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DOE OSTI2024

Effects of Strain Gauge Coatings on Water Intrusion in Submerged Composite Coupon Testing

Marine energy structures are typically made using composite materials and are repeatedly loaded by currents and waves. Submersion and repeated loading lead to two environmental effects: moisture intrusion and mechanical fatigue. To understand their combined effects, submerged fatigue testing can be used. Submerged fatigue testing often requires submerged instrumentation to validate component manufacturing methods and models. Strain measurements are critical for understanding marine energy component loads. One common method for measuring strain is by using foil strain gauges, but the durability of strain gauges in submerged fatigue conditions is not well-understood. To increase strain gauge durability and protection from contamination, delamination, and water intrusion, strain gauge coatings may be applied over strain gauges and wire connections. In this study, strain gauges were adhered to composite coupons, coated, and mechanically tested in a water tank. Cycles to composite failure, cycles to strain gauge failure (SGF), strains, and SGF modes were used to measure the effects of strain gauge coatings on composite fatigue life and strain gauge durability. The coatings did not have significant effects on composite fatigue life or strain gauge durability. The methods developed and measurements taken at the coupon scale in this study will be used to inform methods and designs for subsequent submerged subcomponent testing, full-scale testing, and standards development. The benefits of designing marine energy structures to informed standards and designs are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

composite materials↗
DOE OSTI2015

Synthesis and Characterization of Mixed-Conducting Corrosion Resistant Oxide Supports

An extensive search and evaluation of electrochemically stable catalyst supports (including metal oxides like RuO2-SiO2, RuO2-TiO2, and ITO was perfomed during the 4 years of the project. The suports were also catalyzed by deposition of Pt and tested for its performance and electrochemical stability in RDE and fuel cell experiments. For testing the electrochemical stability and fuel cell performance of the catalysts and supports, we have employed the protocols in use at the Department of Energy and Nissan Technological Center North America (NTCNA). The use of such procedures allows a precise and reproducible estimation of the performance and stability of the materials and permits comparisons among laboratories and DOE funded projects. RuO2-SiO2 catalyst supports showed no loss in surface area during start-stop stability tests that were performed by cycling the electrode potential between 0 V to 1.8 V for 1000 cycles. Catalyzed support (40% Pt/RuO2-SiO2; 1:1 mole ratio) were tested in a PEFC, resulting in a current density of 750 mA/cm2 at 0.6 Volts, and a maximum power density of 570 mW/cm2. Measurements were conducted at 80 ºC with 75% relative humidity of the inlet gases (H2/O2); Pt loadings were 0.4 mg/cm2 at the cathode and 0.2 mg/cm2 at the anode. Start-stop stability tests for support and catalyzed support performed in RDE and PEFC set-ups have confirmed RuO2-TiO2 support stability. The beginning of life performance was exactly equal to end of life performance (in an MEA that has been subjected to severe start-stop cycling for 10,000 start/stop cycles between 1 V to 1.5 V). This result was in sharp contrast to baseline Pt/C catalyst that showed significant performance deterioration after accelerated stability tests. The Pt/TRO showed minimal loss in performance upon exposure to start-stop cycles. The loss in cell voltage at 1 A/cm2 at 100% RH was almost 700 mV for Pt/C whereas it was only ca. 15 mV for Pt/TRO. 40% RH data (of inlet gases) revealed a similar trend in terms of stability – exceptional stability for Pt/TRO as opposed to very poor stability for Pt/HSAC. These observations were attributed to the much higher stability of the TRO support compared to Carbon. The carbon dioxide concentration in the cathode exit stream during the accelerated degradation test with Pt/TRO (start-stop protocol) was extremely low (between 3 to 10 ppm of CO2). In contrast, the CO2 emission levels from a conventional Pt/C catalyst were found to be approx. 200 ppm. This observation was a clear indicator that the main source of carbon being oxidized to carbon dioxide in an MEA was the carbon catalyst support, and not the gas diffusion layer or the graphite flow fields. Indium tin oxide (ITO) was also evaluated as a catalyst support for PEFCs. Pt/ITO was very stable under start-up/shutdown accelerated degradation protocol (RDE tests in perchloric acid). The ECSA change was less than 4% over 10,000 cycles. The load cycling accelerated protocol (from 0.6 to 0.95 V vs. RHE) resulted in a loss of approximately 34% of the initial ECSA after 10,000 cycles. However, fuel cell testing resulted in a very low performing catalyst. XPS spectroscopy was employed to investigate the changes in the catalysts occuring during fuel cell operation. It was observed a shift of In 3d5/2 and In 3d3/2 peaks towards higher binding energies. This can be explained by the formation of hydroxides or oxy-hydroxides in the surface of the catalyst. O1s spectrum for Pt/ITO catalyst after being operated in the fuel cell, also confirmed the formation of significant amounts of surface hydroxides (12 to 16%). The presence of surface hydroxides in the catalyst increased the electrode resistivity affecting fuel cell performance. NTCNA performed a detailed analysis of transport phenomena (reactants and products to/from the Pt active sites) in both commercial catalyst and Pt/RTO (in order to have a better understanding at the basic level). The proton resistance (Rionomer) in Pt/C and Pt/RTO cathode catalyst layers were 150 and 12 mΩ-cm2, respectively. Pt/RTO catalyst layer has about an order or magnitude lower proton transfer resistance than Pt/C catalyst layer. Since the ionomer/support ratio that was used in formulating the ink for both catalysts was the same (0.9), it is expected that the volumetric coverage of ionomer of both catalysts will be significantly different due to the disparity in the surface areas (Pt/C had ~ 800 m2/g, while Pt/RTO had ~ 50 m2/g). The differences in the ionomer volumetric coverage and the ionomer film thickness may explain the significantly higher proton conductivity in the Pt/RTO catalyst layer when compared to Pt/HSAC. It is therefore very important to optimize the ionomer loadings when synthesizing new catalyst supports (and never rely on values for carbon-based commercial catalysts). Finally, NTCNA has elaborated a cost model for non-carbon support materials considering their durability benefits. Material costs for production of Pt/ RuO2-TiO2 electrodes were compared to Pt/C. RuO2-TiO2 support was more expensive than carbon but the total material cost was still dominated by platinum cost. Though ruthenium is considered a precious metal, its cost is far less than platinum. It should also be noted that ruthenium only makes up 38% of the mass of the support, while the rest is inexpensive TiO2. After considering the durability advantages of Pt/RTO, cost model showed that even with almost double the Pt loading (0.35 vs 0.18 mgPt/cm2), Pt/RTO ($22.7/kWnet) is only slightly more expensive than Pt/C ($21.9/kWnet).

08 HYDROGEN↗
DOE OSTI2012

Improved Accelerated Stress Tests Based on Fuel Cell Vehicle Data

UTC will led a top-tier team of industry and national laboratory participants to update and improve DOE’s Accelerated Stress Tests (AST’s) for hydrogen fuel cells. This in-depth investigation will focused on critical fuel cell components (e.g. membrane electrode assemblies - MEA) whose durability represented barriers for widespread commercialization of hydrogen fuel cell technology. UTC had access to MEA materials that had accrued significant load time under real-world conditions in PureMotion® 120 power plant used in transit buses. These materials are referred to as end-of-life (EOL) components in the rest of this document. Advanced characterization techniques were used to evaluate degradation mode progress using these critical cell components extracted from both bus power plants and corresponding materials tested using the DOE AST’s. These techniques were applied to samples at beginning-of-life (BOL) to serve as a baseline. These comparisons advised the progress of the various failure modes that these critical components were subjected to, such as membrane degradation, catalyst support corrosion, platinum group metal dissolution, and others. Gaps in the existing ASTs predicted the degradation observed in the field in terms of these modes were outlined. Using the gaps, new AST’s were recommended and tested to better reflect the degradation modes seen in field operation. Also, BOL components were degraded in a test vehicle at UTC designed to accelerate the bus field operation.

08 HYDROGEN↗
DOE OSTI2024

Effects of Coatings on Water Intrusion and Strain Gauge Durability in Submerged Fatigue Conditions: Preprint

Marine energy structures are typically made using composite materials and are repeatedly loaded by currents and waves. Submersion and repeated loading lead to two environmental effects: moisture intrusion and mechanical fatigue. To understand the combined effects of moisture intrusion and mechanical fatigue on marine energy structures, submerged fatigue testing can be used. Submerged fatigue testing often requires submerged instrumentation to validate component manufacturing methods and models. Measuring strain is critical for understanding marine energy component loads. One common method for measuring strain is by using foil strain gauges, but the durability of strain gauges in submerged fatigue conditions was not well-understood. To increase strain gauge durability and protection from contamination, delamination, and water intrusion, strain gauge coatings may be applied over strain gauges and wire connections. In this study, strain gauges were adhered to composite coupons, coated, and mechanically tested in a water tank. Cycles to composite failure, cycles to strain gauge failure, strains, and strain gauge failure modes were used to measure the effects of strain gauge coatings on composite fatigue life and strain gauge durability. The methods developed and measurements taken at the coupon scale in this study will be used to inform methods and designs for subsequent submerged subcomponent testing, full-scale testing, and standards development. The benefits of designing marine energy structures to informed standards and designs are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

composite fatigue testing↗
DOE OSTI2024

Assessment of Accelerated Stress Testing Data for Silicon Photovoltaics Using Tensor Decomposition Methods

In this work, we examine the use of high-order tensor decompositions to analyze degradation pathways emerging from accelerated stress testing of silicon photovoltaic (PV) modules. Matrix-based decompositions are powerful tools for studying two-dimensional data arrays and form the foundation of a host of classical data analysis techniques. Tensors are high-order extrapolations of matrices that are able to account for more parameter dimensions, and a variety of tensor decomposition methods have been developed that similarly seek to extend insights from matrix decompositions to higher dimensions. Applying and interpreting tensor decomposition methods to sequences of PV module image data, we seek to uncover and isolate different degradation modes occurring from accelerated stress testing procedures. Further, we consider the contributions of different modes to PV module performance degradations.

data analysis↗
DOE OSTI2012

Full-length U-xPu-10Zr (x=0, 8, 19 wt%) Fast Reactor Fuel Test in FFTF

The Integral Fast Reactor-1 (IFR-1) experiment performed in the Fast Flux Test Facility (FFTF) was the only U-Pu-10Zr (Pu-0, 8 and 19 wt%) metallic fast reactor test with commercial-length (91.4 cm active fuel column length) conducted to date. With few remaining test reactors there is little opportunity for performing another test with a long active fuel column. The assembly was irradiated to the goal burnup of 10 at.%. The beginning of life (BOL) peak cladding temperature of the hottest pin was 608?C, cooling to 522?C at end of life (EOL). Selected fuel pins were examined non destructively using neutron radiography, precision axial gamma scanning, and both laser and spiral contact cladding profilometry. Destructive exams included plenum gas pressure, volume, and gas composition determinations on a number of pins followed by optical metallography, electron probe microanalysis (EPMA), and alpha and beta gamma autoradiography on a single U-19Pu-10Zr pin. The post-irradiation examinations (PIEs) showed very few differences compared to the short-pin (34.3 cm fuel column) testing performed on fuels of similar composition in Experimental Breeder Reactor-II (EBR-II). The fuel column grew axially slightly less than observed in the short pins, but with the same pattern of decreasing growth with increasing Pu content. There was a difference in the fuel-cladding chemical interaction (FCCI) in that the maximum cladding penetration by interdiffusion with fuel/fission products did not occur at the top of the fuel column where the cladding temperature is highest, as observed in EBR-II tests. Instead, the more exaggerated fission-rate profile of the FFTF pins resulted in a peak FCCI at ~0.7 X/L axial location along the fuel column. This resulted from a lower production of rare earth fission products higher in the fuel column as well as a much smaller delta-T between fuel center and cladding, and therefore less FCCI, despite the higher cladding temperature. This behavior could actually help extend the life of a fuel pin in a “long pin” reactor design to a higher peak fuel burnup.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Industry Facing PV Degradation Prediction Tool and Database to Enable a 50-Year Life Module

The Photovoltaic (PV) industry constantly aims for lower costs, higher-efficiency cells, and improved module designs. These trends lead to using new materials, designs, and manufacturing processes, resulting in a continually changing technological landscape. These changes can potentially introduce new, unknown degradation mechanisms and failure modes that are difficult to diagnose, analyze, test, and model. This introduces uncertainty into the expected lifetime of PV modules of 25 years. Furthermore, research efforts aim for up to 50 years of service life while keeping performance degradation at a minimum for decades of outdoor weathering - putting additional pressure on improving the accuracy of long-term durability and reliability assessments. Here there is a need to organize the existing degradation data into an accessible format and to provide industry relevant tools for extrapolation from laboratory to field conditions. Because the core of this type of analysis involves calculations that are complicated but ubiquitous for many degradation processes, an enhanced predictive modeling framework will facilitate the analysis to help researchers keep up with the rapid pace of technological changes. In this work, we present an online tool that can be used to search for and analyze degradation information and extrapolate PV module performance and durability to field exposure. A graphical user interface will aid in the understanding of the results. The prediction tool will be built modular and published as open source, enabling users to expand on the existing framework. We use an integration pipeline approach that allows us to leverage weather data from the National Solar Radiation Database to perform geospatial degradation analysis in the US and worldwide. Our repository will contain various degradation models and material parameters suitable for the reliability and durability assessment of materials and components deployed outdoors. We hope to become a repository that can be used for weathering and degradation analysis for various applications beyond the PV industry.

degradation↗
DOE OSTI2015

Life cycle costing of waste management systems: Overview, calculation principles and case studies

Highlights: • We propose a comprehensive model for cost assessment of waste management systems. • The model includes three types of LCC: Conventional, Environmental and Societal LCCs. • The applicability of the proposed model is tested with two case studies. - Abstract: This paper provides a detailed and comprehensive cost model for the economic assessment of solid waste management systems. The model was based on the principles of Life Cycle Costing (LCC) and followed a bottom-up calculation approach providing detailed cost items for all key technologies within modern waste systems. All technologies were defined per tonne of waste input, and each cost item within a technology was characterised by both a technical and an economic parameter (for example amount and cost of fuel related to waste collection), to ensure transparency, applicability and reproducibility. Cost items were classified as: (1) budget costs, (2) transfers (for example taxes, subsidies and fees) and (3) externality costs (for example damage or abatement costs related to emissions and disamenities). Technology costs were obtained as the sum of all cost items (of the same type) within a specific technology, while scenario costs were the sum of all technologies involved in a scenario. The cost model allows for the completion of three types of LCC: a Conventional LCC, for the assessment of financial costs, an Environmental LCC, for the assessment of financial costs whose results are complemented by a Life Cycle Assessment (LCA) for the same system, and a Societal LCC, for socio-economic assessments. Conventional and Environmental LCCs includes budget costs and transfers, while Societal LCCs includes budget and externality costs. Critical aspects were found in the existing literature regarding the cost assessment of waste management, namely system boundary equivalency, accounting for temporally distributed emissions and impacts, inclusions of transfers, the internalisation of environmental impacts and the coverage of shadow prices, and there was also significant confusion regarding terminology. The presented cost model was implemented in two case study scenarios assessing the costs involved in the source segregation of organic waste from 100,000 Danish households and the subsequent co-digestion of organic waste with animal manure. Overall, source segregation resulted in higher financial costs than the alternative of incinerating the organic waste with the residual waste: 1.6 M€/year, of which 0.9 M€/year was costs for extra bins and bags used by the households, 1.0 M€/year for extra collections and −0.3 M€/year saved on incineration.

09 BIOMASS FUELS↗
DOE OSTI2017

A NOVEL TOOL FOR IMPROVING THE DATA COLLECTION PROCESS DURING CONTROL ROOM MODERNIZATION HUMAN-SYSTEM INTERFACE TESTING AND EVALUATION ACTIVITIES

The U.S. Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program is developing a scientific basis to extend the existing U.S. nuclear power plant (NPP) operating life beyond the current 60-year licensing period and to ensure NPP long-term reliability, productivity, safety, and security. Under the Advanced Instrumentation, Information, and Control (II&C) Systems Technologies pathway, the LWRS Program conducts targeted research and development to address long-term aging and obsolescence of existing instrumentation and control technologies, as well as to implement and test new digital II&C technology that enables broad innovation and business improvement in the NPP operating model. To this end, the role of human factors engineering (HFE) is important as part of ensuring that the control room modernization (CRM) activities account for the operator’s cognitive and physiological characteristics. Part of the HFE process for CRM entails conducting tests and evaluations (T&Es) that will inform the design of new human-system interface (HSI) technologies. Qualitative data that captures operator feedback and important human-system interactions are an important part of T&E. However, the analyzing this qualitative data in order to provide actionable design recommendations can be time-consuming and error prone. This paper presents an early version of a tool that can be used to analyze this qualitative data to (1) sift through freeform text for improved design issue identification, (2) maintain consistency in theme coding conventions, and (3) readily provide actionable design guidance that can be traceable to state-of-the-art HFE guidelines such as NUREG-0700. A description of this tool is discussed next.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2016

Design Principles for Optimum Performance of Porous Carbons in Lithium-Sulfur Batteries

Here, a series of experiments is presented that establishes for the first time the role of some of the key design parameters of porous carbons including surface area, pore volume, and pore size on battery performance. A series of hierarchical porous carbons is used as a model system with an open, 3D, interconnected porous framework and highly controlled porosity. Specifically, carbons with surface areas ranging from ≈500–2800 m 2 g -1 , pore volume from ≈0.6–5 cm 3 g -1 , and pore size from micropores (≈1 nm) to large mesopores (≈30 nm) are synthesized and tested. At high sulfur loadings (≈80 wt% S), pore volume is more important than surface area with respect to sulfur utilization. Mesopore size, in the range tested, does not affect the sulfur utilization. No relationship between porosity and long-term cycle life is observed. All systems fail after 200–300 cycles, which is likely due to the consumption of the LiNO 3 additive over cycling. Moreover, cryo-scanning transmission electron microscopy imaging of these carbon–sulfur composites combined with X-ray diffraction (XRD) provides further insights into the effect of initial sulfur distribution on sulfur utilization while also revealing the inadequacy of the indirect characterization techniques alone in reliably predicting distribution of sulfur within porous carbon matrices.

25 ENERGY STORAGE↗
DOE OSTI2019

Influence of Y-Rich Compounds on High-Cycle Fatigue Performance of Y-Doped M951 Superalloy

The performance of Y-doped M951 superalloy under high-cycle fatigue was investigated experimentally to determine the effect of Y-rich compounds on this behavior. The selected testing temperatures were 700 and 900 °C, and the stress ratio was R = 0.1. The fatigue life was shown to decrease as the stress amplitude increased, according to a typical Whöler S-N diagram. Two types of crack initiation sites were observed on the fractured surfaces: microshrinkage clusters and Y-rich compounds. Analysis by TEM indicated that the Y-rich compounds consisted of Al{sub 2}Ni{sub 6}Y{sub 3} particles with BCC structure and Ni{sub 5}Y particles with hexagonal structure. Cracks had initiated and propagated along the interface between Al{sub 2}Ni{sub 6}Y{sub 3} phase and the matrix. These Y-rich compounds varied considerably in size, from 1 to 769 μm, and the large-size Y-rich compounds were shown to be the preferred site for fatigue crack origin. The ability of Y in the removal of sulfur was considered. And the small-size Y-S product from the reaction between Y and S was shown to exhibit no deleterious effect on the fatigue property of the M951 Ni-based superalloy.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Bisphenol A-elicited miR-146a-5p impairs murine testicular steroidogenesis through negative regulation of Mta3 signaling

The epigenetic effects on expression of non-coding RNAs (e.g. microRNAs) of environmental toxin bisphenol A (BPA) have extended our understanding of the etiology of human reproductive disorders including hypospermatogenesis and androgen deficiency. BPA-induced miR-146a-5p is a potent regulator of endocrine and immune homeostasis, but its role in testis remain unexplored. We show here that in murine testis, miR-146a-5p was exclusively expressed in interstitial Leydig cells (LCs). This expression was significantly induced by BPA exposure. Consequently, the elevated miR-146a-5p exacerbated the deleterious effects of BPA on testicular steroidogenesis. Mechanistically, miR-146a-5p repressed the expression of Mta3, a pivotal chromatin remodeling transcription factor recently involved in controlling the steroidogenic activity, via directly targeting its 3′UTR. This repression thereafter rendered LCs more sensitive to BPA-elicited inhibitory effects. Conversely, ectopic expression of hMTA3 successfully rescued miR-146a-5p-elicited inhibitory effects on testicular steroidogenesis in BPA-challenged LCs. Taken together, the available data provide novel evidence that deregulation of testicular miR-146a-5p/Mta3 cascade mediates, at least in part, the steroidogenic dysfunction caused by BPA exposure.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2018

Diphenyl diselenide abrogates chlorpyrifos-induced hypothalamic-pituitary-testicular axis impairment in rats

Highlights: • Chlorpyrifos (CPF) induced testicular dysfunction in rats. • Diphenyl diselenide (DPDS) increased hormone concentrations in CPF-treated rats. • DPDS increased antioxidant status in CPF-treated rats. • DPDS enhanced marker enzymes of testicular function in CPF-treated rats. • DPDS augmented sperm functional characteristics status in CPF-treated rats. Exposure to pesticide chlorpyrifos (CPF) has been implicated in reproductive deficits in both humans and animals. Diphenyl diselenide (DPDS) is an organoselenium compound widely reported to elicit potent pharmacological activities in several chemically-induced toxicity and disease models. However, there is paucity of scientific information on the influence of DPDS on CPF-induced reproductive dysfunction. The present study investigated the influence of DPDS on CPF-induced functional changes along the hypothalamic-pituitary- testicular axis in rats. CPF was administered alone at 5 mg/kg body weight or orally co-treated with DPDS at 2.5 and 5 mg/kg body weight for 35 consecutive days. Results showed that DPDS co-treatment significantly (p via inhibition of lipid peroxidation, enhancement of antioxidant enzymes activities and testicular function. Thus, DPDS may be a possible chemoprotective drug candidate against CPF-induced male reproductive deficits in humans.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2022

The bright frontiers of microbial metabolic optogenetics

In recent years, light-responsive systems from the field of optogenetics have been applied to several areas of metabolic engineering with remarkable success. By taking advantage of light's high tunability, reversibility, and orthogonality to host endogenous processes, optogenetic systems have enabled unprecedented dynamical controls of microbial fermentations for chemical production, metabolic flux analysis, and population compositions in co-cultures. In this article, we share our opinions on the current state of this new field of metabolic optogenetics. Furthermore, we make the case that it will continue to impact metabolic engineering in increasingly new directions, with the potential to challenge existing paradigms for metabolic pathway and strain optimization as well as bioreactor operation.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2017

Maternal exposure to a mixture of persistent organic pollutants (POPs) affects testis histology, epididymal sperm count and induces sperm DNA fragmentation in mice

Persistent organic pollutants (POPs) are widespread throughout the environment and some are suspected to induce reproductive toxicity. As animals and humans are exposed to complex mixtures of POPs, it is reasonable to assess how such mixtures could interact with the reproductive system. Our aim is to investigate how maternal exposure to a mixture of 29 different persistent organic pollutants, formulated to mimic the relative POP levels in the food basket of the Scandinavian population, could alter reproductive endpoints. Female mice were exposed via feed from weaning, during pregnancy and lactation in 3 exposure groups (control (C), low (L) and high (H)). Testicular morphometric endpoints, epididymal sperm concentration and sperm DNA integrity were assessed in adult male offspring. We found that the number of tubules, proportion of tubule compartments and epididymal sperm concentration significantly decreased in both POP exposed groups. Epididymal sperm from both POP exposed groups showed increased DNA fragmentation. It is concluded that maternal exposure to a defined POP mixture relevant to human exposure can affect testicular development, sperm production and sperm chromatin integrity. - Highlights: • Male mice were maternally exposed to a mixture of persistent organic pollutants. • Exposure significantly affected the testis histology. • Exposure significantly decreased sperm count and induced sperm DNA fragmentation. • Maternal exposure to POP mixture induced reproductive toxicity in male offspring.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2012

High resolution stationary digital breast tomosynthesis using distributed carbon nanotube x-ray source array

Purpose: The purpose of this study is to investigate the feasibility of increasing the system spatial resolution and scanning speed of Hologic Selenia Dimensions digital breast tomosynthesis (DBT) scanner by replacing the rotating mammography x-ray tube with a specially designed carbon nanotube (CNT) x-ray source array, which generates all the projection images needed for tomosynthesis reconstruction by electronically activating individual x-ray sources without any mechanical motion. The stationary digital breast tomosynthesis (s-DBT) design aims to (i) increase the system spatial resolution by eliminating image blurring due to x-ray tube motion and (ii) reduce the scanning time. Low spatial resolution and long scanning time are the two main technical limitations of current DBT technology. Methods: A CNT x-ray source array was designed and evaluated against a set of targeted system performance parameters. Simulations were performed to determine the maximum anode heat load at the desired focal spot size and to design the electron focusing optics. Field emission current from CNT cathode was measured for an extended period of time to determine the stable life time of CNT cathode for an expected clinical operation scenario. The source array was manufactured, tested, and integrated with a Selenia scanner. An electronic control unit was developed to interface the source array with the detection system and to scan and regulate x-ray beams. The performance of the s-DBT system was evaluated using physical phantoms. Results: The spatially distributed CNT x-ray source array comprised 31 individually addressable x-ray sources covering a 30 angular span with 1 pitch and an isotropic focal spot size of 0.6 mm at full width at half-maximum. Stable operation at 28 kV(peak) anode voltage and 38 mA tube current was demonstrated with extended lifetime and good source-to-source consistency. For the standard imaging protocol of 15 views over 14, 100 mAs dose, and 2 x 2 detector binning, the projection resolution along the scanning direction increased from 4.0 cycles/mm [at 10% modulation-transfer-function (MTF)] in DBT to 5.1 cycles/mm in s-DBT at magnification factor of 1.08. The improvement is more pronounced for faster scanning speeds, wider angular coverage, and smaller detector pixel sizes. The scanning speed depends on the detector, the number of views, and the imaging dose. With 240 ms detector readout time, the s-DBT system scanning time is 6.3 s for a 15-view, 100 mAs scan regardless of the angular coverage. The scanning speed can be reduced to less than 4 s when detectors become faster. Initial phantom studies showed good quality reconstructed images. Conclusions: A prototype s-DBT scanner has been developed and evaluated by retrofitting the Selenia rotating gantry DBT scanner with a spatially distributed CNT x-ray source array. Preliminary results show that it improves system spatial resolution substantially by eliminating image blur due to x-ray focal spot motion. The scanner speed of s-DBT system is independent of angular coverage and can be increased with faster detector without image degration. The accelerated lifetime measurement demonstrated the long term stability of CNT x-ray source array with typical clinical operation lifetime over 3 years.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2014

Ultra Barrier Topsheet Film for Flexible Photovoltaics with 3M Company

In this DOE sponsored program, 3M achieved the critical UBT features to enable durable flexible high efficiency modules to be produced by a range of customers who have now certified the 3M UBT and are actively developing said flexible modules. The specific objectives and accomplishments of the work under this program were; Scale-up the current Generation-1 UBT from 12” width, as made on 3M’s pilot line, to 1+meter width full-scale manufacturing, while maintaining baseline performance metrics (see table below); This objective was fully met; Validate service life of Generation-1 UBT for the 25+ year lifetime demanded by the photovoltaic market; Aggressive testing revealed potential failure modes in the Gen 1 UBT. Deficiencies were identified and corrective action taken in the Gen 2 UBT; Develop a Generation-2 UBT on the pilot line, targeting improved performance relative to baseline, including higher %T (percent transmission), lower water vapor transmission rate (WVTR) with targets based on what the technology needs for 25 year lifetime, proven lifetime of 25 years in solar module construction in the field, and lower cost; Testing of UBT Gen 2 under a wide range of conditions presented in this report failed to reveal any failure mode. Therefore UBT Gen 2 is known to be highly durable. 3M will continue to test towards statistically validating a 25 year lifetime under 3M funding; Transfer Generation-2 UBT from the pilot line to the full-scale manufacturing line within three years; and This objective was fully met.

14 SOLAR ENERGY↗
DOE OSTI2015

NREL Energy Storage Projects. FY2014 Annual Report

The National Renewable Energy Laboratory supports energy storage R&D under the Office of Vehicle Technologies at the U.S. Department of Energy. The DOE Energy Storage Program’s charter is to develop battery technologies that will enable large market penetration of electric drive vehicles. These vehicles could have a significant impact on the nation’s goal of reducing dependence on imported oil and gaseous pollutant emissions. DOE has established several program activities to address and overcome the barriers limiting the penetration of electric drive battery technologies: cost, performance, safety, and life. These programs are; Advanced Battery Development through the United States Advanced Battery Consortium (USABC); Battery Testing, Analysis, and Design; Applied Battery Research (ABR); and Focused Fundamental Research, or Batteries for Advanced Transportation Technologies (BATT) In FY14, DOE funded NREL to make technical contributions to all of these R&D activities. This report summarizes NREL’s R&D projects in FY14 in support of the USABC; Battery Testing, Analysis, and Design; ABR; and BATT program elements. The FY14 projects under NREL’s Energy Storage R&D program are briefly described below. Each of these is discussed in depth in this report.

25 ENERGY STORAGE↗