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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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18 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Comprehensive Automated Welder System

The Comprehensive Automated Welder System - PDRD SR-17-007 project was initiated to develop hardware and software to eliminate possible error pre-cursor functions of the pinch welding process that require manual manipulation and data entry as well as leveraging 21st century technology advances by replacing obsolete hardware with state of the art maintainable equipment. The project plan targeted three primary areas for improvement: 1. Replacing the existing welding power supply system with a solid-state power supply, 2. Improving the data acquisition system, sensors and controls, and 3. Updating the software to a FPGA “real-time” program with automated steps. SRNL purchased, designed and installed in 723-A, a system to meet the requirements for these areas. While improvements in hardware controls and sensor selection were achieved and a successful software automation routine was demonstrated, the performance goals were not met with the custom solid-state power transformer.

42 ENGINEERING↗
DOE OSTI2023

Laser Welder Startup Capacitor Failure Analysis & Suggested Potential Mitigation Factors [Slides]

On the morning of the failure (Mon 2/23/2023 5 AM), an unclassified Yttrium Aluminum Garnet Laser Welder system was working within operational parameters. However, when another part was positioned for drilling and it was activated, the coolant compressor was heard shutting off by everyone working on the laser. The coolant pump reportedly failed due to blown 5-amp fuses. Since the coolant pump was offline, the laser was automatically placed into an inoperable state. Failure of the coolant pump was due to a failed capacitor in the startup circuit for the pump.

42 ENGINEERING↗
DOE OSTI2024

Weather effects on the lifecycle of U.S. Department of Defense equipment replacement (WELDER)

Extreme weather has a direct and significant impact on buildings and infrastructure, resulting in billions of dollars of damage each year. This problem continues to grow as climate patterns change and buildings are exposed to new and different hazards than what they were designed to withstand. In order to better plan for the long-range sustainment, restoration, modernization, and eventual recapitalization of these buildings, organizations with large building portfolios, such as the U.S. Department of Defense (DoD), must have an awareness of the risks that these extreme weather events present. This research aimed to develop an approach to estimate condition loss and reduction in service life for the components of a building due to extreme weather hazards, to understand the risks that may be present in certain buildings and building systems. To achieve this objective, a damage association matrix was developed that categorizes climate hazards, the damage modes that they produce, and the individual component types impacted. This damage matrix formally links state-of-the-art climate model output, which provides projections of the probability of various climate hazards with a damage effects model that quantifies the consequence on component-level condition and service life. This method is applied to an actual portfolio of buildings in a particular geographic location and with a pre-defined component inventory that comprises the building. This approach can be aggregated to the system-, facility-, and site-level thus helping support billions of dollars in recapitalization decisions related to restoration/modernization of facilities.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Seismic Anchorage of Equipment Being Relocated to B226 - IPG Laser Welder

The purpose of the enclosed calculations is to determine the required seismic anchorage for the relocation of the Multi-Axis SYS-MA-YLS Workstation and its auxiliary equipment into B226. Analysis of the equipment frames are excluded from the scope of this safety note; it is assumed that they are capable of transferring the load demands to the anchorage detailed in this package.

42 ENGINEERING↗
DOE OSTI2017

Clamp force and alignment checking device

A check fixture measures a total clamp force applied by a welder device. The welder device includes a welding horn having a plurality of weld pads and welding anvil having a plurality of weld pads. The check fixture includes a base member operatively supporting a plurality of force sensors. The base member and the force sensors are received between the weld pads of the welding horn and the anvil pads of the welding anvil. Each force sensor is configured to measure an individual clamp force applied thereto by corresponding weld and anvil pads when the base member is received between the welding horn and the welding anvil and the welder device is in the clamped position. The individual clamp forces are used to determine whether the weld and/or anvil pads are worn or misaligned.

42 ENGINEERING↗
DOE OSTI2017

Intelligent Weld Manufacturing: Role of Integrated Computational Welding Engineering

A master welder uses his sensory perceptions to evaluate the process and connect them with his/her knowledge base to take the necessary corrective measures with his/her acquired skills to make a good weld. All these actions must take place in real time. Success depends on intuition and skills, and the procedure is labor-intensive and frequently unreliable. The solution is intelligent weld manufacturing. The ultimate goal of intelligent weld manufacturing would involve sensing and control of heat source position, weld temperature, weld penetration, defect formation and ultimately control of microstructure and properties. This involves a solution to a problem (welding) with many highly coupled and nonlinear variables. The trend is to use an emerging tool known as intelligent control. This approach enables the user to choose a desirable end factor such as properties, defect control, or productivity to derive the selection of process parameters such as current, voltage, or speed to provide for appropriate control of the process. Important elements of intelligent manufacturing are sensing and control theory and design, process modeling, and artificial intelligence. Significant progress has been made in all these areas. Integrated computational welding engineering (ICWE) is an emerging field that will aid in the realization of intelligent weld manufacturing. The paper will discuss the progress in process modeling, microstructure, properties, and process control and automation and the importance of ICWE. Also, control and automation strategies for friction stir welding will be discussed.

42 ENGINEERING↗
DOE OSTI2021

Prediction of Thermal Conditions of DED With FEA Metal Additive Simulation

This paper presents the integration of wire-arc additive manufacturing (WAAM) using Gas Metal Arc Welding (GMAW) into a machine tool to create a retrofit hybrid computer numeric control (CNC) machine tool. GMAW, along with other direct energy deposition systems, has the capacity to deposit material faster than the excess thermal energy can dissipate. This results in the need to allow the part to cool between consecutive layers, which is the most time-consuming part of the additive process. Finite element analysis (FEA) was used in conjunction with monitored build plate surface temperatures during deposition samples to improve adequate dwell time prediction and to develop a cooling system. A deposition was completed where no dwell time was used and the build plate along with the machine table temperatures were monitored. A second deposition was completed where only one bead was deposited and the traverse speed was increased. The GMAW welder was mounted on a 3-axis CNC machine where two square deposition samples were completed. A FEA model was designed and verified using the monitored samples. The model will be used to determine improved depositions speeds and whether forced cooling would allow for an increased deposition rate without structural failure. It was determined the FEA software can be used to accurately model and predict the thermal response of WAAM AM components.

Heinrich, Lauren↗
DOE OSTI2021

QXF Cold Mass Friction Test

The purpose of this test is to determine the longitudinal force on the stainless steel shell that is required to break the friction between the stainless steel shell and the aluminum shell underneath. This is achieved by suspending the short magnet between two backing plates on the eight grade 8 threaded rods which replace the 8 stainless steel toke tie rods in the magnet assembly. Eight hydraulic cylinders are mounted to each backing plate. Six, 22" sections of the stainless steel shell are welded in place on the magnet, each of which has a slightly different developed length, starting from the baseline design, and becoming progressively looser. A pushing flange is mounted to the stainless steel shells via small tack welds. Four load cells are then attached to the flange at designated points, while additional tooling is attached to each of the cylinders to facilitate the transfer of force from the cylinders to the stainless steel shell During the test, the cylinders will be slowly energized to no more than 7000 psi, with a resultant, longitudinal force on the flange of no more than 125,400 lbf. For each set of shells, the test ends when the load cell monitoring software detects a sharp decrease in force. This will indicate that the friction has broken. The cullenders will then be de-energized and the cycle will repeat for the next test. Welding operations outlined in the procedure (US-HiLumi-doc-4200) are outside the scope of the HA as the work is occurring under a previously-issued burn permit by qualified welders.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2022

Classification of Ultrasonic Weld Quality using Acoustic Signatures Acquired During Manufacture

Ultrasonic welding is a process is based on generating a solid-state bond between two metals by applying moderate pressure and high intensity sound waves (20-70 kHz frequencies) at their interface. During the solid-state process numerous material, surface, instrument, and environmental factors contribute to bond formation, strength, and durability. The inherent difficulty of measuring and controlling each of these factors has, to date, made predicting bond quality elusive. In this work, a Sonics model MWB20 ultrasonic spot welder with integral base, was used to produce a variety of welds of different metal foils under varying weld conditions. Acoustic measurements were recorded throughout the measurement process. Subsequent analysis of the signals using metrics that approximate the energy dispersed during the weld proved to successfully predict weld quality. Two metrics based on normalized energy differential and Renyi entropy were developed into Python and C++ scripts for direct analysis of weld acoustic data.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Open Source Laser Polymer Welding System: Design and Characterization of Linear Low-Density Polyethylene Multilayer Welds

The use of lasers to weld polymer sheets provides a means of highly-adaptive and custom additive manufacturing for a wide array of industrial, medical, and end user/consumer applications. This paper provides an open source design for a laser polymer welding system, which can be fabricated with low-cost fused filament fabrication and off-the-shelf mechanical and electrical parts. The system is controlled with free and open source software and firmware. The operation of the machine is validated and the performance of the system is quantified for the mechanical properties (peak load) and weld width of linear low density polyethylene (LLDPE) lap welds manufactured with the system as a function of linear energy density. The results provide incident laser power and machine parameters that enable both dual (two layers) and multilayer (three layers while welding only two sheets) polymer welded systems. The application of these parameter sets provides users of the open source laser polymer welder with the fundamental requirements to produce mechanically stable LLDPE multi-layer welded products, such as heat exchangers.

Laureto, John↗
DOE OSTI2019

Re-establishment of Light-Weight Radioisotope Heater Unit Platinum-30% Rhodium Alloy Components Production at Oak Ridge National Laboratory

During FY2018 the Oak Ridge National Laboratory (ORNL) Radioisotope Power Systems (RPS) Program completed re-establishment of capability to produce platinum-30% rhodium (Pt-30Rh) alloy components for the Light Weight Radioisotope Heater Unit (LWRHU) Program. These components were last produced at Mound Laboratory in the mid/late-1990s for the National Aeronautics and Space Administration (NASA) Cassini mission. The LWRHU Pt-30Rh Clad Body Subassembly and component fabrication operations are being performed in the iridium alloy Clad Vent Set (CVS) production area at ORNL. Existing equipment (furnaces, electron beam welders, presses, inspection, etc.) are being utilized along with new equipment (two lathes and laser marker) that were purchased for this work. ORNL purchased and qualified an initial quantity of starting materials (Pt powder, Pt-30Rh foil, sheet, and tubing). Equipment, tooling, and materials were procured/fabricated and qualified. Drawings and specifications were updated/modified/developed to the ORNL RPS Program format. Procedures were developed and qualified. All drawings, specifications, and procedures were reviewed/approved by the Idaho National Laboratory (INL) RPS Lead Lab Document Configuration Control Board (DCCB). The dimensional inspection operations and special processes (cleaning, heat treating, sintering, dye penetrant inspection, leak testing, and welding) were successfully qualified and documented. This paper will discuss the process of re-establishing LWRHU production at ORNL to provide for future NASA space exploration science mission needs10.

Veach Jr, Rex↗
DOE OSTI2019

Thermal Process Monitoring for Wire-Arc Additive Manufacturing Using IR Cameras

Wire-arc additive manufacturing systems use robotic MIG welders to build parts using welding wire. As a part is built the temperature rises as energy is input and the thermal mass increases. While some pre-heat is ideal for welding, improper thermal management can lead to defects and negatively affect material properties. Thermal imaging allows for non-contact thermal monitoring and can be used to track thermal gradients as well as layer temperatures before and after deposition providing a method to ensure proper thermal management. A typical IR camera setup on an mBAAM system is discussed along with methods to use thermal monitoring to improve material properties and reduce defects in the final part.

Carter, William↗
DOE OSTI2022

Fabrication and installation of the Mu2e cryogenic distribution system

The muon-to-electron conversion (Mu2e) experiment at Fermilab will be used to search for the charged lepton flavor-violating conversion of muons to electrons in the field of an atomic nucleus. The Mu2e experiment is currently in the construction stage. The scope of this paper is the cryogenic distribution system and superconducting power leads for four superconducting solenoid magnets: Production Solenoid (PS), an Upstream and Downstream Transport Solenoids (TSu and TSd) and Detector Solenoid (DS). The design of the cryogenic distribution system and the fabrication of several sub-systems was reported previously. This paper reports on additional fabrication and installation progress that has been performed over the past two years. Lessons learned during fabrication and testing of the cryogenic distribution system components are described. In particular, the challenges and solutions implemented for aluminum welding are reported. A description of the process used to qualify the welding procedure and welders for welding the aluminium stabilized NbTi superconducting power leads is provided. Additionally, the progress made with regards to installing the power leads into the cryogenic Feedboxes is covered.

White, Michael J.↗
DOE OSTI2023

Retractable Sensors for In-Core Use in Material Test Reactors - conf paper

Material Test Reactors (MTRs) such as the Advanced Test Reactor (ATR) at the Idaho National Laboratory (INL) are used to irradiate nuclear fuels and materials to evaluate their performance after high levels of exposure to a reactor in-core environment. The most critical tests are equipped with instrumentation leads, which allow real-time data collection. However, because of the very harsh environment inside high-power MTR experiments, there are very few sensors that can survive and maintain their calibrated readings for the time periods required to obtain the high neutron doses needed for new fuels and materials qualification. As a result, sometimes sponsoring programs are forced to accept low reliability of sensors, collecting useful data for only part of the experiment duration. The work described herein is based on the observation that MTRs normally run at constant power and the corresponding conditions within reactor experiments typically evolve relatively slowly. Therefore, even one or two measurements per day would provide a complete and representative data set. With this in mind, INL has embarked on a program to develop a mechanism capable of pushing a very small-diameter sensor (typically a thermocouple or optical fiber) into the location to be measured, leave the sensor for roughly 60 seconds to allow it to reach equilibrium and transmit the signal, then pull it up and away from the high neutron flux and high-temperature region. Small-diameter capillary tubes, up to 8 m long, are used to guide the sensors to the appropriate locations. These capillary tubes serve as essentially very deep, thin-walled thermowells. The distance a thermocouple or optical fiber would need to traverse is on the order of 40 - 80 cm. By adopting this infrequent cycling strategy, the thermocouple or optical fiber would spend only a few hours in the high-neutron flux/high-temperature environment over the duration of even the longest irradiation experiment. To date, INL has developed two styles of drive mechanisms. The first is based on friction drive wheels which drive the sensors in a manner similar to a small MIG welder. This has the advantage of being able to accommodate a very long insertion length. The second is based on a ball screw drive and has the advantages of positive attachment and being able to move more than one sensor at a time. Both drive mechanisms have been fabricated and tested in a laboratory setting. Both systems can handle hard mineral insulated cable (such as thermocouples) or optical fibers encased in small diameter tube. The sizes tested to date are 1 - 1.6 mm diameter. Work in this area is ongoing with an eye toward demonstration in the Massachusetts Institute of Technology's MITR reactor, followed by deployment in an ATR irradiation experiment.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Retractable Sensors for In-Core Service in Material Test Reactors

Material Test Reactors (MTRs) such as the Advanced Test Reactor (ATR) at the Idaho National Laboratory (INL) are used to irradiate nuclear fuels and materials to evaluate their performance after high levels of exposure to a reactor in-core environment. The most critical tests are equipped with instrumentation leads, which allow real-time data collection. However, because of the very harsh environment inside high-power MTR experiments, there are very few sensors that can survive and maintain their calibrated readings for the time periods required to obtain the high neutron doses needed for new fuels and materials qualification. As a result, sometimes sponsoring programs are forced to accept low reliability of sensors, collecting useful data for only part of the experiment duration. The work described herein is based on the observation that MTRs normally run at constant power and the corresponding conditions within reactor experiments typically evolve relatively slowly. Therefore, even one or two measurements per day would provide a complete and representative data set. With this in mind, INL has embarked on a program to develop a mechanism capable of pushing a very small-diameter sensor (typically a thermocouple or optical fiber) into the location to be measured, leave the sensor for roughly 60 seconds to allow it to reach equilibrium and transmit the signal, then pull it up and away from the high neutron flux and high-temperature region. Small-diameter capillary tubes, up to 8 m long, are used to guide the sensors to the appropriate locations. These capillary tubes serve as essentially very deep, thin-walled thermowells. The distance a thermocouple or optical fiber would need to traverse is on the order of 40 - 80 cm. By adopting this infrequent cycling strategy, the thermocouple or optical fiber would spend only a few hours in the high-neutron flux/high-temperature environment over the duration of even the longest irradiation experiment. To date, INL has developed two styles of drive mechanisms. The first is based on counter-rotating wheels which drive the sensors in a manner similar to a small MIG welder. This has the advantage of being able to accommodate a very long insertion length. The second is based on a ball screw drive and has the advantages of positive attachment and being able to move more than one sensor at a time. Both drive mechanisms have been fabricated and tested in a laboratory setting. Both systems can handle hard mineral insulated cable (such as thermocouples) or optical fibers encased in small diameter tube. The sizes tested to date are 1 - 1.6 mm diameter. Work in this area is ongoing with an eye toward demonstration in the Massachusetts Institute of Technology's MITR reactor, followed by deployment in an ATR irradiation experiment.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Retractable Sensors for In-Core Service in Material Test Reactors

Material Test Reactors (MTRs) such as the Advanced Test Reactor (ATR) at the Idaho National Laboratory (INL) are used to irradiate nuclear fuels and materials to evaluate their performance after high levels of exposure to a reactor in-core environment. The most critical tests are equipped with instrumentation leads, which allow real-time data collection. However, because of the very harsh environment inside high-power MTR experiments, there are very few sensors that can survive and maintain their calibrated readings for the time periods required to obtain the high neutron doses needed for new fuels and materials qualification. As a result, sometimes sponsoring programs are forced to accept low reliability of sensors, collecting useful data for only part of the experiment duration. The work described herein is based on the observation that MTRs normally run at constant power and the corresponding conditions within reactor experiments typically evolve relatively slowly. Therefore, even one or two measurements per day would provide a complete and representative data set. With this in mind, INL has embarked on a program to develop a mechanism capable of pushing a very small-diameter sensor (typically a thermocouple or optical fiber) into the location to be measured, leave the sensor for roughly 60 seconds to allow it to reach equilibrium and transmit the signal, then pull it up and away from the high neutron flux and high-temperature region. Small-diameter capillary tubes, up to 8 m long, are used to guide the sensors to the appropriate locations. These capillary tubes serve as essentially very deep, thin-walled thermowells. The distance a thermocouple or optical fiber would need to traverse is on the order of 40 – 80 cm. By adopting this infrequent cycling strategy, the thermocouple or optical fiber would spend only a few hours in the high-neutron flux/high-temperature environment over the duration of even the longest irradiation experiment. To date, INL has developed two styles of drive mechanisms. The first is based on counter-rotating wheels which drive the sensors in a manner similar to a small MIG welder. This has the advantage of being able to accommodate a very long insertion length. The second is based on a ball screw drive and has the advantages of positive attachment and being able to move more than one sensor at a time. Both drive mechanisms have been fabricated and tested in a laboratory setting. Both systems can handle hard mineral insulated cable (such as thermocouples) or optical fibers encased in small diameter tube. The sizes tested to date are 1 – 1.6 mm diameter. Work in this area is ongoing with an eye toward demonstration in the Massachusetts Institute of Technology’s MITR reactor, followed by deployment in an ATR irradiation experiment.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2017

Building the Future Nuclear Workforce Through Regional Partnerships - 17219

Industries across the United States of America are competing for highly skilled talent at a time when worker retirements are increasing and fewer students are pursuing science, technology, engineering and math (STEM) related fields of study. This specialized workforce is necessary for many industries, and it is essential for the processing and management of nuclear materials and operations of the nuclear security enterprise. Competition for STEM talent impacts the region that includes the Savannah River Site (SRS), a Department of Energy complex that is responsible for environmental stewardship, environmental cleanup, waste management and disposition of nuclear materials. SRS employs nearly 11,000 people and anticipates significant workforce attrition due to retirements over the next several years. In the SRS region, nuclear industry workers are also needed for the growing nuclear power industry as construction of four new nuclear power plants is taking place within an 80-mile radius of SRS. To address growing nuclear workforce needs in this region of Georgia and South Carolina, the SRS Community Reuse Organization (SRSCRO) established the Nuclear Workforce Initiative (NWI{sup R}) during 2009. Through NWI{sup R}, the SRSCRO has developed a network of partnerships with nuclear employers and regional educators to expand nuclear workforce development capabilities. Most notably, through NWI{sup R}, the SRSCRO established a partnership with five local colleges and universities and the Department of Energy Office of Environmental Management. Together, they have produced significant results. Recently, the National Nuclear Security Administration joined the partnership to help build the future nuclear workforce that includes scientists and engineers, but also skilled technicians, production operators, welders, nuclear quality specialists and other highly skilled professionals prepared to work in a secure and procedure-oriented environment. This paper highlights results from a successful partnership between a non-profit organization, academic institutions and the United States Department of Energy designed to expand the nuclear industry talent pool. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Robotic Solutions for Remote Access and Retrieval of High-Level Radioactive Waste - 19544

This paper describes the ongoing development of robotic solutions for accessing and retrieving high-level radioactive waste from underground storage bins as part of the Calcine Retrieval Project at the INL Site. The waste is in the form of a solid powder, referred to as calcine, stored in a set of stainless steel bins within an underground concrete vault. Due to the radiation field produced by the calcine, all operations must be performed remotely. The Calcine Retrieval Project is currently carrying out proof-of-concept testing of methods for the various stages of calcine retrieval. The bins were designed with no means for access, so retrieval operations will require welding access riser pipes to the bins, followed by cutting through the bin walls from within the risers. These tasks are complicated by the fact that four of the risers must be placed off center on a domed surface, resulting in a weld joint that is curved and tilted relative to the riser axis. The Access Riser Connection robot is being developed to perform these operations using interchangeable welding and plasma cutting attachments. The majority of the calcine will be removed using a vacuum system and pneumatically transferred to storage. This system is not described in this paper. However, the bins contain several internal features that are expected to retain calcine, most notably circumferential stiffening rings on the walls and radial ribs on the floors. One of the solutions being developed for the task of retrieving this residual calcine is a vacuum crawler, a wheeled robot using vacuum to adhere to the interior walls of the bins. The vacuum crawler would use a separate vacuum system to remove residual calcine or would use compressed air to move calcine to a location from which it can be retrieved more easily. While comparable welding and wall-climbing robots have been developed before, this particular application has several constraints that are not satisfied by existing systems. For this reason, both the access riser welder and the vacuum crawler, although still under development, may be of interest to other projects faced with similar constraints. (author)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗