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DOE OSTI2012

Modeling and Validation of Performance Limitations for the Optimal Design of Interferometric and Intensity-Modulated Fiber Optic Displacement Sensors [Dissertation]

Optical fiber sensors offer advantages over traditional electromechanical sensors, making them particularly well-suited for certain measurement applications. Generally speaking, optical fiber sensors respond to a desired measurand through modulation of an optical signal’s intensity, phase, or wavelength. Practically, non-contacting fiber optic displacement sensors are limited to intensity-modulated and interferometric (or phase-modulated) methodologies. Intensity-modulated fiber optic displacement sensors relate target displacement to a power measurement. The simplest intensity-modulated sensor architectures are not robust to environmental and hardware fluctuations, since such variability may cause changes in the measured power level that falsely indicate target displacement. Differential intensity-modulated sensors have been implemented, offering robustness to such intensity fluctuations, and the speed of these sensors is limited only by the combined speed of the photodetection hardware and the data acquisition system (kHz-GHz). The primary disadvantages of intensity-modulated sensing are the relatively low accuracy (μm-mm for low-power sensors) and the lack of robustness, which consequently must be designed, often with great difficulty, into the sensor’s architecture. White light interferometric displacement sensors, on the other hand, offer increased accuracy and robustness. Unlike their monochromatic-interferometer counterparts, white light interferometric sensors offer absolute, unambiguous displacement measurements over large displacement ranges (cm for low-power, 5 mW, sources), necessitating no initial calibration, and requiring no environmental or feedback control. The primary disadvantage of white light interferometric displacement sensors is that their utility in dynamic testing scenarios is limited, both by hardware bandwidth and by their inherent high-sensitivity to Doppler-effects. The decision of whether to use either an intensity-modulated interferometric sensor depends on an appropriate performance function (e.g., desired displacement range, accuracy, robustness, etc.). In this dissertation, the performance limitations of a bundled differential intensity-modulated displacement sensor are analyzed, where the bundling configuration has been designed to optimize performance. The performance limitations of a white light Fabry-Perót displacement sensor are also analyzed. Both these sensors are non-contacting, but they have access to different regions of the performance-space. Further, both these sensors have different degrees of sensitivity to experimental uncertainty. Made in conjunction with careful analysis, the decision of which sensor to deploy need not be an uninformed one.

Engineering(42)↗

DOE OSTI2015

Submerged Medium Voltage Cable Systems at Nuclear Power Plants: A Review of Research Efforts Relevant to Aging Mechanisms and Condition Monitoring

In a submerged environment, power cables may experience accelerated insulation degradation due to water-related aging mechanisms. Direct contact with water or moisture intrusion in the cable insulation system has been identified in the literature as a significant aging stressor that can affect performance and lifetime of electric cables. Progressive reduction of the dielectric strength is commonly a result of water treeing which involves the development of permanent hydrophilic structures in the insulation coinciding with the absorption of water into the cable. Water treeing is a phenomenon in which dendritic microvoids are formed in electric cable insulation due to electrochemical reactions, electromechanical forces, and diffusion of contaminants over time. These reactions are caused by the combined effects of water presence and high electrical stresses in the material. Water tree growth follows a tree-like branching pattern, increasing in volume and length over time. Although these cables can be “dried out,” water tree degradation, specifically the growth of hydrophilic regions, is believed to be permanent and typically worsens over time. Based on established research, water treeing or water induced damage can occur in a variety of electric cables including XLPE, TR-XLPE and other insulating materials, such as EPR and butyl rubber. Once water trees or water induced damage form, the dielectric strength of an insulation material will decrease gradually with time as the water trees grow in length, which could eventually result in failure of the insulating material. Under wet conditions or in submerged environments, several environmental and operational parameters can influence water tree initiation and affect water tree growth. These parameters include voltage cycling, field frequency, temperature, ion concentration and chemistry, type of insulation material, and the characteristics of its defects. In this effort, a review of academic and industrial literature was performed to identify: 1) findings regarding the degradation mechanisms of submerged cabling and 2) condition monitoring methods that may prove useful in predicting the remaining lifetime of submerged medium voltage power cables. The research was conducted by a multi-disciplinary team, and sources included official NRC reports, national laboratory reports, IEEE standards, conference and journal proceedings, magazine articles, PhD dissertations, and discussions with experts. The purpose of this work was to establish the current state-of-the-art in material degradation modeling and cable condition monitoring techniques and to identify research gaps. Subsequently, future areas of focus are recommended to address these research gaps and thus strengthen the efficacy of the NRC’s developing cable condition monitoring program. Results of this literature review and details of the testing recommendations are presented in this report.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2015

Hydrogen Fracture Toughness Tester Completion

The Hydrogen Fracture Toughness Tester (HFTT) is a mechanical testing machine designed for conducting fracture mechanics tests on materials in high-pressure hydrogen gas. The tester is needed for evaluating the effects of hydrogen on the cracking properties of tritium reservoir materials. It consists of an Instron Model 8862 Electromechanical Test Frame; an Autoclave Engineering Pressure Vessel, an Electric Potential Drop Crack Length Measurement System, associated computer control and data acquisition systems, and a high-pressure hydrogen gas manifold and handling system.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Final Report of the HyPER Harvester Project

The HyPER Harvester Project resulted in the first fullscale design, fabrication and testing of two verticalaxis harvester prototypes at the Elephant Butte Irrigation District Drop 8 Station in Southern New Mexico. The design, followed by fabrication, and deployment clearly demonstrated the feasibility to manufacture and deploy harvester prototypes at low cost. While several issues common to irrigation canal systems have to be overcome, the electromechanical performance of the integrated turbinegenerator system demonstrated proofofconcept. Proofofconcept includes 1) feasibility for using additive manufacturing techniques to fabricate Carboncomposite turbinegenerator components at low cost, 2) ease of transportation and deployment, and 3) the harvester performance. The benefits of modularity were demonstrated in terms of rapid deployment at the Drop 8 Station. Scalability and adaptability were proven in terms of the customfitting characteristics that enabled rapid deployment. While keeping the same shape and form, the harvester can be easily adapted to any drop environment. Selfsupporting ability makes the harvester design minimally intrusive on existing structures. There are two technical challenges ahead that have to be addressed. Irregular flow patterns in canal flow induce vertical oscillations due to pressure change across the impeller. Despite the nosecone in conventional Kaplan turbine design that ordinarily dampens oscillations, an effective coupling design is required to eliminate the hydrodynamic effect on the generating system. In arid areas where tumbleweed is present, a robust design to prevent trash entering the drop is required. The compact shape and form have an aesthetic appearance and appear to illustrate an environmentally friendly attribute. The systemsengineered design enables rapid manufacturing and assembly of desired size units that can be deployed at sites along U.S. waterways as small hydropower plants. There is worldwide potential for this technology to provide sustainable hydropower to communities isolated from grid supply.

13 HYDRO ENERGY↗

DOE OSTI2016

Power Converter Control Algorithm Design and Simulation for the NREL Next-Generation Drivetrain: July 8, 2013 - January 7, 2016

The National Renewable Energy Laboratory (NREL) and NREL Next-Generation Drivetrain Partners are developing a next-generation drivetrain (NGD) design as part of a Funding Opportunity Announcement award from the U.S. Department of Energy. The proposed NGD includes comprehensive innovations to the gearbox, generator, and power converter that increase the gearbox reliability and drivetrain capacity, while lowering deployment and operation and maintenance costs. A key task within this development effort is the power converter fault control algorithm design and associated computer simulations using an integrated electromechanical model of the drivetrain. The results of this task will be used in generating the embedded control software to be utilized in the power converter during testing of the NGD in the National Wind Technology Center 2.5-MW dynamometer. A list of issues to be addressed with these algorithms was developed by review of the grid interconnection requirements of various North American transmission system operators, and those requirements that presented the greatest impact to the wind turbine drivetrain design were then selected for mitigation via power converter control algorithms.

17 WIND ENERGY↗

DOE OSTI2016

Nuclear-Renewable Hybrid Energy Systems: 2016 Technology Development Program Plan

The United States is in the midst of an energy revolution, spurred by advancement of technology to produce unprecedented supplies of oil and natural gas. Simultaneously, there is an increasing concern for climate change attributed to greenhouse gas (GHG) emissions that, in large part, result from burning fossil fuels. An international consensus has concluded that the U.S. and other developed nations have an imperative to reduce GHG emissions to address these climate change concerns. The global desire to reduce GHG emissions has led to the development and deployment of clean energy resources and technologies, particularly renewable energy technologies, at a rapid rate. At the same time, each of the major energy sectors—the electric grid, industrial manufacturing, transportation, and the residential/commercial consumers— is increasingly becoming linked through information and communications technologies, advanced modeling and simulation, and controls. Coordination of clean energy generation technologies through integrated hybrid energy systems, as defined below, has the potential to further revolutionize energy services at the system level by coordinating the exchange of energy currency among the energy sectors in a manner that optimizes financial efficiency (including capital investments), maximizes thermodynamic efficiency (through best use of exergy, which is the potential to use the available energy in producing energy services), reduces environmental impacts when clean energy inputs are maximized, and provides resources for grid management. Rapid buildout of renewable technologies has been largely driven by local, state, and federal policies, such as renewable portfolio standards and production tax credits that incentivize investment in these generation sources. A foundational assumption within this program plan is that renewable technologies will continue to be major contributors to the future U.S. energy infrastructure. While increased use of clean renewable technologies will aid in achieving reduced GHG emissions, it also presents new challenges to grid management that must be addressed. These challenges primarily derive from the fundamental characteristics of variable renewable generators, such as wind and solar: non-dispatchability, variable production, and reduced electromechanical inertia. This document presents a preliminary research and development (R&D) plan for detailed dynamic simulation and analysis of nuclear-renewable hybrid energy systems (N-R HES), coupled with integrated energy system design, component development, and integrated systems testing. N-R HES are cooperatively-controlled systems that dynamically apportion thermal and/or electrical energy to provide responsive generation to the power grid.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2016

On the Path to SunShot - Emerging Issues and Challenges with Integrating High Levels of Solar into the Distribution System

Wide use of advanced inverters could double the electricity-distribution system’s hosting capacity for distributed PV at low costs—from about 170 GW to 350 GW (see Palmintier et al. 2016). At the distribution system level, increased variable generation due to high penetrations of distributed PV (typically rooftop and smaller ground-mounted systems) could challenge the management of distribution voltage, potentially increase wear and tear on electromechanical utility equipment, and complicate the configuration of circuit-breakers and other protection systems—all of which could increase costs, limit further PV deployment, or both. However, improved analysis of distribution system hosting capacity—the amount of distributed PV that can be interconnected without changing the existing infrastructure or prematurely wearing out equipment—has overturned previous rule-of-thumb assumptions such as the idea that distributed PV penetrations higher than 15% require detailed impact studies. For example, new analysis suggests that the hosting capacity for distributed PV could rise from approximately 170 GW using traditional inverters to about 350 GW with the use of advanced inverters for voltage management, and it could be even higher using accessible and low-cost strategies such as careful siting of PV systems within a distribution feeder and additional minor changes in distribution operations. Also critical to facilitating distributed PV deployment is the improvement of interconnection processes, associated standards and codes, and compensation mechanisms so they embrace PV’s contributions to system-wide operations. Ultimately SunShot-level PV deployment will require unprecedented coordination of the historically separate distribution and transmission systems along with incorporation of energy storage and “virtual storage,” which exploits improved management of electric vehicle charging, building energy systems, and other large loads. Additional analysis and innovation are neede

14 SOLAR ENERGY↗

DOE OSTI2017

Using Modeling and Simulation to Complement Testing for Increased Understanding of Weapon Subassembly Response.

As part of Sandia’s nuclear deterrence mission, the B61-12 Life Extension Program (LEP) aims to modernize the aging weapon system. Modernization requires requalification and Sandia is using high performance computing to perform advanced computational simulations to better understand, evaluate, and verify weapon system performance in conjunction with limited physical testing. The Nose Bomb Subassembly (NBSA) of the B61-12 is responsible for producing a fuzing signal upon ground impact. The fuzing signal is dependent upon electromechanical impact sensors producing valid electrical fuzing signals at impact. Computer generated models were used to assess the timing between the impact sensor’s response to the deceleration of impact and damage to major components and system subassemblies. The modeling and simulation team worked alongside the physical test team to design a large-scale reverse ballistic test to not only assess system performance, but to also validate their computational models. The reverse ballistic test conducted at Sandia’s sled test facility sent a rocket sled with a representative target into a stationary B61-12 (NBSA) to characterize the nose crush and functional response of NBSA components. Data obtained from data recorders and high-speed photometrics were integrated with previously generated computer models in order to refine and validate the model’s ability to reliably simulate real-world effects. Large-scale tests are impractical to conduct for every single impact scenario. By creating reliable computer models, we can perform simulations that identify trends and produce estimates of outcomes over the entire range of required impact conditions. Sandia’s HPCs enable geometric resolution that was unachievable before, allowing for more fidelity and detail, and creating simulations that can provide insight to support evaluation of requirements and performance margins. As computing resources continue to improve, researchers at Sandia are hoping to improve these simulations so they provide increasingly credible analysis of the system response and performance over the full range of conditions.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2017

Final Scientific/Technical Report: Correlations and Fluctuations in Weakly Collisional Plasma

Plasma is a state of matter that exhibits a very rich range of phenomena. To begin with, plasma is both electrical and mechanical - bringing together theories of particle motion and the electromagnetic field. Furthermore, and especially important for this project, a weakly-collisional plasma, such as is found in high-temperature (fusion energy) experiments on earth and the majority of contexts in space and astrophysics, has many moving parts. For example, sitting in earth’s atmosphere we are immersed in a mechanical wave field (sound), a possibly turbulent fluid motion (wind), and an electromagnetic vector wave field with two polarizations (light). This is already enough to produce a rich range of possibilities. In plasma, the electromagnetic field is coupled to the mechanical motion of the medium because it is ionized. Furthermore, a weakly-collisional plasma supports an infinite number of mechanically independent fluids. Thus, plasmas support an infinite number of independent electromechanical waves. Much has been done to describe plasmas with "reduced models" of various kinds. The goal of this project was to both explore the validity of reduced plasma models that are in use, and to propose and validate new models of plasma motion. The primary means to his end was laboratory experiments employing both electrical probes and laser spectroscopy. Laser spectroscopy enables many techniques which can separate the spectrum of independent fluid motions in the ion phase-space. The choice was to focus on low frequency electrostatic waves because the electron motion is relatively simple, the experiments can be on a spatial scale of a few meters, and all the relevant parameters can be measured with a few lasers systems. No study of this kind had previously been undertaken for the study of plasmas. The validation of theories required that the experimental descriptions be compared with theory and simulation in detail. It was found that even multi-fluid theories leave out a large part of the complexity of plasma motion. Reduced descriptions were found to fail under most circumstances. A new technique was developed that enabled a measurement of the phase-space resolved ion correlation function for the first time. The wide range of plasma dynamics possible became clear through this technique. It was found that collisionless (Vlasov) theory has a large field of application even when the plasma is weakly-collisional. A new approach, the kinetic wave expansion, was proposed, tested and found to be very useful for describing electrostatic ion waves. This project demonstrated a new way of looking at the "degrees-of-freedom" of plasmas and provided significant validation tests of fluid and kinetic plasma descriptions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2018

Structural Health Monitoring of Nuclear Spent Fuel Storage Facilities

Interim storage of spent nuclear fuel from reactor sites has gained additional importance and urgency for resolving waste-management-related technical issues. To ensure that nuclear power remains clean energy, monitoring has been identified by DOE as a high priority cross-cutting need, necessary to determine and predict the degradation state of the systems, structures, and components (SSCs) important to safety (ITS). Therefore, nondestructive structural condition monitoring becomes a need to be installed on existing or to be integrated into future storage system to quantify the state of health or to guarantee the safe operation of nuclear power plants (NPPs) during their extended life span. In this project, the lead university and the collaborating national laboratory teamed to develop a nuclear structural health monitoring (n-SHM) system based on in-situ piezoelectric sensing technologies that can monitor structural degradation and aging for nuclear spent fuel DCSS and similar structures. We also aimed to identify and quantify possible influences of nuclear spent fuel environment (temperature and radiation) to the piezoelectric sensor system and come up with adequate solutions and guidelines therefore. We have therefore developed analytical model for piezoelectric based n-SHM methods, with considerations of temperature and irradiation influence on the model of sensing and algorithms in acoustic emission (AE), guided ultrasonic waves (GUW), and electromechanical impedance spectroscopy (EMIS). On the other side, experimentally the temperature and irradiation influence on the piezoelectric sensors and sensing capabilities were investigated. Both short-term and long-term irradiation investigation with our collaborating national laboratory were performed. Moreover, we developed multi-modal sensing, validated in laboratory setup, and conducted the testing on the We performed multi-modal sensing development, verification and validation tests on very complex structures including a medium-scale vacuum drying chamber and a small-scale mockup canister available for the desired testing. Our work developed the potential candidate for long term structural health monitoring of spent fuel canister through piezoelectric wafer sensors and provided the sensing methodologies based on AE and GUW methodologies. It overall provides an innovative system and methodology for enhancing the safe operation of nuclear power plant. All major accomplishments planned in the original proposal were successfully achieved.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2018

Conformable Hydrogen Storage Pressure Vessel

Existing commercially available hydrogen storage technologies are largely based on bulky and costly pressure vessels. These pressure vessels come in various forms, ranging from Type I steel cylinders to Type III and Type IV composite wrapped cylinders with metallic or polymer liners. In efforts to increase the pressure vessel storage density and meet DOE hydrogen storage targets, manufacturers are making incremental improvements. This approach alone is unlikely to meet DOE hydrogen storage targets and increase adoption of hydrogen fuel cell vehicles. The project team, led by the Center for Transportation and the Environment (CTE) and consisting of High Energy Coil Reservoirs, LLC (HECR) and The University of Texas at Austin's Center for Electromechanics (UT-CEM), has investigated a transformational hydrogen storage technology using high pressure modulus polymeric pressure vessels. These vessels are constructed by overwrapping an extruded thermoplastic elastomeric resin liner with high performance tensile fiber. This technology is used in commercially available compressed air storage for firefighters. The result is a lightweight, flexible, non-explosive, and non-fragmenting pressure vessel that can be shaped (prior to pressurization) to conform to specific applications. Although this project was funded to investigate the potential for this technology for vehicle applications, a potential significant cost reduction allowed with this approach may make it effective for high pressure ground storage as well. As part of Phase I of this project, the research team demonstrated a Kevlar™ over-braid that achieves a burst pressure in excess of 3.1X the operating pressure of 700 bar. The conformable vessel is able to achieve this pressure rating with reduced weight and cost when compared to Type IV vessels. The researchers also identified two potential resins to serve as the liner of the vessel. These resins have excellent hydrogen barrier properties that could enable a liner thickness of 0.06 inches or less; however, difficulties in manufacturing the core due to the extrusion manufacturing processes required testing with prototype resins as commercially available resins were not found that had the required properties. The team was able to build and test a vessel with one such blend, which outperformed the baseline Hytrel resin materials but did not meet the project hydrogen permeability rate goals.

08 HYDROGEN↗

DOE OSTI2018

Nonlinear Modeling of Macroscopic Plasma Dynamics Final Scientific Report May 1, 2006 – April 30, 2018

The project entitled, "Nonlinear Modeling of Macroscopic Plasma Dynamics," applied numerical computation to solve mathematical models of plasma behavior in laboratory systems. Plasma is the state of matter with sufficiently large internal energy density such that electrons dissociate from atoms to form gas of electrically charged particles. It occurs naturally in stars, planetary magnetospheres, and interstellar and intergalactic media. It is also used for industrial purposes and in lighting. Fusion energy science seeks to create and sustain plasma conditions where atomic nuclei fuse to create energy that can be captured for power production. Many laboratory experiments for this effort use magnetic field to contain plasma and to thermally insulate it from its surroundings. Possible plasma dynamics in magnetized systems include collective behavior over spatial scales that are comparable to the configuration size, and these dynamics often include evolution of the magnetic field that is used for confinement. Solving the mathematical models that describe these dynamics in specific experiments often requires computer simulations, as done in this project. This project analyzed plasma magnetic relaxation dynamics in the laboratory configurations known as the reversed-field pinch (RFP), the spheromak, and the spherical torus (ST). It also developed capabilities for modeling disruptive plasma dynamics in the tokamak, which has achieved the highest performance for magnetized plasma and is the design of the large international ITER experiment (https://www.iter.org) that is under construction and is expected to be the first to achieve self-heating conditions. Dynamic evolution to states of low energy, the aforementioned magnetic relaxation, is known to be important for generating the RFP and spheromak configurations. Nonlinear computational modeling with the Non-Ideal Magnetohydrodynamics with Rotation, Open Discussion code (NIMROD, https://nimrodteam.org) was applied to understand specific aspects of magnetic relaxation in RFPs, spheromaks, and STs. The RFP study considered how the nonlinear transfer of power among different fluctuation harmonics is altered due to the application of pulses of electric field, as done experimentally in the Madison Symmetric Torus RFP device at the University of Wisconsin-Madison. It also investigated the separation of electron and ion dynamics, known as two-fluid effects, including effects on the evolution of the plasma flow profile. The spheromak study considered the influence of these two-fluid effects in conditions relevant to the Sustained Spheromak Experiment (SSPX), formerly at Lawrence Livermore National Laboratory. Our study found that two-fluid effects enhance stability with respect to interchange in SSPX-relevant conditions, but having a complete model with two-fluid effects in separate electron and ion temperature equations is important. The study for STs focused on plasma startup in the Pegasus Toroidal Experiment at UW-Madison, which uses DC voltage applied through a small plasma gun. The simulations show how the resulting helical current stream relaxes through repetitive merging, forming current rings that accumulate into a tokamak-like configuration. Analytical theory was also developed to help explain behavior that was observed in the RFP and spheromak computations. Although the tokamak configuration has outperformed other magnetic confinement configurations, it has a tendency to undergo discharge-terminating dynamics that release energy onto plasma-facing surfaces and exert electromechanical forces on magnetic coils and structures. Our efforts have improved NIMROD's capabilities to model tokamak disruption by incorporating a resistive wall model that can be applied to axisymmetric, as well as asymmetric, distortions of the magnetic field configuration. Computations addressed whether mathematical conditions applied to plasma flow at the wall influence disruptive dynamics.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2013

Neutronics Benchmark Specifications for EBR-II Shutdown Heat Removal Test SHRT-45R - Revision 1

A neutronics benchmark specification was developed to support the analysis of SHRT-45R test, which was conducted in April 1986 using Experimental Breeder Reactor II (EBR-II) to demonstrate that a sodium-cooled fast reactor (SFR) with a sodium-bonded metallic fuel could be designed such that passive phenomena, as opposed to active electromechanical systems, are effective in protecting the reactor against the potentially adverse consequences of unprotected accidents.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2017

Durability of Corrosion Protection Coatings for Aluminum

The objectives of this work are to (1) Develop a detailed understanding of the performance characteristics of current chromate conversion coatings utilized in the stockpile, (2) Develop a detailed understanding of the performance characteristics of non-chromate conversion coatings proposed to replace their chromate containing counterparts, (3) Provide an informed assessment of the aforementioned coatings and a recommended course of action for the replacement of chromate containing coatings, and (4) establish subject matter expertise in the area of replacement coatings to provide as a resource to the systems organization. These tasks will be accomplished by performing a battery of traditional corrosion performance tests (in accordance with the relevant MIL specifications governing chemical conversion coatings), combined with more detailed analytical evaluation of the materials. Coatings will be evaluated in the as-received and artificially aged condition. Four different coating systems were evaluated on four different aluminum alloys in FY16. The focus this year was to continue populating the test matrix initiated in previous years, evaluating key coatings in the as received and thermally stressed condition, as compared to the baseline chromate conversion coating (Bonderite (formerly Alodine) 1200S). The non-chromate conversion coatings included Bonderite T 5900, Chemeon TCP-HF, Luster-On Aluminescent, and MacDermid-Enthone Iridite NCP. A second effort that was completed this year was to address a bottleneck that existed for the electrical evaluation of the coatings, assessing their conformance with the MIL specification. An electromechanical test system was assembled and automated, eliminating the need to rely on an already heavily utilized mechanical test system and operator in Materials Mechanics and Tribology.

36 MATERIALS SCIENCE↗

DOE OSTI2018

The Control of an Array of Micro-mirrors

The goal of this project is to develop an array of micro electromechanical systems (MEMS) mirrors with the following characteristics: three degrees of freedom (tip, tilt, piston); ±10° range of motion; and 40kHz closed-loop bandwidth. The combination of these characteristics will push the boundaries of devices currently in the literature, enabling a myriad of applications, from glasses-less stereo imagery to high-performance beam steering.

42 ENGINEERING↗

DOE OSTI2016

Carbon Composite Microelectromechanical Systems (CMEMS)

Pyrolyzed carbon as a mechanical material is promising for applications in harsh environments. In this work, we characterized the material and developed novel processes for fabricating carbon composite micro-electromechanical systems (CMEMS) structures. A novel method of increasing Young's modulus and the conductivity of pyrolyzed AZ 4330 was demonstrated by loading the films with graphene oxide prior to pyrolysis. By incorporating 2 wt.% graphene stiffeners into the film, a 65% increase in Young's modulus and 11% increase in conductivity were achieved. By reactive ion etching pyrolyzed blanket AZ 50XT thick film photoresist, a high aspect ratio process was demonstrated with films >7.5um thick. Two novel multi-level, volume-scalable CMEMS processes were developed on 6" diameter wafers. Young's modulus of 23 GPa was extracted from nanoindentation measurements of pyrolyzed AZ 50XT films. The temperature-dependent resistance was characterized from room temperature to 500C and found to be nearly linear over this range. By fitting the results of self-heated bridges in an inert ambient, we calculated that the bridges survived to 1000C without failure. Transmission electron microscopy (TEM) results showed the film to be largely amorphous, containing some sub-micrometer sized graphite crystallites. This was consistent with our Raman analysis, which also showed the film to be largely sp 2 bonded. The calculated average density of pyrolyzed AZ 4330 films was 1.32 g/cm 2 . Thin level of disorder and the conductivity of thin film resistors were found to unchanged by 2Mrad gamma irradiation from a Co 60 source. Thin film pyrolyzed carbon resistors were hermetically sealed in a nitrogen ambient in 24-pin dual in-line packages (DIP's). The resistance was measured periodically and remained constant over 6 months' time.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Linear and Nonlinear Constitutive Model for Piezoelectricity in ALEGRA-FE

This report develops and documents linear and nonlinear constitutive relations implemented in ALEGRA-FE (ferroelectric). A thermodynamic framework is created to describe the electromechanical system in the form of a free energy functional. Constitutive relations are derived by taking series expansions of the free energy functional with respect to the independent fields. First order expansion terms yield linear constitutive relations and higher order expansion terms yield non-linear constitutive relations. This document serves as supplement to Section 4 of Sandia Report SAND2013-7363, Rev 3. Methods for implementation of kinematic relations of piezoelectric models and rotation of material principal axes are covered in the supplemented report. Additional discussion on phase velocity calculation is also presented.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2017

Baseline Characterization Database Verification Report – NBG-18 Billet 635-4

This engineering calculations and analysis report is a validity evaluation of the physical and mechanical property databases collected on a billet of nuclear grade graphite (i.e., NBG-18 Billet 635-4) in support of the Advanced Reactor Technologies Baseline Graphite Characterization Program. Millions of raw data points that have been collected during testing and quantification analyses for these billets, the summary scalar property values and supplementary traceability data are collected into comprehensive spreadsheets. Data sets are comprised of single billets of graphite for any given grade, organized by mechanical test specimen type and further subdivided into individual spreadsheet tabs according to the specific test or evaluation being performed. This report is not a direct analysis of properties and will not provide information on the validity or performance characteristics of the graphite itself. Rather, it is intended as a verification of the completeness of actual data collected in accordance with PLN-3467, “Baseline Graphite Characterization Plan: Electromechanical Testing,” and its representation of the measurement and test results with sole regard to the graphite billets under evaluation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗