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NASA's National Center for Advanced Manufacturing

NASA has designated the Principal Center Assignment to the Marshall Space Flight Center (MSFC) for implementation of the National Center for Advanced Manufacturing (NCAM). NCAM is NASA s leading resource for the aerospace manufacturing research, development, and innovation needs that are critical to the goals of the Agency. Through this initiative NCAM s people work together with government, industry, and academia to ensure the technology base and national infrastructure are available to develop innovative manufacturing technologies with broad application to NASA Enterprise programs, and U.S. industry. Educational enhancements are ever-present within the NCAM focus to promote research, to inspire participation and to support education and training in manufacturing. Many important accomplishments took place during 2002. Through NCAM, NASA was among five federal agencies involved in manufacturing research and development (R&D) to launch a major effort to exchange information and cooperate directly to enhance the payoffs from federal investments. The Government Agencies Technology Exchange in Manufacturing (GATE-M) is the only active effort to specifically and comprehensively address manufacturing R&D across the federal government. Participating agencies include the departments of Commerce (represented by the National Institute of Standards and Technology), Defense, and Energy, as well as the National Science Foundation and NASA. MSFC s ongoing partnership with the State of Louisiana, the University of New Orleans, and Lockheed Martin Corporation at the Michoud Assembly Facility (MAF) progressed significantly. Major capital investments were initiated for world-class equipment additions including a universal friction stir welding system, composite fiber placement machine, five-axis machining center, and ten-axis laser ultrasonic nondestructive test system. The NCAM consortium of five universities led by University of New Orleans with Mississippi State University, Tennessee Technological University, Texas A&M University, and Virginia Polytechnic Institute and State University provided wide-ranging engineering research, new degree/curriculum programs, and a web-based lecture series. NCAM has fostered an important presence and leadership role within the national manufacturing community. Its progressive influence can be seen in government, industry and academia, and in national associations, professional organizations, conferences, workshops, and forums.

Vickers, John↗

PUFFIn Software Modeling for Quality Management

PUFFIn (PENELOPE User Friendly Fast Interface) was designed as a fast and simple Monte Carlo simulation tool for the transport of photons and electrons, with a primary purpose as a learning and education tool for a broad range of static configurations in the radiation processing industry. Development of the PUFFIn software is funded by the Office of Radiological Security (ORS) within the United States National Nuclear Security Administration (NNSA). PUFFIn helps fill the education and knowledge gaps in the industry, as identified in reports by Fermilab (2017) and the IAEA (2020). PUFFIn uses the PENELOPE (NEA-2023) physics engine to perform simulations on static configurations. PUFFIn has support for multiple geometry types from simple, single material simulations to full 3D configurations created from CAD input files or images from X-Ray Tomography scans. PUFFin was designed to be easy for the novice user, it will generate the input and geometry files required by PENLOPE and will display the output plots within the PUFFIn interface. PUFFin is distributed for free but requires a free workshop so users can be adequately trained in its use. Workshops have been presented in the past at Texas A&M university, the Aerial-CRT facility in Strasbourg France and Jakarta Indonesia. PUFFIn simulations have been validated by 10 MeV ebeam experiments done at Aerial-CRT in France (Radiation Physics and Chemistry 222 (2024) 111774). Further user experimental comparisons were made at the medical product hands on workshop at Texas A&M in October 2024.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

The Chemical Management System (CMS): A Useful Tool for Inventory Management

Comprehensive inventory management is central to the efficient operation of any facility that uses and stores chemicals. There are numerous software packages available that perform this function satisfactorily. Most commercially available inventory management software is regulatory or procurement focused and usually comes with upfront or monthly fees. Finally, this report describes freely downloadable software developed at Sandia National Laboratories that delivers an effective inventory management system with an additional focus on chemical security.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Global Analysis of Nonlinear Second-Mode Development in a Mach-6 Boundary Layer From High-Speed Schlieren Data

The second-mode instability on a 7◦ half-angle sharp cone at Mach 6 is analyzed using high-speed calibrated schlieren imagery at a frame rate near the expected fundamental frequency. Experiments were conducted in the NASA Langley 20-Inch Mach 6 facility at unit Reynolds number between 6.56×106 and 9.71×106 m−1. Time-resolved pixel intensity signals throughout the boundary layer are reconstructed using spatially available data in the schlieren images to recover an effective sampling rate of over 10 MHz; these are then converted to quantitative density gradients using a thin-lens-based calibration technique. A global analysis is performed on the schlieren data to investigate the nonlinear growth of the second-mode fundamental and harmonic content. Point-wise measures of the auto-bicoherence are used to identify specific triadic interactions and the locations of their highest levels of quadratic phase coupling. Significant resonance interactions between the second-mode fundamental and harmonic instabilities were found along with interactions between these and the mean flow. Bispectral mode decomposition is employed to educe the flow structures associated with these interactions. A similar analysis is performed for the power spectrum, with power spectral densities computed for each pixel’s time-series and spectral proper orthogonal decomposition employed to derive the modal structure and energy of the flow at specific frequencies. Comparisons between the bispectral quantities and second-mode power show that nonlinear interactions, particularly resonance interactions, are closely correlated with space-time modulation of disturbances during the nonlinear stage of transition.

boundary layer transition↗

Innovating the next generation of commercial smart building software

Nearly 30% of commercial building energy use is wasted due to equipment faults and HVAC controls problems. The result is increased emissions, compromised comfort and productivity, and less reliable coordination of building power needs with a clean grid. The energy impact alone represents $17 billion in potential savings. Today’s smart building software provides a robust solution to address these operational deficiencies. Energy management and information systems (EMIS) are saving up to 9% on average, with two-year paybacks. They are being incorporated into energy management processes, commissioning services, and utility programs. As effective as they are, two barriers prevent even deeper benefits; limited personnel to fix problems once they are identified, and the expense and time to manually implement changes in control systems. In partnership with the research community, the EMIS industry is developing new capabilities to overcome these barriers. Moving beyond siloed products for either fault detection and diagnostics, or optimal control, these new capabilities empower users to not only automatically identify faults, but also to push corrective action, and control improvements to their buildings. In this paper, several areas for enhancements are documented: ‘one-time’ correction of faults such as setpoints, schedules, and economizer lockouts; short-term active testing for automated proportional integral derivative (PID) loop tuning and functional testing; and continuous supervisory control for demand flexibility and year-round efficiency. Results are presented from a pair of partner implementations out of a dozen providers integrating these enhancements into their products, including field tests from across the country, and insights into operator acceptance and integration into operations and maintenance practices.

Casillas, Armando↗

PUFFIn – A user friendly fast interface for calculating and visualizing the dose distribution in materials

This article describes a new graphical user interface that uses the PENELOPE Monte Carlo code to calculate dose distributions in materials. It is named PUFFIn, for the Penelope User-Friendly Fast Interface and was developed as an educational and scoping analysis tool for non-experts in radiation modeling. PUFFIn enables the user to visualize and compare the dose distributions in objects (e.g., sterilized healthcare products) irradiated with cobalt-60 gamma-rays, electron beam (E-beam) or X-rays. From such comparisons, the user can determine the most efficient product and/or packaging designs for any given radiation field – whether for conceptual or existing products and packaging. PUFFIn is distributed in a complete, self-contained package of software, including the PENELOPE radiation transport code, a standard graphics package, and a set of simple exercises. The package is available to any user at no cost and requires a minimal amount of training compared to other similar software. PUFFIn's capabilities are described, as well as validation measurements performed at Texas A&M University E-beam facility and the Aerial E-beam Facility in France.

97 MATHEMATICS AND COMPUTING↗

A Grassroots Network and Community Roadmap for Interconnected Autonomous Science Laboratories for Accelerated Discovery

Scientific discovery is being revolutionized by AI and autonomous systems, yet current autonomous laboratories remain isolated islands unable to collaborate across institutions. We present the Autonomous Interconnected Science Lab Ecosystem (AISLE), a grassroots network transforming fragmented capabilities into a unified system that shorten the path from ideation to innovation to impact and accelerates discovery from decades to months. AISLE addresses five critical dimensions: (1) cross-institutional equipment orchestration, (2) intelligent data management with FAIR compliance, (3) AI-agent driven orchestration grounded in scientific principles, (4) interoperable agent communication interfaces, and (5) AI/ML-integrated scientific education. By connecting autonomous agents across institutional boundaries, autonomous science can unlock research spaces inaccessible to traditional approaches while democratizing cutting-edge technologies. This paradigm shift toward collaborative autonomous science promises breakthroughs in sustainable energy, materials development, and public health.

Ferreira da Silva, Rafael [Oak Ridge National Labo↗

Decision-making Framework to Support the End-of-Life Management of High-Activity Radioactive Sources

Sealed radioactive sources are used for an extremely wide range of purposes, including as radiation sources in various nuclear facilities, universities, hospitals, biomedical and industrial applications, as well as for geological prospecting and exploration. The proper management of these sealed radioactive sources once they have reached their end-of-life is still a global challenge. Very few field-tested Mobile Hot Cells (MHC) exist in the world to support the end-of-life management of disused high-activity radioactive sources. One of the critical challenges that a source recovery team encounters on each site is to find adequate space, and access to that space to complete the staging and recapture process with a MHC; this process is tedious, uncertain, and time-consuming. Therefore, it is essential to understand the planning and management of the MHC setup and takedown. Currently, there isn't an single capable planning tool that will provide an effective medium to plan, inform, educate, and communicate knowledge about the environment where the MHC will be deployed. We present a novel approach for the planning and management of the deployment of the MHC to several different sites that relies on technology. Furthermore, this planning tool will support collaboration, promote information sharing, and foster better decision making processes, resulting in a more efficient, and reliable setup and source recovery with the MHC.

61 RADIATION PROTECTION AND DOSIMETRY↗

Design and development of experimental facilities for short duration, low-gravity combustion and fire experiments

This report contains the results of three projects conducted by undergraduate students from Worcester Polytechnic Institute at the NASA's Lewis Research Center under a NASA Award NCC3-312. The students involved in these projects spent part of the summer of 1993 at the Lewis Research Center (LeRC) under the direction of Dr. Howard Ross, head of the Combustion group and other NASA engineers and scientists. The Principal Investigator at Worcester Polytechnic Institute was Professor Vahid Motevalli. Professor Motevalli served as the principal project advisor for two of the three projects which were in Mechanical Engineering. The third project was advised by Professor Duckworth of Electrical and Computer Engineering, while Professor Motevalli acted as the co-advisor. These projects provided an excellent opportunity for the students to participate in the cutting edge research and engineering design, interact with NASA engineers and gain valuable exposure to a real working environment. Furthermore, the combustion group at LeRC was able to forward their goals by employing students to work on topics of immediate use and interest such as experimental research projects planned for the space shuttle, the future space station, or to develop demonstration tools to educate the public about LeRC activities.

Motevalli, Vahid↗

International Space Weather Initiative (ISWI)

The International Heliophysical Year (IHY), an international program of scientific collaboration to understand the external drivers of planetary environments, has come to an end. The IHY was a major international event of great interest to the member States, which involved the deployment of new instrumentation, new observations from the ground and in space, and an education component. We propose to continue the highly successful collaboration between the heliophysics science community and the United Nations Basic Space Science (UNBSS) program. One of the major thrust of the IHY was to deploy arrays of small instruments such as magnetometers, radio antennas, GPS receivers, all-sky cameras, particle detectors, etc. around the world to provide global measurements of heliospheric phenomena. The United Nations Basic Space Science Initiative (UNBSSI) played a major role in this effort. Scientific teams were organized through UNBSS, which consisted of a lead scientist who provided the instruments or fabrication plans for instruments in the array. As a result of the this program, scientists from UNBSS member states now participate in the instrument operation, data collection, analysis, and publication of scientific results, working at the forefront of science research. As part of this project, support for local scientists, facilities and data acquisition is provided by the host nation. In addition, support at the Government level is provided for local scientists to participate. Building on momentum of the IHY, we propose to continue the highly successful collaboration with the UNBSS program to continue the study of universal processes in the solar system that affect the interplanetary and terrestrial environments, and to continue to coordinate the deployment and operation of new and existing instrument arrays aimed at understanding the impacts of Space Weather on Earth and the near-Earth environment. Toward this end, we propose a new program, the International Space Weather Initiative (ISWI).

Davila, Joseph M.↗

International Space Weather Initiative (ISWI)

The International Heliophysical Year (IHY), an international program of scientific collaboration to understand the external drivers of planetary environments, has come to an end. The IHY was a major international event of great interest to the member States, which involved the deployment of new instrumentation, new observations from the ground and in space, and an education component. We propose to continue the highly successful collaboration between the heliophysics science community and the United Nations Basic Space Science (UNBSS) program. One of the major thrust of the IHY was to deploy arrays of small instruments such as magnetometers, radio antennas, GPS receivers, all-sky cameras, particle detectors, etc. around the world to provide global measurements of heliospheric phenomena. The United Nations Basic Space Science Initiative (UNBSSI) played a major role in this effort. Scientific teams were organized through UNBSS, which consisted of a lead scientist who provided the instruments or fabrication plans for instruments in the array. As a result of the this program, scientists from UNBSS member states now participate in the instrument operation, data collection, analysis, and publication of scientific results, working at the forefront of science research. As part of this project, support for local scientists, facilities and data acquisition is provided by the host nation. In addition, support at the Government level is provided for local scientists to participate. Building on momentum of the IHY, we propose to continue the highly successful collaboration with the UNBSS program to continue the study of universal processes in the solar system that affect the interplanetary and terrestrial environments, and to continue to coordinate the deployment and operation of new and existing instrument arrays aimed at understanding the impacts of Space Weather on Earth and the near-Earth environment. Toward this end, we propose a new program, the International Space Weather Initiative (ISWI).

Davila, Joseph↗

Energy Technology Proving Ground Program Plan

New methods of energy production and distribution are required to meet clean energy goals and demands across all U.S. energy sectors. Idaho National Laboratory’s (INL) Integrated Energy Systems (IES) initiative is enabling clean energy research, development, and demonstration (RD&D) activities. To date, IES demonstration programs have been limited by distributed infrastructure and a lack of large-scale facilities to accommodate industry-scale research of Technical Readiness Level (TRL) 6-8 technologies. The IES initiative plans to eliminate these constraints by establishing a new research complex at INL known as the Energy Technology Proving Ground (Proving Ground) to be led by the Energy and Environment Science and Technology Directorate. The Energy and Environment Science and Technology (EES&T) directorate, one of five Idaho National Laboratory (INL) RD&D organizations, focuses on clean energy technologies that anchor the industry-enabling research of the Proving Ground. The Proving Ground will combine diverse clean energy systems into lean integrated test bed of independent multiscale capabilities available to the government and commercial industries to perform research; and will enable INL’s goal of becoming a Net-Zero entity by 2031. This program encompasses existing and new research space at both the in-town Research and Education Campus (REC) and the Arco desert site (the Site). The Proving Ground will support the maturation of IES technologies from TRL 1 through 8 by providing the infrastructure and capabilities needed to sustain a continuum of RD&D from basic science to industry-scale. To establish The Proving Ground and meet INL’s net-zero goals by 2031, nine research program areas have been identified within the IES initiative that require expanded and new capital infrastructure. This program plan provides guidance for establishing the Proving Ground at the Site for plug-and-play pilot testing and proofing of integrated energy system functionality including fission and renewable energy sources for industry driven application platforms.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Energy Technology Proving Ground FY-2026 Program Plan (Rev.1)

New methods of energy production and distribution are required to meet clean energy goals and demands across all U.S. energy sectors. Idaho National Laboratory’s (INL) Integrated Energy Systems (IES) initiative is enabling clean energy research, development, and demonstration (RD&D) activities. To date, IES demonstration programs have been limited by distributed infrastructure and a lack of large-scale facilities to accommodate industry-scale research of Technical Readiness Level (TRL) 6-8 technologies. The IES initiative plans to eliminate these constraints by establishing a new research complex at INL known as the Energy Technology Proving Ground (Proving Ground) to be led by the Energy and Environment Science and Technology Directorate. The Energy and Environment Science and Technology (EES&T) directorate, one of five Idaho National Laboratory (INL) RD&D organizations, focuses on clean energy technologies that anchor the industry-enabling research of the Proving Ground. The Proving Ground will combine diverse clean energy systems into lean integrated test bed of independent multiscale capabilities available to the government and commercial industries to perform research; and will enable INL’s goal of becoming a Net-Zero entity by 2031. This program encompasses existing and new research space at both the in-town Research and Education Campus (REC) and the Arco desert site (the Site). The Proving Ground will support the maturation of IES technologies from TRL 1 through 8 by providing the infrastructure and capabilities needed to sustain a continuum of RD&D from basic science to industry-scale. To establish The Proving Ground and meet INL’s net-zero goals by 2031, nine research program areas have been identified within the IES initiative that require expanded and new capital infrastructure. This program plan provides guidance for establishing the Proving Ground at the Site for plug-and-play pilot testing and proofing of integrated energy system functionality including fission and renewable energy sources for industry driven application platforms.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Capabilities Development at the University of Texas at El Paso for Hydrogen Generation Research and Education

Gasification-based systems have recently received much attention due to their capability of converting wastes into useful fuels. The gasification of biomass, municipal solid waste (MSW), plastics, and other sustainable resources has shown promise in hydrogen production. When coupled to a CCU or CCS unit, these systems have the potential to achieve carbon neutrality or carbon-negative emissions. In addition, these systems have an edge over conventional incineration or landfill systems by reducing greenhouse gas emissions and recovering useful energy. However, the gasification of MSW and other wastes is still in its early stages. In particular, co-gasification of wastes with biomass has significant unknowns in optimizing the reaction kinetics, operability, design and performance improvements. Currently, Supercritical Water Gasifiers (SCWG) and Plasma Gasifiers are the major systems that are capable of producing high hydrogen amounts from Biomass and MSW, respectively. However, both systems have high capital and operating costs, adversely affecting efficiency and the hydrogen production cost. Additionally, due to lower temperatures, SCWGs are prone to tar formation and fouling in the heat exchangers. Hence, there is a need to look for alternative solutions for MSW and biomass gasifications, particularly in co-gasification. The current effort aims to develop a strategic plan to establish a sustainable gasification facility for hydrogen research at the University of Texas at El (UTEP). A major part of this effort involves an extensive literature survey to identify technological gaps and potential areas of interest. Several concepts were developed in accordance with the current demands from the literature survey. Based on the concepts, a center-wide capability assessment was conducted to measure the current capacity and feasibility of establishing hydrogen research. Afterward, a strategic research plan was developed, and a list of required resources was made for the expansion of hydrogen research at UTEP. In addition, successful partnerships with the local county and the city were developed to pursue hydrogen research. The strategic goal setting and planning of UTEP Aerospace Center resulted in securing $2.5 million in external support to expand the hydrogen research during the project performance period. In addition, during the project period, a course in Hydrogen Energy Systems was developed to expand the energy curriculum at the UTEP Aerospace and Mechanical Engineering Department. The course focused on hydrogen production, storage, supply and delivery and application. The cross-listed course was offered at both undergraduate and graduate levels during the Spring 2024 semester and had 27 enrolled students. Moreover, the students supported under this award were trained in gasification process modeling, CAD, CFD and FEA during the project period. The training enabled the students to move into new projects to support gasification design, integrated gasification combined cycle process plant analysis, gasifier structural and operational analysis, and digitally threading the systems.

08 HYDROGEN↗

Design Visualization Internship Overview

This is a report documenting the details of my work as a NASA KSC intern for the Summer Session from June 2nd to August 8th, 2014. This work was conducted within the Design Visualization Group, a Contractor staffed organization within the C1 division of the IT Directorate. The principle responsibilities of the KSC Design Visualization Group are the production of 3D simulations of NASA equipment and facilities for the purpose of planning complex operations such as hardware transportation and vehicle assembly. My role as an intern focused on aiding engineers in using 3D scanning equipment to obtain as-built measurements of NASA facilities, as well as using CATIA and DELMIA to process this data. My primary goals for this internship focused on expanding my CAD knowledge and capabilities, while also learning more about technologies I was previously unfamiliar with, such as 3D scanning. An additional goal of mine was to learn more about how NASA operates, and how the U.S. Space Program operates on a day-to-day basis. This opportunity provided me with a front-row seat to the daily maneuvers and operations of KSC and NASA as a whole. Each work day, I was able to witness, and even take part of, a small building block of the future systems that will take astronauts to other worlds. After my experiences this summer, not only can I say that my goals have been met, but also that this experience has been the highlight of my experience in higher education.

Telescience↗

Investigation of Liner Characteristics in the NASA Langley Curved Duct Test Rig

The Curved Duct Test Rig (CDTR), which is designed to investigate propagation of sound in a duct with flow, has been developed at NASA Langley Research Center. The duct incorporates an adaptive control system to generate a tone in the duct at a specific frequency with a target Sound Pressure Level and a target mode shape. The size of the duct, the ability to isolate higher order modes, and the ability to modify the duct configuration make this rig unique among experimental duct acoustics facilities. An experiment is described in which the facility performance is evaluated by measuring the sound attenuation by a sample duct liner. The liner sample comprises one wall of the liner test section. Sound in tones from 500 to 2400 Hz, with modes that are parallel to the liner surface of order 0 to 5, and that are normal to the liner surface of order 0 to 2, can be generated incident on the liner test section. Tests are performed in which sound is generated without axial flow in the duct and with flow at a Mach number of 0.275. The attenuation of the liner is determined by comparing the sound power in a hard wall section downstream of the liner test section to the sound power in a hard wall section upstream of the liner test section. These experimentally determined attenuations are compared to numerically determined attenuations calculated by means of a finite element analysis code. The code incorporates liner impedance values educed from measured data from the NASA Langley Grazing Incidence Tube, a test rig that is used for investigating liner performance with flow and with (0,0) mode incident grazing. The analytical and experimental results compare favorably, indicating the validity of the finite element method and demonstrating that finite element prediction tools can be used together with experiment to characterize the liner attenuation.

Gerhold, Carl H.↗

Pulsed laser deposition assisted epitaxial growth of cesium telluride photocathodes for high brightness electron sources

The development of high-brightness electron sources is critical to state-of-the-art electron accelerator applications like X-ray free electron laser (XFEL) and ultra-fast electron microscopy. Cesium telluride is chosen as the electron source material for multiple cutting-edge XFEL facilities worldwide. This manuscript presents the first demonstration of the growth of highly crystalized and epitaxial cesium telluride thin films on 4H-SiC and graphene/4H-SiC substrates with ultrasmooth film surfaces. The ordering of the film was characterized by in situ reflection high energy electron diffraction and multiple X-ray diagnostics. The results of the quantum efficiency performance for epitaxial cesium telluride photocathodes are also reported.

43 PARTICLE ACCELERATORS↗

PopGNN: Graph Neural Network-Based Flexible Future Population Forecasting Model

Accurate population forecasts is important to plan critical infrastructure and services, from housing and education to healthcare and transport. However, traditional population prediction studies have only employed traditional machine learning models limited to capture complex spatial interdependencies and patterns. Althogh recently computer vision-based framework was introduced with with promising accuracy, it has critical limitations for real-world planning applications: it function only at fixed spatial resolutions, restricting their use in diverse boundaries such as census tracts, neighborhoods, or administrative zones. Therefore, this study suggests a Graph Neural Network (GNN)-based population prediction framework, called PopGNN. This model recorded remarkable performance compared with state-of-the-art models and traditional baseline models in the grid and administrative boundaries. Furthermore, our framework achieved comparable predictive accuracy to a computer vision-based model in both the South Korea and Tennessee case studies. Consequently, this study is valuable in that a single model can provide accurate population forecasts that address diverse planning demands, ranging from granular grid-level estimates for precise service allocation and facility location planning to aggregate administrative-level forecasts for macro-scale regional policy and resource distribution.

97 MATHEMATICS AND COMPUTING↗