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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,045 records · Page 58

Remote In-bore Laser Cutting and Welding Tools for use in Future Nuclear Fusion Reactors - 18348

The maintenance, replacement and decommissioning of future nuclear fusion reactors will require quick and reliable cutting and joining of in-vessel pipework. Initial design studies for nuclear fusion reactors for power generation have estimated cutting and welding could account for up to 60% of the maintenance duration using conventional in-situ processing techniques (dry-mechanical cutting and arc welding) and that new methods are required to expedite the process. Additionally, the expected radioactivity and limited access at the cutting and welding sites mean that these processes cannot be done manually and robotic tools are required. To this end, remote in-bore laser cutting and welding tools have been developed for use in 90 mm internal diameter steel pipes. Here, we will present the designs of the remote in-bore laser cutting and welding tools, and how the tools fit within the overall remote maintenance strategy of a nuclear fusion reactor. Initial high-power laser trials were performed with prototype tools which successfully demonstrated their laser processing, thermal management and dust protection functionality. Although the tools described herein have been developed specifically for use within the fusion reactor environment, however the tool design and technology demonstrated here is readily transferable to many remote applications in challenging environments such as fission reactor maintenance, nuclear decommissioning and other in-accessible pipework. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Assessment of passively actuated in-situ cyclic surveillance test specimens for advanced non-light water reactors

The use of surveillance specimens was identified in a roadmap (Sims, 2010, ASME HTGR Code Development Roadmap, STP-NU-045, American Society of Mechanical Engineers, New York, NY) developed for the U.S. Nuclear Regulatory Commission for non-light water reactors that are intended to have very long design lives on the order of 500,000 hours. Creep rupture, long term strain accumulation, creep-fatigue damage, and their interaction with environmental effects require significant extrapolation from shorter term tests. Surveillance specimens provide a means for confirmation of these extrapolations in-situ. The effects of cyclic service on creep-fatigue damage would be particularly challenging based on conventional mechanical testing. Proposed herein is a passive cyclic testing methodology that lends itself well to in-situ surveillance applications. The concept is based on utilizing the difference in the thermal expansion coefficient of candidate materials to generate cyclic loading based on operational thermal transients. Prototypical specimen designs are proposed and their in-situ response to representative plant operation are evaluated.

Messner, M. C.↗

INTEGRATED WORKFLOW MANAGEMENT FOR PARTICLE ACCELERATOR SIMULATION

Supercomputing systems are used for a wide range of computationally demanding tasks in many fields of science and engineering. They play a key role in numerical simulation, in which mathematical models are computed in order to simulate the behavior of physical systems. Scientists and engineers that use supercomputers for numerical simulation often have their productivity limited by the need to manually organize and manage extremely large amounts of data that are often produced and consumed by the software programs run on these systems. Recognizing these limitations, Kitware Inc. (Clifton Park, NY) and SLAC National Accelerator Laboratory (Menlo Park, CA) are developing an advanced software platform that can reduce the cognitive overhead required by knowledge workers when using supercomputers for numerical simulation. Phase I of the project is complete and includes the development of new capabilities for organizing simulation project files, improvements to the user interface and overall usability, and deployment of a “middle tier” server to sit between user desktop machines and supercomputers to offload much of the data management workload. The project also developed prototype software for executing sequences of numerical simulations, and a prototype for migrating supercomputing software to cloud-based computing systems to provide a potential alternative to supercomputers with different logistical and price-to-performance tradeoffs.

Tourtellott, John↗

An end-to-end workflow for executing a classically bootstrapped variational quantum algorithm on an academic quantum computer

Academic quantum computing platforms often face unique challenges in executing quantum workloads due to fragmented software environments and limited engineering support. Unlike commercial ecosystems, academic devices typically evolve without full-stack integration in mind, making it difficult to run complex applications—such as variational quantum algorithms (VQA)—reliably and efficiently. Issues such as incompatible software layers and lack of automated job management significantly increase the overhead of theory-experiment collaboration. To address these challenges, we develop a modular, end-to-end workflow that decouples application-layer code from low-level hardware control, automates circuit submission and result collection, and supports fine-grained circuit-level job scheduling and recovery. The architecture employs a dual-end application programming interface (API) design, enabling robust operation across unstable or resource-constrained hardware backends. For practical use, the framework is lightweight and user-friendly, allowing rapid prototyping of full-stack workflows using basic Python tools. We validate this workflow on a high-fidelity trapped-ion quantum computer by demonstrating a variational quantum eigensolver (VQE) experiment with a classically bootstrapped ansatz initialization technique. The system successfully executed over 60,000 circuits across multiple molecular test cases with minimal human intervention, highlighting the framework’s effectiveness in enabling reproducible, resilient quantum experimentation in academic settings.

Clifford↗

ECC Refrigerator: Characterize Performance of a Prototype Electrochemical Compressor

This report documents experimental study to characterize performance of a prototype electrochemical compressor, provided by Xergy INC. It describes the working mechanism and its electrochemical efficiency and isentropic compression efficiency. The experimental results demonstrate that the prototype compressor is able to pump hydrogen flow from 25 psia to 140 psia, and deliver the flow rate as predicted. On the other hand, its efficiency level is low, having the electrochemical efficiency less than 40%, and isentropic efficiency below 47%. Using two identical ECC compressors in parallel will reduce the current density and ohm loss, which can increase the isentropic efficiency up to 67% with increased cost. Further improvements on the compressor are suggested, e.g. using more conductive membrane, etc.

42 ENGINEERING↗

A 4 x 4 SiPM Sensor Array with Fast Preamplified Output Engineered for the PWO Detectors of the EIC EEEMCAL

The PbWO4 scintillation detectors for the Electron-Ion Collider Electron Endcap Electromagnetic Calorimeter (EEEMCAL) cannot use vacuum photomultipler tubes due to the high magnetic field environment. We are presenting a readout solution with a 4 x 4 SiPM array directly coupled to a preamplification and summing stage. A second amplification stage with variable gain and offset adjustments is also included in the compact electronics module. The integrated power supply feeds the signal processing chain and the adjustable bias control. The parameter settings are saved locally on a EEPROM and are adjustable via the integrated communication interface through USB or RS485. The design was optimized to maximize signal collection energy resolution, for fast timing and wide dynamic range while keeping a small footprint with low power consumption and heat dissipation. The output response is fast enough to meet the 100 ? 200 ns digitization gate requirements for the detector. The electronics assembly requires no active cooling and includes a temperature sensor and a gain compensation of thermal variations which are important features for stable operation in large scale detector structures. A detector prototype was constructed with 20 mm x 20 mm x 200 mm PWO crystals affixed with individual SiPM array readouts and arranged in a 3 x 3 array. This detector was tested at the Thomas Jefferson National Accelerator Facility with 5GeV positrons. We will present the results of these detector characterization measurements.

Philip, O.↗

A concept for non-invasive temperature measurement during injection moulding processes

Current models of the injection moulding process insufficiently consider the thermal interactions between melt, solidified material and the mould. A detailed description requires a deep understanding of the underlying processes and a precise observation of the temperature. Because todays measurement concepts do not allow a non-invasive analysis it is necessary to find new measurement techniques for temperature measurements during the manufacturing process. In this work we present the idea of a set up for a tomographic ultrasound measurement of the temperature field inside a plastics melt. The goal is to identify a concept that can be installed on a specialized mould for the injection moulding process. The challenges are discussed and the design of a prototype is shown. Special attention is given to the spatial arrangement of the sensors. Besides the design of a measurement set up a reconstruction strategy for the ultrasound signals is required. We present an approach in which an image processing algorithm can be used to calculate a temperature distribution from the ultrasound scans. We discuss a reconstruction strategy in which the ultrasound signals are converted into a spartial temperature distribution by using pvT curves that are obtained by dilatometer measurements.

42 ENGINEERING↗

Mechanical Design and Fabrication of a New RF Power Amplifier for LANSCE

A Full-scale prototype of a new 201.25 MHz RF Final Power Amplifier (FPA) for Los Alamos Neutron Science Center (LANSCE) has been designed, fabricated, assembled and installed in the test facility. This prototype was successfully tested and met the physics and electronics design criteria. The team faced design and manufacturing challenges, having a goal to produce 2 MW peak power at 13% duty factor, at the elevation of over 2 km in Los Alamos. The mechanical design of the final power amplifier was built around a Thales TH628 Diacrode{sup R}, a state-of-art tetrode power tube. The main structure includes Input circuit, Output circuit, Grid decoupling circuit, Output coupler, Tuning pistons, and a cooling system. Many types of material were utilized to make this new RF amplifier. The fabrication processes of the key components were completed in the Prototype Fabrication Division shop at Los Alamos National Laboratory. The critical plating procedures were achieved by private industry. The FPA mass is nearly 600 kg and installed in a beam structural support stand. In this paper, we summarize the FPA design basis and fabrication, plating, and assembly process steps with necessary lifting and handling fixtures. In addition, to ensure the quality of the FPA support structure a finite element analysis with seismic design forces has also been carried out.

Accelerator Design, Technology, and Operations↗

Failure Assessments for MQXF Magnet Support Structure with a Graded Approach

The High-Luminosity Large Hadron Collider (HLLHC) upgrade requires new quadrupoles, MQXF, to replace the present LHC inner triplets. The MQXFA magnet is the first prototype that has a 150 mm aperture and uses Nb 3 Sn superconducting technology in a 4.2 m magnetic length structure. The support structure design of the MQXFA magnet is based on the bladder-and-key technology, where a relatively low pre-stress at room temperature is increased to the final preload targets during the cool-down by the differential thermal contraction of the various components. The magnet support structure components experience different load levels from pre-load to cool-down and excitation. Consequently, a few parts experience high stresses that may cause localized plastic deformations or internal fracture development. The concept presented in this paper for the failure assessment of support structures integrates nonlinear finite element analysis with detailed sub-models and fracture mechanics into an advanced engineering tool. The nonlinear FE solutions enable estimations of the structural response to the given loads, and the advanced fracture analysis with failure assessment diagram (FAD) assesses the structure safety index of results obtained from the FE model. The study describes how the MQXFA shell end segments are being optimized based on the failure analyses.

43 PARTICLE ACCELERATORS↗

Monitoring solid metal structures with a nervous system embedded with ultrasonic 3D printing

Active and regular monitoring of structural components is a critical safety precaution, particularly as it concerns infrastructure, aerospace, industry, and many other applications. Solutions for effective structural health monitoring need to be able to probe surface and bulk properties using durable and low-power engineering. Towards these ends it is possible to build smarter, highly networked, and secure materials in order to enable remote real-time material sensing with a lesser-known form of 3D printing, ultrasonic consolidation (UC). This approach harnesses sound waves to weld metal layers in a low temperature process that does not damage sensors and electronics as they are embedded into a solid metal structure. This makes UC perfectly suited for designing solid metal parts with active embedded sensing components. However, the process parameters, material influences and mechanical factors that result in high-quality UC metal components are difficult to control or are loosely understood. The use of trial-and-error optimization during fabrication represents the chief hurdle between its current state of use and its potential to transform rapid prototyping and manufacturing of high-impact technologies (e.g., metal smart structures, wearable sensors, lab-on-a-chip, etc.). In this paper we will describe how embedded sensors may be used for in situ process monitoring and optimization. We will also discuss efforts towards standardizing UC welding for similar and dissimilar metal bonding and for embedding active sensors that can be used to create smart structures that will enable long-term structural health monitoring and other high impact applications.

Suter, Jonathan D.↗

Origin of dielectric relaxor behavior in PVDF-based copolymer and terpolymer films

Relaxor ferroelectrics exhibit frequency-dispersion of their dielectric permittivity peak as a function of temperature, the origin of which has been widely debated. Microscopic understanding of such behavior for polymeric ferroelectrics has presented new challenges since unlike traditional ceramic ferroelectrics, dielectric relaxation in polymers is a consequence of short-range molecular dynamics that are difficult to measure directly. Here, through careful analysis of atomic-level H-atom dynamics as determined by Quasi-elastic Neutron Scattering (QENS), we show that short-range molecular dynamics within crystalline domains cannot explain the macroscopic frequency-dispersion of dielectric properties observed in prototypical polyvinylidene-fluoride (PVDF)-based relaxor ferroelectrics. Instead, from multiscale quantitative microstructural characterization, a clear correlation between the amount of crystalline-amorphous interfaces and dielectric relaxation is observed, which indicates that such interfaces play a central role. These results provide critical insights into the role of atomic and microscopic structures towards relaxor behavior in ferroelectric polymers, which will be important for their future design.

42 ENGINEERING↗

Evaluation of Fish-Related Properties of Kaplan Turbines at the Design Phase: Simulation-based outcomes vs. Experimental Data

The development of turbine technology faces growing demands to maximize the survival of migratory fish passing through turbine flows. In this context, two strategies have emerged for quantifying hazardous hydraulic conditions: computer-based evaluations at design stage and recordings with autonomous sensors deployed in prototypes. The former is a desktop evaluation with many modelling assumptions (idealization) and the latter is a field technique that introduces various unknown and uncontrollable factors (uncertainty.) The present work introduces and implements a third method based on test rig measurements and the corresponding computer-based predictions of conditions that negatively affect fish survivability. The experimental work was conducted in a five-bladed Kaplan turbine model in which miniaturized autonomous sensors (SF Mini, developed at the Pacific Northwest National Laboratory, U.S.) measured fish-relevant hydraulic features. The modelling work involved flow simulations according to industry practices and the representation of fish trajectories through the simulated flow conditions. We compared both the experimental measurements and CFD outcomes and discussed the challenges and advantages of the modelling strategies, as well as the benefits for turbine engineers in need of incorporating effective design concepts to mitigate fish mortality through turbines.

Romero-Gomez, Pedro↗

Update on the Investigation of Commercial Drying Cycles Using the Advanced Drying Cycle Simulator

The purpose of this report is to document updates on the apparatus to simulate commercial vacuum drying procedures at the Nuclear Energy Work Complex at Sandia National Laboratories. Validation of the extent of water removal in a dry spent nuclear fuel storage system based on drying procedures used at nuclear power plants is needed to close existing technical gaps. Operational conditions leading to incomplete drying may have potential impacts on the fuel, cladding, and other components in the system during subsequent storage and disposal. A general lack of data suitable for model validation of commercial nuclear canister drying processes necessitates well-designed investigations of drying process efficacy and water retention. Scaled tests that incorporate relevant physics and well-controlled boundary conditions are essential to provide insight and guidance to the simulation of prototypic systems undergoing drying processes. This report documents a new test apparatus, the Advanced Drying Cycle Simulator (ADCS). This apparatus was built to simulate commercial drying procedures and quantify the amount of residual water remaining in a pressurized water reactor (PWR) fuel assembly after drying. The ADCS was constructed with a prototypic 17×17 PWR fuel skeleton and waterproof heater rods to simulate decay heat. These waterproof heaters are the next generation design to heater rods developed and tested at Sandia National Laboratories in FY20. This report describes the ADCS vessel build that was completed late in FY22, including the receipt of the prototypic length waterproof heater rods and construction of the fuel basket and the pressure vessel components. In addition, installations of thermocouples, emissivity coupons, pressure and vacuum lines, pressure transducers, and electrical connections were completed. Preliminary power functionality testing was conducted to demonstrate the capabilities of the ADCS. In FY23, a test plan for the ADCS will be developed to implement a drying procedure based on measurements from the process used for the High Burnup Demonstration Project. While applying power to the simulated fuel rods, this procedure is expected to consist of filling the ADCS vessel with water, draining the water with applied pressure and multiple helium blowdowns, evacuating additional water with a vacuum drying sequence at successively lower pressures, and backfilling the vessel with helium. Additional investigations are expected to feature failed fuel rod simulators with engineered cladding defects and guide tubes with obstructed dashpots to challenge the drying system with multiple water retention sites.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A 50-kW Three-Phase Wireless Power Transfer System Using Bipolar Windings and Series Resonant Networks for Rotating Magnetic Fields

The mass and volume of wireless power transfer (WPT) systems for charging electric vehicles are directly related to the rated power of the system. The difficulties of high-power wireless charging are exacerbated by the need to meet the same practical constraints associated with vehicle integration as lower power systems. Therefore, more advanced techniques are necessary to improve power density and specific power of wireless charging systems for high-power applications. This article presents theory and analysis of three-phase inductive WPT systems with bipolar phase windings. Magnetic coupler topologies and the theoretical and practical aspects of series three-phase resonant compensation networks are discussed. The systems under consideration are designed to utilize rotating magnetic fields to achieve a power transfer characteristic that is temporally smoother than single-phase systems. Other benefits associated with rotating magnetic field based WPT, including reduced ferrite mass, filter component requirements, and electromagnetic field emissions, are discussed. Experimental results of a prototype system are presented in both aligned and misaligned configurations. The system is demonstrated transferring 50 kW with 95% dc-to-dc efficiency over a 150-mm airgap in the aligned case. On a per-pad basis, the magnetic couplers achieve a power density of 195 kW/m 2 and a specific power of 3.65 kW/kg. Finally this article is accompanied by a video of the rotating magnetic field produced by a simulated three-phase WPT system.

42 ENGINEERING↗

Low Voltage Electron Beam Processing Final Report CRADA No. TC-645-93-A

This CRADA project was established to develop a small, inexpensive sealed-tube electron beam processing system having immediate applications in industrial, high speed manufacturing processes, and in the Department of Energy (DOE) waste treatment/cleanup operations. The technical work involved the development and demonstration of a compact, sealed, 50-75 kilovolt (kV) EB generator prototype, including controls and power supply. The specific goals of this project were to develop a low cost vacuum tube capable of shooting an electron beam several inches into the air, and to demonstrate that wide area materials processing is feasible by stacking the tubes to produce continuous beams. During the project, we successfully demonstrated the producibility of a low cost electron beam system and several material processing operations of interest to US industry, DOE and, since September 11, 2001, the Homeland Security.

36 MATERIALS SCIENCE↗

Chromium versus Aluminum: Impact of Nickel Alloy Composition and Interfacial Kinetics on High-Temperature Passivating Oxide Formation

High-temperature corrosion resistance depends critically on the formation of a passivating surface oxide, which is highly sensitive to alloy composition and structure. Such details often elude experimental investigation, and simplified analytical models fail to provide a truly chemical view of passivating oxide evolution. Here, we explicitly compare the fundamental chemistry of Cr and Al as prototypical passivating elements in Ni alloys by directly simulating competing reaction and diffusion processes within the oxide film using kinetic Monte Carlo and density functional theory. We find that the origin and expression of passivating behavior during early-stage thermal oxidation are qualitatively different between the two alloy systems. Ni–Cr alloys feature a sudden onset of passivation associated with a sharp phase transition upon Cr enrichment that directly couples oxidation kinetics to phase transformation behavior. In contrast, Ni–Al alloys display more continuous oxide phase variation with Al enrichment, ultimately resulting in a lower composition threshold for passivation and a thinner passivating layer. In addition, we elucidate the nonobvious role of metal exchange within the alloy near the oxide boundary, which fundamentally alters film composition and passivating behavior. Furthermore, our results have key implications for engineering improved corrosion-resistant alloys, both in terms of compositional variation and processing.

Alloys↗

Remote Robotic Equipment for Retrieval of High Level Waste to Support Environmental Closure - 18162

The Idaho Cleanup Project contractor, Fluor Idaho, LLC, is responsible for managing HLW calcine stored in the Calcined Solids Storage Facility at the Idaho Nuclear Technology and Engineering Center. The Idaho Nuclear Technology and Engineering Center is a DOE managed facility located at the INL Site in the remote portions of southeast Idaho. In 2016, DOE directed Fluor Idaho to develop and test a full-scale retrieval system to demonstrate the ability to safely retrieve HLW calcine from the Calcined Solids Storage Facility for future retrieval and processing. Removing HLW calcine from the State of Idaho is required by the 1995 Settlement Agreement, which mandates that DOE have HLW calcine ready to be moved out of Idaho by December 2035. Fluor Idaho is currently testing retrieval and transfer concepts to ensure that the Calcined Solids Storage Facility is placed in a final configuration that is protective of human health and the environment after HLW calcine has been removed to the maximum extent practical. This paper describes the full-scale prototype that will be used to prove retrieval and transfer system design capabilities, verify operating parameters, and establish a basis for calcine retrieval efficacy. Additionally, it describes the retrieval (bulk and residual) and visual monitoring systems that were designed and tested in 2017 and will continue to be tested with the full-scale prototype. Testing (i.e., full-scale mockup, bulk retrieval, residual clean-out, and visualization monitoring) performed by Fluor Idaho will demonstrate the maximum extent practical of HLW calcine removal that is achievable. This is critical to (1) establish criteria for ending calcine removal activities, (2) evaluate cost and benefits associated with performing additional removal, and (3) ensure clean up and closure standards under applicable requirements (e.g., statutes, orders, and agreements) are met. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

A novel electro-hydraulic unit design based on a shaftless integration of an internal gear machine and a permanent magnet electric machine

In recent years, increasingly stringent emission regulations have spurred an electrification trend in off-highway vehicle technology. To address challenges such as the high cost of power electronics components, limited battery capacity, and the substantial modifications required for the vehicles, there is a pressing need to develop high-speed, cost-effective, compact, and efficient electro-hydraulic units capable of powering vehicle functions. In response to these demands, this paper introduces an innovative morphology for an electro-hydraulic unit and outlines the integration method for a crescent-type internal gear machine with a permanent magnet synchronous electric machine. The proposed morphology aims to minimize component count through a shaftless solution while incorporating a cooling system that utilizes the same working fluid as the hydraulic machine. The design approach utilizes a genetic algorithm optimization process to maximize overall energy efficiency and compactness. Insights gained from the optimization results shed light on the relationship between key design parameters and unit performance, enhancing the understanding of this electro-hydraulic unit. A prototype of the unit was manufactured and tested, demonstrating a volumetric efficiency ranging from 81 % to 97 % at a maximum rotational velocity of the pinion of 6000 rpm. Finally, these results validate both the morphology and the design approach, indicating the feasibility of designing compact electro-hydraulic units that leverage hydraulic machines with higher maximum rotational velocities than commercially available counterparts as a mean to enhance efficiency and compactness.

30 DIRECT ENERGY CONVERSION↗