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At least 199 records · Page 11

FY2022 Filter Test for TRU Waste Drum Prototype Unit

Continuing last year’s (fiscal year 2021) work, a prototype instrument and an NPI-6 Integrated Work Document (IWD) were developed to assess the functionality of filters on transuranic waste containers (commonly called 55 Gallon ring-top drums) without requiring the removal of the drum lid. The purpose of this work is to determine the air flow and pressure characteristics associated with filter clogging, filter pressure drop at a fixed flow rate, and leakage around the lid seal. The FY22 objectives included: (A) Development of prototype device, (B) Drafting an IWD document, (C) Defining a filter clogging parameter, (D) Assessing filter damage due to over-pressure events, and (E) A path forward to obtain approval of the system safety filters in compliance with P101-16 Industrial Ventilation – non HVACR (LANL 2022).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Space Suit Portable Life Support System (PLSS) 2.0 Pre-Installation Acceptance (PIA) Testing

Following successful completion of the space suit Portable Life Support System (PLSS) 1.0 development and testing in 2011, the second system-level prototype, PLSS 2.0, was developed in 2012 to continue the maturation of the advanced PLSS design. This advanced PLSS is intended to reduce consumables, improve reliability and robustness, and incorporate additional sensing and functional capabilities over the current Space Shuttle/International Space Station Extravehicular Mobility Unit (EMU) PLSS. PLSS 2.0 represents the first attempt at a packaged design comprising first generation or later component prototypes and medium fidelity interfaces within a flight-like representative volume. Pre-Installation Acceptance (PIA) is carryover terminology from the Space Shuttle Program referring to the series of test sequences used to verify functionality of the EMU PLSS prior to installation into the Space Shuttle airlock for launch. As applied to the PLSS 2.0 development and testing effort, PIA testing designated the series of 27 independent test sequences devised to verify component and subsystem functionality, perform in situ instrument calibrations, generate mapping data, define set-points, evaluate control algorithms, evaluate hardware performance against advanced PLSS design requirements, and provide quantitative and qualitative feedback on evolving design requirements and performance specifications. PLSS 2.0 PIA testing was carried out in 2013 and 2014 using a variety of test configurations to perform test sequences that ranged from stand-alone component testing to system-level testing, with evaluations becoming increasingly integrated as the test series progressed. Each of the 27 test sequences was vetted independently, with verification of basic functionality required before completion. Because PLSS 2.0 design requirements were evolving concurrently with PLSS 2.0 PIA testing, the requirements were used as guidelines to assess performance during the tests; after the completion of PIA testing, test data served to improve the fidelity and maturity of design requirements as well as plans for future advanced PLSS functional testing.

Anchondo, Ian↗

Rapid Biochemical Analysis on the International Space Station (ISS): Preparing for Human Exploration of the Moon and Mars

The Lab-on-a-Chip Application Development - Portable Test System, known as LOCAD-PTS, was launched to the International Space Station (ISS) aboard Space Shuttle Discovery (STS-116) on December 9th,2006. Since that time, it has remained onboard ISS and has been operated by the crew on 10 separate occasions LOCAD-PTS is a handheld device for rapid biochemical analysis; it consists of a spectrophotometer, a series of interchangeable cartridges, a pipette and several clean/sterilized swabbing kits to obtain samples from ISS surfaces. Sampling, quantitative analysis and data retrieval is performed onboard, therefore reducing the need to return samples to Earth. Less than 20 minutes are required from sampling to data, significantly faster than existing culture-based methods on ISS, which require 3-5 days. Different cartridges are available for the detection of different target molecules (simply by changing the formulation within each cartridge), thereby maximizing the benefit and applications addressed by a single instrument. Initial tests on ISS have focused on the detection of the bact.erial macromolecule endotoxin, a component of bacterial cell walls. LOCAD-PTS detects endotoxin with a cartridge that contains a formulation known as Limulus Amebocyte Lysate (LAL) assay. LAL is derived from blood of the horseshoe crab, Limulus polyphemus, and detects enodotoxin with an enzyme cascade that triggers generation Of a yellow colored dye, p-nitroanaline. The more p-nitroanaline product, the more endotoxin is in the original sample. To enable quantitative analysis, the absorbance of this color is measured by LOCAD-PTS through a 395 nm filter and compared with an internal calibration curve, to provide a reading on the LED display that ranges from 0.05 Endotoxin Units (EU)/ml to 5 EU/ml. Several surface sites were analyzed within ISS between March 2007 and February 2008, including multiple locations in the US Laboratory Destiny, Node 1 Unity, AMock, and Service Module Zvezda. The goals of this initial study were to i) test the cleanliness of reagents/supplies on orbit, ii) test the crew's ability to collect and process a sample in microgravity without contamination, iii) demonstrate nominal function of the LOCAD-PTS, and iv) provide a general survey of endotoxin within the ISS. The surface sites varied greatly in terms of their frequency-of-use and material texture/composition; from relatively smooth aluminum, to fabric, to the room temperature vulcanizing (RTV) rubber of a Extravehicular Mobility Unit (EMU) spacesuit. Results showed that: i) the swabbing kits and reagents remained clean on orbit, ii) the crew could collect and process a sample without contamination, and iii) the LOCAD-PTS functioned nominally in > 99% of the 55 tests completed. We will present detailed results of the survey of endotoxin on ISS surfaces. These results and technology are important in the near-term - by providing an extra tool in the toolbox for ISS microbial monitoring. They are also important in the longer term as valuable preparation for human exploration of the Moon and Mars. One of the proposed science goals for the human exploration of Mars will be to detect and characterize any indigenous biological molecules that may exist on the Martian surface. To achieve that goal, the crew must have the technology available onboard to differentiate indigenous biology from any terrestrial biological material brought to Mars by the spacecraft and crew (termed 'forward contamination'). The LAL assay is already one of the official methods used by NASA's planetary protection program to certify cleanliness of interplanetary robotic spacecraft prior to launch; and therefore endotoxin is a good marker of forward contamination (as well as other microbial molecules detectable with LOCAD-PTS e.g. box-1, 3-glucan and lipoteichoic acid). Furthermore, the distribution and abundance of these molecules on the ISS provides a good indicator of what to expect on the Crew Exploratioehicle Orion, the lunar lander Antares, and future crewed spacecraft destined for Mars. In addition, technology such as LOCAD-PTS has been proposed to help evaluate forward contamination during lunar surface operations by the crew, as preparation for the human exploration of Mars.

Maule, J.↗

Universal Controller for Spacecraft Mechanisms

An electronic control unit has been fabricated and tested that can be replicated as a universal interface between the electronic infrastructure of a spacecraft and a brushless-motor (or other electromechanical actuator) driven mechanism that performs a specific mechanical function within the overall spacecraft system. The unit includes interfaces to a variety of spacecraft sensors, power outputs, and has selectable actuator control parameters making the assembly a mechanism controller. Several control topologies are selectable and reconfigurable at any time. This allows the same actuator to perform different functions during the mission life of the spacecraft. The unit includes complementary metal oxide/semiconductor electronic components on a circuit board of a type called rigid flex (signifying flexible printed wiring along with a rigid substrate). The rigid flex board is folded to make the unit fit into a housing on the back of a motor. The assembly has redundant critical interfaces, allowing the controller to perform time-critical operations when no human interface with the hardware is possible. The controller is designed to function over a wide temperature range without the need for thermal control, including withstanding significant thermal cycling, making it usable in nearly all environments that spacecraft or landers will endure. A prototype has withstood 1,500 thermal cycles between 120 and +85 C without significant deterioration of its packaging or electronic function. Because there is no need for thermal control and the unit is addressed through a serial bus interface, the cabling and other system hardware are substantially reduced in quantity and complexity, with corresponding reductions in overall spacecraft mass and cost.

Levanas, Greg↗

Test Hardware Design for Flightlike Operation of Advanced Stirling Convertors (ASC-E3)

NASA Glenn Research Center (GRC) has been supporting development of the Advanced Stirling Radioisotope Generator (ASRG) since 2006. A key element of the ASRG project is providing life, reliability, and performance testing of the Advanced Stirling Convertor (ASC). For this purpose, the Thermal Energy Conversion branch at GRC has been conducting extended operation of a multitude of free-piston Stirling convertors. The goal of this effort is to generate long-term performance data (tens of thousands of hours) simultaneously on multiple units to build a life and reliability database. The test hardware for operation of these convertors was designed to permit in-air investigative testing, such as performance mapping over a range of environmental conditions. With this, there was no requirement to accurately emulate the flight hardware. For the upcoming ASC-E3 units, the decision has been made to assemble the convertors into a flight-like configuration. This means the convertors will be arranged in the dual-opposed configuration in a housing that represents the fit, form, and thermal function of the ASRG. The goal of this effort is to enable system level tests that could not be performed with the traditional test hardware at GRC. This offers the opportunity to perform these system-level tests much earlier in the ASRG flight development, as they would normally not be performed until fabrication of the qualification unit. This paper discusses the requirements, process, and results of this flight-like hardware design activity.

Oriti, Salvatore M.↗

Test Hardware Design for Flight-Like Operation of Advanced Stirling Convertors

NASA Glenn Research Center (GRC) has been supporting development of the Advanced Stirling Radioisotope Generator (ASRG) since 2006. A key element of the ASRG project is providing life, reliability, and performance testing of the Advanced Stirling Convertor (ASC). For this purpose, the Thermal Energy Conversion branch at GRC has been conducting extended operation of a multitude of free-piston Stirling convertors. The goal of this effort is to generate long-term performance data (tens of thousands of hours) simultaneously on multiple units to build a life and reliability database. The test hardware for operation of these convertors was designed to permit in-air investigative testing, such as performance mapping over a range of environmental conditions. With this, there was no requirement to accurately emulate the flight hardware. For the upcoming ASC-E3 units, the decision has been made to assemble the convertors into a flight-like configuration. This means the convertors will be arranged in the dual-opposed configuration in a housing that represents the fit, form, and thermal function of the ASRG. The goal of this effort is to enable system level tests that could not be performed with the traditional test hardware at GRC. This offers the opportunity to perform these system-level tests much earlier in the ASRG flight development, as they would normally not be performed until fabrication of the qualification unit. This paper discusses the requirements, process, and results of this flight-like hardware design activity.

Oriti, Salvatore M.↗

Graphic Three-Axes Presentation of Residual Gas Analyser Data

Residual gas analyzers (RGA) are commonly used to measure the composition of residual gases in thermal-vacuum test chambers. Measurements from RGAs are often used to identify and quantify outgassing contaminants from a test article during thermal-vacuum testing. RGA data is typically displayed as snapshots in time, showing instantaneous concentrations of ions from ionized residual gas molecules at different atomic masses. A method was devised by the authors to present RGA data in a three-axis format, plotting atomic mass unit (AMU), ion concentration as a function of AMU, and time, to provide a clear graphic visualization ot trends in gas concentration changes and to initiate a valuable analytical tool to interpret test article outgassing rates during thermal-vacuum testing.

data analysis↗

Design, processing, and testing of LSI arrays for space station

At wafer probe, units of the TA6567 circuit, a beam leaded COS/MOS/SOS 256-bit RAM, were demonstrated to be functionally perfect. An aluminum gate current-sense version and a silicon-gate voltage-sense version of this memory were developed. Initial base line data for the beam lead SOS process using the TA5388 circuit show the stability of the dc device characteristics through the beam lead processing.

Schneider, W. C.↗

Helicopter /RSRA/ in-flight escape system - Component qualification

The paper describes the design, development, and qualification approach for the RSRA (Rotor Systems Research Aircraft) system explosive and pyrotechnic components. The approach was based on previous experience and included: (1) the application of good design practice and quality control, (2) a thorough examination of component interfaces through demonstration testing of functional margins, (3) the carrying out of thorough real-world sequential environmental testing, and (4) the operation of environmentally exposed units in subsystem-level tests at temperature, force, and energy limits. Owing largely to this approach, the RSRA became the first helicopter system to contain a fully qualified and operational in-flight escape system.

Bement, L. J.↗

Electrochemical Technology for Oxygen Removal and Measurement in the CELSS Test Facility, Engineering Development Unit

The Life Support Flight Program is evaluating regenerative technologies, including those that utilize higher plants, as a means to reduce resupply over long duration space missions. Constructed to assist in the evaluation process is the CELSS Test Facility Engineering Development Unit (CTF-EDU) an environmentally closed (less than 1% mass and thermal leakage) technology test bed. This ground based fully functional prototype is currently configured to support crop growth, utilizing the power, volume and mass resources allocated for two space station racks. Sub-system technologies were selected considering their impact on available resources, their ability to minimize integration issues, and their degree of modularity. Gas specific mass handling is a key sub-system technology for both biological and physical/chemical life support technologies. The CTF-EDU requires such a system to accommodate non-linear oxygen production from crops, by enabling the control system to change and sustain partial pressure set points in the growth volume. Electrochemical cells are one of the technologies that were examined for oxygen handling in the CTF-EDU. They have been additionally considered to meet other regenerative life support functions, such as oxygen generation, the production of potable water from composite waste streams, and for having the potential to integrate life support functions with those of propulsion and energy storage. An oxygen removal system based on an electrochemical cell was chosen for the EDU due to it's low power, volume and mass requirements (10W, 0.000027 cu m, 4.5 kg) and because of the minimal number of integration considerations. Unlike it's competitors, the system doesn't require post treatments of its byproducts, or heat and power intensive regenerations, that also mandate system redundancy or cycling. The EDUs oxygen removal system only requires two resources, which are already essential to controlled plant growth: electricity and water. Additionally, the amount of oxygen that is removed from the EDU is directly proportional to the cell input current via Faraday's constant, potentially allowing for a mol/electron measurement of photosynthetic rate. The currently operative oxygen removal system has maintained reduced oxygen set points within the EDU, and preparation is underway to verify of the accuracy of electrochemical measurement of oxygen production and hence, photosynthesis. This paper examines the working principles of the electrochemical cell, outlines the overall design of the oxygen removal system and its integration with other EDU subsystems, and summarizes test results obtained over crop growth cycles in the CTF-EDU.

Drews, Michael E.↗

Integration of a MicroCAT Propulsion System and a PhoneSat Bus into a 1.5U CubeSat

NASA Ames Research Center and the George Washington University have developed an electric propulsion subsystem that can be integrated into the PhoneSat bus. Experimental tests have shown a reliable performance by firing three different thrusters at various frequencies in vacuum conditions. The three thrusters were controlled by a SmartPhone that was running the PhoneSat software. The subsystem is fully operational and it requires low average power to function (about 0.1 W). The interface consists of a microcontroller that sends a trigger pulses to the PPU (Plasma Processing Unit), which is responsible for the thruster operation. Frequencies ranging from 1 to 50Hz have been tested, showing a strong flexibility. A SmartPhone acts as the main user interface for the selection of commands that control the entire system. The micro cathode arc thruster MicroCAT provides a high 1(sub sp) of 3000s that allows a 4kg satellite to obtain a (delta)V of 300m/s. The system mass is only 200g with a total of volume of 200(cu cm). The propellant is based on a solid cylinder made of Titanium, which is the cathode at the same time. This simplicity in the design avoids miniaturization and manufacturing problems. The characteristics of this thruster allow an array of MicroCATs to perform attitude control and orbital correcton maneuvers that will open the door for the implementation of an extensive collection of new mission concepts and space applications for CubeSats. NASA Ames is currently working on the integration of the system to fit the thrusters and PPU inside a 1.5U CubeSat together with the PhoneSat bus into a 1.5U CubeSat. This satellite is intended to be deployed from the ISS in 2015 and test the functionality of the thrusters by spinning the satellite around its long axis and measure the rotational speed with the phone byros. This test flight will raise the TRL of the propulsion system from 5 to 7 and will be a first test for further CubeSats with propulsion systems, a key subsystem for long duration or interplanetary CubeSat missions.

PhoneSat↗

A Step Towards the Final Frontier: Lessons Learned from Acceptance Testing of the First HPE/Cray EX 3000 System at ORNL

In this paper, we summarize the deployment of the Air Force Weather (AFW) HPC11 system at Oak Ridge National Laboratory (ORNL) including the process followed to successfully complete acceptance testing of the system. HPC11 is the first HPE/Cray EX 3000 system that has been successfully released to its user community in a federal facility. HPC11 consists of two identical 800-node supercomputers, Fawbush and Miller, with access to two independent and identical Lustre parallel file systems. HPC11 is equipped with Slingshot 10 interconnect technology and relies on the HPE Performance Cluster Manager (HPCM) software for system configuration. ORNL has a clearly defined acceptance testing process used to ensure that every new system deployed can provide the necessary capabilities to support user workloads. We worked closely with HPE and AFW to develop a set of tests that used the United Kingdom’s Meteorological Office’s Unified Model (UM) and 4DVAR. We also included benchmarks and applications from the Oak Ridge Leadership Computing Facility (OLCF) portfolio to fully exercise the HPE/Cray programming environment and evaluate the functionality and performance of the system. Acceptance testing of HPC11 required parallel execution of each element on Fawbush and Miller. In addition, careful coordination was needed to ensure successful acceptance of the newly deployed Lustre file systems alongside the compute resources. In this work, we present test results from specific system components and provide an overview of the issues identified, challenges encountered, and the lessons learned along the way.

Melesse Vergara, Veronica↗

ON THE EFFECTIVENESS OF LLMS IN UNIT TEST GENERATION FOR STRUCTURED TEXT PROGRAMS

The reliability of industrial automation systems heavily depends on the correctness of Programmable Logic Controller (PLC) programs, which are often written in Structured Text (ST). While Large Language Models (LLMs) have shown promise in automating test generation for mainstream programming languages, their effectiveness for the syntactically strict ST language remains underexplored. This thesis presents a systematic empirical evaluation of three state-of-the-art LLMs—GPT-4o, Gemini 2.5 Pro, and Claude Sonnet 4.5—for generating ST unit tests. We examine three prompting strategies: Natural Language (NL), Code Language (CL), and Chain-of-Thought (CoT), across a curated set of 11 ST function blocks. The quality of the generated tests is assessed using Compilation Success Rate (CSR), Statement Coverage (SC), and Branch Coverage (BC). In the zero-shot setting, Claude Sonnet 4.5 achieves the highest CSR, while Gemini 2.5 Pro consistently delivers the best statement and branch coverage, particularly under CL prompts. By incorporating a one-shot CL prompt, all models exhibit substantial improvements—most notably GPT-4o, whose CSR increases from 45.45% to 90.91%, with substantial gains in both SC and BC. To further contextualize these findings, we compare GPT-4o’s one-shot results with PLCAutoTester, a state-ofthe- art ST unit test generation tool, on an additional benchmark dataset. While LLMgenerated tests approach competitive coverage levels, PLCAutoTester maintains significantly higher and more stable coverage across programs. This study provides the first comprehensive benchmark of modern LLMs for ST unit testing, highlighting their strengths, limitations, and improvements through one-shot prompting, and positioning their performance relative to specialized automated testing tools in industrial automation.

42 ENGINEERING↗

Development and testing of the infrared radiometer for the Mariner Venus/Mercury 1973 spacecraft

The science objectives, development history, functional description, and testing of the Mariner Venus/Mercury 1973 infrared radiometer are discussed. Included in the functional description section is a thorough discussion of the IRR optical system, electronic operation, and thermal control. Signal development and its conversion to engineering units is traced, starting with the radiant space object, passing through the IRR optics and electronics, and culminating with data number development and interpretation. The test program section includes discussion of IRR calibration and alignment verification. Finally, the problems and failures encountered by the IRR during the period of its development and testing are reviewed.

Clarke, T. C.↗

Studies of LAPPD and HRPPD photodetectors for Cherenkov imaging applications

HRPPDs are the baseline single-photon sensors for a classic proximity-focusing RICH (pfRICH) counter, one of the Cherenkov radiation-based PID subsystems of the ePIC detector at the EIC. We report SPE time resolution of 87 ps rms for an LAPPD unit detecting Cherenkov photons in a quartz lens at a CERN PS test beam (2022). We also present the degradation and partial recovery of gain and relative efficiency of an LAPPD unit as a function of the B-field strength (up to 1.5 T) and angular orientation, measured with vertical dipole magnets at CERN (2023–2024). Finally, we report preliminary results of an accelerated ageing study performed on an HRPPD unit in Trieste laboratory (2025).

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Multi-hundred kilowatt roll ring assembly

A program was completed to develop an evaluation unit of a high power rotary transfer device for potential application in a space environment. This device was configured around a Roll Ring concept which performs the same function as a slip ring/brush assembly with a rolling instead of sliding interface. An eight circuit Evaluation Unit (EU) and a portable Test Fixture (TF) were designed and fabricated. The EU was designed to transfer currents to 200 amperes at a potential of as high as 500 volts for an ultimate 100 kW/circuit transfer capability. The EU was evaluated in vacuum at dc transfer currents of 50 to 200 amperes at voltages to 10 volts and at 500 volts at 2 amperes. Power transfer to levels of 2 kW through each of the eight circuits was completed. Power transfer in vacuum at levels and efficiencies not previously achieved was demonstrated. The terminal-to-terminal resistance was measured to be greater than 0.42 milliohms which translates to an efficiency at 100 kW of 99.98 percent. The EU and TF have been delivered to the Lewis Research Center and are being prepared tor testing at increased power levels and for life testing, which will include both dc and ac power.

Jacobson, Peter E.↗

Enhanced Master Controller Unit Tester

The Enhanced Master Controller Unit Tester (EMUT) software is a tool for development and testing of software for a master controller (MC) flight computer. The primary function of the EMUT software is to simulate interfaces between the MC computer and external analog and digital circuitry (including other computers) in a rack of equipment to be used in scientific experiments. The simulations span the range of nominal, off-nominal, and erroneous operational conditions, enabling the testing of MC software before all the equipment becomes available.

Benson, Patricia↗

A step towards the final frontier: Lessons learned from acceptance testing of the first HPE/Cray EX 3000 system at ORNL

Summary In this article, we summarize the deployment of the Air Force Weather (AFW) HPC11 system at Oak Ridge National Laboratory (ORNL) including the process followed to successfully complete acceptance testing of the system. HPC11 is the first HPE/Cray EX 3000 system that has been successfully released to its user community in a federal facility. HPC11 consists of two identical 800‐node supercomputers, Fawbush and Miller, with access to two independent and identical lustre parallel file systems. HPC11 is equipped with Slingshot 10 interconnect technology and relies on the HPE Performance Cluster Manager software for system configuration. ORNL has a clearly defined acceptance testing process used to ensure that every new system deployed can provide the necessary capabilities to support user workloads. We worked closely with HPE and AFW to develop a set of tests that used the United Kingdom's Meteorological Office's Unified Model and 4‐dimensional variational data assimilation. We also included benchmarks and applications from the Oak Ridge Leadership Computing Facility portfolio to fully exercise the HPE/Cray programming environment and evaluate the functionality and performance of the system. Acceptance testing of HPC11 required parallel execution of each element on Fawbush and Miller. In addition, careful coordination was needed to ensure successful acceptance of the newly deployed lustre file systems alongside the compute resources. In this work, we present test results from specific system components and provide an overview of the issues identified, challenges encountered, and the lessons learned along the way.

Melesse Vergara, Verónica G.↗