Wrap-able, Radiation-Resistant Electrical Insulators for Superconducting Magnet Applications - Initial Phase II Final Report
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11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
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Wrap-able, Radiation-Resistant Electrical Insulators for Superconducting Magnet Applications
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21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
COPOLYMER COMPOSITES FOR HIGH VOLTAGE INSULATION WRAPS FOR SUPERCONDUCTING MAGNET COILS
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36 MATERIALS SCIENCE↗
Helical scan recording with a self-acting negative air bearing
A flat head and a tape transport arrangement impart a wrap angle to the tape at the upstream corner of the head. The wrap angle, corner sharpness and tape stiffness are sufficient to cause a moving tape to form a hollow bump at the upstream corner, thereby creating a hollow into which entrained air can expand, causing a subambient pressure within and downstream of the bump. This pressure keeps the tape in contact with the head. It is created without the need for a groove or complex pressure relief slot(s). No contact pressure arises at the signal exchange site due to media wrap. The highest contact pressures are developed at a wrapped upstream corner. For a tape drive, traveling in both forward and reverse, the wrap can be at both the upstream and downstream (which is the reverse upstream) corners. Heads that are not flat can also be used, if the wrap angle relative to a main surface is sufficient and not too large. The wrapped head can also be used with rotating media, such as disks (floppy and hard) and rotating heads, such as helical wound heads for video recording. Multiple flat tape bearing surfaces can be separated by grooves and/or angles. Each flat can carry heads along one or more gap lines. Multiple adjacent narrow tracks can thus be written for extreme high track density recording.
Muftu , Sinan↗
Contact sheet recording with a self-acting negative air bearing
A flat head and a tape transport arrangement impart a wrap angle to the tape at the upstream corner of the head. The wrap angle, corner sharpness and tape stiffness are sufficient to cause a moving tape to form a hollow bump at the upstream corner, thereby creating a hollow into which entrained air can expand, causing a subambient pressure within and downstream of the bump. This pressure keeps the tape in contact with the head. It is created without the need for a groove or complex pressure relief slot(s). No contact pressure arises at the signal exchange site due to media wrap. The highest contact pressures are developed at a wrapped upstream corner. For a tape drive, traveling in both forward and reverse, the wrap can be at both the upstream and downstream (which is the reverse upstream) corners. Heads that are not flat can also be used, if the wrap angle relative to a main surface is sufficient and not too large. The wrapped head can also be used with rotating media, such as disks (floppy and hard) and rotating heads, such as helical wound heads for video recording. Multiple flat tape bearing surfaces can be separated by grooves and/or angles. Each flat can carry heads along one or more gap lines. Multiple adjacent narrow tracks can thus be written for extreme high track density recording.
Muftu , Sinan↗
Rocket Engine Thrust Chamber Assembly
A thrust chamber assembly for liquid fueled rocket engines and the method of making it wherein a two-piece mandrel having the configuration of an assembly having a combustion chamber portion connected to a nozzle portion through a throat portion is wrapped with a silica tape saturated with a phenolic resin, the tape extending along the mandrel and covering the combustion chamber portion of the mandrel to the throat portion. The width of the tape is positioned at an angle of 30 to 50 deg. to the axis of the mandrel such that one edge of the tape contacts the mandrel while the other edge is spaced from the mandrel. The phenolic in the tape is cured and the end of the wrap is machined to provide a frusto-conical surface extending at an angle of 15 to 30 deg. with respect to the axis of the mandrel for starting a second wrap on the mandrel to cover the throat portion. The remainder of the mandrel is wrapped with a third silica tape having its width positioned at a angle of 5 to 20 deg. from the axis of the mandrel. The resin in the third tape is cured and the assembly is machined to provide a smooth outer surface. The entire assembly is then wrapped with a tow of graphite fibers wetted with an epoxy resin and, after the epoxy resin is cured, the graphite is machined to final dimensions.
Cornelius, Charles S.↗
Mechanical Solution for Existing Conductors
The rapid growth in energy demand, driven by advancements in AI technology, renewable energy integration, and increased industrial activity, highlights the need for innovative solutions to improve the resiliency and efficiency of the power grid. This report details the fire testing of GridWrap’s Composite WiRe Wrap, to evaluate the wrap's ability to enhance conductor performance under wildfire-simulated conditions. Conductors were prepared and tested in a controlled environment at 400°C for 18 minutes, during which sag and temperature data were recorded. The results demonstrated that the unwrapped conductor sagged 3/16ths of an inch, while the WiRe Wrapped conductor sagged only 1/16th of an inch under identical conditions, indicating a significant improvement in mechanical performance. This project, conducted as part of a collaborative effort between BEA (Idaho National Laboratory’s managing contractor) and GridWrap, Inc., demonstrates the potential of grid-enhancing technologies like WiRe Wrap to reduce sag, increase grid resiliency, and support the future energy landscape. By validating the performance of such technologies in real-world scenarios, this work provides critical insights for industry adoption, benefiting both grid operators and U.S. taxpayers through improved reliability, reduced emissions, and enhanced energy delivery.
24 - POWER TRANSMISSION AND DISTRIBUTION↗
Super Conducting REBCO Cable Wrapper
Future upgrades to CERN particle accelerator magnets require flat, high-temperature superconducting cables, created by wrapping brittle REBCO tape around a Rutherford copper core. Because current manual wrapping processes are time-consuming and prone to damaging the delicate ceramic tape, our team was tasked with automating the fabrication. We developed a modular, wrapping machine featuring adjustment for repeatable 10°to 45° wrap angles and a precise magnetic tensioning mechanism. While full-scale testing is pending final machined parts, our 3D-printed prototype successfully validates the system’s motion and sets the stage for future testing.
Gillen, Kameron [Northern Illinois U.]↗
Magnetic reconnection and magnetic activity
A large-scale magnetic field extending through a highly conducting tenuous fluid may become distorted on a small scale as a consequence of slow small-scale shuffling of the magnetic lines of force at the boundaries of the tenuous fluid. Any slow wrapping and winding introduced at the boundaries is distributed along the field (at the Alfven speed). It is a curious and little-known fact that such wrapping and winding possesses no static equilibrium (except for a set of solutions of extreme symmetry). The result is neutral-point reconnection of the strains in the field, rapidly dissipating the wrapping and winding. It is suggested that this is the principal cause of the extreme heating that produces the active corona of the sun and other stars. The shuffling of the footpoints of the magnetic field in the photospheric turbulence introduces small-scale wrapping and twisting into the coronal loops. The work done by the turbulence in twisting the fields is dissipated within a matter 10-20 hours by neutral-point reconnection, introducing heat into the corona at a rate of about 10 Mergs/sq cm sec for photospheric turbulence of 0.5 km/sec. It is suggested that this is the basic cause of the X-ray corona.
Parker, E. N.↗
An approach to integrating and creating flexible software environments
Engineers and scientists are attempting to represent, analyze, and reason about increasingly complex systems. Many researchers have been developing new ways of creating increasingly open environments. In this research on VEHICLES, a conceptual design environment for space systems, an approach was developed, called 'wrapping', to flexibility and integration based on the collection and then processing of explicit qualitative descriptions of all the software resources in the environment. Currently, a simulation is available, VSIM, used to study both the types of wrapping descriptions and the processes necessary to use the metaknowledge to combine, select, adapt, and explain some of the software resources used in VEHICLES. What was learned about the types of knowledge necessary for the wrapping approach is described along with the implications of wrapping for several key software engineering issues.
Bellman, Kirstie L.↗
Rocket Engine Thrust Chamber Assembly
A thrust chamber assembly for liquid fueled rocket engines and the method of making it wherein a two-piece mandrel wrapped with a silica tape saturated with a phenolic resin, the tape extending along the mandrel and covering the combustion chamber portion of the mandrel to the throat portion. The phenolic in the tape is cured and the end of the wrap is machined. The remainder of the mandrel is wrapped with a third silica tape. The resin in the third tape is cured and the assembly is machined. The entire assembly is then wrapped with a tow of graphite fibers wetted with an epoxy resin and, after the epoxy resin is cured, the graphite is machined to final dimensions.
Cornelius, Charles S.↗
Iterative-Transform Phase Retrieval Using Adaptive Diversity
A phase-diverse iterative-transform phase-retrieval algorithm enables high spatial-frequency, high-dynamic-range, image-based wavefront sensing. [The terms phase-diverse, phase retrieval, image-based, and wavefront sensing are defined in the first of the two immediately preceding articles, Broadband Phase Retrieval for Image-Based Wavefront Sensing (GSC-14899-1).] As described below, no prior phase-retrieval algorithm has offered both high dynamic range and the capability to recover high spatial-frequency components. Each of the previously developed image-based phase-retrieval techniques can be classified into one of two categories: iterative transform or parametric. Among the modifications of the original iterative-transform approach has been the introduction of a defocus diversity function (also defined in the cited companion article). Modifications of the original parametric approach have included minimizing alternative objective functions as well as implementing a variety of nonlinear optimization methods. The iterative-transform approach offers the advantage of ability to recover low, middle, and high spatial frequencies, but has disadvantage of having a limited dynamic range to one wavelength or less. In contrast, parametric phase retrieval offers the advantage of high dynamic range, but is poorly suited for recovering higher spatial frequency aberrations. The present phase-diverse iterative transform phase-retrieval algorithm offers both the high-spatial-frequency capability of the iterative-transform approach and the high dynamic range of parametric phase-recovery techniques. In implementation, this is a focus-diverse iterative-transform phaseretrieval algorithm that incorporates an adaptive diversity function, which makes it possible to avoid phase unwrapping while preserving high-spatial-frequency recovery. The algorithm includes an inner and an outer loop (see figure). An initial estimate of phase is used to start the algorithm on the inner loop, wherein multiple intensity images are processed, each using a different defocus value. The processing is done by an iterative-transform method, yielding individual phase estimates corresponding to each image of the defocus-diversity data set. These individual phase estimates are combined in a weighted average to form a new phase estimate, which serves as the initial phase estimate for either the next iteration of the iterative-transform method or, if the maximum number of iterations has been reached, for the next several steps, which constitute the outerloop portion of the algorithm. The details of the next several steps must be omitted here for the sake of brevity. The overall effect of these steps is to adaptively update the diversity defocus values according to recovery of global defocus in the phase estimate. Aberration recovery varies with differing amounts as the amount of diversity defocus is updated in each image; thus, feedback is incorporated into the recovery process. This process is iterated until the global defocus error is driven to zero during the recovery process. The amplitude of aberration may far exceed one wavelength after completion of the inner-loop portion of the algorithm, and the classical iterative transform method does not, by itself, enable recovery of multi-wavelength aberrations. Hence, in the absence of a means of off-loading the multi-wavelength portion of the aberration, the algorithm would produce a wrapped phase map. However, a special aberration-fitting procedure can be applied to the wrapped phase data to transfer at least some portion of the multi-wavelength aberration to the diversity function, wherein the data are treated as known phase values. In this way, a multiwavelength aberration can be recovered incrementally by successively applying the aberration-fitting procedure to intermediate wrapped phase maps. During recovery, as more of the aberration is transferred to the diversity function following successive iterations around the ter loop, the estimated phase ceases to wrap in places where the aberration values become incorporated as part of the diversity function. As a result, as the aberration content is transferred to the diversity function, the phase estimate resembles that of a reference flat.
Dean, Bruce H.↗
Electrostatic‐Attraction‐Driven Self‐Assembled Graphene‐Disordered Rocksalt Composite Cathode for Lithium‐Ion Batteries
Disordered rocksalt cathodes hold promise for achieving high-capacity lithium-ion batteries while using low-cost, earth-abundant elements. However, their electrochemical performance remains critically limited by their poor electronic conductivity. Conventional strategies such as high-energy ball milling with excess carbon additives can improve conductivity but remain challenging to scale and often produce defects and increase surface area, thereby accelerating capacity degradation. Herein, we report an alternative approach of electrostatic-attraction-driven self-assembly to fabricate Li 1.2 Mn 0.6 Ti 0.2 O 1.8 F 0.2 (LMTOF) particles uniformly wrapped with electronically conductive graphene sheets without associated materials degradation. The graphene-wrapped LMTOF demonstrates significantly improved cycling stability (89% capacity retention after 100 cycles) and superior rate capability compared with an LMTOF-carbon composite electrode fabricated using the conventional high-energy ball-milling process. Post-cycling analysis reveals reduced oxygen evolution, suppressed unwanted side reactions, and improved structural integrity for the graphene-LMTOF composite. This work highlights the advantages of solution-based carbon wrapping and offers a scalable strategy to prepare high-performance DRX cathodes for lithium-ion batteries.
carbon composite↗
Moisture Performance of Unvented Attics With Vapor Diffusion Ports and Buried Ducts in Hot, Humid Climates
Energy efficiency measures, such as cool roofs, radiant barriers, interior radiative control coatings, and buried ducts are increasing in popularity and are promoted by energy codes because of their energy-saving potential. However, these strategies can also pose moisture risks in attics by lowering surface temperatures and increasing condensation potential and moisture accumulation. Of particular concern in hot-humid climates is dripping condensation on cold air-conditioning ductwork in the summer - commonly referred to as duct "sweating" - which threatens the attic floor with conditions conducive to mold growth and rot. One strategy to mitigate these moisture issues is to wrap ductwork in thicker duct-wrap insulation with an integrated exterior vapor barrier, but thick duct wrap can be difficult to come by, expensive, and unwieldy to work with. This study explores an alternative strategy of reducing moisture issues while embracing energy efficiency by using unvented attics with vapor diffusion ports and buried ductwork in hot-humid climates. Vapor diffusion ports have been studied so far in a wide range of U.S. climates, mostly in the context of conditioned attics. In this study, the strategy is implemented in the novel context of hot-humid climates with ductwork sitting atop blown-in attic floor insulation in unconditioned attics. Using a combination of field experiments and hygrothermal modeling, the findings of this project indicate that an unvented attic with vapor diffusion ports and buried ducts may be a key part of a successful low-cost method for reducing the attic moisture load by venting excess moisture out of the attic, keeping duct-jacket surfaces above dew point temperature, and keeping the roof deck safe from winter moisture accumulation.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Explosive welding technique for joining aluminum and steel tubes
Silver sheet is wrapped around aluminum portion of joint. Mylar powder box is wrapped over silver sheet. Explosion welds silver to aluminum. Stainless-steel tube is placed over silver-aluminum interface. Mylar powder box, covered with Mylar tape, is wrapped around steel member. Explosion welds steel to silver-aluminum interface.
Wakefield, M. E.↗
Rotary actuator
Rotary actuators and other mechanical devices incorporating shape memory alloys are provided herein. Shape memory alloys are a group of metals which when deformed at temperatures below their martensite temperatures, resume the shapes which they had prior to the deformation if they are heated to temperatures above their austensite temperatures. Actuators in which shape memory alloys are employed include bias spring types, in which springs deform the shape memory alloy (SMA), and differential actuators, which use two SMA members mechanically connected in series. Another type uses concentric cylindrical members. One member is in the form of a sleeve surrounding a cylinder, both being constructed of shape memory alloys. Herein two capstans are mounted on a shaft which is supported in a framework. Each capstan is capable of rotating the shaft. Shape memory wire, as two separate lengths of wire, is wrapped around each capstan to form a winding around that capstan. The winding on one capstan is so wrapped that the wire is in a prestretched state. The winding on the other capstan is so wrapped that the wire is in a taut, but not a prestretched, state. Heating one performs work in one direction, thus deforming the other one. When the other SMA is heated the action is reversed.
Brudnicki, Myron↗
ODC-Free Solvent Implementation for Phenolics Cleaning
During phenolic liner manufacture, resin-impregnated (pre-preg) bias tape of silica, glass, or carbon cloth is tape-wrapped, cured, machined, and then wiped with 1,1,1 tri-chloroethane (TCA) to remove contaminants that may have been introduced during machining and handling. Following the TCA wipe, the machined surface is given a resin wet-coat and over-wrapped with more prepreg and cured. A TCA replacement solvent for these wiping operations must effectively remove both surface contaminants, and sub-surface oils and greases while not compromising the integrity of this interface. Selection of a TCA replacement solvent for phenolic over-wrap interface cleaning began with sub-scale compatibility tests with cured phenolics. Additional compatibility tests included assessment of solvent retention in machined phenolic surfaces. Results from these tests showed that, while the candidate solvent did not degrade the cured phenolics, it was retained in higher concentrations than TCA in phenolic surfaces. This effect was most pronounced with glass and silica cloth phenolics with steep ply angles relative to the wiped surfaces.
Wurth, Laura↗
Development of a Thin-Film Solar Cell Interconnect for the Powersphere Concept
Dual junction amorphous silicon (a-Si) solar cells produced on polyimide substrate have been selected as the best candidate to produce a lightweight solar array for the PowerSphere program. The PowerSphere concept features a space-inflatable, geodetic solar array approximately 0.6 meters in diameter and capable of generating about 20W of electrical power. Trade studies of various wiring concepts and connection methods led to an interconnect design with a copper contact that wraps around the edge, to the back of the solar cell. Applying Plasma Vapor Deposited (PVD) copper film to both sides and the edge of the solar cell produces the wrap around contact. This procedure results in a contact pad on the back of the solar cell, which is then laser welded to a flex circuit material. The flex circuit is constructed of copper in a custom designed routing pattern, and then sandwiched in a Kapton insulation layer. The flex circuit then serves as the primary power distribution system between the solar cells and the spacecraft. Flex circuit material is the best candidate for the wiring harness because it allows for low force deployment of the solar cells by the inflatable hinges on the PowerSphere. An additional frame structure, fabricated and assembled by ILC Dover, will reinforce the wrap around contact-flex blanket connection, thus providing a mechanically robust solar cell interconnect for the PowerSphere multifunctional program. The PowerSphere team will use the wraparound contact design approach as the primary solution for solar cell integration and the flex blanket for power distribution.
Simburger, Edward J.↗