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At least 289 records · Page 16

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DOE OSTI2025

Standardization of ancillary installation tooling for SRF cavities at Fermilab

For assemblies of cavities in cleanrooms, single-use tooling systems are made for the alignment and installation of ancillary components such as couplers and bellows. To minimize the number of tooling sets created, a design has been created to standardize alignment features to allow for assembly of different components with one set of tooling. A prototype set of tooling has been developed to with the required degrees of freedom for multiple assemblies while minimizing deformation during the assembly process. Prototype designs have been created for PIP-II SSR2 and 650 Cavities and for AUP Crab Cavities. Using 3D printing, this tooling can be quickly adjusted to allow for different ancillary components. The development process and status of the design will be discussed.

Narug, C. [Fermilab]↗

DOE OSTI2024

Standardization of Ancillary Installation Tooling for SRF Cavities at Fermilab

For assemblies of cavities in cleanrooms, single-use tooling systems are made for the alignment and installation of ancillary components such as couplers and bellows. To try and minimize the amount of tooling sets used, a design has been created to standardize alignment features to allow for assembly of different components with one set of tooling. A prototype set of tooling has been developed to with the required degrees of freedom for multiple assemblies while minimizing deformation during the assembly process. Prototype designs have been created for PIP-II SSR2 and 650 Cavities and for AUP Crab Cavities. Using 3D printing, this tooling can be quickly adjusted to allow for different ancillary components. The development process and status of the design will be discussed.

Narug, Colin↗

NASA NTRS1997

Predictive Modeling in Plasma Reactor and Process Design

Research continues toward the improvement and increased understanding of high-density plasma tools. Such reactor systems are lauded for their independent control of ion flux and energy enabling high etch rates with low ion damage and for their improved ion velocity anisotropy resulting from thin collisionless sheaths and low neutral pressures. Still, with the transition to 300 mm processing, achieving etch uniformity and high etch rates concurrently may be a formidable task for such large diameter wafers for which computational modeling can play an important role in successful reactor and process design. The inductively coupled plasma (ICP) reactor is the focus of the present investigation. The present work attempts to understand the fundamental physical phenomena of such systems through computational modeling. Simulations will be presented using both computational fluid dynamics (CFD) techniques and the direct simulation Monte Carlo (DSMC) method for argon and chlorine discharges. ICP reactors generally operate at pressures on the order of 1 to 10 mTorr. At such low pressures, rarefaction can be significant to the degree that the constitutive relations used in typical CFD techniques become invalid and a particle simulation must be employed. This work will assess the extent to which CFD can be applied and evaluate the degree to which accuracy is lost in prediction of the phenomenon of interest; i.e., etch rate. If the CFD approach is found reasonably accurate and bench-marked with DSMC and experimental results, it has the potential to serve as a design tool due to the rapid time relative to DSMC. The continuum CFD simulation solves the governing equations for plasma flow using a finite difference technique with an implicit Gauss-Seidel Line Relaxation method for time marching toward a converged solution. The equation set consists of mass conservation for each species, separate energy equations for the electrons and heavy species, and momentum equations for the gas. The sheath is modeled by imposing the Bohm velocity to the ions near the walls. The DSMC method simulates each constituent of the gas as a separate species which would be analogous in CFD to employing separate species mass, momentum, and energy equations. All particles including electrons are moved and allowed to collide with one another with the stipulation that the electrons remain tied to the ions consistent with the concept of ambipolar diffusion. The velocities of the electrons are allowed to be modified during collisions and are not confined to a Maxwellian distribution. These benefits come at a price in terms of computational time and memory. The DSMC and CFD are made as consistent as possible by using similar chemistry and power deposition models. Although the comparison of CFD and DSMC is interesting, the main goal of this work is the increased understanding of high-density plasma flowfields that can then direct improvements in both techniques. This work is unique in the level of the physical models employed in both the DSMC and CFD for high-density plasma reactor applications. For example, the electrons are simulated in the present DSMC work which has not been done before for low temperature plasma processing problems. In the CFD approach, for the first time, the charged particle transport (discharge physics) has been self-consistently coupled to the gas flow and heat transfer.

Hash, D. B.↗

NASA NTRS2016

Dynamic Systems Analysis for Turbine Based Aero Propulsion Systems

The aircraft engine design process seeks to optimize the overall system-level performance, weight, and cost for a given concept. Steady-state simulations and data are used to identify trade-offs that should be balanced to optimize the system in a process known as systems analysis. These systems analysis simulations and data may not adequately capture the true performance trade-offs that exist during transient operation. Dynamic systems analysis provides the capability for assessing the dynamic tradeoffs at an earlier stage of the engine design process. The dynamic systems analysis concept, developed tools, and potential benefit are presented in this paper. To provide this capability, the Tool for Turbine Engine Closed-loop Transient Analysis (TTECTrA) was developed to provide the user with an estimate of the closed-loop performance (response time) and operability (high pressure compressor surge margin) for a given engine design and set of control design requirements. TTECTrA along with engine deterioration information, can be used to develop a more generic relationship between performance and operability that can impact the engine design constraints and potentially lead to a more efficient engine.

dynamic analysis↗

NASA NTRS2019

Using Virtual Reality and Motion Capture as tools for Human Factors Engineering at NASA Marshall Space Flight Center

NASA Marshall Space Flight Center (MSFC) Human Factors Engineering (HFE) Team is implementing virtual reality (VR) and motion capture (MoCap) into HFE analyses of various projects through its Virtual Environments Lab (VEL). VR allows for multiple analyses early in the design process and more opportunities to give design feedback. This tool can be used by engineers in most disciplines to compare design alternatives and is particularly valuable to HFE to give early input during these evaluations. These techniques are being implemented for concept development of Deep Space Habitats (DSH), and work is being done to implement VR for design aspects of the Space Launch System (SLS). VR utilization in the VEL will push the design to be better formulated before mockups are constructed, saving budget and time. The MSFC VEL will continue forward leaning implementation with VR technologies in these and other projects for better models earlier in the design process.

Andrews, Tanya↗

NASA NTRS2012

Extended Testability Analysis Tool

The Extended Testability Analysis (ETA) Tool is a software application that supports fault management (FM) by performing testability analyses on the fault propagation model of a given system. Fault management includes the prevention of faults through robust design margins and quality assurance methods, or the mitigation of system failures. Fault management requires an understanding of the system design and operation, potential failure mechanisms within the system, and the propagation of those potential failures through the system. The purpose of the ETA Tool software is to process the testability analysis results from a commercial software program called TEAMS Designer in order to provide a detailed set of diagnostic assessment reports. The ETA Tool is a command-line process with several user-selectable report output options. The ETA Tool also extends the COTS testability analysis and enables variation studies with sensor sensitivity impacts on system diagnostics and component isolation using a single testability output. The ETA Tool can also provide extended analyses from a single set of testability output files. The following analysis reports are available to the user: (1) the Detectability Report provides a breakdown of how each tested failure mode was detected, (2) the Test Utilization Report identifies all the failure modes that each test detects, (3) the Failure Mode Isolation Report demonstrates the system s ability to discriminate between failure modes, (4) the Component Isolation Report demonstrates the system s ability to discriminate between failure modes relative to the components containing the failure modes, (5) the Sensor Sensor Sensitivity Analysis Report shows the diagnostic impact due to loss of sensor information, and (6) the Effect Mapping Report identifies failure modes that result in specified system-level effects.

Melcher, Kevin↗

NASA NTRS2000

An Advanced User Interface Approach for Complex Parameter Study Process Specification in the Information Power Grid

The creation of parameter study suites has recently become a more challenging problem as the parameter studies have now become multi-tiered and the computational environment has become a supercomputer grid. The parameter spaces are vast, the individual problem sizes are getting larger, and researchers are now seeking to combine several successive stages of parameterization and computation. Simultaneously, grid-based computing offers great resource opportunity but at the expense of great difficulty of use. We present an approach to this problem which stresses intuitive visual design tools for parameter study creation and complex process specification, and also offers programming-free access to grid-based supercomputer resources and process automation.

Yarrow, Maurice↗

NASA NTRSDate not supplied

Parametric Cost Modeling of a Mid-Lift-to-Drag Ratio Vehicle for Human Mars Entry, Descent, and Landing

Cost is one of the biggest obstacles to sending humans to Mars. However, spacecraft costs are typically estimated after the preliminary vehicle and mission concepts have been designed. By automating the cost estimation process, the effect of any change in vehicle or mission design on the mission cost can be determined more rapidly. This paper uses the tool SAPE-C (Systems Analysis for Planetary Entry, Descent, and Landing-Cost). SAPE-C integrates the cost modeling software SEER-H (System Estimation and Evaluation of Resources-Hardware) with a number of systems analysis tools and enables large design tradespace exploration early in the design process. SAPE-C is used to analyze several tradespaces of the Mid-Lift-to-Drag ratio rigid entry vehicle for human Mars missions. Key findings include quantifying the impacts of payload, vehicle length, and main engine specific impulse on the overall cost of the vehicle, and how the payload per lander and number of landers affects the cost of a campaign to Mars.

Mid L/D↗

NASA NTRSDate not supplied

Parametric Cost Modeling of a Mid-Lift-to-Drag Ratio Vehicle for Human Mars Entry, Descent, and Landing

Paul D Friz↗

NASA NTRSDate not supplied

Parametric Cost Modeling of a Mid-Lift-to-Drag Ratio Vehicle for Human Mars Entry, Descent, and Landing

Paul D Friz↗

DOE OSTI2026

MARVEL Reactor Digital Engineering Developments

The MARVEL reactor project has served to introduce a new generation of engineers to the processes required to transform a reactor design from simply an idea on paper into what will be an approved, constructed, and operational nuclear power system. Much as there have been advances in materials, analysis, and evaluation methodologies over the 50 years since the last reactor was built at INL, so too has the technology for managing the engineering process itself advanced. Digital Engineering tools and methods provide improved coordination between previously siloed engineering disciplines, reduced burdens of non-value-added data transcription processes and bring forward insights and improvements that might otherwise fall later in the design stage, where changes are much more costly. While the tools and techniques to support the full digital engineering vision are not yet complete, the MARVEL design processes provide valuable demonstrations and validations of key aspects and illuminate further areas for implementation by subsequent projects.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

NASA NTRS1993

Investigate zero-stress replicated optics

The contracted activities for the procurement of 'Investigate Zero-Stress Replicated Optics' to support the AXAF-S x-ray spectrometer mirrors has been completed. To date four large Wolter I grazing incidence x-ray optical shells have been electroformed from nickel. The mirrors were fabricated utilizing each of two nickel alloy plated aluminum substrates twice. A wide variety of testing has been completed by NASA MSFC and UAH. This testing includes heat treatment control tests, subscale plating and fixture testing, alloy control of the electroless nickel, adhesion and release testing of the gold to electroless nickel, electroforming instrumentation and software and fabrication of subscale models. The full scale shells are one millimeter thick nickel electrodeposited over a thin gold layer which in turn has the optical surface on the inside. The optical surface is the replicate of the surface prepared on the substrate. Appendix I briefly outlines the fabrication process. Major objectives which were shared by UAH and MSFC include the design of facilities, equipment and tooling and procurement of materials and equipment. Process development followed with the fabrication of small scale pilot units. Procurement commenced immediately and equipment and materials were ordered to implement the fabrication of first surface full scale substrates (mandrels) and the second surface electroformed optical components. All principal objectives have been achieved. Inspection of the mirrors in visible and x-ray modes validates that the required performance and the quality can be achieved by an electroforming replication process. A very distinct progressive improvement has been achieved with each of the four mirrors produced. The final mirror exceeded the original goals and set an improved standard for flight hardware. The future goal of a 30 arc second resolution at 8 KEV x-ray appears to be achievable by this process when proper cleanliness and process control is utilized.

Engelhaupt, Darell↗

DOE OSTI2022

High Flux Isotope Reactor Low Enriched Uranium U-10Mo Fuel Design Parameters

Activities to convert the HFIR from HEU to LEU are ongoing as part of the US Department of Energy (DOE) National Nuclear Security Administration (NNSA) nuclear nonproliferation mission. Design activities to study the conversion of HFIR from HEU to LEU fuel explored different fuel design features and shapes with a uranium-molybdenum (U-10Mo) monolithic alloy fuel. This high-density alloy contains 90 wt % uranium and 10 wt % molybdenum and has a uranium density of 15.318gU/cm 3 . The goal of these studies is to generate several candidate HFIR LEU fuel designs of varying fuel fabrication complexity that meet the current HEU performance metrics and safety requirements. Recent advancements in modeling and simulation tools and design methods enabled a thorough analysis of the available design space with U-10Mo fuel. A surrogate model used this analysis as training data to quickly determine the performance of a design given specific design parameters. An optimization module used this surrogate model to quickly search this multidimensional search space given specific desired performance characteristics. This approach was made possible by the large available design space with U-10Mo fuel. Shift, a Monte Carlo tool optimized for high-performance computing (HPC) architectures, was used for faster calculation and better data management for reactor physics simulations. Once most of these design studies were complete, a new suite called the Python HFIR Analysis and Measurement Engine (PHAME) was developed to connect all fuel design analysis steps, making design studies more efficient and reproducible. The post-processing capabilities of these new tools are leveraged for the information provided herein. Leveraging these tools, several candidate fuel designs were selected with varying levels of feature complexity and reactor performance. This report provides design feature details for four selected HFIR LEU U-10Mo fuel designs and their corresponding performance and safety metrics. Nominal best-estimate design parameters and irradiation conditions, including fission rate densities, power densities, heat fluxes, and cumulative fission densities, are provided. Simulations show that the high uranium density of U-10Mo fuel provides a large potential design space that enables various LEU designs to meet HEU core performance metrics and safety requirements with a power increase from 85 MW (HEU) to 95 MW or 100 MW (LEU).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2004

On Nonlinear Combustion Instability in Liquid Propellant Rocket Motors

All liquid propellant rocket instability calculations in current use have limited value in the predictive sense and serve mainly as a correlating framework for the available data sets. The well-known n-t model first introduced by Crocco and Cheng in 1956 is still used as the primary analytical tool of this type. A multitude of attempts to establish practical analytical methods have achieved only limited success. These methods usually produce only stability boundary maps that are of little use in making critical design decisions in new motor development programs. Recent progress in understanding the mechanisms of combustion instability in solid propellant rockets"' provides a firm foundation for a new approach to prediction, diagnosis, and correction of the closely related problems in liquid motor instability. For predictive tools to be useful in the motor design process, they must have the capability to accurately determine: 1) time evolution of the pressure oscillations and limit amplitude, 2) critical triggering pulse amplitude, and 3) unsteady heat transfer rates at injector surfaces and chamber walls. The method described in this paper relates these critical motor characteristics directly to system design parameters. Inclusion of mechanisms such as wave steepening, vorticity production and transport, and unsteady detonation wave phenomena greatly enhance the representation of key features of motor chamber oscillatory behavior. The basic theoretical model is described and preliminary computations are compared to experimental data. A plan to develop the new predictive method into a comprehensive analysis tool is also described.

Sims, J. D.↗

NASA NTRSDate not supplied

Application of a Rapid Design Tool to a 3D Woven Structural Joint

The optimization of composite structural joints is an iterative process and a multiscale problem. High fidelity finite element modeling of joints with 3D woven and laminated materials can become computationally expensive. The aim of this paper is to establish a reliable analysis process for the optimization of a composite Y-joint (curved Pi-joint), to be used in an aircraft fuselage, using commercial rapid joint design, analysis, and optimization software. The rapid joint design tool was investigated as a substitute and/or complement to a finite element analysis software. A composite Pi-joint and a composite Y-joint were evaluated using the rapid joint design tool to determine the applicability and limits of the software. Furthermore, three main preliminary parametric studies were performed to better understand the capability of the tool in predicting the stress distributions and trends in the Y-joint. The parameters investigated were the joint curvature, the laminated skin thickness, the adhesive systems, and the ply composition. Lastly, trends in predicted failure load were produced as a function of skin thickness (16ply, 24ply and 32ply). Failure loads were found with varying joint curvature and skin thickness using stress-based adherend failure criterion. The rapid joint design tool was also validated against existing experimental results.

Bonded Joints↗

NASA NTRS2008

Cassini Information Management System in Distributed Operations Collaboration and Cassini Science Planning

Launched on October 15, 1997, the Cassini-Huygens spacecraft began its ambitious journey to the Saturnian system with a complex suite of 12 scientific instruments, and another 6 instruments aboard the European Space Agencies Huygens Probe. Over the next 6 1/2 years, Cassini would continue its relatively simplistic cruise phase operations, flying past Venus, Earth, and Jupiter. However, following Saturn Orbit Insertion (SOI), Cassini would become involved in a complex series of tasks that required detailed resource management, distributed operations collaboration, and a data base for capturing science objectives. Collectively, these needs were met through a web-based software tool designed to help with the Cassini uplink process and ultimately used to generate more robust sequences for spacecraft operations. In 2001, in conjunction with the Southwest Research Institute (SwRI) and later Venustar Software and Engineering Inc., the Cassini Information Management System (CIMS) was released which enabled the Cassini spacecraft and science planning teams to perform complex information management and team collaboration between scientists and engineers in 17 countries. Originally tailored to help manage the science planning uplink process, CIMS has been actively evolving since its inception to meet the changing and growing needs of the Cassini uplink team and effectively reduce mission risk through a series of resource management validation algorithms. These algorithms have been implemented in the web-based software tool to identify potential sequence conflicts early in the science planning process. CIMS mitigates these sequence conflicts through identification of timing incongruities, pointing inconsistencies, flight rule violations, data volume issues, and by assisting in Deep Space Network (DSN) coverage analysis. In preparation for extended mission operations, CIMS has also evolved further to assist in the planning and coordination of the dual playback redundancy of highvalue data from targets such as Titan and Enceladus. This paper will outline the critical role that CIMS has played for Cassini in the distributed ops paradigm throughout operations. This paper will also examine the evolution that CIMS has undergone in the face of new science discoveries and fluctuating operational needs. And finally, this paper will conclude with theoretical adaptation of CIMS for other projects and the potential savings in cost and risk reduction that could potentially be tapped into by future missions.

Equils, Douglas J.↗

DOE OSTI2023

Using Co-Optimized Machine Learned Manifolds for Modeling Chemically Reacting Flows

Chemically reacting flows play a key role in a wide range of engineered systems, from chemical and polymer processing to combustion-based energy conversion technologies. Simulations of these flows involve solving a coupled set of partial differential equations for mass, momentum, energy, and all relevant chemical species in the system. Chemical reaction pathways may be extremely complex and involve hundreds or more intermediate species, with reactions that occur over timescales varying by several orders of magnitude - presenting a significant numerical stiffness challenge. The combination of these factors makes simulation of chemically reacting flows vastly more expensive than nonreactive simulations, and often makes direct solution of the governing equations intractable. It is necessary to apply lower-fidelity models in place of the detailed governing equations in order to reduce computational cost to enable reacting flow simulation tools to be used in the engineering design process. Many of the models employed for this purpose are based on reducing the dimension of the thermochemical state, motivated by the observation that the observed thermochemical states in a system lie on a low-dimensional manifold in thermochemical state space. This behavior occurs due to the fast equilibration of certain reactive and transport processes, and physics-based manifold models rely on idealized assumptions about the balance of timescales and the way in which chemistry and transport are coupled. In this work, we apply a novel method for data-driven manifold-based modeling that can leverage data from high-fidelity reacting flow simulations to improve model accuracy in cases where the physics-based modeling assumptions break down. The approach is designed to be broadly applicable across chemically reacting flow systems but is applied here to turbulent combustion modeling.

machine learning↗

NASA NTRS1984

Data flow modeling techniques

There have been a number of simulation packages developed for the purpose of designing, testing and validating computer systems, digital systems and software systems. Complex analytical tools based on Markov and semi-Markov processes have been designed to estimate the reliability and performance of simulated systems. Petri nets have received wide acceptance for modeling complex and highly parallel computers. In this research data flow models for computer systems are investigated. Data flow models can be used to simulate both software and hardware in a uniform manner. Data flow simulation techniques provide the computer systems designer with a CAD environment which enables highly parallel complex systems to be defined, evaluated at all levels and finally implemented in either hardware or software. Inherent in data flow concept is the hierarchical handling of complex systems. In this paper we will describe how data flow can be used to model computer system.

Kavi, K. M.↗