Integrated Test Stand
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43 PARTICLE ACCELERATORS↗
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Flat TBPS Integration Testing for the CMS Outer Tracker Upgrade
The upcoming High-Luminosity (HL) LHC will significantly increase luminosity, introducing more demanding operating conditions for the CMS detector. To meet these challenges, CMS is undergoing major upgrades, including a complete replacement of its tracking detector. This poster presents recent integration testing efforts conducted at Fermilab on the Flat Tracker Barrel with pixel-strip (PS) modules integration test stand, a subcomponent of the outer tracker located in the central barrel region. In this region, PS modules are mounted on structures that provide mechanical support and cooling, called planks. The testing focuses on validating the integrated system’s thermal and electrical performance. Results from these tests will be discussed, highlighting their importance for ensuring reliable tracker operation in the HL-LHC era.
Salazar Segovia, Itzelli [UC, Davis]↗
In‐operando thermal transport characterization of moving particle bed heat exchanger
The project aimed to develop modulated photothermal radiometry (MPR) for conducting in-operando measurements of thermal transport in moving particle bed heat exchangers (MPBE) located at Sandia National Laboratory (SNL). The plan was to initially conduct lab-scale measurements on a 1-meter-long particle channel at UCSD, followed by in- operando measurements at SNL on a 20 kWth MPBE prototype built for this project, and if time permitting, potential final deployment on SNL’s 1 MWth G3P3 MPBE. The first two goals were successfully achieved but due to changes with commissioning timeline of the G3P3 MPBE, in-operando measurements on the G3P3 MPBE could not be conducted. The measurement campaigns have resulted in some promising results and the MPR tool has been handed over to trained SNL personnel for future use. MPR measurements on UCSD’s 1-meter-long particle channel showed a peculiar length dependence of the particle bed thermal conductivity and near-wall thermal resistance. The bed thermal conductivity increased, and the near-wall thermal resistance decreased, with increasing distance from the channel inlet, both eventually reaching a plateau. This was found to be due to hydrostatic pressure screening by the channel walls, known as the “Janssen effect”, and is the first experimental study on its role in granular heat transfer. A 20 kWth small-scale MPBE prototype, the first of its kind with 3 mm particle channels and 2 mm sCO2 plates, was designed and manufactured by Vacuum Process Engineering (VPE) for this project. This MPBE prototype was installed in SNL’s HEX test stand and the MPR tool was integrated into the test stand for in-operando measurements. Several modifications have been made to the MPR setup for facile installation and easy operation at SNL. Measurements with Carbo HSP40/70 particles were conducted with various particle and sCO2 temperatures and flow rates. Further, apart from regular MPBE operation, fault scenarios such as plate warping, particle stagnation, and choking were also detected and MPR showed excellent sensitivity to the detection of such conditions. Through the course of this project, MPR has evolved from a sensitive laboratory technique to a rugged industrial tool with various applications in high temperature measurements and diagnostics.
14 SOLAR ENERGY↗
Operando X-Ray Diffraction During High Temperature Electrolysis
This work presents the design, development, and deployment of an operando X-ray diffraction (XRD) system for high-temperature electrolysis (HTE), enabling real-time characterization of solid oxide electrolysis cells (SOECs) under true operational conditions. The integration of an HTE test stand within a synchrotron radiation environment, mimicking the conditions of a laboratory setup, aims to enhance our understanding of the degradation processes affecting the performance and longevity of SOECs. Utilizing a custom furnace and a high precision motor stack assembly at the Stanford Synchrotron Radiation Lightsource (SSRL), the system revealed unparalleled insights into the structural evolution of SOEC components through various operational stages, including initial heat ramp, cell reduction, fuel ramp, and wet electrolysis. Initial results demonstrate the significant impact of the initial heating and cooling on secondary phase formation within the SOEC, highlighting the utility of operando XRD for developing more efficient and durable hydrogen production technologies.
08 HYDROGEN↗
US HL-LHC cryo-assemblies at FNAL - testing and lessons learned
The U.S. High-Luminosity LHC Accelerator Upgrade Project (AUP) is fabricating ten cryogenic assemblies for the HL-LHC Q1/Q3 quadrupole optics at CERN, each integrating two Nb_{3}Sn-based magnets. Fermilab has tested three assemblies (LQXFA/B01–03) at its upgraded horizontal test stand under 1.9 K conditions. Overview of the test stand and the cryo-assembly tests is given along with main results. Challenges met and lessons learned are discussed. Successful testing validates the design and integration of U.S.-produced cryo-assemblies, keeping the project on track for timely delivery to CERN.
Stoynev, Stoyan [Fermilab] (ORCID:0000000345637702↗
Automating Testing of DUNE Electronics via a Finite State Machine
The Deep Underground Neutrino Experiment (DUNE) is a flagship international collaboration designed to study neutrinos tiny, nearly massless particles that may hold answers to fundamental questions about the Universe. Fermilab s Robotic Test Stand (RTS) plays a critical role in ensuring the quality of approximately 50,000 Application-Specific Integrated Circuit (ASIC) chips that will be used in DUNE s massive liquid argon detectors. These electronics will be inside the cryostat; therefore, they will need to have a high yield of working chips and low noise. To improve the automation and reliability of the RTS, this project focused on designing and implementing a Python-based finite state machine (FSM) to manage chip handling workflows. The FSM was developed as a modular software framework to coordinate robotic arm movements, manage chip tray positions, and monitor system states during testing. Key features include robust error handling routines, a pause/resume system for safe mid-cycle interruptions, and a simulation mode for iterative testing without hardware dependencies. The system was designed to prepare for seamless integration with RTS hardware components such as the robotic arm and vision system. This integration will streamline collaboration and enable efficient deployment of updates across the six total institutions performing testing. The outcomes of this internship contribute to Fermilab s mission to advance high-energy physics and support the DOE s national goals by directly improving the testing of equipment to be used in DUNE. The project also provided valuable experience in software design and contributing to the success of DUNE.
Kang, Caleb [William Rainey Harper Coll.]↗
Automating Testing of DUNE Electronics via a Finite State Machine
The Deep Underground Neutrino Experiment (DUNE) is a flagship international collaboration designed to study neutrinos—tiny, nearly massless particles that may hold answers to fundamental questions about the Universe. Fermilab’s Robotic Test Stand (RTS) plays a critical role in ensuring the quality of approximately 50,000 Application-Specific Integrated Circuit (ASIC) chips that will be used in DUNE’s massive liquid argon detectors. These electronics will be inside the cryostat; therefore, they will need to have a high yield of working chips and low noise. To improve the automation and reliability of the RTS, this project focused on designing and implementing a Python-based finite state machine (FSM) to manage chip handling workflows. The FSM was developed as a modular software framework to coordinate robotic arm movements, manage chip tray positions, and monitor system states during testing. Key features include robust error handling routines, a pause/resume system for safe mid-cycle interruptions, and a simulation mode for iterative testing without hardware dependencies. The system was designed to prepare for seamless integration with RTS hardware components such as the robotic arm and vision system. This integration will streamline collaboration and enable efficient deployment of updates across the six institutions performing testing. The outcomes of this internship contribute to Fermilab’s mission to advance high-energy physics and support the DOE’s national goals by directly improving the testing of equipment to be used in DUNE. The project also provided valuable experience in software design and contributing to the success of DUNE.
Kang, Caleb [Fermilab]↗
In-Cell Deployment and First Use of Digital Image Correlation for In-Situ Strain Analysis of Irradiated Nuclear Fuel Rods During LOCA Transient
Digital image correlation (DIC) is a noncontact, optical method increasingly used across industries and research environments for acquiring multidimensional strain data. At Oak Ridge National Laboratory’s (ORNL’s) Severe Accident Test Station (SATS), DIC has been extensively applied to study the thermomechanical response of nuclear fuel claddings, yielding fundamental insights into material behavior. However, these efforts have focused exclusively on unirradiated materials and relied on the SATS out-of-cell infrastructure. Efforts over the past two years have been made to extend these capabilities to ORNL’s Irradiated Fuels Examination Laboratory SATS system within the hot-cells to enable testing of irradiated fuel cladding materials. Integrating DIC into the hot-cell SATS infrastructure presents unique challenges, including enabling remote operation of optical equipment and adapting auxiliary hot-cell systems for DIC implementation. This report discusses design, stand-up testing, and application of DIC to an irradiated nuclear fuel cladding segment. A DIC testing rig was successfully built and validated out-of-cell through extensive surrogate tests and calibrations. The rig and specialized DIC furnace were installed in the hot-cell, and a DIC test was successfully conducted. Results from that test correspond to expectations for Zr-based alloys and showed similar uncertainties compared to out-of-cell tests.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Full Submersion Water Testing of SAVY-4000 Nuclear Material Storage Containers
SAVY-4000 (SAVY) containers are the primary container used at Technical Area (TA) TA-55 plutonium facility for the prevention of water ingress to mitigate against a criticality event. The basis for water resistance of these containers has long been attributed to the Polytetrafluoroethylene (PTFE) membrane that is assembled on the outermost surface of the filter assembly. On August 22nd a test of a container used inside of a glovebox was performed that brought into question this long-standing-basis. This test was performed by inverting a SAVY-lid onto a specialized piece of equipment for evaluating the integrity of the PTFE membrane. During the test water was observed passing through the filter indicating that the filter membrane was no longer preventing the ingress of water through the filter. The assumption after making this observation was that alpha-particles were rapidly degrading the membrane creating a leak path through the underlying aluminosilicate media (Fiberfrax®). The apparatus used was designed to only test the lid rather than the entire SAVY assembly. A test plan, PA-PLAN-01921, was developed to investigate whether a fully assembled container with a fully degraded PTFE membrane would be capable of meeting the criteria defined in PA-RD-1009 of not allowing more than 200 ml of water to enter the container with a water column of 6-inches applied over a 2-hour period. This report provides the results of the testing performed against PA-PLAN-01921.
36 MATERIALS SCIENCE↗
An Open-Source Framework for Rapid Validation of Scientific ASICs
Spacely is an open-source framework for the post-silicon validation of analog, digital, and mixed-signal ASICs (Application-Specific Integrated Circuits) which maximizes the reuse of hardware and software, reducing the time taken to achieve meaningful test results. Spacely specifically addresses the needs of small, flexible ASIC design teams commonly found in academia or research institutions which benefit most from sharing the overhead of test stand creation between many unique ASIC designs. Spacely is a set of software, firmware, and design practices. It targets two primary hardware platforms (NI-PXI and Caribou) as well as offering extensible support for bench instruments. Spacely provides a high-level Python interface to all test hardware for accessibility, while also giving more sophisticated teams the opportunity to integrate custom test firmware. The design principles of Spacely are presented in brief. Current documentation is available at https://github.com/SpacelyProject/spacely-docs.
Quinn, Adam [Fermilab]↗
Warm Front End Upgrade for the PIP-II Linac
The warm front end for the PIP-II Linac consists of an Ion-source, an RFQ, and four buncher cavities. The LLRF systems for these were the first ones developed more than a decade ago for use at the test stands. Some were VXI crate based, and others used early generation FPGA boards that are light in resources. These LLRF systems and the one for the first superconducting cryomodule, the HWR will be upgraded with the ARRIA 10 SOC-FPGA chassis with EPICS interfaces like the rest of the PIP-II Linac. The RFQ and the HWR have unique resonance control systems which are integrated into the LLRF controller hardware. The results of the initial testing with a cavity emulator will be presented.
Reyes, Lennon [Fermilab] (ORCID:0009000891155652)↗
Facile Tensile Testing Platform for In Situ Transmission Electron Microscopy of Nanomaterials
In situ tensile testing using transmission electron microscopy (TEM) is a powerful technique to probe structure-property relationships of materials at the atomic scale. In this work, a facile tensile testing platform for in situ characterization of materials inside a transmission electron microscope is demonstrated. The platform consists of: 1) a commercially available, flexible, electron-transparent substrate (e.g., TEM grid) integrated with a conventional tensile testing holder, and 2) a finite element simulation providing quantification of specimen-applied strain. The flexible substrate (carbon support film of the TEM grid) mitigates strain concentrations usually found in free-standing films and enables in situ straining experiments to be performed on materials that cannot undergo localized thinning or focused ion beam lift-out. The finite element simulation enables direct correlation of holder displacement with sample strain, providing upper and lower bounds of expected strain across the substrate. The tensile testing platform is validated for three disparate material systems: sputtered gold-palladium, few-layer transferred tungsten disulfide, and electrodeposited lithium, by measuring lattice strain from experimentally recorded electron diffraction data. The results show good agreement between experiment and simulation, providing confidence in the ability to transfer strain from holder to sample and relate TEM crystal structural observations with material mechanical properties.
2D materials↗
High-power test of a C-band linear accelerating structure with an RFSoC-based LLRF system
Normal conducting linear particle accelerators consist of multiple rf stations with accelerating structure cavities. Low-level rf (LLRF) systems are employed to set the phase and amplitude of the field in the accelerating structure and to compensate for the pulse-to-pulse fluctuation of the rf field in the accelerating structures with a feedback loop. The LLRF systems are typically implemented with analog rf mixers, heterodyne-based architectures, and discrete data converters. There are multiple rf signals from each of the rf stations, so the number of rf channels required increases rapidly with multiple rf stations. With a large number of rf channels, the footprint, component cost, and system complexity of the LLRF hardware will increase significantly. To meet the design goals of being compact and affordable for future accelerators, we have designed the next-generation LLRF (NG-LLRF) with a higher integration level based on RFSoC technology. The NG-LLRF system samples rf signals directly and performs rf mixing digitally. Further, the NG-LLRF has been characterized in loopback mode to evaluate the performance of the system and has also been tested with a standing-wave accelerating structure, a prototype for the Cool Copper Collider (C 3 ) with a peak rf power level up to 16.45 MW. The loopback test demonstrated amplitude fluctuation below 0.15% and phase fluctuation below 0.15°, which are considerably better than the requirements of C 3 . The rf signals from the different stages of the accelerating structure at different power levels are measured by the NG-LLRF, which will be critical references for the control algorithm designs. The NG-LLRF also offers flexibility in waveform modulation, so we have used rf pulses with various modulation schemes, which could be useful for controlling some of the rf stations in accelerators. In this paper, the high-power test results at different stages of the test setup will be summarized, analyzed, and discussed.
47 OTHER INSTRUMENTATION↗
Generalized Hydrodynamics: A Perspective
Conventional hydrodynamics describes systems with few long-lived excitations. In one dimension, however, many experimentally relevant systems feature a large number of long-lived excitations and conserved quantities even at high temperature, because they are proximate to integrable limits. Such models cannot be treated using conventional hydrodynamics. The framework of generalized hydrodynamics (GHD) was recently developed to treat the dynamics of one-dimensional models: It combines ideas from integrability, hydrodynamics, and kinetic theory to come up with a quantitative theory of transport. GHD has successfully settled several long-standing questions about one-dimensional transport; it has also been leveraged to study dynamical questions beyond the transport of conserved quantities and to systems that are not integrable. In this article, we introduce the main ideas and predictions of GHD, survey some of the most recent theoretical extensions and experimental tests of the GHD framework, and discuss some open questions in transport that the GHD perspective might elucidate. Published by the American Physical Society 2025
75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
Preparation and Qualification of Preproduction SSR2 Jacketed Cavities for PIP-II
The qualification of 325 MHz Single Spoke Resonators type 2 (SSR2) jacketed cavities to meet technical requirements represents a significant milestone in the development of the SSR2 cryomodules for the PIP-II Project at Fermilab. This poster reports the procedures and lessons learned in processing and preparing these cavities for horizontal cold testing prior to integration into a cavity string assembly, with a focus on addressing the field emission issues observed during the cold testing. A comprehensive root cause analysis identified critical fabrication, processing, and handling factors impacting field emission onset. New techniques were successfully developed and implemented to achieve field emission-free SSR2 cavities, and efforts were made to correlate radiation levels measured at the test stand with expected levels in the LINAC tunnel. Additionally, the evolution of field emission through assembly steps was thoroughly investigated, leading to a reassessment of design choices and enhancing our understanding of their effects on cavity performance.
Grassellino, L. [Fermilab]↗
Probabilistic Programming for Transportable Source Characterization and Uncertainty Quantification of the North Korean Nuclear Tests 2006–2017
Here, we introduce a transportable technique to determine the yield and depth of burial (DOB) from seismic source spectra of underground nuclear explosions. We demonstrate this technique on the six declared North Korean nuclear tests. This approach derives source spectra in absolute units from regional phase (Pg) amplitudes by correcting the observations for geometric spreading, attenuation, and site amplification. We couple the source spectra and explosion source models with a probabilistic programming framework that integrates deep learning techniques and Bayesian modeling. This approach permits the exchange of information across various data categories to quantify both the data and model uncertainty. This technique stands out as an innovative use of broad‐area propagation models, making it transportable across various geologic settings. This method proves to be effective in scenarios with diverse and/or limited observational data, even when the source depth is unknown. We present new independent estimates of absolute yield and DOB that are consistent with the prior assessments, underscoring the potential of this method in enhancing transportable nuclear explosion monitoring capabilities.
58 GEOSCIENCES↗
Innovative approach to counterfeit and noncompliant refrigerant detection: A cost-effective, portable solution
The increasing prevalence of counterfeit and incompatible refrigerants presents significant risks to Heating, Ventilation, Air Conditioning, and Refrigeration (HVAC&R) systems, including compromised equipment performance, safety hazards, and non-compliance. This article details the development of a novel, cost-effective, and portable detection device designed to accurately verify refrigerants. The device utilizes a controlled gas sampling and analysis system within a sealed chamber, ensuring precise measurements while maintaining safety through a purging mechanism. The system features a high-sensitivity sensor integrated with an onboard control module that analyzes gas composition in real-time, providing feedback within a 2-minute duration. Laboratory validation demonstrated the device’s high accuracy (>95 % based on correct identification of compliant vs. non-compliant blends) in detecting unauthorized refrigerant blends. The projected cost of the product stands at ∼ $150, based on the retail pricing of individual components. Laboratory validation demonstrated the device’s high accuracy (>95 % for composition identification, 100 % rejection of tested counterfeit/incorrect blends) in detecting unauthorized refrigerant blends with a response time <2 min. The device correctly identified authentic R-454A/B/C blends and reliably rejected R-407F and closely related counterfeit mixtures. Key advantages include affordability, ease of use, rapid response time, and compatibility with a wide range of refrigerants. This solution supports compliance with regulatory frameworks, enhances safety in HVAC&R operations, and mitigates the risks associated with counterfeit refrigerants.
Counterfeit refrigerants↗
Detection and imaging of chemicals and hidden explosives using terahertz time-domain spectroscopy and deep learning
Detecting concealed chemicals and explosives remains a critical challenge in global security. Terahertz time-domain spectroscopy (THz-TDS) offers a promising non-invasive and stand-off detection technique owing to its ability to penetrate optically opaque materials without causing ionization damage. While many chemicals exhibit distinct spectral features in the terahertz range, conventional terahertz-based detection methods often struggle in real-world environments, where variations in sample geometry, thickness, and packaging can lead to inconsistent spectral responses. In this study, we present a chemical imaging system that integrates THz-TDS with deep learning to enable accurate pixel-level identification and classification of different explosives. Operating in reflection mode and enhanced with plasmonic nanoantenna arrays, our THz-TDS system achieves a peak dynamic range of 96 dB and a detection bandwidth of 4.5 THz, supporting practical, stand-off operation. By analyzing individual time-domain pulses with deep neural networks, the system exhibits strong resilience to environmental variations and sample inconsistencies. Blind testing across eight chemicals—including pharmaceutical excipients and explosive compounds—resulted in an average classification accuracy of 99.42% at the pixel level. Notably, the system maintained an average accuracy of 88.83% when detecting explosives concealed under opaque paper coverings, demonstrating its robust generalization capability. These results highlight the potential of combining advanced terahertz spectroscopy with neural networks for highly sensitive and specific chemical and explosive detection in diverse and operationally relevant scenarios.
Imaging and sensing↗