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DOE OSTI2020

Application and Certification of Comparative Vacuum Monitoring Sensors for Structural Health Monitoring of 737 Wing Box Fittings

Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today's extensive fleet of aging aircraft and space vehicles. The use of in-situ sensors for real-time health monitoring of aircraft structures are a viable option to overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. Prevention of unexpected flaw growth and structural failure can be improved if on-board health monitoring systems are used to continuously assess structural integrity. Such systems are able to detect incipient damage before catastrophic failures occurs. Condition-based maintenance practices could be substituted for the current time-based maintenance approach. Other advantages of on-board distributed sensor systems are that they can eliminate costly, and potentially damaging, disassembly, improve sensitivity by producing optimum placement of sensors and decrease maintenance costs by eliminating more time- consuming manual inspections. This report presents a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Boeing, Delta Air Lines, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp. and the Federal Aviation Administration (FAA) carried out a certification program to formally introduce Comparative Vacuum Monitoring (CVM) as a structural health monitoring solution to a specific aircraft wing box application. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM into an airline maintenance program and the document revisions necessary to allow for routine use of CVM as an alternate means of performing periodic structural inspects. To carry out the validation process, knowledge of aircraft maintenance practices was coupled with an unbiased, independent evaluation. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically-relevant experimental effort to quantify the reliability of the CVM system applied to the Boeing 737 Wing Box fitting application. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for CVM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and also is acceptable to both the aviation industry and regulatory bodies. This report presents the use of several different statistical methods, some of them adapted from NDI performance assessments and some proposed to address the unique nature of damage detection via SHM systems, and discusses how they can converge to produce a confident quantification of SHM performance An important element in developing SHM validation processes is a clear understanding of the regulatory measures needed to adopt SHM solutions along with the knowledge of the structural and maintenance characteristics that may impact the operational performance of an SHM system. This report describes the major elements of an SHM validation approach and differentiates the SHM elements from those found in NDI validation. The activities conducted in this program demonstrated the feasibility of routine SHM usage in general and CVM in particular for the application selected. They also helped establish an optimum OEM-airline-regulator process and determined how to safely adopt SHM solutions. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM technology. It will also streamline the regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗

DOE OSTI2022

Damage Detection and Electrical Performance Impact of Flat-Flexible Circuits

Flat-flexible circuits or ‘flex circuits’ have varied applications in electronics and in explosive detonation systems. They pose advantages over conventional coaxial cables in their ability to fit into small mechanical envelopes and routings. A typical flex circuit is composed of a laminated assembly of multiple layers of conductor and dielectric materials. Copper, because of its high electrical conductivity, is one of the primary materials used in flex circuit conductors. The conductor must maintain structural integrity and electrical continuity when the flexible circuit is bent during processing or to fit an application envelope. Under some strain conditions a cable may have degraded electrical performance even though visible damage may not be evident. Dislocation density can increase by mechanisms such as dislocation forest hardening, where gliding dislocations in primary slip planes get pinned at obstacles and form Frank-Read sources. Dislocation density increases within the conductor layers may impact electrical resistivity but would not necessarily result in visible mechanical failure. In some detonation applications, such as for building implosion for demolition, the time for signal transmission and voltage used for firing detonators can be critical. If the resistance in a single flex cable within a building demolition array is too high, the resultant demolition shape may be asymmetric, leading to unplanned damage to nearby structures and potential hazards to public safety. This study will apply non-destructive evaluation techniques to evaluate the detectability of damage accumulation in flat, flexible copper-conductor cables and discuss potential implications to their practical use.

42 ENGINEERING↗

DOE OSTI2023

Fusion Materials Research at Oak Ridge National Laboratory in FY22

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Fusion Materials Research at Oak Ridge National Laboratory in Fiscal Year 2023

The materials science challenge of providing a suite of suitable materials to satisfy the technology to achieve fusion energy is addressed in this ORNL program. The inability of currently available materials and components to withstand the harsh fusion nuclear environment requires development of new materials, and an understanding of their response to the fusion environment. The overarching goal of the ORNL Fusion Materials program is to provide the applied materials science support and materials understanding to underpin the ongoing DOE Office of Science—Fusion Energy Sciences program, in parallel with developing the materials for fusion power systems. In this effort the program continues to be integrated both with the larger U.S. and international fusion materials communities and with the U.S. and international fusion design and technology communities. The excitement of this program comes from the priorities given to this subject in the two recent fusion reviews, by the FESAC and NAS committees. An important element of those recommendations is the support for pivoting the national R&D emphasis to the Fusion Materials and Technologies (FM&T), the long-advocated Fusion Prototypic Neutron Source, and for the Fusion Pilot Plant study that will help focus program direction and efforts. Furthermore, the surge of venture capital investment into the private fusion industry start-ups over the last few years is anticipated to help accelerate all aspects of the fusion energy development. This twelfth annual report of the ORNL (Oak Ridge National Laboratory) Fusion Reactor Materials Program summarizes the accomplishments in Fiscal Year 2023 (FY2023). The year was the first to return to full post-COVID-restriction operations, with students and international assignees no longer impacted by COVID restrictions, as in FY20-21-22. Following the pattern of planning used in this program, work for the year FY2023 focused on having the data and productivity to support a strong presence at the International Conference on Fusion Reactor Materials (ICFRM) 21, organized by Spain and occurred in October 2023. Twenty-nine ORNL-led abstracts were submitted, with all accepted. Four were invited presentations, nine contributed oral, fourteen posters, and two withdrawn due to unforeseen circumstances. Additionally, nine external abstracts with ORNL contributing authors were presented. These will be reported in the FY24 report next year.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1974

A note on the effect of bending stiffness of stringers attached to a plate with a crack

An infinite stringer partially bonded to a plate through a layer of adhesive is considered. The stringer had bending as well as longitudinal stiffness. The effect of the stringer's bending rigidity on the stress intensity factor at the tip of the crack is illustrated. Shear stress distribution between the plate and the stringer and the stress intensity factors are obtained from the solution of a system of Fredholm integral equations. The continuity of displacements along the line of bond is represented by the equations.

Arin, K.↗

NASA NTRS1975

On the time-weighted quadratic sum of linear discrete systems

A method is proposed for obtaining the time-weighted quadratic sum for linear discrete systems. The formula of the weighted quadratic sum is obtained from matrix z-transform formulation. In addition, it is shown that this quadratic sum can be derived in a recursive form for several useful weighted functions. The discussion presented parallels that of MacFarlane (1963) for weighted quadratic integral for linear continuous systems.

Jury, E. I.↗

NASA NTRS1980

Kinetic energy budgets in areas of intense convection

A kinetic energy budget analysis of the AVE-SESAME 1 period which coincided with the deadly Red River Valley tornado outbreak is presented. Horizontal flux convergence was found to be the major kinetic energy source to the region, while cross contour destruction was the major sink. Kinetic energy transformations were dominated by processes related to strong jet intrusion into the severe storm area. A kinetic energy budget of the AVE 6 period also is presented. The effects of inherent rawinsonde data errors on widely used basic kinematic parameters, including velocity divergence, vorticity advection, and kinematic vertical motion are described. In addition, an error analysis was performed in terms of the kinetic energy budget equation. Results obtained from downward integration of the continuity equation to obtain kinematic values of vertical motion are described. This alternate procedure shows promising results in severe storm situations.

Fuelberg, H. E.↗

NASA NTRS1983

A photoelectric lightcurve survey of small main belt asteroids

A survey to obtain photoelectric lightcurves of small main-belt asteroids was conducted from November 1981 to April 1982 using the 0.91- and 2.1-m telescopes at the University of Texas McDonald Observatory. A total of 18 main-belt asteroids having estimated dimaters under 30 km were observed with over half of these being smaller than 15 km. Rotational periods were determined or estimated from multiple nights of observation for nearly all of these yielding a sample of 17 small main-belt asteroids which is believed to be free of observational selection effects. All but two of these objects were investigated for very short periods in the range of 1 min to 2 hr using power spectrum analysis of a continuous set of integrations. No evidence for such short periods was seen in this sample. Rotationally averaged B(1,0) magnitudes were determined for most of the surveyed asteroids, allowing diameter estimates to be made. Imposing the suspected selection effects of photogaphic photometry on the results of this survey gives excellent agreement with the results from that technique. This shows that the inability of photographic photometry to obtain results for many asteroids is indeed due to the rotational parameter of those asteroids.

Binzel, R. P.↗

NASA NTRS1986

Compact Hybrid Automotive Propulsion System

Power train proposed for experimental vehicle powered by internal combustion engine and electric motor. Intended for front-wheel drive automobile, power train mass produced using existing technology. System includes internal-combustion engine, electric motor, continuously variable transmission, torque converter, differential, and control and adjustment systems for electric motor and transmission. Continuously variable transmission integrated into hydraulic system that also handles power steering and power brakes. Batteries for electric motor mounted elsewhere in vehicle.

Lupo, G.↗

NASA NTRS1985

Steady inviscid three-dimensional flows

The present analysis combines some of the theoretical concepts suggested by Hawthorne (1955) with a numerical integration procedure suggested by Martin (1978). The resulting algorithm is for inviscid subsonic flows. Thus, it is restricted to high Reynolds number flows. Chang and Adamczyk (1983) have provided a detailed derivation of the present algorithm along with a discussion of its stability bounds. The present paper represents a summary of this work. The integration of the continuity equation is considered along with an evaluation of the entropy, total temperature, and vorticity field. Attention is given to the shear-flow algorithm construction, and an application to a shear flow in a turning channel. A description of numerical results is also provided. The discussed algorithm represents a new procedure for solving inviscid subsonic three-dimensional rotational flows.

Adamczyk, J. J.↗

NASA NTRS1987

Nonlinear filter design

A technique for identifying nonlinear systems was introduced, beginning with a single input-single output system. Assuming the system is initially at rest, the first kernel (first convolution integral in the continuous case or first convolution sum in the discrete case) was calculated. A controllable and observable linear realization was then obtained in a particular canonical form. The actual nonlinear system was probed with an appropriate input (or inputs) and the output (or outputs) determined. For the linear system, the input was computed that produces the same output. In the difference between the inputs to the nonlinear and linear systems, basic information was found about the nonlinear system. There is an interesting class of nonlinear systems for which this type of identification scheme should prove to be accurate.

Hunt, L. R.↗

NASA NTRS1988

Investigation of viscous/inviscid interaction in transonic flow over airfoils with suction

The viscous/inviscid interaction over transonic airfoils with and without suction is studied. The streamline angle at the edge of the boundary layer is used to couple the viscous and inviscid flows. The potential flow equations are solved for the inviscid flow field. In the shock region, the Euler equations are solved using the method of integral relations. For this, the potential flow solution is used as the initial and boundary conditions. An integral method is used to solve the laminar boundary-layer equations. Since both methods are integral methods, a continuous interaction is allowed between the outer inviscid flow region and the inner viscous flow region. To avoid the Goldstein singularity near the separation point the laminar boundary-layer equations are derived in an inverse form to obtain solution for the flows with small separations. The displacement thickness distribution is specified instead of the usual pressure distribution to solve the boundry-layer equations. The Euler equations are solved for the inviscid flow using the finite volume technique and the coupling is achieved by a surface transpiration model. A method is developed to apply a minimum amount of suction that is required to have an attached flow on the airfoil. The turbulent boundary layer equations are derived using the bi-logarithmic wall law for mass transfer. The results are found to be in good agreement with available experimental data and with the results of other computational methods.

Vemuru, C. S.↗

NASA NTRS1989

A planning and scheduling lexicon

A lexicon related to mission planning and scheduling for spacecraft is presented. Planning and scheduling work is known as sequencing. Sequencing is a multistage process of merging requests from both the science and engineering arenas to accomplish the objectives defined in the requests. The multistage process begins with the creation of science and engineering goals, continues through their integration into the sequence, and eventually concludes with command execution onboard the spacecraft. The objective of this publication is to introduce some formalism into the field of spacecraft sequencing-system technology. This formalism will make it possible for researchers and potential customers to communicate about system requirements and capabilities in a common language.

Cruz, Jennifer W.↗

NASA NTRS1992

The National Space Science Data Center: An operational perspective

The National Space Science Data Center (NSSDC) manages over 110,000 data tapes with over 4,000 data sets. The size of the digital archive is approximately 6,000 GBytes and is expected to grow to more than 28,000 GBytes by 1995. The NSSDC is involved in several initiatives to better serve the scientific community and improve the management of current and future data holdings. These initiatives address the need to manage data to ensure ready access by the user and manage the media to ensure continuing accessibility and integrity of the data. This paper will present an operational view of the NSSDC, outlining current policies and procedures that were implemented to ensure the effective use of available resources to support service and mission goals, and maintain compliance with prescribed data management directives.

Blitstein, Ronald↗

NASA NTRS1991

The National Space Science Data Center: An operational perspective

The National Space Science Data Center (NSSDC) manages over 110,000 data tapes with over 4,000 data sets. The size of the digital archive is approximately 6,000 GBytes and is expected to grow to more than 28,000 GBytes by 1995. The NSSDC is involved in several initiatives to better serve the scientific community and improve the management of current and future data holdings. These initiatives address the need to manage data to ensure ready access by the user and manage the media to ensure continuing accessibility and integrity of the data. An operational view of the NSSDC, outlining current policies and procedures that have been implemented to ensure the effective use of available resources to support service and mission goals, and maintain compliance with prescribed data management directives is presented.

Blitstein, Ronald↗

NASA NTRS1992

Polycyclic aromatic hydrocarbon formation in carbon-rich stellar envelopes

A detailed chemical kinetic scheme is applied to stellar envelope profiles of gas density and temperature profiles in order to study the formation of PAH molecules in carbon-rich stellar outflows. Chemical concentration profiles are calculated for several envelope models by integrating the coupled continuity equations that include spherically expanding flows from an inner boundary at the shock formation radius. The influence of the 'inverse greenhouse' effect experienced by small PAHs is investigated and shown to increase the PAH yield by many orders of magnitude. It is shown that the route through propargyl radicals could be an important channel to produce benzene. PAH formation yields are found to be extremely sensitive to gas density and temperature and are much smaller than values inferred from the observed dust content of late-type carbon-rich stellar envelopes. It is therefore unlikely that aromatic molecules are generated in the stellar outflow itself.

Cherchneff, Isabelle↗

NASA NTRS1993

A low-power battery ampere-hour meter

A digital device has been developed to meter the current drain of a battery in ampere hours. The device consists of a voltage controlled oscillator (VCO), a frequency divider, an accumulator, and a liquid crystal display. A voltage proportional to load current is converted into a clock signal whose pulse rate is scaled by the frequency divider to the desired engineering units. Final output pulses are counted and displayed. The use of MOSFET and CMOS integrated circuits allows continuous battery-powered operation over a 3-month time period to an accuracy of +/- 2 percent. The instrument will find application where accurate monitoring of battery charge/discharge status is required over long time intervals.

Tripp, John S.↗

NASA NTRS1993

Navier-Stokes relaxation to sinh-Poisson states at finite Reynolds numbers

A mathematical framework is proposed in which it seems possible to justify the computationally-observed relaxation of a two-dimensional Navier-Stokes fluid to a 'most probable', or maximum entropy, state. The relaxation occurs at large but finite Reynolds numbers, and involves substantial decay of higher-order ideal invariants such as enstrophy. A two-fluid formulation, involving interpenetrating positive and negative vorticity fluxes (continuous and square integrable) is developed, and is shown to be intimately related to the passive scalar decay problem. Increasing interpenetration of the two fluids corresponds to the decay of vorticity flux due to viscosity. It is demonstrated numerically that, in two dimensions, passive scalars decay rapidly, relative to mean-square vorticity (enstrophy). This observation provides a basis for assigning initial data to the two-fluid field variables.

Montgomery, David↗