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DOE OSTI2017

Structural Transformations in Nematic Liquid Crystals with a Hybrid Orientation

The structural transformations in a nematic liquid crystal (NLC) layer with a hybrid orientation (planar director orientation is created on one substrate and homeotropic director orientation is created on the other) are studied. In the case of a dc voltage applied to the NLC layer, the primary instability is flexoelectric. It causes the appearance of flexoelectric domains oriented along the director on the substrate with a planar orientation. When the voltage increases further, an electroconvective instability in the form of rolls moving almost normal to flexoelectric domains develops along with these domains. Thus, the following spatially periodic structures of different natures coexist in one system: equilibrium static flexoelectric deformation of a director and dissipative moving oblique electroconvection rolls. The primary instability in the case of an ac voltage is represented by electroconvection, which leads to moving oblique or normal rolls depending on the electric field frequency. Above the electroconvection threshold, a transition to moving “abnormal” rolls is detected. The wavevector of the rolls coincides with the initial director orientation on the substrate with a planar orientation, and the projection of the director at the midplane of the NLC layer on the layer plane makes a certain angle with the wavevector. The results of numerical calculations of the threshold characteristics of the primary instabilities agree well with the obtained experimental data.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2020

Characterization Report for the MP-1 Experiment Fabrication Campaign

This report covers the results of MP 1 fuel characterization analysis to provide a detailed understanding of the as-fabricated fuel that would be irradiated in the MP 1 (Mini-Plate 1) experiment. The work was performed at Pacific Northwest National Laboratory (PNNL), Idaho National Laboratory (INL), and Los Alamos National Laboratory (LANL). Characterization of the as-fabricated fuel was performed in accordance with Characterization Plan for the Fabrication of U 10Mo for the MP 1 Experiment, hereinafter the MP 1 Characterization Plan (MAQP 2016). Under the MP 1 Characterization Plan, fuel foils at different points in the foil fabrication process (e.g., hot rolled annealed, cold rolled annealed) were studied to understand the effect of various thermomechanical processes on the fuel microstructure. Samples were sent to each of the three organizations so that testing and analysis could be performed independently using similar equipment and a standardized set of measurement and analysis procedures. The MP 1 experiment will provide an opportunity to understand the effects of processing conditions on the final fuel microstructure, to compare independently obtained results, and achieve a three-way validation. PNNL characterized 28 uranium–10 wt% molybdenum (U 10Mo) samples. Six pieces/specimens from each sample/foil were sectioned, in accordance with the MP 1 Characterization Plan. Similarly, INL and LANL also examined 24 and 17 U 10Mo specimens, respectively. These total 69 samples consist of six types of MP 1 characterization foils fabricated by Babcock and Wilcox Technologies (BWXT) from ingots produced by the Y-12 National Security Complex: • 0.047 in.-thick hot-rolled and annealed samples with and without Zr layers • 0.02 in.-thick cold-rolled and annealed samples with and without Zr layers • 0.01 in.-thick cold-rolled and annealed samples with and without Zr layers. Microstructure, chemical composition, carbide morphology, U 10Mo foil thickness, Zr thickness, mechanical properties (microhardness), and density were evaluated in both longitudinal and transverse directions for foils of the three different thicknesses.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

Combining Fluorescence and Phosphorescence to Achieve Very Long Lifetime and Efficient White OLEDs (Final Technical Report)

The objective of our project was to develop a high efficiency, long lived WOLED using a hybrid approach to harvesting singlet and triplet excitons, as described above. WE met out GONOGO metric at the end of year one, achieving an efficiency of nearly 50 lm/W for high quality white light emission. We faced an unforeseen problem in achieving this high efficiency level at high brightness. Our hybrid devices showed a significant roll off in device efficiency as the current is raised, such that our efficiency dropped to ca. 10 lm/W at 1000 nits. This roll off precluded us form achieving our send year targets with regards to efficiency at high brightness and long device lifetime. We spent the majority of our efforts in year two trying to decrease or eliminate this efficiency roll off, but this roll off prevented us from reaching our end of program target of high efficiency at high brightness with long device lifetime. Toward the end of the sixth quarter of the program we began to investigate a new approach, which involved a tandem WOLED, with a hybrid blue/red OLED stacked on a phosphorescent green OLED. The resultant emission from the stack will be white and the tandem structure relaxes the constraints on the materials, which we believe is key issue in the high roll off in efficiency.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

High-Silicon Steel Strip by Single-Step Shear Deformation Processing

It is well known that Fe-Si alloys with Si content higher than in conventional electrical sheet steels (>3.2% Si) can make a significant impact in improving the efficiency of electrical motors if they are available in sheet/foil (strip) forms at suitable cost. While the magnetic and electrical attributes (e.g., resistivity, core loss) of these high-Si Fe alloys, of relevance to electrical motor core laminations, are known to be exceptional, the alloys have limited workability, making them difficult to produce consistently in sheet/foil (strip) forms. Current processing techniques such as rolling, while adequate for producing conventional electrical steel sheet, do have important disadvantages - large energy consumption and emissions, limitations in processing of low-workability alloys (e.g., high-Si content steels), large-scale plant infrastructure, and less than adequate capability to engineer sheet metals with specific microstructures (e.g., fine-grained) and crystallographic textures (e.g., shear textures). It is therefore of interest to have an alternative commercial process that can produce sheet/foil (strip) from high-Si Fe alloys and which can also overcome some of the deficiencies of current multistage strip processes. The goal of the present project was design and demonstration of a new energy-efficient pilot process for producing high-Si electrical steel strip of commercial widths and thickness, and with superior electrical and magnetic properties than current electrical steels (Fe-3.2% Si as benchmark). The applications domain for these steels is electrical motor core laminations. We have addressed this goal by accomplishment of the following specific objectives and tasks: a) Development of an Fe-4Si-4Cr alloy with electrical resistivity >80 μΩ-cm, induction flux density >1.48 T at 5000 A/m and core loss 35% lower than the benchmark 3.2% Si alloy. The alloy which meets DOE target specifications for motor core attributes was designed with the Si content controlled for the electrical properties and the Cr content tailored to meet material/process workability requirements. b) A unique machining-based deformation processing system was designed and scaled-up to produce strip of commercial width (25 mm to 150 mm) and thickness (up to 0.5 mm) from the Fe-4Si-4Cr alloy and other alloys of varied workability including copper, Al6061-T6 and naval brass. The key attributes of the machining-based strip production are deformation processing by concentrated simple-shear; single-step production of strip from ingot using compact machine infrastructure; strip surface finish of Ra 0.35 to 1 micrometer that is comparable/superior to that of rolled strip; discrete production of strip that can potentially be done at point of use; and controllability of strip mechanical/formability properties by deformation control. c) The electrical, magnetic, surface quality, mechanical, formability, and metallurgical properties/attributes of the machining-based strip were established by direct ASTM standard or equivalent measurement techniques. d) Punching characteristics of the strip in terms of load, edge quality and macro defects were similar to those of conventional 3.2% Si electrical steels. These punching characteristics are critical from a manufacturability perspective for motor/transformer core applications. e) A modeling framework for energy analysis of multistage rolling and the machining-based deformation processing has been established. Application of this modeling to the two strip-processes showed that the machining-based process requires significantly lower specific energy for processing, ~ 25% of that for rolling. The modeling framework can be adapted for a range of sheet-metal forming, bulk metal forming, and machining processes. It can be used to identify key parameters controlling process specific energy. f) A comparative analysis of advantages and disadvantages of machining-based processing against rolling for strip production. The single stage machining-based processing, with compact infrastructure, represents a new manufacturing paradigm for sheet and foil manufacturing that can potentially also be applied to advanced titanium, aluminum, copper and magnesium alloys. The goals and objectives were accomplished by a cross-disciplinary project team comprising of personnel from Purdue University; M4 Sciences LLC, a small-business focused on advanced manufacturing technology development; the Pacific Northwest National Labs; and tool manufacturers. The team is currently in advanced discussions with multiple entities for future process development for commercialization.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Characterization Report for the MP-1 Experiment Fabrication Campaign (Rev.1)

This report covers the results of MP 1 fuel characterization analysis to provide a detailed understanding of the as-fabricated fuel that would be irradiated in the MP 1 (Mini-Plate 1) experiment. The work was performed at Pacific Northwest National Laboratory (PNNL), Idaho National Laboratory (INL), and Los Alamos National Laboratory (LANL). Characterization of the as-fabricated fuel was performed in accordance with Characterization Plan for the Fabrication of U 10Mo for the MP 1 Experiment, hereinafter the MP 1 Characterization Plan (MAQP 2016). Under the MP 1 Characterization Plan, fuel foils at different points in the foil fabrication process (e.g., hot rolled annealed, cold rolled annealed) were studied to understand the effect of various thermomechanical processes on the fuel microstructure. Samples were sent to each of the three organizations so that testing and analysis could be performed independently using similar equipment and a standardized set of measurement and analysis procedures. The MP 1 experiment will provide an opportunity to understand the effects of processing conditions on the final fuel microstructure, to compare independently obtained results, and achieve a three-way validation. PNNL characterized 28 uranium–10 wt% molybdenum (U 10Mo) samples. Six pieces/specimens from each sample/foil were sectioned, in accordance with the MP 1 Characterization Plan. Similarly, INL and LANL also examined 24 and 17 U 10Mo specimens, respectively. These total 69 samples consist of six types of MP 1 characterization foils fabricated by Babcock and Wilcox Technologies (BWXT) from ingots produced by the Y-12 National Security Complex: (a.) 0.047 in.-thick hot-rolled and annealed samples with and without Zr layers; (b.) 0.02 in.-thick cold-rolled and annealed samples with and without Zr layers; and (c.) 0.01 in.-thick cold-rolled and annealed samples with and without Zr layers. Microstructure, chemical composition, carbide morphology, U 10Mo foil thickness, Zr thickness, mechanical properties (microhardness), and density were evaluated in both longitudinal and transverse directions for foils of the three different thicknesses.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Liquid Core Detection and Strand Condition Monitoring in a Continuous Caster Using Optical Fiber

Real-time monitoring of the liquid core position during the continuous casting of steel has been demonstrated using low-cost distributed optical-fiber-based strain sensors. These sensors were installed on the containment roll support structures in the segments of a production continuous caster to detect the position of the solid–liquid interface and monitor the strand condition during the continuous casting. Distributed Fiber Bragg Grating sensors (FBGs) were used in this work to monitor strain at six roll positions in the caster. The sensor performance was first validated by comparing optical strain measurements with conventional strain gauge measurements in the lab. Next, optical strain measurements were performed on an isolated caster segment in a segment maintenance facility using hydraulic jacks to simulate the presence of a liquid core under the roll. Finally, the sensors were evaluated during caster operation. The sensors successfully detected the load increase associated with the presence of a liquid core under each instrumented roll location. Incidents of bulging and roll eccentricity were also detected using frequency analysis of the optical strain signal. The liquid core position measurements were compared using predictions from computer models (digital twins) in use at the production site. The measurements were in good agreement with the model predictions, with a few exceptions. Under certain transient caster operating conditions, such as spraying practice changes and SEN exchanges, the model predictions deviated slightly from the liquid core position determined from strain measurements.

47 OTHER INSTRUMENTATION↗

NASA NTRS1974

Study of stability of large maneuvers of airplanes

A predictive method of nonlinear system analysis is used to investigate airplane stability and dynamic response during rolling maneuvers. The maneuver roll-rate is not assumed to be constant, and the airplane motion is represented by a set of coupled nonlinear differential equations. The general rolling maneuver is kinematically specified by its roll-rate variation p(t). A method for relating the airplane dynamic response to p(t) is developed. The method provides analytical expressions for the motion variables in terms of the maneuver descriptor p(t). A parameterized family of rolling maneuvers is considered, for which the method is used to predict specific dynamic response information, such as the dependence of the peak angle-of-attack excursion on the maneuver parameters. The stability and motion of the airplane in response to an arbitrary actuation of aileron input is considered. Analytical expressions relating motion variables to aileron input are obtained. Explicit analytical bounds on the motion variables are derived. A stability criterion which guarantees nondivergence of motion in response to aileron actuation is presented.

Haddad, E. K.↗

NASA NTRS1977

Supersonic aerodynamic characteristics of a series of wrap-around-fin missile configurations

A parametric study of wrap-around-fin missile configurations was conducted at Mach numbers from 1.60 to 2.86 in the Langley Unitary Plan wind tunnel. The fin configurations investigated included variations in chord length, leading edge sweep, thickness ratio, and leading edge shape. The investigation also included a smooth and a stepped-down afterbody required for flush retraction of the wrap-around-fin configuration. The investigation indicated no unusual longitudinal characteristics; however, all the wrap-around-fin configurations tested indicated erratic lateral behavior, particularly in the form of induced roll at zero angle of attack and irregular variations of roll with angle of attack and Mach number. The magnitude of rolling moment at an angle of attack of 0 deg is estimated to represent approximately 0.25 deg or less roll control deflection. The stepped-down afterbody has a marked effect on reducing the induced roll.

Fournier, R. H.↗

NASA NTRS1978

A head-up display for mid-air drone recovery

During mid-air retrieval of parachute packages, the absence of a natural horizon creates serious difficulties for the pilot of the recovery helicopter. A head-up display (HUD) was tested in an attempt to solve this problem. Both a roll-stabilized HUD and a no-roll (pitch only) HUD were tested. The results show that fewer missed passes occurred with the roll-stabilized HUD when the horizon was obscured. The pilots also reported that the workload was greatly reduced. Roll-stabilization was required to prevent vertigo when flying in the absence of a natural horizon. Any HUD intended for mid-air retrieval should display pitch, roll, sideslip, airspeed, and vertical velocity.

Augustine, W. L.↗

NASA NTRS1979

Convective instability when the temperature gradient and rotation vector are oblique to gravity. I - Fluids without diffusion

A linear stability analysis of fluid layers under uniform rotation (generally oblique to gravity) which possess both vertical and horizontal temperature gradients is made by considering ideal fluids without diffusion within a Boussinesq approximation. This simplified configuration is used to assess the preferred convective modes as a function of latitude on a planet like Jupiter. The tilted rotation vector introduces a preference for roll-like disturbances with north-south orientations, while the horizontal temperature gradient produces a thermal wind shear which favors convective rolls oriented parallel to the flow in an east-west direction. It is found that the horizontal temperature gradient needed to produce a preference for the axisymmetric or east-west rolls increases with an increasing rotation rate and a decreasing latitude. The parameter values for Jupiter are estimated with the use of a simple radiative convective model, indicating a preference for axisymmetric rolls at nearly all latitudes if the convection zone depth is greater than about 200 km below the one atmosphere pressure level and convective roll characteristics which contribute to an equatorial acceleration.

Hathaway, D. H.↗

NASA NTRS1983

Aircraft body-axis rotation measurement system

A two gyro four gimbal attitude sensing system having gimbal lock avoidance is provided with continuous azimuth information, rather than roll information, relative to the magnetic cardinal headings while in near vertical attitudes to allow recovery from vertical on a desired heading. The system is comprised of a means for stabilizing an outer roll gimbal that is common to a vertical gyro and a directional gyro with respect to the aircraft platform which is being angularly displaced about an axis substantially parallel to the outer roll gyro axis. A means is also provided for producing a signal indicative of the magnitude of such displacement as an indication of aircraft heading. Additional means are provided to cause stabilization of the outer roll gimbal whenever the pitch angle of the aircraft passes through a threshold prior to entering vertical flight and destabilization of the outer roll gimbal upon passing through the threshold when departing vertical flight.

Cowdin, K. T.↗

NASA NTRS1985

On cloud street development in three dimensional parallel and Rayleigh instabilities

Expected orientation angles and horizontal wavelengths of boundary layer rolls or cloud streets are determined from an analysis of a truncated spectral model of three dimensional shallow moist Boussinesq convection in a shearing environment. The nonlinear secondary circulations are organized into two dimensional forms by the height dependent wind field, and these rolls may develop from the combined effects of thermal stratification and mean wind shear. The associated thermal and parallel instability mechanisms are shown to be special cases of a single one. Only one mode is found when the stratification is unstable or neutral, but a second one is possible when the stratification is weakly stable. The first corresponds to relatively broadly spaced rolls having orientations for which the Fourier component of the roll perpendicular shear is nearly zero, but the second corresponds to relatively narrowly spaced rolls having orientations for which the Fourier coefficients of both the perpendicular and the parallel components of the shear are nearly equal.

Shirer, H. N.↗

NASA NTRS1985

Microstructure and fracture in SiC whisker reinforced 2124 aluminum composite

The microstructures of extruded and hot-rolled 2124 Al-15 percent (by weight) SiC whisker composites have been investigated, experimentally. Among the specific factors studied were: the strength of the whisker-matrix interfaces; (2) the presence of oxides; (3) the presence of defective whiskers; (4) and the presence of distribution of intermetallic compounds, impurities in the SiC(w) powder, and microstructural inhomogeneities. Modifications in the microstructure of the SiC/AL composites due to hot rolling and extrusion are illustrated in a series of microphotographs. It was found that hot rolling along the axis of extrusion was associated with some types of whisker damage, while the whiskers still retain their original orientation. Hot-rolling perpendicular to the axis of extrusion, however, tended to rotate the whiskers and produced a nearly isotropic material. Whisker free zones were virtually eliminated or reduced in size by hot rolling. In situ Auger fractography of the composite showed that the interfacial bonding between the SiC and the Al matrix was good and that Al2O2 had no significant influence on the fracture mechanics of the composite.

Nieh, T. G.↗

NASA NTRS1986

On cloud street development in three dimensions - Parallel and Rayleigh instabilities

Shirer, H. N.↗

NASA NTRS1990

Aeroservoelastic tailoring for lateral control enhancement

The application of an automated optimization approach to the integrated structural and control design of an aircraft wing and its control surface is illustrated. The performance index or cost function for optimization is the aileron hinge moment required to sustain a specified terminal roll rate at a chosen design speed at which aeroelastic effects are significant. The design variables used for aileron hinge-moment minimization are the aileron flap-to-chord ratio; the location of the aileron with respect to the roll axis; and the orientations of three advanced composite plies comprising 60 percent of the wing structure. The effects of aileron location and advanced composite ply orientation on the terminal roll rate and aileron hinge moment are examined. Optimization is seen to involve a compromise between a laminated structure/aileron combination that is effective in creating large rolling moments and one that minimizes the damping-in-roll. These two requirements are in conflict; the optimization driver must locate a compromise design point by moving the control surface and changing its size while also creating a suitable structural design.

Weisshaar, Terrence A.↗

NASA NTRS1992

The multiple-function multi-input/multi-output digital controller system for the AFW wind-tunnel model

A real time multiple-function digital controller system was developed for the Active Flexible Wing (AFW) Program. The digital controller system (DCS) allowed simultaneous execution of two control laws: flutter suppression and either roll trim or a rolling maneuver load control. The DCS operated within, but independently of, a slower host operating system environment, at regulated speeds up to 200 Hz. It also coordinated the acquisition, storage, and transfer of data for near real time controller performance evaluation and both open- and closed-loop plant estimation. It synchronized the operation of four different processing units, allowing flexibility in the number, form, functionality, and order of control laws, and variability in the selection of the sensors and actuators employed. Most importantly, the DCS allowed for the successful demonstration of active flutter suppression to conditions approximately 26 percent (in dynamic pressure) above the open-loop boundary in cases when the model was fixed in roll and up to 23 percent when it was free to roll. Aggressive roll maneuvers with load control were achieved above the flutter boundary. The purpose here is to present the development, validation, and wind tunnel testing of this multiple-function digital controller system.

Hoadley, Sherwood T.↗

NASA NTRS1992

The multiple-function multi-input/multi-output digital controller system for the AFW wind tunnel model

A real-time multiple-function digital controller system was developed for the Active Flexible Wing (AFW) Program. The digital controller system (DCS) allowed simultaneous execution of two control laws: flutter suppression and either roll trim or a rolling maneuver load control. The DCS operated within, but independently of, a slower host operating system environment, at regulated speeds up to 200 Hz. It also coordinated the acquisition, storage, and transfer of data for near real-time controller performance evaluation and both open- and closed-loop plant estimation. It synchronized the operation of four different processing units, allowing flexibility in the number, form, functionality, and order of control laws, and variability in selection of sensors and actuators employed. Most importantly, the DCS allowed for the successful demonstration of active flutter suppression to conditions approximately 26 percent (in dynamic pressure) above the open-loop boundary in cases when the model was fixed in roll and up to 23 percent when it was free to roll. Aggressive roll maneuvers with load control were achieved above the flutter boundary.

Hoadley, Sherwood T.↗

NASA NTRS1993

Experimental and numerical analysis of the wing rock characteristics of a 'wing-body-tail' configuration

Free-to-roll wind tunnel tests were conducted and a computer simulation exercise was performed in an effort to investigate in detail the mechanism of wing rock on a configuration that consisted of a highly-slender forebody and a 78 deg swept delta wing. In the wind tunnel test, the roll angle and wing surface pressures were measured during the wing rock motion. A limit cycle oscillation was observed for angles of attack between 22 deg and 30 deg. In general, the wind tunnel test confirmed that the main flow phenomena responsible for the wing-body-tail wing rock are the interactions between the forebody and the wing vortices. The variation of roll acceleration (determined from the second derivative of the roll angle time history) with roll angle clearly showed the energy balance necessary to sustain the limit cycle oscillation. Pressure measurements on the wing revealed the hysteresis of the wing rock process. First, second and nth order models for the aerodynamic damping were developed and examined with a one degree of freedom computer simulation. Very good agreement with the observed behavior from the wind tunnel was obtained.

Suarez, Carlos J.↗