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NASA NTRS2017

Risk-Significant Adverse Condition Awareness Strengthens Assurance of Fault Management Systems

As spaceflight systems increase in complexity, Fault Management (FM) systems are ranked high in risk-based assessment of software criticality, emphasizing the importance of establishing highly competent domain expertise to provide assurance. Adverse conditions (ACs) and specific vulnerabilities encountered by safety- and mission-critical software systems have been identified through efforts to reduce the risk posture of software-intensive NASA missions. Acknowledgement of potential off-nominal conditions and analysis to determine software system resiliency are important aspects of hazard analysis and FM. A key component of assuring FM is an assessment of how well software addresses susceptibility to failure through consideration of ACs. Focus on significant risk predicted through experienced analysis conducted at the NASA Independent Verification & Validation (IV&V) Program enables the scoping of effective assurance strategies with regard to overall asset protection of complex spaceflight as well as ground systems. Research efforts sponsored by NASAs Office of Safety and Mission Assurance (OSMA) defined terminology, categorized data fields, and designed a baseline repository that centralizes and compiles a comprehensive listing of ACs and correlated data relevant across many NASA missions. This prototype tool helps projects improve analysis by tracking ACs and allowing queries based on project, mission type, domain/component, causal fault, and other key characteristics. Vulnerability in off-nominal situations, architectural design weaknesses, and unexpected or undesirable system behaviors in reaction to faults are curtailed with the awareness of ACs and risk-significant scenarios modeled for analysts through this database. Integration within the Enterprise Architecture at NASA IV&V enables interfacing with other tools and datasets, technical support, and accessibility across the Agency. This paper discusses the development of an improved workflow process utilizing this database for adaptive, risk-informed FM assurance that critical software systems will safely and securely protect against faults and respond to ACs in order to achieve successful missions.

IV&V↗

DOE OSTI2025

Characterization of Infrasonic Signatures of Earth-Grazing Fireballs as Analogues to Hypersonic Vehicles (Final Report)

Accurate detection, discrimination, and characterization of high-altitude hypersonic events using infrasonic monitoring are critical to planetary defense and global strategic surveillance. This report synthesizes recent advances achieved through rigorous analysis of infrasonic signatures from natural meteoroids, emphasizing shallow entry-angle meteoroids as essentially proxies for artificial hypersonic systems. Meteoroids naturally encompass diverse velocities, trajectories, altitudes, and fragmentation behaviors, enabling systematic validation of empirical period–yield relationships, waveform morphology classifiers, and trajectory-induced back-azimuth deviation models. Integration of adaptive array-processing enhancements within Cardinal software further extends infrasonic detection sensitivity and signal classification reliability. Collectively these advances, based solely on infrasonic signatures or limited optical data, offer robust methodologies for distinguishing natural from artificial hypersonic sources, significantly reducing event geolocation uncertainties and refining source-function determination. The outcomes detailed herein lay foundational groundwork for improved global hypersonic event-surveillance frameworks, supporting improved security preparedness and informing strategic monitoring and defense policies.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Virtual Inspection of Advanced Manufacturing via Process-Scale Digital Twins (Abbreviated Report)

Inspection and certification comprise the most significant bottlenecks in advanced manufacturing for NNSA applications, often requiring far more time and resources than the fabrication of the parts themselves. Traditional methods, such as manual review and X-ray computed tomography, are not only slow and costly, but also struggle to provide a clear connection between manufacturing instructions and the final performance of critical components. This gap limits both the agility and assurance needed to support the modernization and safety of the United States nuclear stockpile. In response, our Strategic Initiative established a digital twin framework that integrates realtime process monitoring, automated data analysis, and immersive virtual reality collaboration into a unified inspection pipeline. By leveraging data from sensors, machine instructions, and imaging, we created high-fidelity virtual models of manufactured parts that could be rapidly analyzed and certified. This approach was first demonstrated with Direct Ink Write, and then extended to other manufacturing settings, including conventional (or “subtractive”) manufacturing and to predict the end of life performance of parts per the aging and lifetimes programs. The result is a transformational capability: inspection times have been reduced by a factor of 120,000 without loss of accuracy and while simultaneously improving traceability and confidence in part quality. This framework not only streamlines certification for critical applications, but also positions the national security enterprise to respond more flexibly to emerging challenges, supporting agile manufacturing and digital engineering practices across a broad range of mission-relevant domains.

42 ENGINEERING↗

DOE OSTI2025

A structured framework for predicting sustainable aviation fuel properties using liquid-phase FTIR and machine learning

Sustainable aviation fuels have the potential to improve efficiency, reduce emissions, and enhance energy security. To help identify viable sustainable aviation fuels and accelerate research, machine learning models have been developed to predict relevant physicochemical properties. However, many models have limited applicability, leverage data from complex analytical techniques with confined spectral ranges, or use feature decomposition methods that offer limited interpretability. Using liquid-phase Fourier Transform Infrared (FTIR) spectra, this study presents a structured method for creating accurate and interpretable property prediction models for neat molecules, aviation fuels, and blends. Liquid FTIR spectra can be collected quickly and consistently, offering high reliability, sensitivity, and component specificity using less than 2 ml of sample. The method first decomposes FTIR spectra into fundamental building blocks using non-negative matrix factorization (NMF) to enable scientific analysis of FTIR spectra attributes and fuel properties. The NMF features are then used to create five ensemble models for predicting final boiling point, flash point, freezing point, density at 15°C, and kinematic viscosity at -20°C. All models were trained using experimental property data from neat molecules, aviation fuels, and blends. The models accurately predict key properties across a broad range of neat molecules and representative fuels and blends, while enabling interpretation of relationships between compositional elements, such as functional groups or chemical classes, and their resulting properties. This demonstrates strong potential to support sustainable aviation fuel research and development. The models and data are available on an interactive web tool.

Fourier transform infrared spectroscopy↗

NASA NTRS2001

Numerical Propulsion System Simulation: A Common Tool for Aerospace Propulsion Being Developed

The NASA Glenn Research Center is developing an advanced multidisciplinary analysis environment for aerospace propulsion systems called the Numerical Propulsion System Simulation (NPSS). This simulation is initially being used to support aeropropulsion in the analysis and design of aircraft engines. NPSS provides increased flexibility for the user, which reduces the total development time and cost. It is currently being extended to support the Aviation Safety Program and Advanced Space Transportation. NPSS focuses on the integration of multiple disciplines such as aerodynamics, structure, and heat transfer with numerical zooming on component codes. Zooming is the coupling of analyses at various levels of detail. NPSS development includes using the Common Object Request Broker Architecture (CORBA) in the NPSS Developer's Kit to facilitate collaborative engineering. The NPSS Developer's Kit will provide the tools to develop custom components and to use the CORBA capability for zooming to higher fidelity codes, coupling to multidiscipline codes, transmitting secure data, and distributing simulations across different platforms. These powerful capabilities will extend NPSS from a zero-dimensional simulation tool to a multifidelity, multidiscipline system-level simulation tool for the full life cycle of an engine.

Follen, Gregory J.↗

NASA NTRS2002

Compact Video Microscope Imaging System Implemented in Colloid Studies

Long description Photographs showing fiber-optic light source, microscope and charge-coupled discharge (CCD) camera head connected to camera body, CCD camera body feeding data to image acquisition board in PC, and Cartesian robot controlled via PC board. The Compact Microscope Imaging System (CMIS) is a diagnostic tool with intelligent controls for use in space, industrial, medical, and security applications. CMIS can be used in situ with a minimum amount of user intervention. This system can scan, find areas of interest in, focus on, and acquire images automatically. Many multiple-cell experiments require microscopy for in situ observations; this is feasible only with compact microscope systems. CMIS is a miniature machine vision system that combines intelligent image processing with remote control. The software also has a user-friendly interface, which can be used independently of the hardware for further post-experiment analysis. CMIS has been successfully developed in the SML Laboratory at the NASA Glenn Research Center and adapted for use for colloid studies and is available for telescience experiments. The main innovations this year are an improved interface, optimized algorithms, and the ability to control conventional full-sized microscopes in addition to compact microscopes. The CMIS software-hardware interface is being integrated into our SML Analysis package, which will be a robust general-purpose image-processing package that can handle over 100 space and industrial applications.

McDowell, Mark↗

DOE OSTI2025

Digital Droplet PCR and Mesocosm-Based Methods to Evaluate Biocontainment Strategies in a Native Soil Ecosystem

Genetically modified industrial production microbes and their associated bioproducts have emerged as an integral component of a sustainable bioeconomy. However, the rapid development of these innovative technologies raises biosecurity concerns, namely, the risk of environmental escape. Thus, the realization of a bioeconomy hinges not only on the development and deployment of microbial production hosts, but also on the development of secure biosystems and biocontainment designs. Current laboratory-based biocontainment testing systems do not accurately reflect the complexities found in natural environments, necessitating an environmentally relevant analysis pipeline that allows for the detection of rare escapees within a complex soil microbiome and differentiation between closely related strains. To this end, we have developed an approach that utilizes soil mesocosms and integrated digital droplet PCR (ddPCR) system to evaluate the efficacy of novel biocontainment strategies. We demonstrate the utility of this approach by modeling contamination with industrial microbial chasses versus their biocontained counterparts. Here we demonstrate the broad utility of this system by highlighting findings from strains of Saccharomyces cerevisiae that are contained with an inducible toxin anti-toxin system, strains of Synechocystis sp. PCC 6803 contained via gene knockout or toxin anti-toxin system, and strains of Escherichia coli that are contained via genomic recoding. We also show that ddPCR can be used to detect gene copies from E. coli equal to those counted by traditional spot plating assays. The resultant data demonstrates that this system has broad utility across diverse microbial chassis and biocontainment strategies and enables researchers to track the fate of our contaminating microbe with high sensitivity in the soil. The findings presented here support the use of this mesocosm-based approach to assess the environmental impact of industrial microbes and to validate biocontainment strategies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRSDate not supplied

NASA Open Science Data Repository: Maximizing Spaceflight Bioscience Data

The next era in human space exploration is rapidly approaching and will require the use of countermeasures to deep space health hazards. The development of countermeasures (or, the re-purposing of existing agents) will be highly dependent on our understanding of basic biological responses to space stressors (e.g. ionizing radiation, altered gravitational fields, altered day-night cycles, confinement, isolation, hostile-closed environments, distance-duration from Earth, exposure to celestial regolith, etc.). The fast-growing array of space biological data, which in the past was simply archived after minimal analysis, holds great potential if it can be reorganized and formatted for data re-analysis and re-use via Open Science. Organizing the data for such analysis is a challenge because of its diverse nature (molecular, cellular, tissue, imaging, whole organism and behavior). To address the challenges posed by gaining new knowledge from a vast and diverse amount of biological, health and environmental data in space, the NASA Open Science Data Repository (OSDR - osdr.nasa.gov/bio) plays a crucial role in curating and openly publishing biological data from space-related experiments. Its design incorporates successes and lessons from NASA GeneLab, encompassing not only high-throughput sequencing data but also physiological, phenotypic, and telemetry data. The OSDR makes space biological data FAIR (findable, accessible, interoperable, reusable), and facilitates effective data ingestion, dissemination, and Open Science collaborations. The OSDR also has the capability to integrate human astronaut data with state-of-the-art security and accessibility procedures. We will discuss here several strategies that NASA’s Biological and Physical Science Division have put in place to maximize the return on investment for spaceflight bioscience data.

space biology↗

DOE OSTI2024

Flexible operation of nuclear hybrid energy systems for load following and water desalination

Nuclear hybrid energy systems (NHES) have the potential to provide dependable and emission-free electricity to the grid while also increasing the flexibility and reliability of the electrical grid. Molten salt reactor (MSR) technology can provide consistent, carbon-free electricity while also increasing efficiency, security, and sustainability and reducing nuclear waste. This study investigates the integration of Molten Salt Reactors (MSR) and conventional Pressurized Water Reactors (PWR) with desalination technologies: Direct Contact Membrane Distillation (DCMD), Multi-Stage Flash Distillation (MSFD), and Reverse Osmosis (RO). Dynamic first-principles models were developed and tested using real grid data from the New York Independent System Operator. The results demonstrate that nuclear power is capable of flexibly responding to changing grid demand while simultaneously producing clean water, particularly during periods of low electricity demand. The MSR-RO system was found to be the most efficient in electricity generation and water production, and all hybrid systems reduced CO2 emissions by 356,000 to 682,000 tons annually. Economic analysis reveals that nuclear desalination technologies are cost-competitive with conventional systems, especially when paired with RO. Finally, these findings confirm the technical feasibility and environmental benefits of nuclear hybrid systems for sustainable electricity and water production.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS2013

A City and National Metric measuring Isolation from the Global Market for Food Security Assessment

The World Bank has invested in infrastructure in developing countries for decades. This investment aims to reduce the isolation of markets, reducing both seasonality and variability in food availability and food prices. Here we combine city market price data, global distance to port, and country infrastructure data to create a new Isolation Index for countries and cities around the world. Our index quantifies the isolation of a city from the global market. We demonstrate that an index built at the country level can be applied at a sub-national level to quantify city isolation. In doing so, we offer policy makers with an alternative metric to assess food insecurity. We compare our isolation index with other indices and economic data found in the literature.We show that our Index measures economic isolation regardless of economic stability using correlation and analysis

Brown, Molly E.↗

DOE OSTI2026

Cybersecurity Center for Offshore Wind Energy (Final Project Report)

This project establishes a Cybersecurity Center for Offshore Wind Energy with the objective of designing and operating a cyber-physical testbed for wind energy farms (WEFs) that enables comprehensive cybersecurity research. The testbed incorporates a Supervisory Control and Data Acquisition (SCADA) system connected to turbine models via industrial-grade programmable logic controllers (PLCs) and remote terminal units (RTUs). It supports side-channel data acquisition, implementation and analysis of various cyberattack scenarios, and development of attack detection, mitigation, and best-practice guidance tailored to wind energy systems. During the project, the team expanded the number and fidelity of mathematical turbine models (MTMs), integrated these models with SCADA infrastructure, and deployed a scaled physical turbine and associated sensors. High-resolution operational and side-channel data streams were collected and used to refine machine-learning (ML)-based attack detection systems and to extend the WindCRAFT framework to multi-turbine threat scenarios. The project demonstrated a realistic, scalable environment for evaluating cyber threats, validated attack detection approaches using enriched datasets, and identified new multi-turbine and inter-turbine communication attack vectors. The resulting testbed, models, and security mechanisms provide a foundation for ongoing R&D and deployment of cyber-resilient offshore wind energy systems.

17 WIND ENERGY↗

DOE OSTI2025

Comprehensive Evaluation of Agrivoltaics Research: Breadth, Depth, and Insights for Future Research

Agrivoltaics integrates agricultural production with solar energy generation to address challenges related to land use, food security, and renewable energy development. This study provides the most comprehensive evaluation to date of global agrivoltaic research, aiming to classify the literature, identify strengths and gaps, and guide future work. We systematically screened over 3000 English-language publications through 2023 for relevant agrivoltaic publications. A total of 670 studies were categorized in the InSPIRE Data Portal across five agrivoltaic activities and multiple hierarchical themes, including physical, biological, technological, social, and crosscutting domains. We found that research was concentrated on crop production, microclimate dynamics, and PV performance, with gaps in areas like human health, wildlife, policy, and standardized methodologies. Although the U.S. emphasizes animal grazing and habitat-based systems in practice, most U.S.-based studies focused disproportionately on crop production. The analysis revealed uneven geographic and topical representation and highlighted a lack of integrated, interdisciplinary approaches. This study concludes that while agrivoltaic research has grown rapidly, more coordinated efforts could support standardized data collection, address overlooked ecological and social impacts, and align research focus with real-world system implementation, ultimately improving the scalability and successful deployment of agrivoltaic systems.

14 SOLAR ENERGY↗

NASA NTRS2007

Simulating Operations at a Spaceport

SPACESIM is a computer program for detailed simulation of operations at a spaceport. SPACESIM is being developed to greatly improve existing spaceports and to aid in designing, building, and operating future spaceports, given that there is a worldwide trend in spaceport operations from very expensive, research- oriented launches to more frequent commercial launches. From an operational perspective, future spaceports are expected to resemble current airports and seaports, for which it is necessary to resolve issues of safety, security, efficient movement of machinery and people, cost effectiveness, timeliness, and maximizing effectiveness in utilization of resources. Simulations can be performed, for example, to (1) simultaneously analyze launches of reusable and expendable rockets and identify bottlenecks arising from competition for limited resources or (2) perform what-if scenario analyses to identify optimal scenarios prior to making large capital investments. SPACESIM includes an object-oriented discrete-event-simulation engine. (Discrete- event simulation has been used to assess processes at modern seaports.) The simulation engine is built upon the Java programming language for maximum portability. Extensible Markup Language (XML) is used for storage of data to enable industry-standard interchange of data with other software. A graphical user interface facilitates creation of scenarios and analysis of data.

Nevins, Michael R.↗

DOE OSTI2025

Real-World Cyber Security Demonstration for Networked Electric Drives

In this article, we present the design and implementation of a cyber-physical security testbed for networked electric drive systems, aimed at conducting real-world security demonstrations. To our knowledge, this is one of the first security testbeds for networked electric drives, seamlessly integrating the domains of power electronics and computer science, and cybersecurity. By doing so, the testbed offers a comprehensive platform to explore and understand the intricate and often complex interactions between cyber and physical systems. The core of our testbed consists of four electric machine drives, meticulously configured to emulate small-scale but realistic information technology (IT) and operational technology (OT) networks. This setup both provides a controlled environment for simulating a wide array of cyber-attacks, and mirrors potential real-world attack scenarios with a high degree of fidelity. The testbed serves as an invaluable resource for the study of cyber-physical security, offering a practical and dynamic platform for testing and validating cybersecurity measures in the context of networked electric drive systems. As a concrete example of the testbed's capabilities, we have developed and implemented a Python-based script designed to execute step-stone attacks over a wireless local area network (WLAN). This script leverages a sequence of target IP addresses, simulating a real-world attack vector that could be exploited by adversaries. To counteract such threats, we demonstrate the efficacy of our developed cyber-attack detection algorithms, which are integral to our testbed's security framework. Furthermore, the testbed incorporates a real-time visualization system using InfluxDB and Grafana, providing a dynamic and interactive representation of networked electric drives and their associated security monitoring mechanisms. This visualization component not only enhances the testbed's usability but also offers insightful, real-time data for researchers and practitioners, thereby facilitating a deeper understanding of cyber-physical security dynamics in networked electric drive systems.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Impact of light output on the timing resolution of organic glass scintillator bars in a dual-ended readout configuration

The effectiveness of detector system modeling and validation depends on the quality of characterization performed on the system. For nuclear nonproliferation applications, which require detectors to address complex and variable field conditions, access to accurate system models is essential. This study presents the timing characterization of organic glass scintillator bars used in an imaging system developed at the University of Michigan. 137 Cs and 60 Co gamma-ray sources were used to determine the coincidence time resolution as a function of measured light output for two Compton scatter events between two organic glass scintillator bars. Timing resolution for two events, each with light output ranging from 100 to 1100 keVee were characterized. The resulting data were fit to a parametric function that was validated to agree with experimental results within ±25 ps. Simulations were performed to establish appropriate calibration points for each organic scintillator, thereby ensuring accurate calibration of light output values during analysis. This work successfully characterized the light output dependence of the coincidence timing resolution of a pair of organic glass detectors for use in an imaging system. Depending on the amount of scintillation light output from the events, the full width at half maximum of the measured coincidence time resolution ranged from 653.2 ± 16.1 ps for low light yields, 100 keVee, to 121.0 ± 8.4 ps for higher yields at 1100 keVee. The insights obtained from the timing resolution behavior will allow for accurate simulation capabilities in future security and verification efforts using scatter-based imaging systems.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS2013

Mars Sample Return Using Commercial Capabilities: Mission Architecture Overview

Mars Sample Return (MSR) is the highest priority science mission for the next decade as recommended by the recent Decadal Survey of Planetary Science. This paper presents an overview of a feasibility study for a MSR mission. The objective of the study was to determine whether emerging commercial capabilities can be used to reduce the number of mission systems and launches required to return the samples, with the goal of reducing mission cost. The major element required for the MSR mission are described and include an integration of the emerging commercial capabilities with small spacecraft design techniques; new utilizations of traditional aerospace technologies; and recent technological developments. We report the feasibility of a complete and closed MSR mission design using the following scenario that covers three synodic launch opportunities, beginning with the 2022 opportunity: A Falcon Heavy injects a SpaceX Red Dragon capsule and trunk onto a Trans Mars Injection (TMI) trajectory. The capsule is modified to carry all the hardware needed to return samples collected on Mars including a Mars Ascent Vehicle (MAV); an Earth Return Vehicle (ERV); and hardware to transfer a sample collected in a previously landed rover mission to the ERV. The Red Dragon descends to land on the surface of Mars using Supersonic Retro Propulsion (SRP). After previously collected samples are transferred to the ERV, the single-stage MAV launches the ERV from the surface of Mars to a Mars phasing orbit. The MAV uses a storable liquid, pump fed bi-propellant propulsion system. After a brief phasing period, the ERV, which also uses a storable bi-propellant system, performs a Trans Earth Injection (TEI) burn. Once near Earth the ERV performs Earth and lunar swing-bys and is placed into a Lunar Trailing Orbit (LTO0 - an Earth orbit, at lunar distance. A later mission, using a Dragon and launched by a Falcon Heavy, performs a rendezvous with the ERV in the lunar trailing orbit, retrieves the sample container and breaks the chain of contact with Mars by transferring the sample into a sterile and secure container. With the sample contained, the retrieving spacecraft, makes a controlled Earth re-entry preventing any unintended release of pristine Martian materials into the Earth's biosphere. Other capsule type vehicles and associated launchers may be applicable. The analysis methods employed standard and specialized aerospace engineering tools. Mission system elements were analyzed with either direct techniques or by using parametric mass estimating relationships (MERs). The architecture was iterated until overall mission convergence was achieved on at least one path. Subsystems analyzed in this study include support structures, power system, nose fairing, thermal insulation, actuation devices, MAV exhaust venting, and GN&C. Best practice application of loads, mass growth contingencies, and resource margins were used. For Falcon Heavy capabilities and Dragon subsystems we utilized publically available data from SpaceX; published analyses from other sources; as well as our own engineering and aerodynamic estimates. Earth Launch mass is under 11 mt, which is within the estimated capability of a Falcon Heavy, with margin. Total entry masses between 7 and 10 mt were considered with closure occurring between 9 and 10 mt. Propellant mass fractions for each major phase of the EDL - Entry, Terminal Descent, and Hazard Avoidance - have been derived. An assessment of the entry conditions on the thermal protection system (TPS), currently in use for Dragon missions, has been made. And shows no significant stressors. A useful mass of 2.0 mt is provided and includes mass growth allowances for the MAV, the ERV, and mission unique equipment. We also report on alternate propellant options for the MAV and options for the ERV, including propulsion systems; crewed versus robotic retrieval mission; as well as direct Earth entry. International Planetary Protection Policies as well as verifiable means of compliance will have a large impact on any MSR mission design. We identify areas within our architecture where such impacts occur. This work shows that emerging commercial capabilities can be used to effectively integrated into a mission to achieve an important planetary science objective.

Mars Sample Return↗

NASA NTRS2004

Architecture and Functionality of the Advanced Life Support On-Line Project Information System

An ongoing effort is underway at NASA Ames Research Center (ARC) to develop an On-line Project Information System (OPIS) for the Advanced Life Support (ALS) Program. The objective of this three-year project is to develop, test, revise and deploy OPIS to enhance the quality of decision-making metrics and attainment of Program goals through improved knowledge sharing. OPIS will centrally locate detailed project information solicited from investigators on an annual basis and make it readily accessible by the ALS Community via a Web-accessible interface. The data will be stored in an object-oriented relational database (created in MySQL) located on a secure server at NASA ARC. OPE will simultaneously serve several functions, including being an research and technology development (R&TD) status information hub that can potentially serve as the primary annual reporting mechanism for ALS-funded projects. Using OPIS, ALS managers and element leads will be able to carry out informed R&TD investment decisions, and allow analysts to perform accurate systems evaluations. Additionally, the range and specificity of information solicited will serve to educate technology developers of programmatic needs. OPIS will collect comprehensive information from all ALS projects as well as highly detailed information specific to technology development in each ALS area (Waste, Water, Air, Biomass, Food, Thermal, Controls and Systems Analysis). Because the scope of needed information can vary dramatically between areas, element-specific technology information is being compiled with the aid of multiple specialized working groups. This paper presents the current development status in terms of the architecture and functionality of OPIS. Possible implementation approaches for OPIS are also discussed.

Hogan, John A.↗

DOE OSTI2024

Materials Characterization, Prediction, and Control Project: Characterization of 316L Stainless Steel after Solid Phase Processing using Ultrasonic NDE Method

The Pacific Northwest National Laboratory undertook the Materials Characterization, Prediction, and Control Laboratory Directed Research and Development Project to advance understanding of nuclear material processing and enable multifold acceleration in the development and qualification of new material systems produced via advanced manufacturing methods, such as solid phase processing, for use in national security and advanced energy applications (Smith 2021). A motivation of the Materials Characterization, Prediction, and Control Project was to demonstrate ultrasonic testing as a nondestructive evaluation method to complement traditional destructive methods for characterizing material microstructure with emphasis on grain size determination using a method that may have future applications for real-time inline process monitoring. The objective of the work described in this report is to establish the process and an analysis method for measuring grain sizes of polycrystalline metals with ultrafine grains using ultrasonic shear wave backscattering, building on prior studies on coarser-grained material. The work involves five tasks: Measured ultrasonic backscattering experimentally for a series of 316L stainless steel specimens with various grain sizes made by friction stir processing. Calculated ultrasonic backscattering coefficients from experimental data based on a physical measurement model. Measured ground truth grain sizes of the specimens from electron backscatter diffraction grain boundary images using a generalization of the ASTM E112 (ASTM 2021) intercept method. Built a curve of ultrasonic backscattering coefficients versus the ground truth intercept-based grain sizes to determine the correlation between mean grain sizes and ultrasonic measurements. Demonstrated the ability of using the correlation curve to deduce grain sizes with measured ultrasonic backscattering coefficients for a few 316L stainless steel specimens whose grain sizes were unknown beforehand but were targeted to be an extrapolation to larger grain sizes than used to formulate the correlation curves. Experimental procedures and computational algorithms are developed and validated for these tasks. This work establishes an ultrasonic technique for characterizing material microstructure with ultrafine grains that are often resulted by solid-phase processing. The technique is nondestructive, and it has the potential to be used for real time inline process monitoring. This work successfully demonstrates the viability of an ultrasonic nondestructive evaluation method for microstructural characterization of material having ultrafine grain structure (as small as 1?mm) and produced by an advanced manufacturing method. This includes a demonstration of the method to extrapolate to other conditions. While not demonstrated here, the method is expected to be viable for in-line, or near-inline, process monitoring in advanced manufacturing applications with suitable consideration for access of instrumentation to the material being manufactured.

316 L Stainless Steel↗