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At least 19 records

Example Evaluation of a Representative Heat Pipe Test Article Design for Structural Acceptability using ASME Design Rules

This report describes a design analysis of a test article mimicking a core block of a heat-pipe mi-croreactor using the ASME Boiler & Pressure Vessel Code Section III, Division 5, Subsection HB, Subpart B rules. These rules cover the design and construction of elevated temperature nu-clear reactor structural components, like the core block of a heat-pipe microreactor emulated by the test article. The purposes of the report are to: (1) provide a step-by-step example of applying the ASME rules to a reasonable core block geometry and corresponding loading conditions, (2) to provide design feedback on the test article, and (3) to evaluate the ASME rules for use in the design of complex heat-pipe microreactor components. The test article design has a relatively short ASME design life, limited by high thermal stresses. The current ASME rules are adequate for evaluating the core block component designs, though they could be optimized to increase the design efficiency and reduce the amount of designer/analyst time required to execute the design process. The report covers both the current, 2019 edition ASME rules and modified, currently unapproved, rules designed to improve the design process for components with complex geometries and high secondary stresses, like the core block test article.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Establishing the Quality Assurance programme for the strip sensor production of the ATLAS tracker upgrade including irradiation with neutrons, photons and protons to HL-LHC fluences

The successful pre-production delivery of strip sensors for the new Inner Tracker (ITk) for the upgraded ATLAS detector at the High Luminosity LHC (HL-LHC) at CERN was completed and based on their performance full production has commenced. The overall delivery period is anticipated to last 4 years to complete the approximately 22000 sensors required for the ITk. For Quality Assurance (QA), a number of test structures designed by the collaboration, along with a large area diode and miniature version of the main sensor, are produced in every wafer by the foundry Hamamatsu Photonics K.K (HPK). As well as Quality Control (QC) checks on every main sensor, samples of the QA pieces from each delivery batch are tested both before and after irradiation with results after exposure to neutrons, gammas or protons to fluences and doses corresponding to those anticipated after operation at the HL-LHC to roughly 1.5 times the ultimate integrated luminosity of 4000 fb -1 . In this paper the procedures are presented and the studies carried out to establish that the seven ITk QA Strip Sensor irradiation and test sites meet all the requirements to support this very extensive programme throughout the strip sensor production phase for the ITk project.

47 OTHER INSTRUMENTATION↗

Characterization of the polysilicon resistor in silicon strip sensors for ATLAS inner tracker as a function of temperature, pre- and post-irradiation

The high luminosity upgrade of the Large Hadron Collider, foreseen for 2029, requires the replacement of the ATLAS Inner Detector with a new all-silicon Inner Tracker (ITk). The expected ultimate total integrated luminosity of 4000 fb –1 means that the strip part of the ITk detector will be exposed to the total particle fluences and ionizing doses reaching the values of 1.6 · 10 15 1 MeV n eq /cm 2 and 0.66 MGy, respectively, including a safety factor of 1.5. Radiation hard n + -in-p micro-strip sensors were developed by the ATLAS ITk strip collaboration and are produced by Hamamatsu Photonics K.K. The active area of each ITk strip sensor is delimited by the n-implant bias ring, which is connected to each individual n + implant strip by a polysilicon bias resistor. The total resistance of the polysilicon bias resistor should be within a specified range to keep all the strips at the same potential, prevent the signal discharge through the grounded bias ring and avoid the readout noise increase. While the polysilicon is a ubiquitous semiconductor material, the fluence and temperature dependence of its resistance is not easily predictable, especially for the tracking detector with the operational temperature significantly below the values typical for commercial microelectronics. Dependence of the resistance of polysilicon bias resistor on the temperature, as well as on the total delivered fluence and ionizing dose, was studied on the specially-designed test structures called ATLAS Testchips, both before and after their irradiation by protons, neutrons, and gammas to the maximal expected fluence and ionizing dose. The resistance has an atypical negative temperature dependence. It is different from silicon, which shows that the grain boundary has a significant contribution to the resistance. Finally, we discuss the contributions by parameterizing the activation energy of the polysilicon resistance as a function of the temperature for unirradiated and irradiated ATLAS Testchips.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Pre-production results from ATLAS ITk Strip Sensors Quality Assurance Testchip

The production of strip sensors within the framework of the ATLAS Inner Tracker (ITk) development is a process which requires continuous evaluation during the full production period (about 4 years). Such an evaluation is divided into two different parts: Quality Control (QC), which focuses on the final product (the actual sensors) and tries to identify possible defects once the fabrication is completed, and Quality Assurance (QA), which aims to prevent deviations in the manufacturing process and uses specifically-designed test structures. The initial sensor pre-production consists of 5% (1041 sensors) of the total number of sensors expected during production. As part of pre-production, the collaboration has measured key parameters from miniature strip sensors (minis), monitor diodes (MD8), and the ATLAS Testchip, before and after irradiation. In this contribution we focus on the analysis of the results of the MD8 and the Testchip. All parameters have been obtained from the test structures (MD8, bias resistors, interdigitated structures, field oxide capacitors, coupling capacitors, punch-through protection structures and cross-bridge resistors) measured at the different test sites (KEK/Tsukuba, Birmingham, Toronto, Ljubljana, Valencia, Carleton, Prague, CNM-Barcelona). The results are compared to predefined pre- and post-irradiation specifications for each tested parameter.

47 OTHER INSTRUMENTATION↗

Analysis of TPA Pulsed-Laser-Induced Single-Event Latchup Sensitive-Area

Two-photon absorption (TPA) testing is employed to analyze the laser-induced latchup sensitive-volume (SV) of a specially designed test structure. This method takes into account the existence of an onset region in which the probability of triggering latchup transitions from zero to one as the laser pulse energy increases. This variability is attributed to pulse-to-pulse variability, uncertainty in measurement of the pulse energy, and variation in local carrier density and temperature. For each spatial position, the latchup probability associated with a given energy is calculated from multiple pulses. The latchup probability data are well-described by a Weibull distribution. The results show that the area between p-n-p-n cell structures is more sensitive than the p+ and n+ source areas, and locations far from the well contacts are more sensitive than those near the contact region. The transition from low probability of latchup to high probability is more abrupt near the source contacts than it is for the surrounding areas.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

ADDITIVE MANUFACTURING AND REGULATORY TESTING OF CANISTERS FOR SPENT NUCLEAR FUEL MANAGEMENT

The back end of the fuel cycle focuses on the interim storage, transportation, and final disposition of the spent nuclear fuel from nuclear reactors. Commercial light water nuclear power stations across the United States operate with fuel assemblies being irradiated for up to 6 years (planned) in the reactor pressure vessel. After their planned irradiation, the fuel assemblies are moved to a spent fuel pool within the facility complex. After the spent nuclear fuel is removed from the fuel pool, it is typically inserted into a welded metal canister that can be transferred between overpacks for storage, transportation and possibly disposal. Most dry storage systems being used by industry today use dual purpose canisters (DPCs), designed for use in storage and transportation overpacks, but not specifically designed for disposal. Triple purpose-canisters, designed for disposal in addition to storage and transportation, have also been researched. Traditional manufacturing methods for spent fuel canisters involve fusion welding along the length or circumference of the canister which results in high tensile residual stresses in the joint weld zone (WZ) and heat affected zone (HAZ). In this paper, spent fuel canister designs were printed by wire arc additive manufacturing (AM) using the 316L SS welding wire to demonstrate: 1. Feasibility of spent nuclear fuel canister fabrication using this advanced manufacturing method, 2. Dynamic response of the additive manufacture canister design when subjected to the federally mandated Normal Conditions of Transport (NCT) and Hypothetical Accident Conditions (HAC) physical tests for Type B packages. This paper will focus on the canister printing design and structural tests. The AM 3D printed design, regulatory testing, and post-test evaluation of the canister tested to the 10 CFR 71.71 and 10 CFR 71.73 requirements will be presented. One AM canister design was subjected to the penetration, free drop, and puncture test. Before and after the dynamic structural tests, the AM canister design was scanned with a handheld scanner to capture a 3D CAD geometry to compare to the 3D printed canister design in the deformed shape. The scanned geometry was sectioned in areas with deformation and the cross-section profile was measured to determine accurate and repeated results of the deformed shape of the AM canister design.

Martinez, Oscar↗

A standard capsule design for structural material testing in the Advanced Test Reactor

Nuclear materials testing is commonly completed in various material test and research reactors throughout the world, including the Advanced Test Reactor (ATR), but the current capsule design, analysis, and fabrication process can take years to complete. To decrease the costs and time associated with materials testing, a standard capsule has been designed which houses various specimen geometries and allows irradiation in virtually any ATR test position. The standard capsule features locking end caps which connect and lock together to form the capsule stack, eliminating the need for a basket and maximizing the quantity of specimens which are contained within the capsule. A customizable internal gas gap provides thermal resistance between the specimens and reactor coolant, making specimen temperatures from approximately 370 to 1000 K achievable. The flexibility of the capsule design allows experimenters to choose irradiation positions based off desired neutron flux, with typical fluences per cycle ranging from 8.8x10 19 to 2.3x10 21 n/cm 2 , depending on experiment position. Here this paper presents and discusses the standard capsule design and analysis.

36 MATERIALS SCIENCE↗

Structural Design of a 1/5th Scale Gravo-Aeroelastically Scaled Wind Turbine Demonstrator Blade for Field Testing

This paper presents the structural design of a 21-meter 1/5th scale SUMR demonstrator (SUMR-D) blade, which was designed to replicate the full-scale behavior of a 104-meter SUMR13 initial blade rated at 13.2 MW. This is a challenging structural design as two competing objectives were required including the traditional safety objectives and novel scaling objectives based on gravo-aeroelastic scaling (GAS) requirements. To satisfy the two competing requirements, the spar cap, shear webs and materials were optimized while also ensuring a manufacturable and cost-effective design solution. Based on the wind turbine operating conditions of the test site, which is the NWTC, the blade was analyzed under the extreme loading case and corresponding safety factors were applied. The final blade model had an acceptable maximum strain, buckling performance, and displayed a safe level of deflection under the extreme loading condition. The flutter speed and fatigue life of the blade were also vetted. The mode shape was analyzed for the installation of the blade sensors. This paper documents the structural design process of SUMR-D to achieve both the safety and scaling objectives. At the end, we provide an acceptable solution to control blade mass, limiting the blade deflection, blade max strain and buckling under extreme loading condition by optimizing spar cap, shear web, and core materials while satisfying scaling requirements.

17 WIND ENERGY↗

High-gradient performance of a prototype accelerator cavity for a 3 GeV proton radiography booster

This paper reports the design, fabrication, and results of the high-gradient conditioning and testing for a two-cell, π -mode, standing wave normal-conducting prototype booster cavity for the proposed 3 GeV proton linac upgrade at Los Alamos Neutron Science Center. Increasing the energy of proton beam from the existing 800 MeV to 3 GeV will improve resolution of the proton radiography by up to 10 times. The proposed energy boost can be achieved with a compact normal-conducting high-gradient radio-frequency (rf) linac section. The C-band section of the booster linac was designed with optimized-shaped copper accelerator cavities with distributed rf coupling. A short two-cell test prototype structure was designed for the frequency of 5.712 GHz, fabricated, and tested at the C-band Engineering Research Test Facility in New Mexico (CERF-NM) at Los Alamos National Laboratory. The maximum klystron power coupled into the test structure was 8.3 MW with 1 μ s pulse length and 100 Hz repetition rate. The breakdown probabilities were recorded as functions of the accelerating gradient and peak surface fields. Operation of the test cavity at accelerating gradients of up to 100 MV / m was demonstrated. Published by the American Physical Society 2024

43 PARTICLE ACCELERATORS↗

Design and Construction of a 1/15th Scale Wave Tank Model of the Azura Commercial Wave Energy Converter

The design of a 1/15th geometrically scaled wave tank model of the Azura(TM) commercial-scale wave energy device is presented. The objectives of the wave tank tests, conducted at the University of Maine Harlod Alfond Wind/Wave Ocean Engineering Lab (W2), included verification of the Azura's energy capture in irregular waves, evaluation of performance in survival wave conditions, and testing of two advanced control algorithms. Due to the difficulty in properly Froude Scaling a hydraulic system, the model used a direct-drive rotary motor/generator power take-off (PTO), with the dynamics of the hydraulic PTO included via a hardware-in-the-loop simulation. This PTO implementation led to additional design requirements being imposed on the model drivetrain. In addition to the model PTO design, the instrumentation design, structural design, and test plans are presented. The resulting model and PTO achieved a high level of controllability, and accurately emulated the dynamics of the hydraulic PTO of the full-scale Azura prototype.

16 TIDAL AND WAVE POWER↗

Submerged Fatigue Testing of Marine Energy Advanced Materials

Marine energy structures are typically made of advanced composite materials and are subjected to extreme ocean environments in service. In extreme ocean environments, seawater currents and waves load structures repeatedly, which cause two environmental conditions: water intrusion and mechanical fatigue. In prior research, the two environmental conditions were applied sequentially, where composite specimens were aged and then mechanically tested. To understand the combined effects of dynamic loading and water intrusion on composite materials, the present study involves the static and fatigue four-point bend testing of composite coupons in a water tank. The water tank was designed and built to fit either a 100 kN or a 250 kN load frame. Flexural strength value, cycles to failure, and failure mode results from submerged fatigue testing will be used to inform marine energy structure designs. The coupon-scale test method will be used to scale up to and inform methods for subsequent subcomponent testing and standards development. The benefits of designing marine energy structures to informed standards are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

composite materials↗

Submerged Fatigue Testing of Marine Energy Advanced Materials: Preprint

Marine energy structures are typically made of advanced composite materials and are subjected to extreme ocean environments in service. In extreme ocean environments, seawater currents and waves load structures repeatedly, which cause two environmental conditions: water intrusion and mechanical fatigue. In prior research, the two environmental conditions were applied sequentially, where composite specimens were aged and then mechanically tested. To understand the combined effects of dynamic loading and water intrusion on composite materials, the present study involves the static and fatigue four-point bend testing of composite coupons in a water tank. The water tank was designed and built to fit either a 100 kN or a 250 kN load frame. Flexural strength value, cycles to failure, and failure mode results from submerged fatigue testing will be used to inform marine energy structure designs. The coupon-scale test method will be used to scale up to and inform methods for subsequent subcomponent testing and standards development. The benefits of designing marine energy structures to informed standards are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

composite materials↗

Submerged Fatigue Testing of Marine Energy Advanced Materials

Marine energy structures are typically made of advanced composite materials and are subjected to extreme ocean environments in service. In extreme ocean environments, seawater currents and waves load structures repeatedly, which cause two environmental conditions: water intrusion and mechanical fatigue. In prior research, the two environmental conditions were applied sequentially, where composite specimens were aged and then mechanically tested. To understand the combined effects of dynamic loading and water intrusion on composite materials, the present study involves the static and fatigue four-point bend testing of composite coupons in a water tank. The water tank was designed and built to fit either a 100 kN or a 250 kN load frame. Flexural strength value, cycles to failure, and failure mode results from submerged fatigue testing will be used to inform marine energy structure designs. The coupon-scale test method will be used to scale up to and inform methods for subsequent subcomponent testing and standards development. The benefits of designing marine energy structures to informed standards are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

composite materials↗

Submerged Fatigue Testing of Marine Energy Advanced Materials

Marine energy structures are typically made of advanced composite materials and are subjected to extreme ocean environments in service. In extreme ocean environments, seawater currents and waves load structures repeatedly, which cause two environmental conditions: water intrusion and mechanical fatigue. In prior research, the two environmental conditions were applied sequentially, where composite specimens were aged and then mechanically tested. To understand the combined effects of dynamic loading and water intrusion on composite materials, the present study involves the static and fatigue four-point bend testing of composite coupons in a water tank. The water tank was designed and built to fit either a 100 kN or a 250 kN load frame. Flexural strength value, cycles to failure, and failure mode results from submerged fatigue testing will be used to inform marine energy structure designs. The coupon-scale test method will be used to scale up to and inform methods for subsequent subcomponent testing and standards development. Finally, the benefits of designing marine energy structures to informed standards are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

13 HYDRO ENERGY↗

High power experimental studies of hybrid photonic band gap accelerator structures

This paper reports the first high power tests of hybrid Photonic Band Gap (PBG) accelerator structures. Three hybrid PBG (HPBG) structures were designed, built and tested at 17.14 GHz. Each structure had a triangular lattice array with 60 inner sapphire rods and 24 outer copper rods sandwiched between copper disks. The dielectric PBG band gap map allows the unique feature of overmoded operation in a TM02 mode, with suppression of both lower order modes, such as the TM11 mode, as well as higher order modes. The use of sapphire rods, which have negligible dielectric loss, required inclusion of the dielectric birefringence in the design. The three structures were designed to sequentially reduce the peak surface electric field. Simulations showed relatively high surface fields at the triple point as well as in any gaps between components in the clamped assembly. The third structure used sapphire rods with small pin extensions at each end and obtained the highest gradient of 19 MV/m, corresponding to a surface electric field of 78 MV/m, with a breakdown probability of 0.5 per pulse per meter for a 100-ns input power pulse. Operation at a gradient above 20 MV/m led to runaway breakdowns with extensive light emission and eventual damage. For all three structures, multipactor light emission was observed at gradients well below the breakdown threshold. This research indicated that multipactor triggered at the triple point limited the operational gradient of the hybrid structure.

43 PARTICLE ACCELERATORS↗

Design, fabrication, and high-gradient testing of an X -band, traveling-wave accelerating structure milled from copper halves

A prototype 11.994 GHz, traveling-wave accelerating structure for the Compact Linear Collider has been built, using the novel technique of assembling the structure from milled halves. The use of milled halves has many advantages when compared to a structure made from individual disks. These include the potential for a reduction in cost, because there are fewer parts, as well as a greater freedom in choice of joining technology because there are no rf currents across the halves’ joint. Here we present the rf design and fabrication of the prototype structure, followed by the results of the high-power test and post-test surface analysis. During high-power testing the structure reached an unloaded gradient of 100 MV / m at a rf breakdown rate of less than 1.5×10 –5 breakdowns / pulse / m with a 200 ns pulse. Furthermore, this structure has been designed for the CLIC testing program but construction from halves can be advantageous in a wide variety of applications.

43 PARTICLE ACCELERATORS↗

Modeling and Measurement of a Tunable Acoustoelastic System

Acoustoelastic coupling occurs when a hollow structure's in-vacuo mode aligns with an acoustic mode of the internal cavity. The impact of this coupling on the total dynamic response of the structure can be quite severe depending on the similarity of the modal frequencies and shapes. Typically, acoustoelastic coupling is not a design feature, but rather an unintended result that must be remedied as modal tests of structures are often used to correlate or validate finite element models of the uncoupled structure. Here, however, a test structure is intentionally designed such that multiple structural and acoustic modes are well-aligned, resulting in a coupled system that allows for an experimental investigation. First, coupling in the system is identified using a measure termed the magnification factor. Next, the structural-acoustic interaction is measured. Modifications to the system demonstrate the dependency of the coupling on changes in the mode shape and frequency proximity. This includes an investigation of several practical techniques used to decouple the system by altering the internal acoustic cavity, as well as the structure itself. These results show that acoustic absorption material effectively decoupled the structure while structural modifications, in their current form, proved unsuccessful. Readily available acoustic absorptive material was effective in reducing the coupled effects while presumably adding negligible mass or stiffness to the structure.

42 ENGINEERING↗

Discovery, Design, Synthesis and Testing of High Performance Structural Alloys (Final Technical Report)

The overarching goal of this project is to understand the phase stability and mechanical behavior of non-stoichiometric multi-principal element alloy (MPEA) materials. In order to identify suitable alloys, we plan to use a combinatorial thin film screening approach, in collaboration with scientists at Lawrence Berkeley National Laboratory who are performing computational work as well as complementary experimental work. Specific tasks within the scope of this project include the fabrication, using thin film deposition from six sputtering targets, of combinatorial samples with multi-dimensional gradients in composition and microstructure. These samples are studied to screen MPEA systems for promising candidate alloys with specific composition(s), based on characterization of composition, structure and mechanical behavior across the thin film. We want to produce single-phase MPEAs with chemical homogeneity in a given thin film region, simple grain structures, and no intermetallic phases present. Gradient films facilitate first-pass screening for desirable characteristics and inform the next stage of work that involves fabrication of bulk MPEA specimens for (tensile) mechanical testing and characterization. To make the bulk alloys, metal (elemental) pieces are melted to form MPEAs, followed by heat treatment to homogenize the composition and microstructure. A subset of alloys is also cast, using vacuum arc melting, to yield larger samples (diameter ~1 cm and length ~5-10 cm) and these allow us to assess viability of scale-up for the alloys in structural applications. Further processing plans include rolling and heat treatment to recrystallize selected bulk MPEAs and grow grains to different extents, in order to investigate size effects in the mechanical behavior of MPEAs. Microspecimen testing will be performed (primarily in tension) to assess the mechanical behavior over a range of temperatures. The deformation microstructure of mechanically tested alloys will be characterized using transmission electron microscopy (TEM) to provide a scientific basis for understanding the structure-property relationships in MPEA mechanical behavior.

36 MATERIALS SCIENCE↗