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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Mitigation of Galvanic Corrosion in Bolted Joint of AZ31B and Carbon Fiber-Reinforced Composite Using Polymer Insulation

The use of polymer insulation to mitigate galvanic corrosion was examined for bolted joints of AZ31B Mg alloy and carbon fiber-reinforced composite. To assess the corrosion behaviors of bolted joints with and without polymer insulation, solution immersion and salt spray exposure (ASTM B117) tests were conducted, and the corrosion depths and volumes were determined for the joint specimens after the tests. The polymer-insulated bolted joints exhibited much lower corrosion depths and volumes, highlighting the effective mitigation of galvanic corrosion. The reductions of joint strength in the post-corrosion joint specimens were relatively small (up to ~10%) in the polymer-insulated group but greater (up to 90%) in the group with no insulation. Cross-sectional characterization of post-corrosion joints with polymer insulation revealed local pits developed on AZ31B under galvanic influence, indicating that limited galvanic attack (that did not decrease the joining integrity significantly) could still occur during a long salt spray exposure (~1264 h) owing to the permeation of an aqueous corrosive medium.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Proof-of-concept chemometric approach for environmental forensic sourcing of crude oil samples using SPME-GC-MS

Environmental exposure to crude oil through seepage and spillage poses risks to the immediate environment and the broader ecosystem as areas along the oil distribution path are affected by the influx of crude petroleum as well as the environmental, economic, and civil unrest that accompanies it. There is a large financial burden associated with the lost resources, including the cost of rehabilitation, and the affected sources of revenue for communities affected by oil spills. As such, it is crucial to determine the responsible parties. This work outlines an environmental forensics approach to determining the source of an un-weathered crude oil sample. The researchers employed solid phase microextraction coupled with gas chromatography mass spectrometry (SPME-GC-MS) to capture and analyze the gaseous components emitted by crude oil samples sourced from five locations. Samples were analyzed using Spearman's rank correlation and 3D covariance analysis. Both chemometric approaches yielded optimal performance results with no misclassifications, true positive rate (TPR) = 100 % and false positive rate (FPR) = 0 %. The similarity metrics calculated by each test noted clear delineations between the values of same-source and differently sourced samples. The Spearman's rank correlation test and 3D covariance calculations both demonstrated the ability to correctly identify sample source origin in this dataset. Finally, the authors outline an approach to the future application of these tests and suggest their joint use in future crude oil sourcing endeavors.

3D covariance mapping↗
DOE OSTI2025

An analysis of parameter compression and Full-Modeling techniques with Velocileptors for DESI 2024 and beyond

In anticipation of forthcoming data releases of current and future spectroscopic surveys, we present the validation tests and analysis of systematic effects within velocileptors modeling pipeline when fitting mock data from the AbacusSummit N-body simulations. We compare the constraints obtained from parameter compression methods to the direct fitting (Full-Modeling) approaches of modeling the galaxy power spectra, and show that the ShapeFit extension to the traditional template method is consistent with the Full-Modeling method within the standard ΛCDM parameter space. We show the dependence on scale cuts when fitting the different redshift bins using the ShapeFit and Full-Modeling methods. We test the ability to jointly fit data from multiple redshift bins as well as joint analysis of the pre-reconstruction power spectrum with the post-reconstruction BAO correlation function signal. We further demonstrate the behavior of the model when opening up the parameter space beyond ΛCDM and also when combining likelihoods with external datasets, namely the Planck CMB priors. Finally, we describe different parametrization options for the galaxy bias, counterterm, and stochastic parameters, and employ the halo model in order to physically motivate suitable priors that are necessary to ensure the stability of the perturbation theory.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2020

Validation of selection function, sample contamination and mass calibration in galaxy cluster samples

ABSTRACT We construct and validate the selection function of the MARD-Y3 galaxy cluster sample. This sample was selected through optical follow-up of the 2nd ROSAT faint source catalogue with Dark Energy Survey year 3 data. The selection function is modelled by combining an empirically constructed X-ray selection function with an incompleteness model for the optical follow-up. We validate the joint selection function by testing the consistency of the constraints on the X-ray flux–mass and richness–mass scaling relation parameters derived from different sources of mass information: (1) cross-calibration using South Pole Telescope Sunyaev-Zel'dovich (SPT-SZ) clusters, (2) calibration using number counts in X-ray, in optical and in both X-ray and optical while marginalizing over cosmological parameters, and (3) other published analyses. We find that the constraints on the scaling relation from the number counts and SPT-SZ cross-calibration agree, indicating that our modelling of the selection function is adequate. Furthermore, we apply a largely cosmology independent method to validate selection functions via the computation of the probability of finding each cluster in the SPT-SZ sample in the MARD-Y3 sample and vice versa. This test reveals no clear evidence for MARD-Y3 contamination, SPT-SZ incompleteness or outlier fraction. Finally, we discuss the prospects of the techniques presented here to limit systematic selection effects in future cluster cosmological studies.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2020

Determining Compression Characteristics of Honeycomb Material - 19674

The objective is to determine compression test characteristics of stainless steel honeycomb material to be able to represent honeycomb structures accurately in analytical models used to simulate hypothetical accident scenarios of shipping packages. Honeycomb is a material used primary in the aerospace industry due to its high strength-to-weight ratio. Because it doesn't have a shelf life and can withstand high heats, it is an excellent candidate for a structural material in package designs. Honeycomb has orthotropic material properties. The honeycomb currently being evaluated is made of metal ribbons spot welded together to form hexagon pattern between metal plates. The hexagon ribbons are brazed to the metal plates. The complexity of the honeycomb significantly lengthens the simulation time, which is further complicated when the brazing, welding, and imperfections of the material is considered. This means to affectively represent the honeycomb in simulation programs, such as Abaqus, the material needs to be approximated as a uniform orthotropic material. This requires material properties in each of the three directions, T, W, and L. The T direction is defined as the 'strong' direction, perpendicular to the honeycomb sheet. The L direction is parallel the ribbon and the W direction is perpendicular to the ribbon. Honeycomb has 3 different compression stages. Stage 1 is the initial compression where the honeycomb maintains its structural integrity and does not permanently deform from loads from normal operations. Stage 2 is when the initial buckling causes irreversible damage to the honeycomb. Stage 2 is the one we are most interested in because it absorbs the most energy from a hypothetical accident scenario. During Stage 2, the honeycomb fails layer-by-layer, indicating that the more layers, the longer material crushing is sustained, and thus the more energy that is absorbed. Stage 3 is final compression, similar to compressing solid metal. During stage 3 the stress increases with a diminishing rate of elongation and the honeycomb is completely failed where the plates between the honeycomb core sandwich the crushed honeycomb ribbon. The stress-strain graph bellow shows compression test of 3 different samples in the T direction. The red lines divide the three stages. The far left is Stage 1, the middle stage 2, and the right stage 3. The data collected is displayed in the table below. The expressions in the table represent the regression formula that represents each stage of the compression on a stress-strain graph. Stage 1 is assumed to intersect with the origin; data for stage 3 for the crush in W and L directions where unable to be gathered due to the nature of failure for those directions. Stage 1 and 2 are linear regressions while stage 3 is a degree 2, to best match the curve. Linear regression is used on stage 2 because ultimately that represents the energy absorbed. With more data, a degree n x 2 regression would be a more appropriate regression for stage 2, where n is the number of layers. The table below is the approximation of each scenario and stage. Each stage starts and ends at the intersection of the next stage. There where two main objectives for these tests: firstly to understand how honeycomb performs under extreme compression, and secondly to be able to numerically represent the honeycomb structure. Both of these where completed to varying degrees. It is important understood how the honeycomb fails. If it is crushed in the T direction it retains its integrity even after being crushed, however when crushed in the L and W crush direction, if it fails, it disintegrates, and loses all integrity. Also, the more layers the more time the material spends in stage 2. Failure is started by buckling, thus if there is any imperfection, the stress will not spike but transition straight into stage 2. The data collected and aggregated can be used for initial simulation of honeycomb used in packages. The initial testing has set the ground work for more data to be collected in order to verify results and to allow more confidence in the simulation results. This is only the initial data collected. The next steps is to continue to collect more data to verify results and to test more variants of honeycomb, with different brazing, layers, and shape.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Optimization of Dry Storage Canister Cutting Operations - 20534

A recent project investigated the optimal cutting method for the opening of a welded dry storage/shielded canister (DSC) or dual purpose canister (DPC) containing Used Nuclear Fuel (UNF). Due to the lack of a disposal path for UNF in the U.S., the majority of UNF is currently moved into welded DSCs and DPCs designed by Orano TN, NAC, and Holtec. As the DSCs/DPCs were neither designed nor licensed for disposal and may not be able to be emplaced in a geologic repository due to physical emplacement constraints, near-term thermal limitations, or long-term criticality issues, the UNF in these existing DSCs/DPCs may need to be repackaged into transportation, aging, and disposal canisters (TADs), generic standard TADs (STADs), transportation casks, new cask/canister systems, and/or cask/canister/package systems suitable for disposal. These DSCs/DPCs may also be opened to simply remove the UNF in preparation for recycling, re-storage, or placement into a waste package suitable for disposal. Regardless of need, the DSCs/DPCs would require to be cut open by a potentially large scale operation. This project examined the multiple means for cutting welded metal systems and considered several factors to determine an optimal approach. Issues arose around some of the cutting approaches when applied to systems with 2 or 3 lids and with pre-cutting gas testing required. The resulting preferences in cutting methods with an optimized application for the opening of DSCs/DPCs are presented. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Structural Health Monitoring: Using an Autoencoder to Identify Damage in a Bolted Joint [Capstone Project]

Los Alamos National Laboratory (LANL) is an important fixture in the United States Department of Energy’s (DOE) National Nuclear Security Agency (NNSA) complex. LANL is one of the largest national laboratories in the country, and the laboratory’s primary mission is to support the nation’s nuclear stockpile. The lab functions as a design agencies for the NNSA and performs extensive testing on weapons as part of that mission. The shock and vibration test team at LANL utilizes electrodynamic shaker systems for important qualification testing in support of the laboratory’s mission. Modern engineering relies heavily on bolted joints to connect two objects. During these shaker tests, engineers depend on bolted joints to secure the test article to a fixture and the fixture to the table. The test article may be hazardous and contain high explosives which could create a safety issue if a bolted joint failed. A loss of preload in a bolt will affect the way energy is input to the system and may introduce nonlinearities as the joint opens and closes. The loss of preload can create challenges controlling the test and make acquired signals useless. Being able to monitor preload within bolted joints during testing can improve the quality of the data and keep workers safe.

42 ENGINEERING↗
DOE OSTI2021

Preliminary Cryogenic Cold Test Results of the First 9-Cell LSF Shape Cavity

Following successful prototyping and testing of single- & 5-cell LSF shape cavities *, **, the first 9-cell LSF shape cavity LSF9-1 was successfully constructed using an innovative process at JLab with the in-house facilities. The cavity was then shipped to KEK for post-fabrication mechanical adjustment and ILC TDR style treatment and surface processing. Cold testing was carried out at the JLab VTA facility, instrumented with a suite of Kyoto instruments. Favorable values for the bath pressure detuning sensitivity and Lorentz force detuning coefficient were experimentally measured, validating the design improvement in cell stiffeners. Pass-band measurements indicate 4 out of 9 cells reaching gradient capability of > 45 MV/m, including 2 cells reaching 51 MV/m. Cornell OST detectors identified the cell and location responsible for the current hard quench limit. Multipacting-like barriers observed in end cells are investigated both analytically and numerically. The cavity was shipped to FNAL and received a light EP at the joint ANL/FNAL facility for further cold testing at Jlab. Two new 9-cell LSF cavities are being constructed including one made of large-grain niobium material.

43 PARTICLE ACCELERATORS↗
DOE OSTI2026

Testing of a 15 kA Superconducting Transformer

Here, the manufacturing of superconducting magnets for High Energy Physics (HEP) and Fusion Energy Sciences (FES) applications requires high-current conductors to generate stronger magnetic fields without increasing the inductance of the magnet. Increased inductance is undesirable due to the associated AC losses, which reduce the temperature margin; and the quench protection also becomes complicated. Testing high-current conductors with a direct current (DC) room temperature power supply is unfeasible for two primary reasons: 1) the limited capacity to supply large currents, and 2) the significant heat load losses at the current leads. A superconducting transformer offers a solution to both challenges. A 50-kA superconducting transformer is planned for manufacturing and commissioning at Brookhaven National Laboratory as part of its user facility upgrade. This transformer will facilitate the testing of superconducting cables, conductors, joints, and insert coils under high magnetic field conditions (10 T) and with currents up to 50-kA. To evaluate the manufacturing process and validate the theoretical models, the magnet division has developed and tested a 15-kA prototype transformer. A control loop has been implemented to ensure precise current delivery to the sample. This paper presents the coil design, manufacturing, and experimental results from the cold tests.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2023

Cladding and Butt-Joining Dissimilar Aluminum Alloys Simultaneously via Shear Assisted Processing and Extrusion

Shear assisted processing and extrusion has been used to fabricate multi-metallic tubing that incorporates regions with clad and butt-joined structures. In this work, aluminum alloys 6061, 7075, and 1100 are combined to create a monolithic extruded tubing with weldable ends (6061), a high strength center (7075), and a corrosion-resistant cladding (1100). Optical microscopy shows a gradual, defect-free, transition between alloys at the butt-joint interfaces and a sharp transition between alloys at the clad interface. Tensile testing proved the mechanical coherency of the joint, with failure occurring outside the tri-metallic structure. In conclusion, smoothed particle hydrodynamic simulations identified a spiral pattern of the cladding alloy that leads to inconsistent cladding thickness, and identified a simplified 2-alloy combination of aluminum alloys 6082 and 2014 that accomplished the design objectives of the tri-metallic structure.

Coatings↗
DOE OSTI2023

THE ROLE OF FRACTURE PROPERTIES ON LAP JOINT STRENGTH OF FRICTION STIR WELDED AA7055-T6 SHEETS

Friction stir lap welded (FSLW) joints have weight-saving potential in aluminum-intensive automotive assembly. However, FSLW also modifies the material microstructure close to the joint. Optimizing the FSLW process requires understanding the relationship between the strength and the joint's microstructure. In previous studies, efforts have been dedicated to determining the effects of local softening, the shape of the oxide line, and porosity. However, the impact of changes to the fracture properties on the joint's strength has not been studied. In this work, strength testing, and simulations, aided by material characterization, were used to determine the role of fracture properties on the shear strength of a 3-sheet (aluminum alloys 7055-7055-6022) lap joint. Characterization involved testing for fracture properties in the weld region. This data was then implemented into finite element simulations. As a result, the joint strength was predicted with a deviation of less than 6% from the experimental value. Comparison with strength prediction using only the base metal properties indicates that fracture property in the nugget region determines the strength of AA7055 FSLW.

Finite element analysis, Friction stir welding, ma↗
DOE OSTI2021

Joining Light Metals with Polymer Composites Through Metal Overcasting

This work investigates a unique technique to join aluminum (Al) and magnesium (Mg) alloys to carbon fiber reinforced polymer (CFRP) composites without the use of adhesives or mechanical fasteners. The joints were made using an overcasting technique where the molten alloys were cast around the polymer composites using high pressure die casting method. Rapid cooling during casting allowed the composite to be embedded inside the cast metal without causing any gross damage to the former even though the molten metal temperature exceeded the melting point of the composite matrix by several 100’s of deg. C. The metal/composite interface was examined using optical microscopy and x-ray imaging and the joint strength was examined through tensile testing. Although evidence of polymer melting was evident in the x-ray images, the embedded section of the composite coupons retained their overall shape and integrity. Preliminary tension tests on Al/CFRP composites showed strength degradation of the CFRP and it failed near the metal/CFRP interface (outside the joint). Strength degradation in the CFRP suggests that the overcasting process needs further optimization to minimize thermal excursion in the CFRP. Nevertheless, the overcasting process shows great promise as a unique joining technique with application in fabricating light-weight structures for automotive and transportation industries.

overcasting, Casting, Mg Castings, Al Casting, Joi↗
DOE OSTI2021

A machine learning approach to galaxy properties: joint redshift–stellar mass probability distributions with Random Forest

We demonstrate that highly accurate joint redshift–stellar mass probability distribution functions (PDFs) can be obtained using the Random Forest (RF) machine learning (ML) algorithm, even with few photometric bands available. As an example, we use the Dark Energy Survey (DES), combined with the COSMOS2015 catalogue for redshifts and stellar masses. We build two ML models: one containing deep photometry in the griz bands, and the second reflecting the photometric scatter present in the main DES survey, with carefully constructed representative training data in each case. We validate our joint PDFs for 10 699 test galaxies by utilizing the copula probability integral transform and the Kendall distribution function, and their univariate counterparts to validate the marginals. Benchmarked against a basic set-up of the template-fitting code bagpipes, our ML-based method outperforms template fitting on all of our predefined performance metrics. In addition to accuracy, the RF is extremely fast, able to compute joint PDFs for a million galaxies in just under 6 min with consumer computer hardware. Such speed enables PDFs to be derived in real time within analysis codes, solving potential storage issues. As part of this work we have developed galpro 1, a highly intuitive and efficient python package to rapidly generate multivariate PDFs on-the-fly. galpro is documented and available for researchers to use in their cosmology and galaxy evolution studies.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2020

Robust impurity detection and tracking for tokamaks

A robust impurity detection and tracking code, able to generate large sets of dust tracks from tokamak camera footage, is presented. This machine learning–based code is tested with cameras from the Joint European Torus, Doublet-III-D, and Magnum-PSI and is able to generate dust tracks with a 65 – 100 % classification accuracy. Moreover, the number dust particles detected from a single camera shot can be up to the order of 1000. Several areas of improvement for the code are highlighted, such as generating more significant training data sets and accounting for selection biases. Finally, although the code is tested with dust in single two-dimensional camera views, it could easily be applied to multiple-camera stereoscopic reconstruction or nondust impurities.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Surface engineering to enhance heat generation and joint strength in dissimilar materials AZ31 and DP590 ultrasonic welding

A multiscale simulation approach was developed and employed to optimize the sheet surface conditions for higher interfacial temperature and joint strength in ultrasonic welding of magnesium alloy AZ31 and dual-phase steel DP590. First, a mesoscale model was used to study the relationship between friction coefficient and surface roughness, which can be modified by various engineering methods. Then a macroscopic process model was employed to study the effects of surface roughness on heat generation, indicating that a temperature increase can be achieved with rougher surfaces on two sides of both DP590 and AZ31 sheets. Samples prepared by sanding and filing, as well as grinding, were first characterized for surface roughness and then welded under ultrasonic vibration. An infrared camera was used to measure temperatures in situ for model validation. Overall, lap shear test results for the welded joint showed that the joint strength can be improved by 10~25% using filing and round grinding methods as a result of the enhanced heat generation and mechanical interlocking on the interface.

42 ENGINEERING↗
DOE OSTI2020

A New Capability of E4D For 3D Parallel Joint Inversion of DC Resistivity And Traveltime Data on Unstructured Mesh

A major challenge in interpreting geophysical data is how to derive consistent three-dimensional (3D) earth models of different physical properties from spatially and temporally limited measurements. Joint inversion with cross-gradient constraints is an approach to find such models by imposing structural similarities between different physical parameters. We have developed a parallel distributed-memory joint inversion code for direct-current (DC) resistivity and traveltime data using the cross-gradient constraint on unstructured mesh. The code utilizes existing E4D framework for parallel forward simulation, distributed storage and computation of the Jacobian matrix of forward operator, and parallel execution of matrix-vector multiplication during inversion. Besides, the joint inversion is solved by nonlinear conjugate gradient algorithm parallelized for DC resistivity and traveltime data. The joint inversion capability of E4D was tested using synthetic data from cross-borehole DC resistivity and traveltime data. The results indicate that the shape and size of the anomalies from the joint inversion are more reliable than those from separate inversions.

58 GEOSCIENCES↗
DOE OSTI2025

Formation of Composite SiC/SiC Joints by Embedded Wire Chemical Vapor Deposition

The joining of ceramic monoliths or composites to date has primarily been limited to the formation of brittle monolithic joints using heterogeneous (dissimilar) materials, similar to brazing in metals. The development of a damage-tolerant joint layer by SiC fiber reinforcements is demonstrated here. Tube workpieces made of SiC fiber-SiC matrix composite are joined using a nonwoven SiC fiber mat densified by embedded wire chemical vapor deposition (EWCVD), creating a fiber-reinforced weld-like joint by homogeneous joining. EWCVD uses a localized heating method to target deposition and growth to the joint region specifically, while minimizing thermal damage to the surrounding composite tube material. X-ray computed tomography (XCT) is used to nondestructively characterize as-made joints for relative density, adhesion, and composition. In situ XCT analysis during mechanical testing revealed crack deflections in the bonding layer, which indicates a toughening mechanism typical of ceramic matrix composite phase. Gas permeation testing of these proof-of-concept composite joints identified relatively high leak rates in comparison to fully coated SiC/SiC composite tube workpieces. In conclusion, the novelty of the composite joining method and current technology challenges, including gas permeability, are discussed in comparison with traditional ceramic joints and materials.

SiC↗
DOE OSTI2021

Validation of the TOPAS Monte Carlo toolkit for HDR brachytherapy simulations

The goal of this work is to validate the user-friendly Geant4-based Monte Carlo toolkit TOol for PArticle Simulation (TOPAS) for brachytherapy applications. Brachytherapy simulations performed with TOPAS were systematically compared with published TG-186 reference data. The photon emission energy spectrum, the air-kerma strength, and the dose-rate constant of the model-based dose calculation algorithm (MBDCA)-WG generic Ir-192 source were extracted. For dose calculations, a track-length estimator was implemented. Additionally, the four Joint AAPM/ESTRO/ABG MBDCA-WG test cases were evaluated through histograms of the local and global dose difference volumes. A prostate, a palliative lung, and a breast case were simulated. For each case, the dose ratio map, the histogram of the global dose difference volume, and cumulative dose-volume histograms were calculated. The air-kerma strength was (9.772 ± 0.001) × 10 -8 U Bq -1 (within 0.3% of the reference value). The dose-rate constant was 1.1107 ± 0.0005 cGy h -1 U -1 (within 0.01% of the reference value). For all cases, at least 96.9% of voxels had a local dose difference within [-1%, 1%] and at least 99.9% of voxels had a global dose difference within [-0.1%, 0.1%]. The implemented track-length estimator scorer was more efficient than the default analog dose scorer by a factor of 237. For all clinical cases, at least 97.5% of voxels had a global dose difference within [-1%, 1%]. Dose-volume histograms were consistent with the reference data. TOPAS was validated for high-dose-rate brachytherapy simulations following the TG-186 recommended approach for MBDCAs. Built on top of Geant4, TOPAS provides broad access to a state-of-the-art Monte Carlo code for brachytherapy simulations.

59 BASIC BIOLOGICAL SCIENCES↗