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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Metallization of conductive wires for solar cells

Methods of fabricating a solar cell, and system for electrically coupling solar cells, are described. In an example, the methods for fabricating a solar cell can include placing conductive wires in a wire guide, where conductive wires are placed over a first semiconductor substrate having first doped regions and second doped regions. The method can include aligning the conductive wires over the first and second doped regions, where the wire guide aligns the conductive wires substantially parallel to the first and second doped regions. The method can include bonding the conductive wires to the first and second doped regions. The bonding can include applying a mechanical force to the semiconductor substrate via a roller or bonding head of the wire guide, where the wire guide inhibits lateral movement of the conductive wires during the bonding.

Sewell, Richard Hamilton↗
DOE OSTI2021

Impact of Flux Wire Selection on Neutron Spectrum Adjustment

In reactor dosimetry, spectrum unfolding methods are used to assess the energy-dependent neutron flux following the irradiation of flux wires or foils. For some spectrum unfolding methods, an a priori, or initial guess, spectrum is necessary. However, if the a priori spectrum is not representative of the irradiation spectrum experienced by the flux wires, the spectrum unfolding method may fail or create a nonphysical adjusted spectrum. The unfolded spectrum is dependent on flux wire reaction rates, and therefore cross section. As a result, each selection or combination of flux wires will have a different sensitivity to the group-wise fluence difference between the a priori spectrum and the irradiation spectrum. Therefore, a selection of flux wires that are insensitive to errors in the a priori spectrum would be considered robust choices for reactor dosimetry. In this work, flux wire reaction rates are calculated using a simulated neutron spectrum from the High Flux Isotope Reactor (HFIR) and spectrum unfolding methods are used in each flux wire combinations. The flux wire combinations are compared against a traditional flux wire set of Ti, Fe, and Co, with a summary table of the deemed “good” wire combinations that are insensitive to number of a priori neutron energy groups, group-wise difference between the a priori and irradiation, and magnitude of difference.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Particle Image Velocimetry Measurements in a Wire-Wrapped 61-Pin Hexagonal Fuel Bundle

Liquid metal fast reactor fuel assemblies using sodium as a coolant typically utilize a tightly packed triangular lattice of fuel pins enclosed in a hexagonal duct. The fuel pins are typically wrapped with a helical wire spacer. The primary function of the wire spacers is to maintain a gap between neighboring fuel pins. They also mitigate vortex-induced vibration and enhance sub-channel mixing to increase convective heat transfer. Many experiments have been performed to study thermal-hydraulic characteristics, primarily pressure drops, of the wire-wrapped fuel bundles. Novendstern developed a semi-empirical model to predict pressure losses in a hexagonal array of wire-wrapped pins in the turbulent flow regime. Rehme proposed pressure drop correlations for a wide range of geometrical parameters, such as pitch-to-diameter ratio P/D from 1.125 to 1.417, lead-to-wire diameter ratio H / dm from 6 to 45, and number of pins n from 7 to 61. Cheng and Todreas introduced their hydrodynamic models for subchannel friction factors and mixing parameters in a 37-pin fuel bundle, which covered the laminar, transition and turbulent flow regimes. Computational fluid dynamics (CFD) offers an opportunity to validate the above correlations and investigate the flow characteristics in the subchannels. Several numerical studies of the wire-wrapped fuel bundles have been performed and most of them are Reynolds-Averaged Navier-Stokes (RANS) based simulations with various turbulence models. Ahmad and Kim performed RANS simulations of 7- and 19-pin bundles using the k-omega SST turbulent model, while Gajapathy et al. performed RANS simulations on 7-pin bundles using the k-epsilons model. Recently, Fischer et al. carried out large-eddy simulation (LES) calculations on wire-wrapped fuel bundles to obtain higher-resolution numerical solutions of subchannel behavior. The geometrical complexity of the hexagonal wire-wrapped fuel bundle has limited experimental activities to pressure drop measurements. A database of pressure drops and flow-field measurements in a 61-pin wire-wrapped hexagonal fuel bundle is not available to benchmark the existing correlations and validate the CFD calculations. Texas A and M University is conducting isothermal flow experiments in a wire-wrapped 61-pin hexagonal fuel bundle to support the research on advanced nuclear fuel development sponsored by the Department of Energy (DOE). The purpose of these tests is to perform high spatial and temporal resolution measurements of the flow and pressure measurements at different locations in the fuel bundle. The experimental facility employs matched-index-of-refraction (MIR) techniques and laser diagnostic velocity measurement techniques such as particle image velocimetry (PIV) and laser Doppler velocimetry (LDV). The result of this experimental activity will be an experimental database of pressure and flow-field measurements that will be suitable for validating CFD computer codes. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2014

Radiation from mixed multi-planar wire arrays

The study of radiation from different wire materials in wire array Z-pinch plasma is a very challenging topic because it is almost impossible to separate different plasmas at the stagnation. A new approach is suggested based on planar wire array (PWA) loads to assess this problem. Multi-planar wire arrays are implemented that consist of few planes, each with the same number of wires and masses but from different wire materials, arranged in parallel rows. In particular, the experimental results obtained with triple PWAs (TPWAs) on the UNR Zebra generator are analyzed with Wire Ablation Dynamics Model, non-local thermodynamic equilibrium kinetic model, and 2D radiation magneto-hydrodynamic to illustrate this new approach. In TPWAs, two wire planes were from mid-atomic-number wire material and another plane was from alloyed Al, placed either in the middle or at the edge of the TPWA. Spatial and temporal properties of K-shell Al and L-shell Cu radiations were analyzed and compared from these two configurations of TPWAs. Advantages of the new approach are demonstrated and future work is discussed.

74 ATOMIC AND MOLECULAR PHYSICS↗
DOE OSTI2014

Transforming dielectric coated tungsten and platinum wires to gaseous state using negative nanosecond-pulsed-current in vacuum

With the help of thin dielectric coatings, corona free explosions were achieved in the region of about half a wire length (2 cm) for tungsten wires and nearly the whole wire length for platinum wires under a fast rising (46–170 A/ns) negative polarity current in vacuum. Expansion velocity of the tungsten gas was over 10 km/s. Current waveforms from exploding coated wires were similar to those from bare wires in the air including a current pause stage. Coated wires with different coating parameters had a similar joule energy deposition before voltage collapsed, but a quite different scenario in the region near the electrodes. The axial field under negative current was the main reason for the axial inhomogeneity of coated tungsten wires. Tungsten or platinum gases in the vaporized region were tightly encompassed by the dielectric coating, while gaps or probably low density gases, were observed between the coating and the edge of the dense wire core in the core-corona structure region.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2014

Larger sized wire arrays on 1.5 MA Z-pinch generator

Experiments on the UNR Zebra generator with Load Current Multiplier (LCM) allow for implosions of larger sized wire array loads than at standard current of 1 MA. Advantages of larger sized planar wire array implosions include enhanced energy coupling to plasmas, better diagnostic access to observable plasma regions, and more complex geometries of the wire loads. The experiments with larger sized wire arrays were performed on 1.5 MA Zebra with LCM (the anode-cathode gap was 1 cm, which is half the gap used in the standard mode). In particular, larger sized multi-planar wire arrays had two outer wire planes from mid-atomic-number wires to create a global magnetic field (gmf) and plasma flow between them. A modified central plane with a few Al wires at the edges was put in the middle between outer planes to influence gmf and to create Al plasma flow in the perpendicular direction (to the outer arrays plasma flow). Such modified plane has different number of empty slots: it was increased from 6 up to 10, hence increasing the gap inside the middle plane from 4.9 to 7.7 mm, respectively. Such load configuration allows for more independent study of the flows of L-shell mid-atomic-number plasma (between the outer planes) and K-shell Al plasma (which first fills the gap between the edge wires along the middle plane) and their radiation in space and time. We demonstrate that such configuration produces higher linear radiation yield and electron temperatures as well as advantages of better diagnostics access to observable plasma regions and how the load geometry (size of the gap in the middle plane) influences K-shell Al radiation. In particular, K-shell Al radiation was delayed compared to L-shell mid-atomic-number radiation when the gap in the middle plane was large enough (when the number of empty slots was increased up to ten)

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

Material and Design Optimization of Printed Melt Wire Arrays

Recent work conducted by the Advanced Sensors and Instrumentation (ASI) program at Idaho National Laboratory resulted in the establishment of in-house capabilities for fabricating and testing new advanced manufactured sensors for measuring irradiation temperatures inside a nuclear test reactor. Though current methods of real-time temperature monitoring (e.g., thermocouples) can still be used, the complexity of the feedthroughs and attachments needed for collecting real time measurements greatly increases the experiment-related costs. On the other hand, passive monitoring techniques can be used for collecting post irradiation temperature measurements by inferring reactor temperatures, based on the melting points of well-characterized materials (i.e., standard melt wires). However, challenges have arisen due to the limited space available for including instrumentation in experiments. To resolve this issue, the ASI program expanded its temperature detection capabilities to include advance manufactured melt wires for post-irradiation temperature measurements. These melt wires can determine reactor temperatures while also accommodating space limitations in irradiation experiments. To improve performance reliability and enhance melt wire readability following irradiation, FY-22 efforts have focused on optimizing the materials used in the encapsulation and printed melt wire array. This report details the design and fabrication tasks, along with the subsequent x ray computed tomography (XCT) evaluation process. The melt wire array consisted of indium with a melting point of 157°C, indium/silver (96/4 at%) with a melting point of 219°C, and tin with a melting point of 230°C. The encapsulation disc was made of vanadium due to its low activation properties and radiation resistance when deployed in nuclear reactors. Additionally, the melt wire design consisted of a ceramic sublayer (alumina disc) to further enhance the XCT post melting images of the printed melt wires. However, when sealing the vanadium container, all three melt wires melted, reflecting the temperature limitations that must be considered when employing metal containers in the sealing process.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Advanced silver sheathed 2212/Ag wire for high field magnets

Commercial High Temperature Superconductors (HTS) are all tape shaped (widths > 10 times thickness), because achieving useful current densities required them to be processed into this form, even though this also makes it more problematic to use them in some important coil types. Our product is based on 2212 (Bi2Sr2CaCu2O8) and it is the only HTS that can be processed into high current density wire forms that are similar to proven low temperature superconductors (LTS), while surpassing them in field generating and operating temperature capability. Required now are higher current density, lower cost and longer length 2212 wires to enable broad utilization where HTS tape usage is problematic. In Phase II we developed vital cost-lowering process technology elements and we test-processed longer wires with the standard commercial design as baseline and benchmark for our lower cost, higher quality and longer piece length wire advances. By initial application of Jc-boosting wire features, these wires exhibited significant performance increases. This Phase IIA program has now developed and qualified these technologies for lower cost, higher quality and longer piece length manufacturing in combination with current density-boosting wire features, paving the way to manufacturing capability that is essential for cost-effective commercial utilization of 2212 wire. Technical areas included automated, high uniformity powder packing, advanced drawing, annealing, lubricant cleaning and filament bundling, followed by integration of higher current density wire features and process variations.

17 WIND ENERGY↗
DOE OSTI2024

Area-based composition predictions of materials fabricated using simultaneous wire-powder-directed energy deposition

Functionally graded materials are an emergent method for designing components with programmable site-specific material properties. These materials are typically fabricated using metal additive manufacturing tools by simultaneously feeding multiple wire and/or powder feedstocks at various rates to achieve spatial composition change. The wire-powder-directed energy deposition (WP-DED) technique is of particular interest for many functionally graded material applications by balancing the low raw materials cost of wire with the high resolution of powder. However, feeding wire and powder are inherently different processes since all extruded wire enters the melt pool, while much of the blown powder is scattered, which makes determining the composition of the build challenging. In this study, we devise a simple area-based measurement method for estimating the composition of WP-DED structures. WP-DED single beads are printed using 309L stainless steel wire and commercially pure Fe powder at five wire feed rates (0.5, 0.75, 1.00, 1.25, 1.50 mm/mm) and five powder feed rates (2, 4, 6, 8, 10 rpm). Characteristic defects including interface gaps and macrosegregation (lack of mixing) tendencies are examined. High powder feed rates (8, 10 rpm) result in interface gaps at all wire feed rates, but smooth deposition and complete mixing is achieved at low powder feed rates, particularly with lower wire feed rates as well. The area-based composition measurement method is within ±20% of energy dispersive x-ray spectroscopy measurements for all samples, showing its effectiveness as a rapid composition estimate for WP-DED materials development.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Increasing the K-shell yield of line radiation in Z-pinch implosions using alloyed Al/Mg wire-arrays

The variation of the K-shell yield of pure aluminum wire-array Z-pinch implosions with load parameters is discussed. The mechanism and the efficiency of increasing the K-shell yield using alloyed Al/Mg wire-arrays are numerically investigated. It has been shown that the maximum K-shell yield from a pure aluminum wire-array Z-pinch implosion can be obtained at an optimal load mass for a given generator and at a fixed initial wire-array radius. This optimal load mass is determined by the load energy coupling with the generator, the capability of Z-pinch plasmas to emit the K-shell radiation, and the self absorption of K-shell lines. For different generators, the optimal load mass increases as the drive current increases, and the line absorption limits the further increase of K-shell radiation. The coupled energy per ion is likely decreasing with increased mass, so the plasma might not be able to ionize into the K-shell. Also, the ability of the plasma to radiatively cool can increase with mass, thus, making it difficult for the plasma to ionize into and remain in the K-shell during the stagnation phase of the implosion. Alloyed Al/Mg wire-arrays were thus suggested to be used to decrease the opacity of K-shell lines and to increase the overall K-shell yield. In this paper, we show that using alloyed Al/Mg wire-arrays will decrease the opacity and increase the K-shell yield remarkably if the plasma is optically thick. We will also show that the efficiency of increasing the K-shell yield with alloyed Al/Mg wire-arrays cannot increase indefinitely. The ratio of K-shell yield from an alloyed Al/Mg wire-array to that from a pure aluminum wire-array reaches a limit. For example, we show that when the mass share of magnesium is 10% then this limit is 1.2, and for a 50% mass share, the limit is 1.3.

74 ATOMIC AND MOLECULAR PHYSICS↗
DOE OSTI2016

Quench degradation limit of multifilamentary AgBi 2 Sr 2 CaCu 2 O x round wires

Understanding safe operating limits of composite superconducting wires is important for the design of superconducting magnets. Here we report measurements of quench-induced critical current density Jc degradation in commercial Ag/Bi 2 Sr 2 CaCu 2 O x (Bi-2212) round wires using heater-induced quenches at 4.2 K in self magnetic field that reveal a general degradation behavior. J c degradation strongly depends on the local hot spot temperature T max , and is nearly independent of operating current, the temperature gradient along the conductor dT max /dx, and the temperature rising rate dT max /dt. Both J c and n value (where n is an index of the sharpness of the superconductor-to-normal transition) exhibit small but irreversible degradation when T max exceeds 400-450 K, and large degradation occurs when Tmax exceeds 550 K. This behavior was consistently found for a series of Bi-2212 wires with widely variable wire architectures and porosity levels in the Bi-2212 filaments, including a wire processed using a standard partial melt processing and in which Bi-2212 filaments are porous, an overpressure processed wire in which Bi-2212 filaments are nearly porosity-free and that has a J c (4.2 K, self field) exceeding 8000 A/mm 2 , and a wire that has nearly no filament to filament bridges after reaction. Microstructural observations of degraded wires reveal cracks in the Bi-2212 filaments perpendicular to the wire axis, indicating that the quench-induced I c degradation is primarily driven by strain. These results further suggest that the quench degradation temperature limit depends on the strain state of Bi-2212 filaments and this dependence shall be carefully considered when engineering a high-field Bi-2212 magnet.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Enhanced critical axial tensile strain limit of CORC ® wires: FEM and analytical modeling

Abstract Conductor on Round Core (CORC ® ) cables and wires are composed of spiraled high-temperature superconducting (HTS) rare-earth barium copper oxide (REBCO) tapes, wound in multiple layers, and can carry very high currents in background magnetic fields of more than 20 T. They combine isotropic flexibility and high resilience to electromagnetic and thermal loads. The brittle nature of HTS tapes limits the maximum allowable axial tensile strain in superconducting cables. An intrinsic tensile strain above about 0.45% will introduce cracks in the REBCO layer of straight HTS tapes resulting in irreversible damage. The helical fashion at which the REBCO tapes are wound around the central core allows tapes to experience only a fraction of the total axial tensile strain applied to the CORC ® wire. As a result, the critical strain limit of CORC ® wires can be increased by a factor of more than 10 that of REBCO tapes. Finite element (FE) and analytical models are developed to predict the performance of CORC ® wires under axial tensile strain. A parametric analysis is carried out by varying the winding angle, the Poisson’s ratio of the CORC ® wire core, the core diameter, and the tape width. The results show that a small variation in winding angle can have a significant impact on the cable’s axial tensile strain tolerance. While the radial contraction of the helically wound tapes in a CORC ® wire under axial tensile strain depends on its winding angle, it is mostly driven by the Poisson’s ratio of the central core, affecting the tape strain state and thus its performance. Contact pressure from multiple layers within the CORC ® wire also affects the CORC ® wire performance. The FE model can be used to optimize the cable design for specific application conditions, resulting in an irreversible strain limit of CORC ® cables and wires as high as 7%.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS1990

Frequency response of a thermocouple wire: Effects of axial conduction

Theoretical expressions are derived for the steady-state frequency response of a thermocouple wire. In particular, the effects of axial heat conduction are demonstrated for both a uniform thermocouple wire and a nonuniform wire with unequal material properties and wire diameters across the junction. For the case of a uniform wire, the amplitude ratio and phase angle compare favorably with the series solution of Scadron and Warshawsky (1952) except near the ends of the wire. For the case of a non-uniform wire, the amplitude ratio at low frequency omega yields 0 agrees with the results of Scadron and Warshawsky for a steady-state temperature distribution. Moreover, the frequency response for a non-uniform wire in the limit of infinite length l yields infinity is shown to reduce to a simple expression that is analogous to the classic first order solution for a thermocouple wire with uniform properties.

Forney, L. J.↗
NASA NTRS1995

Electrical short circuit and current overload tests on aircraft wiring

The findings of electrical short circuit and current overload tests performed on commercial aircraft wiring are presented. A series of bench-scale tests were conducted to evaluate circuit breaker response to overcurrent and to determine if the wire showed any visible signs of thermal degradation due to overcurrent. Three types of wire used in commercial aircraft were evaluated: MIL-W-22759/34 (150 C rated), MIL-W-81381/12 (200 C rated), and BMS 1360 (260 C rated). A second series of tests evaluated circuit breaker response to short circuits and ticking faults. These tests were also meant to determine if the three test wires behaved differently under these conditions and if a short circuit or ticking fault could start a fire. It is concluded that circuit breakers provided reliable overcurrent protection. Circuit breakers may not protect wire from ticking faults but can protect wire from direct shorts. These tests indicated that the appearance of a wire subjected to a current that totally degrades the insulation looks identical to a wire subjected to a fire; however the 'fire exposed' conductor was more brittle than the conductor degraded by overcurrent. Preliminary testing indicates that direct short circuits are not likely to start a fire. Preliminary testing indicated that direct short circuits do not erode insulation and conductor to the extent that ticking faults did. Circuit breakers may not safeguard against the ignition of flammable materials by ticking faults. The flammability of materials near ticking faults is far more important than the rating of the wire insulation material.

Cahill, Patricia↗
NASA NTRS2000

B218 Weld Filler Wire Characterization for Al-Li Alloy 2195

NASA Marshall Space Flight Center, Lockheed Martin Space Systems- Michoud Operations, and McCook Metals have developed an aluminum-copper weld filler wire for fusion welding aluminum lithium alloy 2195. The aluminum-copper based weld filler wire has been identified as B218, a McCook Metals designation. B218 is the result of six years of weld filler wire development funded by NASA, Lockheed Martin, and McCook Metals. The filler wire chemistry was developed to produce enhanced 2195 weld and repair weld mechanical properties over the 4043 aluminum-silicon weld filler wire, which is currently used to weld 2195 on the Super Lightweight External Tank for the NASA Space Shuttle Program. An initial characterization was performed consisting of a repair weld evaluation using B218 and 4043 weld filler wires. The testing involved room temperature and cryogenic repair weld tensile testing along with fracture toughness testing. From the testing, B218 weld filler wire produce enhanced repair weld tensile strength, ductility, and fracture properties over 4043. B218 weld filler wire has proved to be a superior weld filler wire for welding aluminum lithium alloy 2195 over 4043.

Bjorkman, Gerry↗
NASA NTRS2000

Aluminum Lithium Alloy 2195 Fusion Welding Improvements with New Filler Wire

A viewgraph presentation outlines NASA Marshall Space Flight Center, Lockheed Martin Michoud Space Systems, and McCook Metals' development an aluminum-copper weld filler wire for fusion welding 2195 aluminum lithium. The aluminum-copper based weld filler wire has been identified as B218, which is the result of six years of weld filler wire development funded by NASA, Lockheed Martin, and McCook Metals. The Super Lightweight External Tank for the NASA Space Shuttle Program consists of 2195 welded with 4043 aluminum-silicon weld filler wire. The B218 filler wire chemistry was developed to produce enhanced 2195 weld and repair weld mechanical properties. An initial characterization of the B218 weld filler wire was performed consisting of initial weld and repair weld evaluation comparing B218 and 4043. The testing involved room temperature and cryogenic tensile testing along with fracture toughness testing. B218 weld filler wire proved to produce enhanced initial and repair weld tensile and fracture properties over 4043. B218 weld filler wire has proved to be a superior weld filler wire for welding 2195 and other aluminum lithium alloys over 4043.

Russell, Carolyn↗
NASA NTRS2000

Model-Based Testability Assessment and Directed Troubleshooting of Shuttle Wiring Systems

We have recently completed a pilot study on the Space shuttle wiring system commissioned by the Wiring Integrity Research (WIRe) team at NASA Ames Research Center, As the space shuttle ages, it is experiencing wiring degradation problems including arcing, chaffing insulation breakdown and broken conductors. A systematic and comprehensive test process is required to thoroughly test and quality assure (QA) the wiring systems. The NASA WIRe team recognized the value of a formal model based analysis for risk-assessment and fault coverage analysis. However. wiring systems are complex and involve over 50,000 wire segments. Therefore, NASA commissioned this pilot study with Qualtech Systems. Inc. (QSI) to explore means of automatically extracting high fidelity multi-signal models from wiring information database for use with QSI's Testability Engineering and Maintenance System (TEAMS) tool.

Deb, Somnath↗
NASA NTRS2005

Application of Ultrasonic Guided Waves for Evaluating Aging Wire Insulation

Aging wiring has become a critical issue to the aerospace and aircraft industries due to Shuttle and aircraft incidents. The problem is that over time the insulation on wire becomes brittle and cracks. This exposes the underlying conductive wire to the potential for short circuits and fire. Popular methods of monitoring aging wire problems focuses on applying electrical sensing techniques that are sensitive to the conductor's condition, but not very sensitive to the wire insulation's condition. Measurement of wire insulation stiffness and ultrasonic properties by ultrasonic guided waves is being examined. Experimental measurements showed that the lowest order extensional mode could be sensitive to stiffness changes in the wire insulation. To test this theory conventional wire samples were heat damaged in an oven, in a range of heating conditions. The samples were 12, 16, and 20 gauge and the heat damage introduced material changes in the wire insulation that made the originally flexible insulation brittle and darker in color. Results showed that extensional mode phase velocity increased for the samples that were exposed to heat for longer duration.

Anastasi, Robert F.↗