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At least 253 records · Page 14

wmpy-power: A Python package for process-based regional hydropower simulation

Hydropower is an important source of renewable energy in many parts of the world. The generation potential for a hydropower facility can vary greatly due to fluctuations in precipitation and snowmelt patterns impacting streamflow and reservoir storage. Human activities such as irrigation, manufacturing, and hydration can also influence water availability at nearby and downstream facilities. wmpy-power--the hydropower model described in this work--is process-based, leveraging explicit reservoir storage and release data to address impacts on hydropower from climate change and human adaptive behaviors to inform long-term planning and resource-adequacy considerations.

13 HYDRO ENERGY↗

Metals for Cryotank Structures. Present and Future: MSFC Perspective

The Cryogenic Tank Technology Program (CTTP) program has been a cooperative effort between NASA LARC, NASA MSFC, NASA Headquarters, and industry (Lockheed Martin Aeronautics, Lockheed Martin Manned Space Systems, Wyman Gordon, and Ladish). The scope of the CTTP is to develop state-of-the-art, flight-size, flight-quality, low cost hardware, and use this hardware to design, fabricate and test an all aluminum-lithium, all near net shape-component 14' diameter cryogenic tank with a unique low profile bulkhead design. The logical conclusion to the CTTP is to validate these various technologies to a Technology Readiness Level (TRL) of 6 through the proposed structural test program. The CTTP supports the advancement of key enabling technologies required for aluminum lithium cryogenic tanks. The technologies are focused towards innovative and low cost manufacturing processes such as near net shape technologies: one piece spun formed domes, extruded barrel panels, and one piece roll forged ring frames. Other innovative technologies include the friction stir weld process and weight-efficient low profile bulkhead designs. All of these technologies are of primary importance for NASA's mission plan for reusable and expendable launch vehicles. This program fills the niche for an all 2195 aluminum lithium alloy cryogenic tank which is not being covered by existing NASA technology work.

Vaughn, Timothy P.↗

NASA/Navy Benchmarking Exchange (NNBE). Volume 1. Interim Report. Navy Submarine Program Safety Assurance

The NASA/Navy Benchmarking Exchange (NNBE) was undertaken to identify practices and procedures and to share lessons learned in the Navy's submarine and NASA's human space flight programs. The NNBE focus is on safety and mission assurance policies, processes, accountability, and control measures. This report is an interim summary of activity conducted through October 2002, and it coincides with completion of the first phase of a two-phase fact-finding effort.In August 2002, a team was formed, co-chaired by senior representatives from the NASA Office of Safety and Mission Assurance and the NAVSEA 92Q Submarine Safety and Quality Assurance Division. The team closely examined the two elements of submarine safety (SUBSAFE) certification: (1) new design/construction (initial certification) and (2) maintenance and modernization (sustaining certification), with a focus on: (1) Management and Organization, (2) Safety Requirements (technical and administrative), (3) Implementation Processes, (4) Compliance Verification Processes, and (5) Certification Processes.

SUBSAFE PROGRAM↗

Review of Computer-Aided Manufacturing (CAM) strategies for hybrid directed energy deposition

Hybrid additive manufacturing intertwines both additive and subtractive manufacturing layer by layer to digitally fabricate parts with complex geometries, improved surface finish and tight dimensional accuracies, the sum of which is difficult to obtain with any single process. Computer-Aided Manufacturing (CAM) software is required to orchestrate the machine toolpathing for both the deposition as well as the machining processes and is crucial for the successful fabrication of high quality structures. Additionally, CAM requires substantial operator input to account for challenging aspects of each fabricated structure. For example, deciding at which layer of deposition will the machining process continue to maintain access to complex cavities for finishing - internal features that would otherwise be unfinishable due to reach limitations or obstructions. Moreover, of the many commercially-available hybrid systems, each has a unique kinematic environment which can benefit from specific optimization of toolpath planning and substantial research has directly correlated toolpathing with the microstructure evolution, mechanical properties, porosity and residual stress state of the final fabricated part. This review explores the available strategies for CAM in the context of hybrid direct energy deposition, discusses the advantages and disadvantages of each and considers future CAM trends for this transformational digital manufacturing technology.

36 MATERIALS SCIENCE↗

Space Resources and Space Settlements

This publication contains the technical papers from the five task groups that took part in the 1977 Ames Summer Study on Space Settlements and Industrialization Using Nonterrestrial Materials. The study was sponsored by the following NASA Headquarters organizations: Office of Space Science, Office of Aeronautics and Space Technology, and Office of Space Transportation Systems. The NASA Ames Research Center hosted the study and provided administrative support through its Life Sciences Directorate. Expert assistance in the many aspects of the study came from NASA Headquarters, NASA centers, universities, industry, and from individual consultants. This summer study was the largest and most comprehensive investigation of space manufacturing and habitation to date; forty senior research workers and ten students participated. The six-week study was preceded by several months of planning and preparation, and was followed by extensive work on manuscript checking, review, and assembly. The study topics reflected the research areas requiring the most intensive attention as ofrnid-1977; they were: Group I: Regenerative life-support systems and controlled environment agriculture. Group II: Parametric studies of efficient habitats in space. Time and cost analysis of a space manufacturing program plan. Group III: Detection and analysis of special classes of asteroids suitable as material resources for space manufacturing; studies of retrieval missions. Group IV: Electromagnetic mass drivers for use as interorbital engines, as devices to launch lunar material into space, and as tugs for the retrieval of asteroidal material. Group V: Chemical processing of non terrestrial material in space; manufacture of metals and glass fibers, beneficiation, and design of processing plants. These five task groups each produced two or more technical papers, signed by the contributing members. The papers were subjected to independent peer review by scientists not connected with the study. During the course of the study, frequent formal and informal exchanges of information occurred between task groups, so that the entire effort evolved in a coherent fashion and was directed toward common goals. However, each group remained responsible for the choice of its topics and for its conclusions. A listing of all the participants is given on pages vii-x. It would be inappropriate for me to single out particular people or groups for special mention, since all involved applied their skills with dedication and enthusiasm. Instead, I thank everyone for their contributions to the success of the study, and also for making it a united and warmly cooperative personal experience.

John Billingham↗

Quiet Clean Short-haul Experimental Engine (QCSEE) under-the-wing engine composite fan blade design report

A total of 38 quiet clean short haul experimental engine under the wing composite fan blades were manufactured for various component tests, process and tooling, checkout, and use in the QCSEE UTW engine. The component tests included frequency characterization, strain distribution, bench fatigue, platform static load, whirligig high cycle fatigue, whirligig low cycle fatigue, whirligig strain distribution, and whirligig over-speed. All tests were successfully completed. All blades planned for use in the engine were subjected to and passed a whirligig proof spin test.

Ravenhall, R.↗

Your Role as a Program Manager in Pit Production Mission Integration (PPMI-DO)

PPMI is responsible for integrating the planning, execution, and reporting for LANL’s Pit Manufacturing efforts, surplus plutonium disposition activities, the Material Recycle and Recovery (MR&R) program, and other programs of national significance. Our programmatic sponsors rely on PPMI to capitalize on the unique capabilities and expertise in PF-4 (the only Security Cat I/Haz Cat II Pu processing facility in the Nation) and other vital facilities across the laboratory to deliver on mission critical products in support of National Security.

42 ENGINEERING↗

Hyperswitch communication network

The Hyperswitch Communication Network (HCN) is a large scale parallel computer prototype being developed at JPL. Commercial versions of the HCN computer are planned. The HCN computer being designed is a message passing multiple instruction multiple data (MIMD) computer, and offers many advantages in price-performance ratio, reliability and availability, and manufacturing over traditional uniprocessors and bus based multiprocessors. The design of the HCN operating system is a uniquely flexible environment that combines both parallel processing and distributed processing. This programming paradigm can achieve a balance among the following competing factors: performance in processing and communications, user friendliness, and fault tolerance. The prototype is being designed to accommodate a maximum of 64 state of the art microprocessors. The HCN is classified as a distributed supercomputer. The HCN system is described, and the performance/cost analysis and other competing factors within the system design are reviewed.

Peterson, J.↗

Effect of High Temperature on the Tensile Behavior of CFRP and Cementitious Composites

Concrete and other composite manufacturing processes are continuing to evolve and become more and more suited for use in non-Earth settings such as the Moon and Mars. The fact that structures built in lunar environments would experience a range of effects from temperature extremes to bombardment by micrometeorites and that all the materials for concrete production exist on the Moon means that concrete appears to be the most feasible building material. it can provide adequate shelter from the harshness of the lunar environment and at the same time be a cost effective building material. With a return to the Moon planned by NASA to occur after the turn of the century, it will be necessary to include concrete manufacturing as one of the experiments to be conducted in one of the coming missions. Concrete's many possible uses and possibilities for manufacturing make it ideal for lunar construction. The objectives of this research are summarized as follows: i) study the possibility of concrete production on the Moon or other planets, ii) study the effect of high temperature on the tensile behavior of concrete, and iii) study the effect of high temperature on the tensile behavior of carbon fiber reinforced with inorganic polymer composites. Literature review indicates that production of concrete on the Moon or other planets is feasible using the indigenous materials. Results of this study has shown that both the tensile strength and static elastic modulus of concrete decreased with a rise in temperature from 200 to 500 C. The addition of silica fume to concrete showed higher resistance to high temperatures. Carbon fiber reinforced inorganic polymer (CFRIP) composites seemed to perform well up to 300 C. However, a significant reduction in strength was observed of about 40% at 400 C and up to 80% when the specimens were exposed to 700 C.

Toutanji, Houssam A.↗

PV DMFA [SWR-21-105]

The Photovoltaic Dynamic Material Flow Assessment (PV DMFA) model (also referred to here as “The model”) is a computational framework written in Python based on utility-scale PV electricity generation to quantify time-series stocks and flows of PV materials primarily in crystalline silicon PV technologies. The model evaluates cradle-to-cradle life cycle of utility-scale solar PV systems in the United States in the period 2000-2100. PV DMFA serves as a sustainability analysis tool to assess the impacts of different material circularity practices (i.e., reduce, reuse/refurbish, remanufacture, and recycle), PV module design shifts and sensitivity of material processing and technology related parameters to material installations, waste creation and raw material depletion in PV material supply chains. This tool enables advanced planning for future material needs and informs sustainable pathways for PV material management in the circular economy. This tool could be helpful to a wide range of stakeholders; Particularly, researchers and manufacturers looking for technoeconomic and/or environmental life cycle analysis (LCA) feedback for renewable energy (RE) systems.

Khalifa, SherifA.↗

Friction Stir Weld Application and Tooling Design for the Multi-purpose Crew Vehicle Stage Adapter

The Multi-Purpose Crew Vehicle (MPCV), commonly known as the Orion capsule, is planned to be the United States' next manned spacecraft for missions beyond low earth orbit. Following the cancellation of the Constellation program and creation of SLS (Space Launch System), the need arose for the MPCV to utilize the Delta IV Heavy rocket for a test launch scheduled for 2014 instead of the previously planned Ares I rocket. As a result, an adapter (MSA) must be used in conjunction with the MPCV to account for the variation in diameter of the launch vehicles; 5.5 meters down to 5.0 meters. Prior to ight article fabrication, a path nder (test article) will be fabricated to ne tune the associated manufacturing processes. The adapter will be comprised of an aluminum frustum (partial cone) that employs isogrid technology and circumferential rings on each end. The frustum will be fabricated by friction stir welding (FSW) three individual panels together on a Vertical Weld Tool (VWT) at NASA Marshall Space Flight Center. Subsequently, each circumferential ring will be friction stir welded to the frustum using a Robotic Weld Tool (RWT). The irregular geometry and large mass of the MSA require that extensive tooling preparation be put into support structures for the friction stir weld. The tooling on the VWT will be comprised of a set of conveyors mounted on pre-existing stanchions so that the MSA will have the ability to be rotated after each of the three friction stir welds. The tooling requirements to friction stir weld the rings with the RWT are somewhat more demanding. To support the mass of the MSA and resist the load of the weld tool, a system of mandrels will be mounted to stanchions and assembled in a circle. The goal of the paper will be to explain the design, fabrication, and assembly of the tooling, to explain the use of friction stir welding on the MSA path nder, and also to discuss the lessons learned and modi cations made in preparation for ight article fabrication in support of the 2014 launch of the Orion MPCV.

Alcorn, John↗

Hexagonal Distributed Embedded Energy Converters (HexDEECs)

The HexDEEC is a small, characteristic length approximating a centimeter, energy transducer that converts the dynamic deformations of its elastomer housing into electricity through a variable capacitance charging-discharging cycle. This device is a type of Distributed Embedded Energy Converter Technology (DEEC-Tec), a new domain for marine renewable energy research that utilizes a conglomeration of small distributed embedded energy converters (DEECs) that, in aggregate, form larger metamaterial frameworks. These resulting DEEC-Tec metamaterials can then, in turn, be used to construct flexible ocean wave energy converters called flexWECs, which can utilize a broad band of ocean wave frequencies and lack highly loaded rigid bodies. These systems also provide new avenues of wave energy harvesting such as actively transforming topologies (e.g., shape and form) and morphologies (e.g., stiffness and damping throughout its entire structure) in real time. Presented, is one specific type of DEEC: the HexDEEC, which is currently being developed by the United States National Renewable Energy Laboratory. This transducer shows promise in aiding the adoption and further development of the DEEC-Tec domain. The following presentation focuses on the promise of this technology and current work being done to analyze the performance of an individual HexDEEC design. The HexDEEC is composed of a hyperelastic hexagonal housing, nominally silicon rubber, with six electrodes on its inner faces. The upper three electrodes share the same charge while the lower three electrodes oppose the upper electrode charges. Externally, the HexDEEC has two arms extending away from the middle vertices of the hexagon. Via principles governing the relationship between electrical capacitance and electrical potential (voltage and charge), electricity is generated when the HexDEEC's arms are dynamically pulled or released under tensile loading, as doing so causes the distance between the upper and lower sets of electrodes to change - varying the energy converter's overall capacitance. Analytical and numerical modeling is being used to evaluate the mechanics and electrical energy generated by the HexDEEC. Equations to describe the capacitance and electrostatic forces acting on this unique system have been developed and implemented into the numerical modeling software STAR-CCM+, along with models to describe its hyperelastic material, such as the Mooney-Rivlin 3-parameter model. So far, an initial design has been analyzed and we plan to further optimize it to increase power production. Individual HexDEECs have been fabricated by drawing uncured liquid silicon rubber into molds via vacuum pressure. To simplify manufacturing, HexDEEC sub-components - e.g., electrodes, wires - can be placed within those molds such that they are directly embedded into the hexagonal housing during the curing process. Furthermore, DEEC-Tec metamaterials can be created by interweaving or sequentially layering multiple HexDEEC strands together. The HexDEEC based metamaterial could then generate electricity through its gross deformations. Ultimately, HexDEECs represent a specific type of energy transducer that can be leveraged, by the DEEC-Tec domain, to create metamaterials used to construct novel flexWECs.

DEEC-Tec↗

Assembly flow simulation of a radar

A discrete event simulation model has been developed to predict the assembly flow time of a new radar product. The simulation was the key tool employed to identify flow constraints. The radar, production facility, and equipment complement were designed, arranged, and selected to provide the most manufacturable assembly possible. A goal was to reduce the assembly and testing cycle time from twenty-six weeks. A computer software simulation package (SLAM 2) was utilized as the foundation for simulating the assembly flow time. FORTRAN subroutines were incorporated into the software to deal with unique flow circumstances that were not accommodated by the software. Detailed information relating to the assembly operations was provided by a team selected from the engineering, manufacturing management, inspection, and production assembly staff. The simulation verified that it would be possible to achieve the cycle time goal of six weeks. Equipment and manpower constraints were identified during the simulation process and adjusted as required to achieve the flow with a given monthly production requirement. The simulation is being maintained as a planning tool to be used to identify constraints in the event that monthly output is increased. 'What-if' studies have been conducted to identify the cost of reducing constraints caused by increases in output requirement.

Rutherford, W. C.↗

Effect of Blown Powder Directed Energy Deposition Angle On Overspray Contamination

Abstract Blown powder directed energy deposition (DED) hybrid machine tools are particularly beneficial when the net shape of a component is to be manufactured in an additive and machined interleaved fashion. This investigation seeks to analyze the effect of the additive head lean angle relative to the part on blown powder DED surface contamination due to overspray. These hybrid DED platforms are commonly installed on multi-axis machining systems where the lean of the deposition head relative to the component surface can be controlled by tilting the component. The blown powder DED process has a 10–50% lower catchment efficiency as compared to wire fed DED systems. This excess powder is still fed towards the deposition location where the particles are heated by the laser and rebound off the melt pool. Some of these heated particles impact the previously machined thin-wall surface. While the deposition process and tool path planning process has been evaluated, the effect of the overspray due to lean angle of the deposition head on the previously thin-wall machined surface is not yet fully understood. This investigation found that minimum lean angle coincides with minimal overspray effect with nearly no contamination. If a lean angle is required, the maximum lean angle possible should be implemented for the smallest effected overspray area on the machined surface which was found to decrease the affect zone by half compared to intermediate lean angles. A diameter divergence was also noticed as the deposition angle was increased. In this study, a thorough analysis of the surface and geometric effects when depositing thin-walled components at varying angles is completed. It has been shown that part quality can be significantly affected by lean angle and thus must be incorporated as an additional design consideration in the manufacturing process.

Heinrich, Lauren↗

Advanced Simulation and Computing: ASC FY24 Implementation Plan

The DOE National Nuclear Security Administration (NNSA) Stockpile Stewardship Program (SSP) is an integrated technical program for maintaining the safety, security, and reliability of the U.S. nuclear stockpile. The SSP incorporates nuclear test data, computational modeling and simulation, and experimental facilities to advance understanding of nuclear weapons. The suite of data analyzed comes from activities including previous nuclear tests, stockpile surveillance, experimental research, and development and engineering programs. This integrated national program requires the continued use of experimental facilities and the computational capabilities to support the SSP missions. These component parts, in addition to an appropriately scaled production capability, enable NNSA to support stockpile requirements. The ultimate goal of the SSP, and thus of the Advanced Simulation and Computing (ASC) program, is to ensure that the U.S. maintains a safe, secure, and effective strategic deterrent. The ASC program is a cornerstone of the SSP, providing simulation capabilities and computational resources to support the annual stockpile assessment and certification process, study advanced nuclear weapons design and manufacturing processes, analyze accident scenarios and weapons aging, and provide the tools to enable stockpile Life Extension Programs (LEPs) and the resolution of Significant Finding Investigations (SFIs). This work requires a balance of resources, including technical staff, hardware, simulation software, and computer science solutions. The ASC program focuses on increasing the predictive capabilities in a three-dimensional (3D) simulation environment while maintaining support to the SSP. The Program continues to improve its unique tools for understanding and solving progressively more difficult stockpile problems (sufficient resolution, dimensionality, and scientific details), and quantifying critical margins and uncertainties. Resolving each issue requires increasingly difficult analyses because the aging process has progressively moved the stockpile further from the original test base. While the focus remains on the U.S. nuclear weapons program, where possible, the Program also enables the use of high-performance computing (HPC) and simulation tools to address broader national security needs, such as foreign nuclear weapon assessments and nuclear counterterrorism. The 2022 Nuclear Posture Review (NPR) calls for NNSA to “deliver a modern, adaptive nuclear security enterprise based on an integrated strategy for risk management, production-based resilience, science and technology innovation, and workforce initiatives.” Furthermore, “NNSA will establish a Science and Technology Innovation Initiative to accelerate the integration of science and technology (S&T) throughout its activities.” Executing this strategy necessitates the continued emphasis on developing and sustaining high-quality scientific and engineering staff, as well as supporting computational and experimental capabilities. These components constitute the foundation of the nuclear weapons program. The continued success of the SSP and LEPs is predicated upon the ability to credibly certify the stockpile, without a return to underground nuclear tests (UGTs). Shortly after the nuclear test moratorium entered into force in 1992, the Accelerated Strategic Computing Initiative (ASCI) was established to provide an extensive simulation capability to underpin stockpile certification. While computing and simulation have always been essential to the success of the nuclear weapons program, the program goal of ASCI was to execute NNSA’s vision of using these tools in support of the stockpile stewardship mission. The ASCI program was essential to the successful demonstration of the SSP, providing critical nuclear weapons simulation and modeling capabilities. ASCI officially evolved into the ASC program in fiscal year (FY) 2005, but the mission remains essentially the same: provide the simulation and computational capabilities that underpin the ability to maintain a safe, secure, effective nuclear weapon stockpile, without returning to underground nuclear testing. The capabilities that the ASC program provides at the national laboratories play a vital role in the nuclear security enterprise and are necessary for fulfilling the stockpile stewardship and life extension requirements outlined for NNSA. The Program develops modern simulation tools that provide insights into stockpile aging issues, provide the computational and simulation tools that enable designers and analysts to certify the current stockpile and life-extended nuclear weapons, and inform the decision-making process when any modifications in nuclear warheads or the associated manufacturing processes are deemed necessary. Furthermore, ASC is enhancing the predictive simulation capabilities that are essential to evaluate weapons effects, design experiments, and ensure test readiness. The ASC program continues to improve its unique tools to solve stockpile problems— with a focus on sufficient resolution, dimensionality, and scientific detail—to enable Quantification of Margins and Uncertainties (QMU) and to resolve the increasingly difficult analyses needed for stockpile stewardship. The needs of the Stockpile Management and Production Modernization programs (formerly Directed Stockpile Work) also drive the requirements for simulation and computational resources. These requirements include planned LEPs, stockpile support activities, and mitigation efforts against the potential for technical surprise. All of the weapons within the current stockpile are in some stage of the life extension process. The simulation and computational capabilities are crucial for successful execution of these life extensions and for ensuring NNSA can certify these life-extended weapons without conducting a UGT.

97 MATHEMATICS AND COMPUTING↗

Fabrication process of a high temperature polymer matrix engine duct

The process that was used in the molding of an advanced composite outer by-pass duct planned for the F404 engine is discussed. This duct was developed as a potential replacement for the existing titanium duct in order to reduce both the weight and cost of the duct. The composite duct is now going into the manufacturing technology portion of the program. The duct is fabricated using graphite cloth impregnated with the PMR-15 matrix system.

Pratt, R. D.↗

Transportation cost - Impacts on commercial users

The potential impact of transportation price on the financial performance of space business ventures is analyzed. Business plans for generic space facilities (both STS based and free-flying), space processing, and communications satellite businesses were developed. Impacts were established parametrically for return on investment and customer product/service price as a function of transportation price. The following businesses were considered: communications satellite; shuttle based and free-flying space facilities; and space pharmaceuticals manufacturing and minilab leasing.

Greenberg, Joel S.↗

The NASA Space Processing Program

The program is intended to initiate utilization of spaceflight for economically beneficial activities in all branches of materials science and technology. In view of the prospect they offer for reducing the costs of space operations, the Spacelab and Space Shuttle are expected to become widely used for work on materials early in the 1980's. At first they will be employed for space experiments and for services, such as sample preparation, that support research and development activities on the ground. Orbital manufacturing operations are expected to develop as well when research has prepared an adequate basis for them. During the past year, NASA has initiated a series of rocket flights on which prospective participants in the Shuttle/Spacelab program can perform preliminary experiments. Participation in these flights is open to investigators from all countries, and experiments are being solicited from private sponsors also. NASA is performing concurrent definition studies of Shuttle/Spacelab payloads, and design work on equipment for the first two years of operations is planned to begin early in 1977. The Office of Applications currently plans to fly two space processing payloads on Orbital Flight Test missions in 1980 and two on operational Spacelab missions in 1981.

Bredt, J. H.↗