Wrap-able, Radiation-Resistant Electrical Insulators for Superconducting Magnet Applications - Initial Phase II Final Report
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11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
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Wrap-able, Radiation-Resistant Electrical Insulators for Superconducting Magnet Applications
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21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
COPOLYMER COMPOSITES FOR HIGH VOLTAGE INSULATION WRAPS FOR SUPERCONDUCTING MAGNET COILS
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36 MATERIALS SCIENCE↗
Helical scan recording with a self-acting negative air bearing
A flat head and a tape transport arrangement impart a wrap angle to the tape at the upstream corner of the head. The wrap angle, corner sharpness and tape stiffness are sufficient to cause a moving tape to form a hollow bump at the upstream corner, thereby creating a hollow into which entrained air can expand, causing a subambient pressure within and downstream of the bump. This pressure keeps the tape in contact with the head. It is created without the need for a groove or complex pressure relief slot(s). No contact pressure arises at the signal exchange site due to media wrap. The highest contact pressures are developed at a wrapped upstream corner. For a tape drive, traveling in both forward and reverse, the wrap can be at both the upstream and downstream (which is the reverse upstream) corners. Heads that are not flat can also be used, if the wrap angle relative to a main surface is sufficient and not too large. The wrapped head can also be used with rotating media, such as disks (floppy and hard) and rotating heads, such as helical wound heads for video recording. Multiple flat tape bearing surfaces can be separated by grooves and/or angles. Each flat can carry heads along one or more gap lines. Multiple adjacent narrow tracks can thus be written for extreme high track density recording.
Muftu , Sinan↗
Contact sheet recording with a self-acting negative air bearing
A flat head and a tape transport arrangement impart a wrap angle to the tape at the upstream corner of the head. The wrap angle, corner sharpness and tape stiffness are sufficient to cause a moving tape to form a hollow bump at the upstream corner, thereby creating a hollow into which entrained air can expand, causing a subambient pressure within and downstream of the bump. This pressure keeps the tape in contact with the head. It is created without the need for a groove or complex pressure relief slot(s). No contact pressure arises at the signal exchange site due to media wrap. The highest contact pressures are developed at a wrapped upstream corner. For a tape drive, traveling in both forward and reverse, the wrap can be at both the upstream and downstream (which is the reverse upstream) corners. Heads that are not flat can also be used, if the wrap angle relative to a main surface is sufficient and not too large. The wrapped head can also be used with rotating media, such as disks (floppy and hard) and rotating heads, such as helical wound heads for video recording. Multiple flat tape bearing surfaces can be separated by grooves and/or angles. Each flat can carry heads along one or more gap lines. Multiple adjacent narrow tracks can thus be written for extreme high track density recording.
Muftu , Sinan↗
Full Length Assembly Testing in PELICAN (Final Report)
In support of the development of the U.S. Department of Energy (DOE) Versatile Test Reactor (VTR), a thermal hydraulics test facility was constructed to generate experimental measurement of the pressure drop across a single full-scale assembly containing prototypic axial reflectors, fuel, and plena components. Constructed and operated at Argonne National Laboratory, the Pressure drop Experimental Loop for Investigations of Core Assemblies in Nuclear reactors (PELICAN) facility was designed to achieve hydraulic conditions identical to those anticipated for a full-scale fuel assembly located in the VTR core in the region with the highest flow rate. Using water as surrogate for liquid sodium, the flow loop was operated at elevated temperatures and pressures to match the thermophysical properties of liquid sodium and ensure matching Reynolds and Euler numbers. The measurement objectives for data generated from this test facility was driven primarily by the validation needs for code calculations and simulations of the reference VTR core. These objectives focused on the need to validate pressure drop results across the various segments of the fuel assembly as they relate directly to the pumping power and safety of the reactor. Presented in this report are experimental results and analytical comparisons based on testing of a full-length assembly in PELICAN. Housed within a hexagonal test section extending 3.4 m in length, the tested assembly features a prototypic lower reflector, grid plates, wire-wrapped rod bundle, upper reflector, and exit region. The rod bundle extends over 1.5 m in length and contains 217 individual wire-wrapped rods with dimensions that best reflect the reference VTR design. The as-tested bundle assembly was fabricated using 316 stainless steel 0.25-inch (6.35-mm) diameter rods wrapped with 0.04-inch (1.016-mm) diameter wire at a helical pitch of 10.51 inch (26.6 cm). Details of the method for in-house wire-wrapping, assembly, and installation are provided later in this report. Experimental measurements of pressure drop at 19 positions along the test assembly were recorded for a range of flow conditions, with special attention paid to key locations within the assembly, including component inlet and outlet, transition, and wire-wrapped rod bundle regions. Testing conditions were based on 110°C water with flow rates ranging from 50 to 450 GPM (3 to 27 kg/s) at the inlet of the test assembly generating Reynolds numbers and velocities up to ~8.0×10 4 and ~7.8 m/s, respectively, within the rod bundle region. Non-dimensional values for the friction factor were then calculated based on these experimental measurements and compared against those predicted by various analytical correlations available from open literature. Predictions by the upgraded Cheng and Todreas, Rehme, and Novendstern correlations fell within 4% to those values measured experimentally.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Rocket Engine Thrust Chamber Assembly
A thrust chamber assembly for liquid fueled rocket engines and the method of making it wherein a two-piece mandrel having the configuration of an assembly having a combustion chamber portion connected to a nozzle portion through a throat portion is wrapped with a silica tape saturated with a phenolic resin, the tape extending along the mandrel and covering the combustion chamber portion of the mandrel to the throat portion. The width of the tape is positioned at an angle of 30 to 50 deg. to the axis of the mandrel such that one edge of the tape contacts the mandrel while the other edge is spaced from the mandrel. The phenolic in the tape is cured and the end of the wrap is machined to provide a frusto-conical surface extending at an angle of 15 to 30 deg. with respect to the axis of the mandrel for starting a second wrap on the mandrel to cover the throat portion. The remainder of the mandrel is wrapped with a third silica tape having its width positioned at a angle of 5 to 20 deg. from the axis of the mandrel. The resin in the third tape is cured and the assembly is machined to provide a smooth outer surface. The entire assembly is then wrapped with a tow of graphite fibers wetted with an epoxy resin and, after the epoxy resin is cured, the graphite is machined to final dimensions.
Cornelius, Charles S.↗
Process for manufacturing SiC composite ceramics
A method is described for manufacturing a ceramic composite structure. The method includes wrapping ceramic fibers (22), such as SiC fibers, about the external surface of at least one form. The method further includes heating the wrapped fibers (22) to a temperature no greater than a first temperature, infiltrating voids (24) in the wrapped fibers (22) with the ceramic composite in a first vessel (12) at the first temperature, transferring the infiltrated wrapped fibers (22) from the first vessel (12) to a second vessel (14), distinct from the first vessel (12), and coating the infiltrated wrapped fibers (22) with the ceramic composite in the second vessel (14) at a second temperature, higher than the first temperature.
Lahoda, Edward J.↗
Mechanical Solution for Existing Conductors
The rapid growth in energy demand, driven by advancements in AI technology, renewable energy integration, and increased industrial activity, highlights the need for innovative solutions to improve the resiliency and efficiency of the power grid. This report details the fire testing of GridWrap’s Composite WiRe Wrap, to evaluate the wrap's ability to enhance conductor performance under wildfire-simulated conditions. Conductors were prepared and tested in a controlled environment at 400°C for 18 minutes, during which sag and temperature data were recorded. The results demonstrated that the unwrapped conductor sagged 3/16ths of an inch, while the WiRe Wrapped conductor sagged only 1/16th of an inch under identical conditions, indicating a significant improvement in mechanical performance. This project, conducted as part of a collaborative effort between BEA (Idaho National Laboratory’s managing contractor) and GridWrap, Inc., demonstrates the potential of grid-enhancing technologies like WiRe Wrap to reduce sag, increase grid resiliency, and support the future energy landscape. By validating the performance of such technologies in real-world scenarios, this work provides critical insights for industry adoption, benefiting both grid operators and U.S. taxpayers through improved reliability, reduced emissions, and enhanced energy delivery.
24 - POWER TRANSMISSION AND DISTRIBUTION↗
Depletion-Driven Assembly of Polymer-Coated Nanocrystals
Depletion-driven assembly has been widely studied for micron-sized colloids, but questions remain at the nanoscale where the governing physics are impacted by stabilizing surface ligands or wrapping polymers, whose dimensions are similar to those of the colloidal core and the depletant. Here, we probe how wrapping colloidal tin-doped indium oxide nanocrystals with polymers affects their depletion-induced interactions and assembly in solutions of polyethylene glycol. Copolymers of polyacrylic acid grafted with polyethylene oxide provide nanocrystal wrappings with different effective polymer graft densities and molecular weights. (Ultra) small angle X-ray scattering, coarse-grained molecular dynamics simulation, and molecular thermodynamic theory were combined to analyze how depletant size and polymer wrapping characteristics affect depletion interactions, structure, and phase behavior. The results show how depletant molecular weight, as well as surface density and molecular weight of polymer grafts, set thresholds for assembly. These signatures are unique to depletion-driven assembly of nanoscale colloids and mirror phase behaviors of grafted nanoparticle–polymer composites. Optical and rheological responses of depletion-driven assemblies of nanocrystals with different polymer shell architectures were probed to learn how their structural differences impact properties. Finally, we discuss how these wrinkles for depletion-driven assembly at the nanoscale may provide fresh opportunities for designing responsive depletion interactions and dynamically reconfigurable materials.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Test beam study of SiPM-on-tile configurations
Light yield and spatial uniformity for a large variety of configurations of scintillator tiles were studied. The light from each scintillator was collected by a Silicon Photomultiplier (SiPM) directly viewing the produced scintillation light (SiPM-on-tile technique). The varied parameters included tile transverse size, tile thickness, tile wrapping material, scintillator composition, and SiPM model. Furthermore, these studies were performed using 120 GeV protons at the Fermilab Test Beam Facility. External tracking allowed the position of each proton penetrating a tile to be measured. The results were compared to a GEANT4 simulation of each configuration of scinitillator, wrapping, and SiPM.
47 OTHER INSTRUMENTATION↗
Super Conducting REBCO Cable Wrapper
Future upgrades to CERN particle accelerator magnets require flat, high-temperature superconducting cables, created by wrapping brittle REBCO tape around a Rutherford copper core. Because current manual wrapping processes are time-consuming and prone to damaging the delicate ceramic tape, our team was tasked with automating the fabrication. We developed a modular, wrapping machine featuring adjustment for repeatable 10°to 45° wrap angles and a precise magnetic tensioning mechanism. While full-scale testing is pending final machined parts, our 3D-printed prototype successfully validates the system’s motion and sets the stage for future testing.
Gillen, Kameron [Northern Illinois U.]↗
Magnetic reconnection and magnetic activity
A large-scale magnetic field extending through a highly conducting tenuous fluid may become distorted on a small scale as a consequence of slow small-scale shuffling of the magnetic lines of force at the boundaries of the tenuous fluid. Any slow wrapping and winding introduced at the boundaries is distributed along the field (at the Alfven speed). It is a curious and little-known fact that such wrapping and winding possesses no static equilibrium (except for a set of solutions of extreme symmetry). The result is neutral-point reconnection of the strains in the field, rapidly dissipating the wrapping and winding. It is suggested that this is the principal cause of the extreme heating that produces the active corona of the sun and other stars. The shuffling of the footpoints of the magnetic field in the photospheric turbulence introduces small-scale wrapping and twisting into the coronal loops. The work done by the turbulence in twisting the fields is dissipated within a matter 10-20 hours by neutral-point reconnection, introducing heat into the corona at a rate of about 10 Mergs/sq cm sec for photospheric turbulence of 0.5 km/sec. It is suggested that this is the basic cause of the X-ray corona.
Parker, E. N.↗
An approach to integrating and creating flexible software environments
Engineers and scientists are attempting to represent, analyze, and reason about increasingly complex systems. Many researchers have been developing new ways of creating increasingly open environments. In this research on VEHICLES, a conceptual design environment for space systems, an approach was developed, called 'wrapping', to flexibility and integration based on the collection and then processing of explicit qualitative descriptions of all the software resources in the environment. Currently, a simulation is available, VSIM, used to study both the types of wrapping descriptions and the processes necessary to use the metaknowledge to combine, select, adapt, and explain some of the software resources used in VEHICLES. What was learned about the types of knowledge necessary for the wrapping approach is described along with the implications of wrapping for several key software engineering issues.
Bellman, Kirstie L.↗
Rocket Engine Thrust Chamber Assembly
A thrust chamber assembly for liquid fueled rocket engines and the method of making it wherein a two-piece mandrel wrapped with a silica tape saturated with a phenolic resin, the tape extending along the mandrel and covering the combustion chamber portion of the mandrel to the throat portion. The phenolic in the tape is cured and the end of the wrap is machined. The remainder of the mandrel is wrapped with a third silica tape. The resin in the third tape is cured and the assembly is machined. The entire assembly is then wrapped with a tow of graphite fibers wetted with an epoxy resin and, after the epoxy resin is cured, the graphite is machined to final dimensions.
Cornelius, Charles S.↗
Iterative-Transform Phase Retrieval Using Adaptive Diversity
A phase-diverse iterative-transform phase-retrieval algorithm enables high spatial-frequency, high-dynamic-range, image-based wavefront sensing. [The terms phase-diverse, phase retrieval, image-based, and wavefront sensing are defined in the first of the two immediately preceding articles, Broadband Phase Retrieval for Image-Based Wavefront Sensing (GSC-14899-1).] As described below, no prior phase-retrieval algorithm has offered both high dynamic range and the capability to recover high spatial-frequency components. Each of the previously developed image-based phase-retrieval techniques can be classified into one of two categories: iterative transform or parametric. Among the modifications of the original iterative-transform approach has been the introduction of a defocus diversity function (also defined in the cited companion article). Modifications of the original parametric approach have included minimizing alternative objective functions as well as implementing a variety of nonlinear optimization methods. The iterative-transform approach offers the advantage of ability to recover low, middle, and high spatial frequencies, but has disadvantage of having a limited dynamic range to one wavelength or less. In contrast, parametric phase retrieval offers the advantage of high dynamic range, but is poorly suited for recovering higher spatial frequency aberrations. The present phase-diverse iterative transform phase-retrieval algorithm offers both the high-spatial-frequency capability of the iterative-transform approach and the high dynamic range of parametric phase-recovery techniques. In implementation, this is a focus-diverse iterative-transform phaseretrieval algorithm that incorporates an adaptive diversity function, which makes it possible to avoid phase unwrapping while preserving high-spatial-frequency recovery. The algorithm includes an inner and an outer loop (see figure). An initial estimate of phase is used to start the algorithm on the inner loop, wherein multiple intensity images are processed, each using a different defocus value. The processing is done by an iterative-transform method, yielding individual phase estimates corresponding to each image of the defocus-diversity data set. These individual phase estimates are combined in a weighted average to form a new phase estimate, which serves as the initial phase estimate for either the next iteration of the iterative-transform method or, if the maximum number of iterations has been reached, for the next several steps, which constitute the outerloop portion of the algorithm. The details of the next several steps must be omitted here for the sake of brevity. The overall effect of these steps is to adaptively update the diversity defocus values according to recovery of global defocus in the phase estimate. Aberration recovery varies with differing amounts as the amount of diversity defocus is updated in each image; thus, feedback is incorporated into the recovery process. This process is iterated until the global defocus error is driven to zero during the recovery process. The amplitude of aberration may far exceed one wavelength after completion of the inner-loop portion of the algorithm, and the classical iterative transform method does not, by itself, enable recovery of multi-wavelength aberrations. Hence, in the absence of a means of off-loading the multi-wavelength portion of the aberration, the algorithm would produce a wrapped phase map. However, a special aberration-fitting procedure can be applied to the wrapped phase data to transfer at least some portion of the multi-wavelength aberration to the diversity function, wherein the data are treated as known phase values. In this way, a multiwavelength aberration can be recovered incrementally by successively applying the aberration-fitting procedure to intermediate wrapped phase maps. During recovery, as more of the aberration is transferred to the diversity function following successive iterations around the ter loop, the estimated phase ceases to wrap in places where the aberration values become incorporated as part of the diversity function. As a result, as the aberration content is transferred to the diversity function, the phase estimate resembles that of a reference flat.
Dean, Bruce H.↗
Parametric Studies of Heat Pump Water Heater Using Low GWP Refrigerants
A storage heat pump water heater (HPWH) comprises a vapor compression system and a hot water tank. It can lead to more than 70% energy saving, compared with electric resistance heating. HPWH usually uses a wrapped-tank coil as the water heater. The wrapped coil has a strong interaction with the water tank and impose a new challenge for the engineering design and simulation study. Based on the US DOE/ORNL Heat Pump Design Model (HPDM), i.e., a public-domain, component-based thermal system modelling platform, a segment-to-segment wrapped-tank coil model coupled with a one-dimensional stratified water tank model were developed, which facilitates modeling and design HPWHs having various configurations and components. Additionally, the hardware-based design model was used to evaluate refrigerants having lower global warming potentials to replace R-134a, including R-1234yf, R-1234ze, R-290, R-513A and R-450A, when effects of compressor size, refrigerant charge on 24-hour uniform energy factor (UEF) and first-hour rating (FHR) were investigated.In the drop-in replacements, R-1234ze achieved the best UEF, and R-290 resulted in the lowest UEF. When downsizing the compressor to maximize the UEFs, the UEFs of R-134a, R-290, R1234yf, R-450A and R-513A ascended to the range of 4.4 to 4.53, with R-513A having the highest UEF. The R-1234ze ended up having the lowest UEF of 4.27. Refrigerants having larger volumetric vaporization heat led to higher FHRs if using the fixed-size compressor, that R-290 resulted in the highest FHR.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Gauge R & R studies for angular measurements
Angular measurements lie on the circumference of a circle and have different characteristics than standard scalar measurements. For applications involving angular data, treating the measured values as scalars can lead to misinterpretation of results if its wrap-around nature is not taken into account. In this article, we propose a variance components wrapped normal model for angular measurements that is analogous to the standard normal model for continuous measurements. This model allows decomposition of contributions to the overall variance to be separated and compared to understand the drivers of the spread of the data. In this work, we analyze gauge R & R study data using Bayesian methods and illustrate the use of this wrapped normal model with simulated and real data. We also performed a small simulation study in considering the design of gauge R & R studies with angular measurements.
42 ENGINEERING↗