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All sources NASA NTRS DOE OSTI

DOE OSTI2023

(U) MIT Capstone Project (Final Report)

This capstone project focuses on modernizing the design development processes, production development processes, and communication between design agencies (DAs) and production agencies (PAs) to decrease the timeline from conceptual study to first production unit. To focus the scope, the researchers looked only at interactions between the DA, Lawrence Livermore National Lab (LLNL), and the PA, Kansas City National Security Campus (KCNSC). The project’s system problem statement (SPS) is: TO decrease the time from conceptual study to first production unit BY reducing the DA to-PA engineering interface complexity USING digital engineering software that centralizes product definition and information exchange protocols.

42 ENGINEERING↗

NASA NTRS1990

Design of a lunar oxygen production plant

To achieve permanent human presence and activity on the moon, oxygen is required for both life support and propulsion. Lunar oxygen production using resources existing on the moon will reduce or eliminate the need to transport liquid oxygen from earth. In addition, the co-products of oxygen production will provide metals, structural ceramics, and other volatile compounds. This will enable development of even greater self-sufficiency as the lunar outpost evolves. Ilmenite is the most abundant metal-oxide mineral in the lunar regolith. A process involving the reaction of ilmenite with hydrogen at 1000 C to produce water, followed by the electrolysis of this water to provide oxygen and recycle the hydrogen has been explored. The objective of this 1990 Summer Faculty Project was to design a lunar oxygen-production plant to provide 5 metric tons of liquid oxygen per year from lunar soil. The results of this study describe the size and mass of the equipment, the power needs, feedstock quantity and the engineering details of the plant.

Radhakrishnan, Ramalingam↗

NASA NTRS2005

Fabrication end Deployment Testing of Meter Solar Sail Quadrants for a Scaleable Square Solar Sail Ground Test System

In order for solar sail propulsion technologies to be considered as a viable option for a wide range of near term practical missions a predictable, stable, reliable, manufactureable, scaleable, and cost effective system must be developed and tested first on earth and then on orbit. The design and development of a Scaleable Square Solar Sail System (S^4) is well underway a t AEC-Able Engineering Co. Inc., and the design and production of the Solar Sails for this system is being carried out by SRS Technologies. In April and May of 2004 a single quadrant 10-meter system was tested at NASA LARC's vacuum chamber and a four quadrant 20-meter system has been designed and built for deployment and testing in the Spring of 2005 at NASA/Glenn Research Center's Plumb Brook Facility. SRS has developed an effective and efficient design for triangular sail quadrants that are supported are three points and provide a flat reflective surface with a high fill factor. This sail design is robust enough for deployments in a one atmosphere, one gravity environment and incorporates several advanced features including adhesiveless seaming of membrane strips, compliant edge borders to allow for film membrane cord strain mismatch without causing wrinkling and low mass (3% of total sail mass) ripstop. This paper will outline the sail design and fabrication process, the lessons learned and the resulting mature production, packaging and deployment processes that have been developed. It will also highlight the scalability of the equipment and processes that were developed to fabricate and package the sails. Based on recent experience, SRS is confidant that flight worthy solar sails in the 40-120-meter size range with areal density in the 4-5g/sq m (sail minus structure) range can be produced with existing technology. Additional film production research will lead to further reductions in film thickness to less than 1 micron enabling production of sails with areal densities as low as 20 g/sq m using the current design resulting in a system areal density of as low as 5.3g/sq m. These areal densities are low enough to allow nearly all of the Solar Sail missions that have been proposed by the scientific community and the fundamental technology required to produce these sails has been demonstrated on the ground test sails that have recently been built. These demonstrations have shown that the technology is mature enough to build sails needed to support critical science missions. Solar Sails will be an enabling technology for NASA's Vision for Space Exploration by allowing communication satellite orbits that can maintain continuous communication with the polar regions of the Moon and Mars and to support solar weather monitoring to provide early warning of solar flares and storms that could threaten the safety of astronauts and other spacecraft.

Laue, Greg↗

NASA NTRS1980

A mass reduction effort of the electric and hybrid vehicle

Weight reduction, cost competitiveness, and elimination of the intrusion beam resulted from the redesign and fabrication using composite materials of the door outer panel and intrusion beam from a Chevrolet Impala. The basis of the redesign involved replacing these two steel parts with a single compression molding using the unique approach of simultaneously curing a sheet molding compound outside panel with a continuous glass fiber intrusion strap. A weight reduction of nearly 11 pounds per door was achieved. Additional weight savings are possible by taking advantage of the elimination of the intrusion beam to design thinner door structures. The parts consolidation approach allows the composite structure to be cost competitive with the original steel design for both the lower production car models and for the near to midterm production vehicles using current state of the art composite production techniques. The design, prototype fabrication, costing, material, properties and compression molding production requirements are discussed.

Freeman, R. B.↗

NASA NTRS2012

Marshall Space Flight Center Materials and Processes Laboratory

Marshall?s Materials and Processes Laboratory has been a core capability for NASA for over fifty years. MSFC has a proven heritage and recognized expertise in materials and manufacturing that are essential to enable and sustain space exploration. Marshall provides a "systems-wise" capability for applied research, flight hardware development, and sustaining engineering. Our history of leadership and achievements in materials, manufacturing, and flight experiments includes Apollo, Skylab, Mir, Spacelab, Shuttle (Space Shuttle Main Engine, External Tank, Reusable Solid Rocket Motor, and Solid Rocket Booster), Hubble, Chandra, and the International Space Station. MSFC?s National Center for Advanced Manufacturing, NCAM, facilitates major M&P advanced manufacturing partnership activities with academia, industry and other local, state and federal government agencies. The Materials and Processes Laborato ry has principal competencies in metals, composites, ceramics, additive manufacturing, materials and process modeling and simulation, space environmental effects, non-destructive evaluation, and fracture and failure analysis provide products ranging from materials research in space to fully integrated solutions for large complex systems challenges. Marshall?s materials research, development and manufacturing capabilities assure that NASA and National missions have access to cutting-edge, cost-effective engineering design and production options that are frugal in using design margins and are verified as safe and reliable. These are all critical factors in both future mission success and affordability.

Tramel, Terri L.↗

DOE OSTI2020

Design Optimization of A generic Fissile Solution for Mo99 production using Electron Beam-based Neutron Generator using MCNP+CFD

Molybdenum-99 ( 99 Mo) is a medical isotope used in 80% of all medical imaging procedures today. However, 99 Mo is not directly administered to patients for imaging; its decay product, technetium-99m ( 99 mTc), is a metastable isotope with a half-life of ~6 hours. Such a short half-life does not allow for production, separation, and application to a patient before decaying further. Therefore, the solution is to produce the precursor to 99 mTc, 99 Mo. 99 Mo has a half-life of 66 hours, long enough to produce the material and send it to the desired location before it fully decays. Under National Nuclear Security Administration’s (NNSA) highly enriched uranium (HEU) minimization mission, the Material Management and Minimization (M3) office leads the Molybdenum-99 (Mo-99) program. A major goal of the Mo-99 program is to develop methods of producing 99 Mo using low enriched uranium (LEU) opposed to the traditionally used HEU domestically in the U.S. Internationally, LEU is the new standard for use in research reactors and isotope production facility. In this study, we introduce a generic fissile solution system for 99 Mo production facility meeting the design requirement of 1) LEU usage as fissile material and 2) subcritical fissile system coupled with a horizontal electron beam (E-beam) accelerator. The focus of this research is to optimize a fissile solution configuration for maximum 99 Mo production yield using MCNP model, and ultimately implement the optimized design with computational fluid dynamics (CFD) model to understand thermal hydraulic behavior and solution convection characteristic. The report consists of two parts: 1) isotope yield calculation and criticality analysis with a wide range of parametric test matrix, and 2) thermal hydraulic analysis for solution mixing and cooling assessment.

60 APPLIED LIFE SCIENCES↗

NASA NTRS1991

National research and education network

Some goals of this network are as follows: Extend U.S. technological leadership in high performance computing and computer communications; Provide wide dissemination and application of the technologies both to the speed and the pace of innovation and to serve the national economy, national security, education, and the global environment; and Spur gains in the U.S. productivity and industrial competitiveness by making high performance computing and networking technologies an integral part of the design and production process. Strategies for achieving these goals are as follows: Support solutions to important scientific and technical challenges through a vigorous R and D effort; Reduce the uncertainties to industry for R and D and use of this technology through increased cooperation between government, industry, and universities and by the continued use of government and government funded facilities as a prototype user for early commercial HPCC products; and Support underlying research, network, and computational infrastructures on which U.S. high performance computing technology is based.

Villasenor, Tony↗

NASA NTRS1996

RADARSAT Processing System at ASF

This paper outlines the ASF (Alaska SAR[synthetic aperture radar] Facility) Radarsat data processing requirements as driven by the science users and describes the Radarsat processing system design and implementaiton approach to meet the challenge of providing ASF with and integrated operational SAR image production facility. Design and implementation attributes that facilitate syswtem growth in handling future SAR missions such as Envisat and HIROS are also addressed.

ASF↗

DOE OSTI2025

Glass-Bonded Monazite Waste Forms for Lanthanide and Actinide Immobilization: From Theoretical Design to Scale-Up Production and Characterization

The development of nuclear waste forms for both existing and future nuclear wastes is critical to ensuring global environmental safety. This study focuses on waste management from molten salt reactors, where fuel exists in a salt form and could be processed in real time for the removal of neutron poisons such as xenon isotopes (e.g., 135 Xe) and rare earth elements (REEs, e.g., 149 Sm). To ensure safe, stable, and long-term disposal in geological repositories, REEs must be incorporated into a durable waste form. Iron-phosphate glasses are a promising candidate due to their low melting points, high chemical durability, and their ability to incorporate high concentrations of REEs. In this study, we successfully prepared iron-phosphate glass waste forms with high Nd loadings (up to 37 mass %) in batch sizes ranging from small (23 g) to large (1600 g). The resulting materials contained up to 75 mass % NdPO 4 , contributing to their mechanical resilience and exceptional chemical durability. These findings highlight the potential of iron-phosphate glasses as high-efficiency, chemically durable waste forms and demonstrate the successful transition from theoretical design to scaled-up production.

amorphous materials↗

DOE OSTI2020

High-Throughput Functional Genomics for Energy Production

Functional genomics remains a foundational field for establishing genotype-phenotype relationships that enable strain engineering. High-throughput (HTP) methods accelerate the Design-Build-Test-Learn cycle that currently drives synthetic biology towards a forward engineering future. Trackable mutagenesis techniques including transposon insertion sequencing and CRISPR-Cas-mediated genome editing allow for rapid fitness profiling of a collection, or library, of mutants to discover beneficial mutations. Due to the relative speed of these experiments compared to adaptive evolution experiments, iterative rounds of mutagenesis can be implemented for next-generation metabolic engineering efforts to design complex production and tolerance phenotypes. Further, the expansion of these mutagenesis techniques to novel bacteria are opening up industrial microbes that show promise for establishing a bio-based economy.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS1996

Miniature rotary actuator

The trend toward smaller satellites has challenged component manufacturers to reduce the size, weight, and cost of their products while maintaining high performance. Both a new stepper motor and a new harmonic drive were developed to meet this need. The resulting actuator embodies small angle stepper technology usually reserved for larger units and incorporates an integral approach to harmonic drive design. By product simplifications, costs were significantly reduced over prior designs.

Fink, R. A.↗

DOE OSTI2020

Long-Term PCT of ILAW Glasses (Final Report FY2020)

About 50 million gallons of high-level mixed waste is currently stored in underground tanks at The United States Department of Energy’s (DOE’s) Hanford site in the State of Washington. The Hanford Tank Waste Treatment and Immobilization Plant (WTP) will provide DOE’s Office of River Protection (ORP) with a means of treating this waste by vitrification for subsequent disposal. The tank waste will be separated into low- and high-activity waste fractions, which will then be vitrified respectively into Immobilized Low Activity Waste (ILAW) and Immobilized High Level Waste (IHLW) products. The ILAW product will be disposed in a near-surface engineered facility – the Integrated Disposal Facility (IDF) – on the Hanford site, while the IHLW product is designed for deep geological disposal in a national facility for high-level nuclear waste. The ILAW and IHLW products must meet a variety of requirements with respect to protection of the environment before they can be accepted for disposal. The objective of the work described in this report is to perform testing, data collection, and analyses for the ILAW glass product for subsequent use in the performance assessment (PA) of the IDF to assess potential environmental risks associated with long-term storage.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

FY2021 Long-Term PCT of ILAW Glasses

Approximately 54 to 56 million gallons of radioactive waste is currently stored in underground tanks at The United States Department of Energy’s (DOE’s) Hanford site in the State of Washington. The Hanford Tank Waste Treatment and Immobilization Plant (WTP) will provide DOE’s Office of River Protection (ORP) with a means of treating this waste by vitrification for subsequent disposal. The tank waste will be separated into low- and high-activity waste fractions, which will then be vitrified respectively into Immobilized Low Activity Waste (ILAW) and Immobilized High Level Waste (IHLW) products. The ILAW product will be disposed in a near-surface engineered facility – the Integrated Disposal Facility (IDF) – on the Hanford site, while the IHLW product is designed for deep geological disposal in a national facility for high-level nuclear waste. The ILAW and IHLW products must meet a variety of requirements with respect to protection of the environment before they can be accepted for disposal. The objective of the work described in this report is to perform testing, data collection, and analyses for the ILAW glass product for subsequent use in the performance assessment (PA) of the IDF to assess potential environmental risks associated with long-term storage.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS1990

Space Transportation Avionics Technology Symposium. Volume 1: Executive summary

The focus of the symposium was to examine existing and planned avionics technology processes and products and to recommend necessary changes for strengthening priorities and program emphases. Innovative changes in avionics technology development and design processes, identified during the symposium, are needed to support the increasingly complex, multi-vehicle, integrated, autonomous space-based systems. Key technology advances make such a major initiative viable at this time: digital processing capabilities, integrated on-board test/checkout methods, easily reconfigurable laboratories, and software design and production techniques.

Source record↗

NASA NTRS1990

Space Transportation Avionics Technology Symposium. Volume 2: Conference Proceedings

The focus of the symposium was to examine existing and planned avionics technology processes and products and to recommend necessary changes for strengthening priorities and program emphases. Innovative changes in avionics technology development and design processes are needed to support the increasingly complex, multi-vehicle, integrated, autonomous space-based systems. Key technology advances make such a major initiative viable at this time: digital processing capabilities, integrated on-board test/checkout methods, easily reconfigurable laboratories, and software design and production techniques.

Source record↗

DOE OSTI2021

Integration of proteomics and metabolomics into the Design, Build, Test, Learn cycle to improve 3-hydroxypropionic acid production in Aspergillus pseudoterreus

Biological engineering of microorganisms to produce value-added chemicals is a promising route to sustainable manufacturing. However, overproduction of metabolic intermediates at high titer, rate, and yield from inexpensive substrates is challenging in non-model systems where limited information is available regarding metabolic flux and its control in production conditions. Integrated multi-omic analyses of engineered strains offers an in-depth look at metabolites and proteins directly involved in growth and production of target and non-target bioproducts. Here we applied multi-omic analyses to overproduction of the polymer precursor 3-hydroxypropionic acid (3HP) in the filamentous fungus Aspergillus pseudoterreus. A synthetic pathway consisting of aspartate decarboxylase, beta-alanine pyruvate transaminase, and 3HP dehydrogenase was designed and built for A. pseudoterreus. Strains with single- and multi-copy integration events were isolated and multi-omics analysis consisting of intracellular and extracellular metabolomics and targeted and global proteomics was used to interrogate the strains in shake-flask and bioreactor conditions. Production of a variety of co-products (organic acids and glycerol) and oxidative degradation of 3HP were identified as metabolic pathways competing with 3HP production. Intracellular accumulation of nitrogen as 2,4-diaminobutanoate was identified as an off-target nitrogen sink that may also limit flux through the engineered 3HP pathway. Elimination of the high-expression oxidative 3HP degradation pathway by deletion of a putative malonate semialdehyde dehydrogenase improved the yield of 3HP by 3.4× after 10 days in shake-flask culture. This is the first report of 3HP production in a filamentous fungus amenable to industrial scale biomanufacturing of organic acids at high titer and low pH.

Pomraning, Kyle R.↗

DOE OSTI2024

Mu2e experiment: Simulation of the Production Target

The Mu2e experiment will search for coherent, neutrinoless conversion of muons to elections in an aluminum stopping target. A simulation program is used to experiment and design the production target of the Mu2e experiment. The module uses programing languages and libraries to work. The program called the Offline uses C++ as the programing language in the module. To construct the simulation, the Geant4 library constructs shapes and uses them in the simulation program, ROOT. The offline program simplifies the creation of the tube by organizing them into parameter objects and nesting them with other variables required to construct the tube-like center point, material, or if it is allowed to conflict with other solids. The parameter varies for every solid tube. The geometry file uploads the parameters by declaring and organizing the parameters in C++ using the configuration tools. The author describes the development and the future of this project.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Mu2e experiment: Simulation of the Production Target

Szewczyk, Albert↗