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At least 19 records

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DOE OSTI2020

An Overview of the Hybrid Illinois Device for Research and Applications Material Analysis Test-stand (HIDRA-MAT)

The Hybrid Illinois Device for Research and Applications (HIDRA) at the University of Illinois at Urbana-Champaign is a toroidal plasma device that enables fusion plasma-material interaction testing with both stellarator and tokamak plasmas. HIDRA’s long-pulse steady state stellarator plasmas provide a testbed for plasma facing component (PFC) plasma exposures. The HIDRA Material Analysis Test-stand (HIDRA-MAT) is a material characterization module attached to HIDRA that is being designed and fabricated to include thermal desorption spectroscopy and laser induced breakdown spectroscopy systems for in-vacuo PFC characterization. A specialized rotatable sample holder positions the sample for liquid metal droplet application from a liquid metal droplet injector on HIDRA-MAT. Early experiments look to investigate the effect liquid lithium has on porous tungsten samples’ retention of H, D, and He after plasma exposure. Preliminary results from a dual residual gas analyzer system show the ability to differentiate D2 and He in HIDRA-MAT. Finally, this work aims to advance the understanding of liquid metal PFCs and further the design and development of new fusion PFCs and technologies.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2018

PUMP-STORAGE HYDROPOWER DESIGN IN A WASTEWATER TREATMENT FACILITY WITH AN AERATING RUNNER, ADDITIVE MANUFACTURED MATERIAL ANALYSIS, AND TESTING OF HYDROKINETIC TURBINE RUNNER.

The feasibility and design of a novel pumped storage system in a wastewater treatment facility is investigated. Analysis covers the added benefit of aeration, costs, and specifications. For the given sub-megawatt system, off-the-shelf runner designs are not available. This research builds on an existing pump-turbine research and design through a combination of introducing aeration into the operating processes, analysis of large format metal additive manufacturing, and testing and validation of a hydrokinetic turbine runner that uses the same response surface optimization methodology as the discussed pump-turbine design. Two concepts are generated and proposed along with a baseline scenario. Two potential site locations are provided with relevant information The Stickney Wastewater Reclamation Plant and The Navy Wastewater Treatment Plant, Joint Base Pearl Harbor-Hickam, Oahu Hawaii. Results show that aeration is the primary benefit of such a system. The system is capable of meeting the required dissolved oxygen (DO) levels in wastewater treatment. The system produces volume averaged DO levels between 1.2 and 1.4 mg/l. The system is shown to be a scalable open-loop system that can be sized for application. Area requirements of the system are acceptable due to the use of a single pedestal elevated tank The implementation timeline and nuances of this system are largely unknown. In attempt to reduce costs, advanced manufacturing methods are investigated. Investigation into advanced methods showed that mechanical properties of additive manufactured metals using a GMAW system produce equal results to wrought materials and have the potential to produce custom wear properties.

additive manufacturing↗

DOE OSTI2019

Accelerator Vacuum Windows: A Review of Past Research and a Strategy for the Development of a New Design for Improved Safety and Longevity for Particle Accelerators

Vacuum window research continues at Fermilab and this paper will examine cost effective, consistent designs which can have a huge impact on accelerator laboratories in terms of safety and cost. Issues such as the design, materials, analysis, testing and fabrication are addressed, including beam scattering plots and materials cost-benefit analysis and examining different materials which can potentially be substitutes for beryllium. A previous research paper has examined current fabrication and design techniques and also failure modes at Fermi, and this paper examines previous research in addition to emerging technologies. Many different paths have been taken by HEP Laboratories throughout the world with varying success. The history of vacuum window development is extensive and not well defined, and a matrix of what research has already been done on materials and joint design for vacuum windows will be shown. This report finally includes a treatise for vacuum window technology and a view towards emerging designs and materials and discusses future advances of research such as fabrication techniques including additive manufacturing and ultrasonic welding. Further exploration into these would prove beneficial to developing vacuum windows that are safer and stronger while being more transparent to the beam.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Project No. 5: Evaluating Dredged Materials for Energy Storage Applications with Economic and Carbon Benefits (CRADA Final Report)

The New York Power Authority (NYPA) is committed to supporting the Climate Leadership and Community Protection Act (CLCPA) through its VISION2030 strategic plan. As a clean energy provider, NYPA is seeking to demonstrate leadership in every aspect of its business by taking a comprehensive approach to sustainability management and integrating sustainability principles into day-to-day decision-making. This effort includes planning for climate resilience through projects that mitigate climate risk in our operations and prioritize climate opportunities in our investments. Canal Corporation, a subsidiary of NYPA, is charged with maintaining minimum water depths for navigation in the Cayuga-Seneca, Champlain, Erie and Oswego Canals. In order to do so, an average volume of 280,000 cubic yards of sediment is dredged annually and held in Upland Disposal Sites (UDS) permitted by the New York Department of Environmental Conservation (NYSDEC). The required on-land storage at UDSes are nearing capacity, and disposal opportunities are costly, both economically and environmentally. Novel energy storage technology developed by NREL provides an opportunity for meeting NYPA's need to find reuse options for dredged materials and commitment to providing clean reliable energy. This would also support NYPA's goal of developing 300 MW of utility scale storage and enabling 150 MW of distributed storage by 2030. NREL will consult NYPA on the environmental and economic impact of reusing dredged materials as useful commodities such as energy storage media, construction sand or industrial uses. Test and material characterization methods will be based on current NREL storage material characterization approaches. NREL worked with NYPA on sample preparation, material testing, test results analysis. Test and material characterization methods were based on current NREL storage material characterization approaches. The team analyzed the environmental and economic impact of reusing dredged materials as useful commodities such as energy storage media, construction sand or industrial uses. The test and analysis works have achieved the project goal in characterizing NYPA dredging materials and verifying their various uses including construction sand and thermal energy storage media. Uses of dredging materials as useful materials will bring economic and environmental benefits and avoid disposal costs.

25 ENERGY STORAGE↗

DOE OSTI2019

Performance of Composite Insulators Used for Electric Transmission under Extreme Climatic Conditions

Composite or polymeric insulators are being used in various parts of the world for high-voltage transmission and distribution lines. In some parts of India, places in the states like Rajasthan and Gujarat experience an increase in the daytime temperature up to 50 °C, while the nighttime temperature reduces as low as 3-5 °C. Because of these extreme temperature variations along with electric stress and humidity conditions, composite insulators have to perform well over their lifetime to ensure the reliability of the transmission network. In the present work, experimental conditions are simulated with temperature variation from 50 to 3-5 °C along with electrical stress, humidity variation, pollution, and ultraviolet radiations. Accelerated aging studies with these stresses are conducted to understand the degradation on the insulator similar to the field conditions. Surface resistivity measurements, leakage current analysis, and surface degradation studies using thermogravimetric analysis, scanning electron microscopy, energy-dispersive x-ray, and Fourier transform infrared spectroscopy (FTIR) are conducted. Some interesting results obtained from the study are presented. Experimentation under extreme conditions with polluted insulators showed considerable degradation which was inferred from the material testing analysis. The insulator slabs on which electrical stress was not applied showed a considerable peak at 1500 cm{sup −1} in the FTIR spectra, indicating the generation of low molecular weight PDMS chains from the bulk due to UV aging and thermal stress, while the degradation pattern of non-polluted sample was severe compared to the slab treated but was considerably less severe in comparison with the polluted insulator sample exhibiting pollution can considerably increase degradation rate.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Monitoring of Photovoltaic (PV) Performance and Degradation: Integrated Renewable Energy Systems (IRES) - PV Monitoring Task

The Integrated Renewable Energy System (IRES) testbed demonstration at the Pacific Northwest National Laboratory (PNNL) Sequim campus includes development of a suite of capabilities for tracking the performance of photovoltaic (PV) renewable energy components located on a floating platform (floating PV) and on a shoreline building rooftop. The marine environment represents potentially harsh and corrosive conditions for PV modules. Compared to terrestrial PV, potential concerns for offshore PV arising from high humidity and occasional contact with saltwater, marine wildlife, and aquaculture. These environmental factors can reduce electricity generation efficiency and increase the risk of electrical faults, polymer insulation or jacketing degradation and hydrolysis of the PV cell encapsulant materials. Offshore PV modules may also be exposed to lower temperatures and buoyant and vibrating motions with a floating platform. It is not clear how the long-term performance of floating PV will be affected by these factors. To understand expected energy generation through solar cells on a floating platform, monitoring of the performance of PV modules in the marine environment is needed. This report outlines a plan for long-term testing of IRES PV components utilizing resources of the PNNL Material Aging and Detection (MAaD) Science team and the Marine and Coastal Research Laboratory (MCRL). Equipment applicable for onsite testing and real-time monitoring of the PV performance associated with environmental conditions including temperature, solar irradiance, shading and soiling is included. In case of performance loss, equipment for fault detection, failure analysis, material testing, and further troubleshooting are also available. Through establishment of this capabilities, the enabling IRES project sets the stage for future research to advance off-shore and near-shore energy options for businesses and communities.

14 SOLAR ENERGY↗

DOE OSTI2020

Testing and analysis of steady-state helicon plasma source for the Material Plasma Exposure eXperiment (MPEX)

Not Available

Lumsdaine, Arnold (ORCID:0000000160708922)↗

DOE OSTI2022

Multi-Modal Characterization of Nuclear Fuels and Materials at the Idaho National Laboratory Materials & Fuels Complex

The Idaho National Laboratory (INL) leads cutting-edge research pertaining to the advancement of nuclear reactor technologies, including nuclear fuels and materials. The INL Irradiated Materials Characterization Laboratory (IMCL), Electron Microscopy Laboratory (EML), and future Sample Preparation Laboratory (SPL) are available to the nuclear research community to assess the behavior of nuclear fuels and materials, efficiently and comprehensively characterizing from the engineering to atomistic scale. The IMCL is a unique, 12,000-square-foot facility located at the INL Materials and Fuels Complex designed for analysis of irradiated materials. The facility operates advanced characterization instruments that are sensitive to vibration, temperature, and electromagnetic interference in modular radiological shielding and confinement systems, granting researchers the ability to assess the microstructural, chemical, mechanical and thermophysical properties of nuclear materials, especially irradiated fuels. The EML is dedicated to advanced characterization of materials with optical and electron microscopy tools, including scanning electron microscopy/focused-ion beam (SEM/FIB) and transmission electron microscopy (TEM). Upon construction, the SPL will be a 3 story, 49,000 sq. ft facility, that is the most modern reactor structural materials testing and analysis facility in the world, designed to investigate reactor structural materials in support of life-extension programs and development of advanced reactor concepts, including mechanical testing and advanced characterization capabilities. This presentation will showcase some of the main capabilities available at both IMCL, EML, and SPL, specifically illustrating how these characterization techniques are incorporated into multi-modal characterization work scopes to elucidate the degradation of nuclear structural materials and irradiated fuels.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Towards Validation of Advanced Accelerated Stress Testing Protocols through Failure Analysis and Materials Characterization

As the lifetime of photovoltaic modules increases toward the goal of 50 years, accelerated stress testing is critical to assessing the viability of newer, improved, and often cheaper materials in the field. However, the validation of accelerated testing to reproduce field failure has remained elusive. The recent developments of more advanced stress testing protocols utilizing sequential and combined stressors have provided another opportunity for validation. Using a suite of mechanical, chemical, and structural characterization methods we report the development of our approach using a known bad backsheet “AAA.” We then apply this approach to PVDF-based backsheets to further confirm the generalizability of this approach. The outcome of this work is two-fold: (1) validation of advanced accelerated testing protocols which will enable the prediction of field failures in new materials, and (2) deeper insights into the degradation mechanisms observed through the extensive characterization allowing for improved materials engineering and development.

accelerated aging↗

DOE OSTI2019

Nanomodified Methyl Methacrylate Polymer for Sealing of Microscale Defects in Wellbore Systems

Microscale defects (microannuli) at the steel-cement and rock-cement interfaces are a significant cause of failure in the integrity of wellbore systems. Microscale defects/microcracks as small as 30 μm are sufficient to create a significant leakage pathway for fluids. Here, the authors propose the use of nanomodified methyl methacrylate (NM-MMA) polymer as a seal material for 30-μm microcracks. Four materials were evaluated for their ability to serve as an effective seal material to seal 30-μm microcracks: microfine cement, epoxy, methyl methacrylate (MMA), and NM-MMA incorporating 0.5% by weight aluminum nanoparticles (ANPs). The seal materials’ bond strengths with shale were investigated using push-out tests. In addition, the ability to flow fluid through the microcracks was investigated using sagittal microscopic images. Viscosity, surface tension, and contact angle measurements explain the superior ability of MMA seal materials to flow into very thin microcracks compared with other materials. Post-test analysis shows MMA repair materials are capable of completely filling the microcracks. In addition, incorporating ANPs in MMA resulted in significant improvement in seal material ductility. Dynamic mechanical analysis (DMA) showed that incorporating ANPs in MMA reduced the creep compliance and improved creep recovery of NM-MMA. X-ray diffraction (XRD) analysis shows that incorporating ANPs in MMA resin increases the degree of polymer crystallization, resulting in significant improvement in seal material ductility.

36 MATERIALS SCIENCE↗

DOE OSTI2022

HIDRA-MAT liquid metal droplet injector for liquid metal applications in HIDRA

A liquid metal droplet injector was explicitly designed for the Hybrid Illinois Device for Research and Applications Material Analysis Test-stand (HIDRA-MAT) at the University of Illinois Urbana-Champaign to prepare liquid metal plasma-facing components (PFCs) for plasma exposure. The design goals were to create a compact, reliable, and robust design that could apply liquid metal droplets in-vacuo to a variety of samples. The injector was designed for liquid metal use, and results discussed pertain to lithium. The injector can produce lithium droplets of consistent size by utilizing programmable piston movement. Here, droplet formation data is presented for four different piston step sizes (0.125 mm, 0.25 mm, 0.5 mm, and 1 mm) at three different nozzle temperatures (185 °C, 230 °C, and 270 °C). Droplets are formed on the injector nozzle tip and a linear shift mechanism vertically translates the droplet to the substrate for application. This design prevents the droplet from inadvertently detaching off the nozzle and falling to the sample. Application of the liquid metal droplet ensures placement consistency on the substrate and helps avoid damage to components in HIDRA-MAT that should not interact with liquid metals. A description of the liquid lithium droplet creation and application results is given and provides additional insight into the cooling and oxidation of lithium droplets under vacuum conditions. A second nozzle was fabricated and demonstrated repeatability in droplet diameter creation having a variance of ±0.14 mm for droplets created from the same number of piston steps. The end-use for the injector on HIDRA-MAT is to apply liquid metals to PFCs and expose them to HIDRA's plasma with subsequent intershot in-vacuo surface analysis in HIDRA-MAT for plasma-material interaction studies.

42 ENGINEERING↗

DOE OSTI2022

First lithium experiments in HIDRA and evidence of helium retention during quasi-steady-state stellarator plasma operations

Recent experiments in Hybrid Illinois Device for Research and Applications (HIDRA) have had operational discharges between t discharge = 60 and 1000 s using electron cyclotron resonant heating (ECRH) of the plasma. This means that quasi-steady-state plasma discharges reach conditions to study long-pulse plasma material interactions (PMIs). The newly commissioned HIDRA-Material Analysis Test-stand PMI diagnostic is used to place a drop of lithium onto a heated tungsten surface, transfer the sample in-vacuo and expose it in a helium plasma. Helium is of interest as there is an open question to whether lithium will be able to remove helium ash in real fusion devices. The introduction of the W-Li sample in HIDRA resulted in evaporation of lithium into the helium plasma during a 600 s pulse and caused a reduction of over 90% in neutral pressure during the discharge. It was also observed that the plasma density and temperature increased by over 2.5 times. Using spectroscopy and a helium collisional radiative model, the peak temperature and density of the helium plasma can be monitored during the discharge. During lithium evaporation, as significant lithium ionization occurs, there is a 85% drop in the HIDRA vessel neutral pressure, despite a constant flow rate of He gas. This reduction in neutral pressure is supported by spectroscopy data with corresponding reductions in He I line intensities (587 nm, 667 nm, 706 nm, and 728 nm), as well as those of other impurities. At one point in the discharge a lithium plasma is created, as indicated by an increase in Li + emission and a complete reduction in He + emission, but the electron density jumps from ne = 3 × 10 18 m –3 to over ne = 8 × 10 18 m –3 while the core temperature stays relatively constant between Te = 16 eV and 20 eV. Once lithium has completely evaporated from the sample and the majority of the ionized lithium has diffused from the plasma to the vessel walls, pressure and spectroscopy data paired with He collisional radiative model calculations shows a re-establishment of a helium plasma in a low recycling regime. In this regime, the density drops down to ne = 2 × 10 18 m –3 and the electron temperature increases from T e = 20 eV to over T e = 50 eV indicating an increase in helium heating efficiency. This is also indicated by the He+ emission re-establishing and having a higher intensity. Here, we show the results from the first lithium campaign in HIDRA. In the presence of lithium, and in particular when lithium ions are present, the helium disappears from the plasma via an as of yet unknown complex relationship that needs to be further studied. The most likely explanation is that the lithium ions are distributed around the vessel and able to trap helium to the surface turning HIDRA into a large gettering surface. These results have potential implications on future plasma facing component design using liquid lithium for impurity and recycling control using limiters and divertors.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2018

Forensic Analysis of Faulted NSTX-U Inner Poloidal Field Coil

The failure of the NSTX-U PF1A upper coil suspended plasma operations during the project's first operational campaign after commissioning. Initial nondestructive testing and examination of the failed coil was followed by extensive nondestructive radiography. Destructive testing facilitated visual borescope/videoscope inspection through the cooling path, vacuum testing, and electrical testing of every conductor segment. One conductor cooling path visually evidenced a void through the sidewall of the cooling path in a layer-to-layer region. The identified void in the conductor cooling path was not proximal to a braze or joggle. Electrical testing indicated that the voided conductor segment was a member of a group of 14 conductor segments that evidenced low-resistance connectivity. Four braze joints and two lead segments were subjected to 400-lbf/in 2 hydrostatic pressure testing followed by helium leak testing and evidenced that there were no detectable leaks in the tested cooling path segments. The faulted region was proximal to the center of the coil pack and evidenced historical electrical pitting and molten conductor debris. Samples of the epoxy resin insulation system were extracted and analyzed with dynamic mechanical analysis and differential scanning calorimetry techniques. Epoxy resin insulation samples were subjected to immersion testing per ASTM D570. Metallurgical samples were extracted from the coil pack conductors and subjected to hardness testing and grain structure analysis. The base material testing results indicated no abnormalities. In conclusion, the coil incipient failure was determined to most likely have resulted from conductive material located between conductor and insulation layers.

25 ENERGY STORAGE↗

DOE OSTI2023

The collaborative effects of intrinsic and extrinsic impurities in low RRR SRF cavities

The superconducting radio-frequency (SRF) community has shown that introducing certain impurities into high-purity niobium can improve quality factors and accelerating gradients. We question why some impurities improve RF performance while others hinder it. The purpose of this study is to characterize the impurity profile of niobium with a low residual resistance ratio (RRR) and correlate these impurities with the RF performance of low RRR cavities so that the mechanism of impurity-based improvements can be better understood and improved upon. The combination of RF testing and material analysis reveals a microscopic picture of why low RRR cavities experience low temperature-dependent BCS resistance behavior more prominently than their high RRR counterparts. We performed surface treatments, low temperature baking and nitrogen-doping, on low RRR cavities to evaluate how the intentional addition of oxygen and nitrogen to the RF layer further improves performance through changes in the mean free path and impurity profile. The results of this study have the potential to unlock a new understanding on SRF materials and enable the next generation of SRF surface treatments.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

The Collaborative Effects of Intrinsic and Extrinsic Impurities in Low RRR SRF Cavities

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

The Collaborative Effects of Intrinsic and Extrinsic Impurities in Low RRR SRF Cavities

The SRF community has shown that introducing certain impurities into high-purity niobium can improve quality factors and accelerating gradients. We question why some impurities improve RF performance while others hinder it. The purpose of this study is to characterize the impurity profile of niobium coupons with a low residual resistance ratio (RRR) and correlate these impurities with the RF performance of low RRR cavities so that the mechanism of impurity-based improvements can be better understood and improved upon. The combination of RF testing and material analysis reveals a microscopic picture of why low RRR cavities experience low BCS resistance behavior more prominently than their high RRR counterparts. We performed surface treatments, low temperature baking and nitrogen-doping, on low RRR cavities to evaluate how the intentional addition of oxygen and nitrogen to the RF layer further improves performance through changes in the mean free path and impurity profile. Th e results of this study have the potential to unlock a new understanding on SRF materials and enable the next generation of high Q/high gradient surface treatments.

Howard, K.↗

DOE OSTI2023

The Collaborative Effects of Intrinsic and Extrinsic Impurities in Low RRR SRF Cavities

The SRF community has shown that introducing certain impurities into high-purity niobium can improve quality factors and accelerating gradients. We question why some impurities improve RF performance while others hinder it. The purpose of this study is to characterize the impurity profile of niobium coupons with a low residual resistance ratio (RRR) and correlate these impurities with the RF performance of low RRR cavities so that the mechanism of impurity-based improvements can be better understood and improved upon. The combination of RF testing and material analysis reveals a microscopic picture of why low RRR cavities experience low BCS resistance behavior more prominently than their high RRR counterparts. We performed surface treatments, low temperature baking and nitrogen-doping, on low RRR cavities to evaluate how the intentional addition of oxygen and nitrogen to the RF layer further improves performance through changes in the mean free path and impurity profile. The results of this study have the potential to unlock a new understanding on SRF materials and enable the next generation of high Q/high gradient surface treatments.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2024

Dynamic Scaling Analysis of Accelerated Irradiation Testing on Additive Manufacturing Materials by Positron Annihilation

The timely applications of Additive Manufacturing (AM) materials in nuclear environments require accelerated irradiation tests, mainly ion irradiation to enable rapid prototyping. Low dose ion irradiation would cause sub-nanostructure changes by generation of lattice defects, vacancies, vacancy clusters and voids and void swelling caused by cellular dislocations. Positron Annihilation Lifetime (PAL), a novel technology, sensitive towards sub-nanostructure morphology with high accuracy (about 10-7 vacancy per atom), supported by Transition Electron Microscope (TEM) would be applied to identify the type and total size of the defects. The subsequent PAL measurements and TEM surface studies would be followed by PAL analysis that includes sophisticated trapping model. The PAS results would become an input to dynamic scaling analysis (that predicts radiation effects from low dose studies for high dose effects), which incorporate mean-field theory model. The final effect is an in-depth understanding of the microstructure evolution of AM materials under ion irradiation which can be extrapolated to the studies of neutron irradiation, since ion-irradiation takes less time and do not cause the irradiation hazard. The working hypothesis is that PAL technology, that have excellent sensitivity to low-defect concentration would help to identify ion-induced material damage on the atomic and nano-scale level, which then could be extrapolated to understand the neutron damage better.

accelerated irradiation testing↗