In-Canal Assay of High Specific Activity 60 Co at the Advanced Test Reactor

Production of high specific activity (HSA) 60 Co has recently resumed at the Advanced Test Reactor (ATR) at the Idaho National Laboratory. The technical steps of performing in-canal assay of HSA 60 Co targets at the ATR are described herein. The HSA targets are assayed on a regular basis, between cycles at the ATR, in order to assess the progress of activation. The targets are also assayed at the conclusion of the irradiation in order to provide activity estimates for the distributor and to be used for safety and shipping evaluations. These target assay activities must take place in the ATR canal to provide sufficient radiological shielding. Furthermore, a specialized assay fixture is used in conjunction with custom 60 Co radiation standards to assess the irradiated target. The specific activity of each irradiated target was determined by first measuring the 60 Co standards to determine a sensitivity factor. Then, each irradiated target was measured, and the integrated measurement was multiplied by the sensitivity factor to determine the total activity of the irradiated target. Finally, a correction factor was determined to adjust the reported activity, accounting for differences in the physical geometries of the standards and targets. These methods were used to accurately assay the gross activity of nine irradiated 60 Co targets, two of which were delivered to the distributor where confirmatory hot-cell assays were performed verifying the accuracy of the in-canal assay method.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2022

High-precision vapor pressure measurement apparatus with facile and inexpensive construction

This study describes an apparatus for high-precision variable temperature measurement of liquid vapor pressure. The apparatus can be used to measure the vapor pressure using only 0.5 ml of the liquid sample. To evaluate the accuracy of the device measurement, water and 2-propanol are utilized as standard liquids, and their vapor pressure is measured with a maximum uncertainty of ~1%. This apparatus can be replicated using inexpensive and commonly used laboratory fittings and fixtures, making it an indispensable tool for synthetic chemists and chemical engineers involved in the iterative synthesis of compounds, targeting different vapor–liquid equilibrium regimes.

Engineering↗
DOE OSTI2025

Shielded magnetic small-angle neutron scattering for characterization of radioactive samples

The development of a Pb-shielded fixture for the execution of a small-angle neutron scattering (SANS)-based workflow for interrogation of highly irradiated nuclear materials has been explored. The Pb shielding was specially designed to reduce the detected radioactivity from the specimen during SANS experiments, and the overall configuration is termed shielded magnetic SANS (SM-SANS). Two FeCrAl-based alloys, C35M and 125YF, were examined with the SM-SANS technique using a free-form size distribution locally monodisperse model in both the as-received and irradiated states. Quantitative values derived from the free-form size distribution were compared with atom probe tomography experiments. Microstructural and compositional parameters determined using the two characterization techniques were complements of each other. The results demonstrate that the SM-SANS technique is an effective means of characterizing nanoscale clustering in irradiated material systems and provides new avenues for investigating radioactive material microstructures.

FeCrAl↗
DOE OSTI2021

PLC-based Impedance Measurement and Current Injection Response Analysis

Studying and mitigating the vulnerabilities of Programmable Logic Controllers (PLCs) to electromagnetic pulse is important for the reliability of the power system. In this paper, an effective impedance measurement scheme is proposed to estimate the susceptibility of PLCs to an electromagnetic pulse. The equivalent non-uniform transmission line model is established to eliminate the impact of the fixture in the de-embedding process. Based on the measured impedance, the equivalent circuit is established to calculate the response of the device when subjected to the electromagnetic pulse. The voltage and current responses of different interfaces are compared utilizing the developed pulse Current Injection (CI) method. Finally, the impedance measurement scheme is verified through testing using three measuring instruments. And the CI simulation experiments reveal the characteristics and susceptibilities of different PLCs interfaces, indicating that some protection measures are required for the reliable operation of PLC.

Qiu, Wei↗
DOE OSTI2022

Voltage and Current Response Characteristics of PMU Device by PCI Simulation

Phasor Measurement Units (PMUs) are critical for the Wide Area Measurement System (WAMS), especially for real-time grid monitoring, disturbance location, and situation awareness. Once they are damaged, the stable operation of power system will be affected directly and greatly. As new electronic devices in power system, their immunity to electromagnetic pulse (EMP) events needs to be studied. In this paper, an effective impedance measurement scheme is proposed for port impedance measurement of PMU. A non-uniform transmission line model is established to eliminate the impact of fixture in the de-embedding process. Then circuit of pulse current generator is established to generate damping sinusoid and double exponential wave applied to the port. Finally, by using measured impedance as load of the generator, the voltage and current responses of different ports are calculated in the pulsed current injection (PCI) simulation. Results shows the characteristics of port impedance, voltage and current waveforms. The relation between port impedance and the waveforms is discussed.

Zhang, Liang↗
DOE OSTI2022

Immunity Study: Port Impedance Measurement of PMU and PCI testing under EMP

Phasor Measurement Units (PMUs) are critical for the Wide Area Measurement System (WAMS), especially for real-time grid monitoring, disturbance location, and situation awareness. Once they are damaged, the stable operation of the power system will be affected directly and greatly. Therefore, it is urgent and necessary to study their immunity to electromagnetic pulse (EMP) events. In this paper, an effective impedance measurement scheme is proposed for port impedance measurement of PMU. The equivalent non-uniform transmission line model is established to eliminate the impact of the fixture in the de-embedding process. Then circuit of pulsed current generator is established to generate damping sinusoid and double exponential wave applied to the port. Finally, by using measured impedance as a load of the generator, the voltage and current responses of different ports are calculated in the pulsed current injection (PCI) testing simulation. Results show that common-mode impedance is large and differential mode impedance is small. The critical condition will appear in the common mode for voltage and differential mode for current.

Zhang, Liang↗
DOE OSTI2022

Evaluating the Durability of Balance of Systems Components Using Combined-Accelerated Stress Testing

The degradation of photovoltaic (PV) balance of systems (BoS) components is not well-studied, but the consequences include offline modules, strings, and inverters; system shutdown; arc faults; and fires. A utility provider experienced a ~30% failure rate in their power transfer chain, originally attributed to branch connectors. Field-failed specimen assemblies were therefore examined, consisting of cable connector, branch connector, and discrete fuse components. In this study, unused field-vintage specimens are examined using combined-accelerated stress testing (C-AST) to clarify the most influential environmental stressors as well as the effect of external mechanical perturbation. A benchtop prototype fixture was used to develop the perturbation capability for the C-AST chamber. The benchtop experiments were also used to develop the in-situ data acquisition of specimen current, voltage, and temperature. A significant increase in operating temperature (~100 degrees C from ~40 degrees C) and a different failure mode were observed promptly once periodic mechanical perturbation was applied. The current at failure was decreased from 35 A (with failure in the fuses) to 15 A (failure at the male/female metal pin connection). After initial examination using X-ray computed tomography, the external plastic was machined away from failed specimens to allow for failure analysis, including the extraction of the internal convolute springs for morphological examination (optical and electron microscopy).

balance of systems↗