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DOE OSTI2024

Testing Protocol Development for the Fracture Toughness of Parts Built with Big Area Additive Manufacturing

The mechanical testing of additively manufactured parts has largely relied on the existing standards developed for traditional manufacturing. While this approach leverages the investment made in current standards development, it inaccurately assumes that the mechanical response of additive manufacturing (AM) parts is identical to that of parts manufactured through traditional processes. When considering thermoplastic, material extrusion AM, the differences in response can be attributed to an AM part’s inherent inhomogeneity caused by porosity, interlayer zones, and surface texture. Additionally, the interlayer bonding of parts printed with large-scale AM is difficult to adequately assess, as much testing is performed such that stress is distributed across many layer interfaces; therefore, the lack of AM-specific standards to assess interlayer bonding is a significant research gap. To quantify interlayer bonding via fracture toughness, double cantilever beam (DCB) testing has been used for some AM materials, and DCB has been generally used for a variety of materials including metal, wood, and laminates. Mode I DCB testing was performed on thermoplastic matrix composites printed with Big Area Additive Manufacturing (BAAM). Of particular interest was the notch shape and deflection speed during testing. The results examine the differences when using two notch types and three deflection speeds. The testing method introduced by the following paper differentiates itself from the ones described in the standards used by modernizing the methodology. This was conducted with the introduction of Digital Image Correlation (DIC) to gather displacement and load data simultaneously without human intervention.

Polymer Science↗

NASA NTRS2013

Lessons Learned During TBCC Design for the NASA-AFRL Joint System Study

NASA and the Air Force Research Laboratory are involved in a Joint System Study (JSS) on Two-Stage-to-Orbit (TSTO) vehicles. The JSS will examine the performance, operability and analysis uncertainty of unmanned, fully reusable, TSTO launch vehicle concepts. NASA is providing a vehicle concept using turbine-based combined cycle (TBCC) propulsion on the booster stage and an all-rocket orbiter. The variation in vehicle and mission requirements for different potential customers, combined with analysis uncertainties, make it problematic to define optimum vehicle types or concepts, but the study is being used by NASA for tool assessment and development, and to identify technology gaps. Preliminary analyses were performed on the entire TBCC booster concept; then higher-fidelity analyses were performed for particular areas to verify results or reduce analysis uncertainties. Preliminary TBCC system analyses indicated that there would be sufficient thrust margin over its mission portion. The higher fidelity analyses, which included inlet and nozzle performance corrections for significant area mismatches between TBCC propulsion requirements versus the vehicle design, resulted in significant performance penalties from the preliminary results. TBCC system design and vehicle operation assumptions were reviewed to identify items to mitigate these performance penalties. The most promising items were then applied and analyses rerun to update performance predictions. A study overview is given to orient the reader, quickly focusing upon the NASA TBCC booster and low speed propulsion system. Details for the TBCC concept and the analyses performed are described. Finally, a summary of "Lessons Learned" are discussed with suggestions to improve future study efforts.

Snyder, Christopher A.↗

NASA NTRS2016

Conceptual Drivers for an Exploration Medical System

Interplanetary spaceflight, such as NASA's proposed three-year mission to Mars, provides unique and novel challenges when compared with human spaceflight to date. Extended distance and multi-year missions introduce new elements of operational complexity and additional risk. These elements include: inability to resupply medications and consumables, inability to evacuate injured or ill crew, uncharted psychosocial conditions, and communication delays that create a requirement for some level of autonomous medical capability. Because of these unique challenges, the approaches used in prior programs have limited application to a Mars mission. On a Mars mission, resource limitations will significantly constrain available medical capabilities, and require a paradigm shift in the approach to medical system design and risk mitigation for crew health. To respond to this need for a new paradigm, the Exploration Medical Capability (ExMC) Element is assessing each Mars mission phase-transit, surface stay, rendezvous, extravehicular activity, and return-to identify and prioritize medical needs for the journey beyond low Earth orbit (LEO). ExMC is addressing both planned medical operations, and unplanned contingency medical operations that meld clinical needs and research needs into a single system. This assessment is being used to derive a gap analysis and studies to support meaningful medical capabilities trades. These trades, in turn, allow the exploration medical system design to proceed from both a mission centric and ethics-based approach, and to manage the risks associated with the medical limitations inherent in an exploration class mission. This paper outlines the conceptual drivers used to derive medical system and vehicle needs from an integrated vision of how medical care will be provided within this paradigm. Keywords: (Max 6 keywords: exploration, medicine, spaceflight, Mars, research, NASA)

Antonsen, Erik↗

NASA NTRS2018

Summary of 2017 NASA Workshop on Assessment of Advanced Battery Technologies for Aerospace Applications

A workshop on assessment of battery technologies for future aerospace applications was held in Cleveland, OH on August 16-17. The focus of the workshop, hosted by NASA GRC, was to assess (1) the battery needs for future aerospace missions, (2) the state of battery technology and projected technology advances, and (3) the need for additional investments for future aerospace missions. The workshop had 109 attendees that included internationally recognized technology leaders from academia and national laboratories, high level executives from government and industry, small businesses, and startup companies. A significant portion of the workshop was focused on batteries for electrified aircraft. The presentation will summarize the finding on the state of battery technologies for electrified aircraft and will include assessment of current state of battery technology, gaps in battery technology for application in electrified aircraft, and recommended technology development options for meeting near-term and long-term needs of electrified aircraft.

Misra, Ajay↗

NASA NTRS2020

Honeywell Enhancing Airplane State Awareness (EASA) Project: Final Report on Refinement and Evaluation of Candidate Solutions for Airplane System State Awareness

The loss of pilot airplane state awareness (ASA) has been implicated as a factor in several aviation accidents identified by the Commercial Aviation Safety Team (CAST). These accidents were investigated to identify precursors to the loss of ASA and develop technologies to address the loss of ASA. Based on a gap analysis, two technologies were prototyped and assessed with a formative pilot-in-the-loop evaluation in NASA Langley’s full-motion Research Flight Deck. The technologies address: 1) data source anomaly detection in real-time, and 2) intelligent monitoring aids to provide nominal and predictive awareness of situations to be monitored and a mission timeline to visualize events of interest. The evaluation results indicated favorable impressions of both technologies for mitigating the loss of ASA in terms of operational utility, workload, acceptability, complexity, and usability. The team concludes that there is a feasible retrofit solution for improving ASA that would minimize certification risk, integration costs, and training impact.

Whitlow, Stephen D.↗

NASA NTRS2020

Striped Mullet Migration Patterns in the Indian River Lagoon: A Network Analysis Approach to Spatial Fisheries Management

Striped mullet (Mugil cephalus) are numerically abundant forage fish, highly valuable as prey and commercially valuable to humans. From September to December, mullet in the Indian River Lagoon (IRL), Florida undergo an annual migration from inshore foraging habitats to oceanic spawning sites. However, their migratory pathways, in particular their intra-estuarine movement pathways, remain unknown. To address this knowledge gap, we utilized passive acoustic telemetry to assess the movement patterns of M. cephalus within the IRL. Thirty-two fish were tagged, generating usable tracks from 18 individuals. The mean (±s.d.) time that fish were detected in the array was ~38 ± 90 days, with the longest at 444 days. We also document the first evidence of skipped spawning in M. cephalus inhabiting waters of the southeastern United States. These data suggest impoundments around the Merritt Island National Wildlife Refuge appear to serve as important refugia for striped mullet while the Banana and Indian Rivers act as corridors during their inshore migratory movements. Through spatial fisheries management, high value habitat and connective elements utilized by mullet and other vital forage fish may be identified, to benefit both natural and human dynamics in estuarine systems.

Acoustic telemetry↗

NASA NTRSDate not supplied

Evaluation of Iodine and Silver as Biocides for Potable Water in Human Missions beyond Low Earth Orbit

Chemical biocides play an important role in potable water storage and distribution systems. They provide protection against microbial growth that can negatively impact efficient water transport and crew health. Molecular iodine and ionic silver have been used on the International Space Station for decades. Future orbiting and surface habitats will have potable water systems that will require reliable potable water storage and challenging transport schemes during daily operations with potentially lengthy and repeated periods of non-use. Based on a review of literature, experimental data, and flight data this paper categorizes the advantages and disadvantages of the two heritage biocides on ISS: iodine and silver. The history of biocide practices on ISS is compared to requirements of future human missions beyond low Earth Orbit. The upstream water quality supply and downstream water uses are defined with respect to the two biocides. The methods of injection and removal of the two biocides are compared for a range of downstream water uses including drinking water, hygiene water, technical water, oxygen generation water, and extravehicular activity water. The paper provides mission planners with a technical and engineering assessment of the two biocides and identifies gaps in knowledge and on-orbit experiences.

Dean Muirhead↗

NASA NTRS2023

Reducing Aerosol Forcing Uncertainty by Combining Models With Satellite and Within-The-Atmosphere Observations: A Three-Way Street

Aerosol forcing uncertainty represents the largest climate forcing uncertainty overall. Its magnitude has remained virtually undiminished over the past 20 years despite considerable advances in understanding most of the key contributing elements. Recent work has produced modest increases only in the confidence of the uncertainty estimate itself. This review summarizes the contributions toward reducing the uncertainty in the aerosol forcing of climate made by satellite observations, measurements taken within the atmosphere, as well as modeling and data assimilation. We adopt a more measurement-oriented perspective than most reviews of the subject in assessing the strengths and limitations of each; gaps and possible ways to fill them are considered. Currently planned programs supporting advanced, global-scale satellite and surface-based aerosol, cloud, and precursor gas observations, climate modeling, and intensive field campaigns aimed at characterizing the underlying physical and chemical processes involved, are all essential. But in addition, new efforts are needed: (a) to obtain systematic aircraft in situ measurements capturing the multi-variate probability distribution functions of particle optical, microphysical, and chemical properties (and associated uncertainty estimates), as well as co-variability with meteorology, for the major aerosol airmass types; (b) to conceive, develop, and implement a suborbital (aircraft plus surface-based) program aimed at systematically quantifying the cloud-scale microphysics, cloud optical properties, and cloud-related vertical velocities associated with aerosol-cloud interactions; and (c) to focus much more research on integrating the unique contributions of satellite observations, suborbital measurements, and modeling, to reduce the persistent uncertainty in aerosol climate forcing.

aerosol climate forcing↗

DOE OSTI2023

Offshore Wind Workforce Safety Standards and Training Resource

The standardization of safety training requirements for people working at sea to build and operate offshore wind energy projects, adoption of those standards, and alignment with offshore safety training curriculum development was identified as a high-priority workforce gap in the U.S. Offshore Wind Workforce Assessment (Stefek, 2022). Safety is a top priority for the offshore wind industry; however, there has been uncertainty surrounding what unique safety standards and training will be needed and how various offshore wind safety stakeholders will be involved. The scope of safety training for this resource includes workers who build and operate offshore wind energy projects at sea and defines the stakeholders in the complex ecosystem. This fact sheet aims to help reduce these uncertainties by: 1) Delineating jurisdictional lines, while clarifying roles and responsibilities amongst stakeholders; 2) Identifying key actions or partnerships that can encourage further success with safety training and workforce development.

offshore wind↗

NASA NTRS1993

Lattice-matched heteroepitaxy of wide gap ternary compound semiconductors

A variety of applications are identified for heteroepitaxial structures of wide gap I-III-VI(sub 2) and II-IV-V(sub 2) semiconductors, and are assessed in comparison with ternary III-V alloys and other wide gap materials. Non-linear optical applications of the I-III-VI(sub 2) and II-IV-V(sub 2) compound heterostructures are discussed, which require the growth of thick epitaxial layers imposing stringent requirements on the conditions of heteroepitaxy. In particular, recent results concerning the MOCVD growth of ZnSi(x)Ge(1-x)P2 alloys lattice matching Si or GaP substrates are reviewed. Also, heterostructures of Cu(z)Ag(1-z)GaS2 alloys that lattice-match Si, Ge, GaP, or GaAs substrates are considered in the context of optoelectronic devices operating in the blue wavelength regime. Since under the conditions of MOCVD, metastable alloys of the II-IV-V(sub 2) compounds and group IV elements are realized, II-IV-V(sub 2) alloys may also serve as interlayers in the integration of silicon and germanium with exactly lattice-matched tetrahedrally coordinated compound semiconductors, e.g. ZnSi(x)Ge(1-x)P2.

Bachmann, Klaus J.↗

DOE OSTI2025

The Technical, Economic, Risk, and Adoption Assessment for Evaluating Work Reduction Opportunities in the Nuclear Industry

Automation and cost-saving initiatives, such as process automation with advances in artificial intelligence, are gaining traction in modernization efforts across the nuclear industry. As these innovations are increasingly adopted, it becomes crucial to evaluate their impacts comprehensively. Various technical and economic attributes, along with risk and human readiness factors, must be achieved to ensure that innovative projects enabling automation and modernization are successful. However, no systematic or integrated framework exists that allows plants to evaluate these innovative projects. To address this gap, the Technical, Economic, Risk, and Adoption (TERA) assessment offers a structured method to evaluate innovative technologies, ensuring solutions meet both operational and safety standards. The TERA framework integrates the disparate perspectives to assess modernization opportunities in nuclear operations. It combines qualitative and quantitative models to evaluate the relationship between performance and business impacts, while also enabling continuous re-evaluation during project development. This approach helps plant owners identify high-priority opportunities, optimize cost savings, and minimize risks, ensuring projects remain on track to achieve desired returns. By providing a comprehensive, systematic methodology, TERA enables informed, data-driven decisions that support successful modernization efforts, enhancing efficiency, safety, and cost savings across nuclear operations. This paper explains the TERA framework and its benefits for the nuclear industry.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

A Review of the Evaluation of Building Energy Code Compliance in the United States

Building energy codes are essential tools for achieving energy efficiency in buildings. However, the full energy savings potential of these codes can only be realized if buildings are constructed in compliance with them. Therefore, evaluating building energy code compliance is crucial in bridging the gap between the energy efficiency requirements set by energy codes and the actualized energy savings achieved. An energy code compliance evaluation serves as a mechanism to assess construction practices, evaluate the effectiveness of code enforcement, identify gaps in compliance, and guide strategies for improvement through training and education. Conducting code compliance evaluation activities involves field studies that require careful design and significant resources. Historically, more emphasis has been placed on developing and adopting building energy codes, while efforts to evaluate compliance have been relatively limited and lacking consistent approaches. The passage of the 2009 American Recovery and Reinvestment Act (ARRA), which mandated that states create plans for achieving 90% compliance within eight years, stimulated the need for an energy code compliance evaluation. As a result, federal, state, and local governments, and utilities have invested in the development of methodologies and tools for code compliance evaluation studies. This paper reviews the code compliance evaluation studies conducted in the United States over the past three decades. It describes and compares the methodologies and metrics used to assess building energy code compliance, summarizes the general elements and steps involved in the evaluation process, and discusses common issues in these studies. Over time, code compliance evaluation methodologies have evolved from isolated development within individual states, regions, and utilities, to widely accepted protocols applicable across different states and local jurisdictions. There has been a transition in compliance metrics, shifting from historical compliance rates to energy-consumption-oriented approaches.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2022

Midwest Water Resources II: Evaluating Evapotranspiration with NASA Earth Observations and In Situ Observations to Understand Water Balance in Midwest Agriculture

Seasonal water variability in the midwestern United States extensively affects the agricultural community, as it impacts irrigation schedules, growing seasons, and overall ecosystem function. Evapotranspiration (ET) is a critical climatic variable in the water cycle and is used to evaluate spatiotemporal trends in drought and flood conditions. The NASA DEVELOP team partnered with the United States Department of Agriculture (USDA) Midwest Climate Hub, the Minnesota Department of Agriculture, the Illinois State Water Survey, and Michigan State University to compare remotely sensed ET products with in situ observations from January 2001 through December 2020. Remotely sensed actual ET (aET) data were sourced from NASA’s Terra Moderate Resolution Imaging Spectroradiometer (MODIS), and reference ET (refET) data were derived from the Gridded Surface Meteorological (gridMET) dataset. For in situ comparison, aET data were downloaded from the AmeriFlux database while refET data were collected from the Illinois Climate Network and Michigan State University’s Enviro-weather database. For a holistic assessment of ET, this project generated comparisons between remotely sensed and in situ observations, calculated descriptive statistics for validation between refET datasets, and spatially produced statistical validation maps regarding in situ sites. The temporal and spatial gaps of AmeriFlux data limited aET analysis. This comparative assessment of ET products across the Midwest can be used by project partners to assess regional water trends and guide future land management decisions.

Addison Pletcher↗

DOE OSTI2024

Benefits and Challenges of California Offshore Wind Electricity: An Updated Assessment

Offshore wind (OSW) technology has recently been included in California’s plans to achieve 100% carbon-free electricity by 2045. As an emerging technology, many features of OSW are changing more rapidly than established renewable options and are shaped by local circumstances in unique ways that limit transferrable experiences globally. This paper fills a gap in the literature by providing an updated technological assessment of OSW in California to determine its viability and competitiveness in the state’s electricity generation mix to achieve its near-term energy and environmental goals. Through a critical synthesis and extrapolation of technical, social, and economic analyses, we identify several major improvements in its potential. First, we note that while estimates of OSW’s costs per MWh of installed capacity have generally documented and projected a long-term decline, recent technical, microeconomic, and macroeconomic factors have caused significant backsliding of this momentum. Second, we project that the potential dollar value benefits of OSW’s greenhouse gas reduction capabilities have increased by one to two orders of magnitude, primarily due to major upward revisions of the social cost of carbon. Several co-benefits, including enhanced reliability, economic growth, and environmental justice, look to be increasingly promising due to a combination of technological advances and policy initiatives. Despite these advancements, OSW continues to face several engineering and broader challenges. We assess the current status of these challenges, as well as current and future strategies to address them. We conclude that OSW is now overall an even more attractive electricity-generating option than at the beginning of this decade.

Rose, Adam (ORCID:0000000333477684)↗

DOE OSTI2026

Integrating Cybersecurity Risk Assessment with Process Safety in Chemical Process Industries

This dissertation bridges the gap between industrial cybersecurity and traditional process safety by introducing an integrated Cyber-LOPA framework that combines the Purdue Enterprise Reference Architecture, Cyber Kill Chain, and CVSS v4.0 metrics. Demonstrated on a High-Density Polyethylene slurry process, the work illustrates how cyber threats targeting automation systems can bypass physical protection layers, proving the necessity of unified risk assessments to prevent cyber-induced physical incidents in chemical manufacturing plants.

Cyber-LOPA (CLOPA)↗

NASA NTRS2010

Certification

Objective 1: Provide regulators with a methodology for development of airworthiness requirements for certification of UAS. a) Rationale: a comprehensive methodology does not currently exist to support development of regulation for certification of UAS. Regulation is essential to enable routine access to the NAS. b) Approach: 1) assess existing approaches and classification schemes for deriving acceptable means of compliance to airworthiness requirements. 2) investigate a service-based approach to classification of UAS. 3) conduct comparative analysis of different methodologies. 4) work with FAA to determine best approach and conduct case study. 5) participate in regulatory/standards organizations developing safety and performance requirements for UAS. Objective 2: Provide regulators and industry with hazard and risk-related data to support criteria for UAS type design. a) Rationale: There is presently little UAS specific data (incident, accident, and reliability), especially in a civil context, to support risk assessment and development of standards and regulation. b) Approach: Identify gaps in existing data, provide measured data as needed, and formulate recommendations by: 1) evaluating UAS incident/accident data collection efforts and determining additional support necessary for regulation. 2) assessing UAS-specific hazards and risks. 3) evaluating need for reliability data for UAS-unique systems, components and subsystem, and determining additional measurement requirements. 4) developing guidance and best practices for UAS type design.

Hayhurst, Kelly↗

DOE OSTI2020

Evidence-based indicator approach to guide preliminary environmental impact assessments of hydropower development

Global expansion of hydropower resources has increased in recent years to meet growing energy demands and fill worldwide gaps in electricity supply. However, hydropower induces significant environmental impacts on river ecosystems - impacts that are addressed through environmental impact assessment (EIA) processes. The need for effective EIA processes is increasing as environmental regulations are either stressed in developing countries undertaking rapid expansion of hydropower capacity or time- and resource-intensive in developed countries. Part of the challenge in implementing EIAs lies in reaching a consensus among stakeholders regarding the most important environmental factors as the focus of impact studies. To help address this gap, we developed a weight-of-evidence approach (and toolkit) as a preliminary and coarse assessment of the most relevant impacts of hydropower on primary components of the river ecosystem, as identified using river function indicators. Through a science-based questionnaire and predictive model, users identify which environmental indicators may be impacted during hydropower development as well as those indicators that have the highest levels of uncertainty and require further investigation. Furthermore, an assessment tool visualizes inter-dependent indicator relationships, which help formulate hypotheses about causal relationships explored through environmental studies. We apply these tools to four existing hydropower projects and one hypothetical new hydropower project of varying sizes and environmental contexts. We observed consistencies between the output of our tools and the Federal Energy Regulatory Commission licensing process (inclusive of EIAs) but also important differences arising from holistic scientific evaluations (our toolkit) versus regulatory policies. The tools presented herein are aimed at increasing the efficiency of the EIA processes that engender environmental studies without loss of rigor or transparency of rationale necessary for understanding, considering, and mitigating the environmental consequences of hydropower.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Critical Evaluation of a Novel Analysis Technique for Assessment of Printed Circuit Heat Exchangers in High-Temperature Nuclear Service

Application of printed circuit heat exchangers (PCHEs) to very high-temperature reactors (VHTRs) requires mechanical performance assessment methodologies. The PCHE morphology consists of thousands of millimeter-scale channels, for enhanced thermal efficiency, enclosed in a meter-scale PCHE core. PCHE geometry under thermomechanical creep-fatigue transients results in multi-axial interactions between its different segments, such as channeled core, walls, and headers. These global-level interactions influence the local channel-level responses. Hence, developing a PCHE performance assessment methodology, following the ASME Code, Section III, Division 5 provisions, is a critical gap to be filled. There is no analysis or design methodology available in ASME Code to assess a PCHE for its global and local level performances under high temperature and pressure loadings. This paper critically evaluates a recently proposed two-step analysis technique to estimate global interactions and local channel-level responses of PCHEs. In this novel analysis technique, the channeled PCHE core is replaced with orthotropic solid blocks of representative stiffness properties for the global thermomechanical analysis. Here, subsequent channel scale submodel analysis with detailed channel geometry, loading, and elastic-perfectly plastic (EPP) material model estimates the local responses for PCHE performance assessment. This paper critically evaluates this novel technique for its effectiveness in PCHE performance assessment. Finite element (FE) models imitating various analysis issues are developed, and FE analysis results are scrutinized. An important outcome of this study is the validation of the novel two-step PCHE analysis technique for application to the performance assessment of PCHEs in VHTRs.

42 ENGINEERING↗