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NASA NTRS1998

Development and Testing of Automatically Generated ACS Flight Software for the MAP Spacecraft

By integrating the attitude determination and control system (ACS) analysis and design, flight software development, and flight software testing processes, it is possible to improve the overall spacecraft development cycle, as well as allow for more thorough software testing. One of the ways to achieve this integration is to use code-generation tools to automatically generate components of the ACS flight software directly from a high-fidelity (HiFi) simulation. In the development of the Microwave Anisotropy Probe (MAP) spacecraft, currently underway at the NASA Goddard Space Flight Center, approximately 1/3 of the ACS flight software was automatically generated. In this paper, we will examine each phase of the ACS subsystem and flight software design life cycle: analysis, design, and testing. In the analysis phase, we scoped how much software we would automatically generate and created the initial interface. The design phase included parallel development of the HiFi simulation and the hand-coded flight software components. Everything came together in the test phase, in which the flight software was tested, using results from the HiFi simulation as one of the bases of comparison for testing. Because parts of the spacecraft HiFi simulation were converted into flight software, more care needed to be put into its development and configuration control to support both the HiFi simulation and flight software. The components of the HiFi simulation from which code was generated needed to be designed based on the fact that they would become flight software. This process involved such considerations as protecting against mathematical exceptions, using acceptable module and parameter naming conventions, and using an input/output interface compatible with the rest of the flight software. Maintaining good configuration control was an issue for the HiFi simulation and the flight software, and a way to track the two systems was devised. Finally, an integrated test approach was devised to support flight software testing at both the unit- and build-test levels using the HiFi simulation to generate data for performance verification. Another benefit of the simulation and code-generation application used on the MAP project is that it supported bringing flight software and test data into the HiFi simulation environment. It was possible to integrate parts of the hand-coded flight software into the HiFi simulation, and also possible to import flight software test data for comparison and performance verification. This capability was used to incorporate the flight software Kalman filter into the HiFi simulation. This enabled us to greatly increase the amount of testing that could be done on the filter, because we could exert a greater degree of control over the software-only simulation than over the flight software test environment. Also, since the simulation could be used to run the Kalman filter faster than real time, our testing efficiency was greatly increased. We will conclude our discussion with a summary of the lessons learned thus far using automatically- generated code for the MAP project, and the spacecraft status as we work towards our scheduled launch in the year 2000.

ODonnell, James R., Jr.↗

NASA NTRS1990

Development Status: Automation Advanced Development Space Station Freedom Electric Power System

Electric power system automation for Space Station Freedom is intended to operate in a loop. Data from the power system is used for diagnosis and security analysis to generate Operations Management System (OMS) requests, which are sent to an arbiter, which sends a plan to a commander generator connected to the electric power system. This viewgraph presentation profiles automation software for diagnosis, scheduling, and constraint interfaces, and simulation to support automation development. The automation development process is diagrammed, and the process of creating Ada and ART versions of the automation software is described.

Dolce, James L.↗

NASA NTRS2004

Space Network Devices Developed

The NASA Glenn Research Center through a contract with Spectrum Astro, Inc., has been developing space network hardware as an enabling technology using open systems interconnect (OSI) standards for space-based communications applications. The OSI standard is a well-recognized layered reference model that specifies how data should be sent node to node in a communications network. Because of this research and technology development, a space-qualifiable Ethernet-based network interface card (similar to the type found in a networked personal computer) and the associated four-port hub were designed and developed to flight specifications. During this research and development, there also have been many lessons learned for determining approaches for migrating existing spacecraft architectures to an OSI-network-based platform. Industry has recognized the benefits of targeting hardware developed around OSI standards such as Transmission Control Protocol/Internet Protocol (TCP/IP) or similar protocols for use in future generations of space communication systems. Some of these tangible benefits include overall reductions in mission schedule and cost and in system complexity. This development also brings us a step closer to the realization of a principal investigator on a terrestrial Internet site being able to interact with space platform assets in near real time. To develop this hardware, Spectrum Astro first conducted a technology analysis of alternatives study. For this analysis, they looked at the features of three protocol specifications: Ethernet (IEEE 802.3), Firewire (IEEE 1394), and Spacewire (IEEE 1355). A thorough analysis was performed on the basis of criteria such as current protocol performance and suitability for future space applications. Spectrum Astro also projected future influences such as cost, hardware and software availability, throughput performance, and integration procedures for current and transitive space architectures. After a thorough analysis, Ethernet was chosen because it was seen as the best longer term fit because of the prevalent commercial market; the current and projected availability of hardware, software, and development tools; and the ease of architecture integration.

Jones, Robert E.↗

NASA NTRSDate not supplied

Characterizing Effects of Potential Build Induced Artifacts in L-PBF Components

Additive manufacture (AM) is utilized for rocket engine component production. Witness marks are visible lines across the surface of an AM part that result from variation in build process. Witness marks have been used as justification to scrap a part with little to no evidence. The probability of witness mark occurrence is relatively high and greatly increases AM part production costs and schedule risks. The objective of this study was to quantify the impact of witness marks generated by intentional build pauses and characterize functional characteristics of the AM components. CT, μ-CT, metallographic, and mechanical test results indicate that witness marks are a surface phenomenon that do not propagate into the bulk of a part and had no statistically significant change on microstructure or properties in AlSi10Mg.

Omar R Mireles↗

DOE OSTI2020

STOCHASTIC OPTIMIZATION FOR LONG TERM CAPITAL STRUCTURES, SYSTEMS, AND COMPONENTS REFURBISHMENT AND REPLACEMENT

As commercial nuclear power plants (NPPs) pursue extended plant operations in the form of Second License Renewals (SLRs), opportunities exist for these plants to provide capital investments to ensure long-term, safe, and economic performance. Several utilities have already announced their intention to pursue extended operations for one or more of their NPPs via SLR2. The goal of this research is to develop a riskinformed approach to evaluate and prioritize plant capital investments made in preparation for, and during the period of, extended plant operations to support decisions in NPP operations. In order to prioritize project selection via a riskinformed approach we developed a single decision-making tool that integrates safety/reliability, cost, and stochastic optimization models to provide users with data analysis capabilities to more cost effectively manage plant assets. Both stochastic analysis methods—such as Monte Carlo-based sampling strategies—and multi-stage stochastic optimization strategies are employed to provide priority lists to decisionmakers in support of risk-informed decisions. We applied the proposed method to a trial application of projected replacement/refurbishment expenditures for plant capital assets (i.e., Structures, Systems, and Components [SSCs]). The objective is to optimize the SSC replacement/refurbishment schedule in terms of economic constraints, data uncertainties, and SSC reliability data, as well to generate a priority list for maximizing returns on investment.

42 ENGINEERING↗

NASA NTRS2016

Analysis of CrIS ATMS and AIRS AMSU Data Using Scientifically Equivalent Retrieval Algorithms

Monthly mean August 2014 Version-6.28 AIRS and CrIS products agree well with OMPS and CERES, and reasonably well with each other. Version-6.28 CrIS total precipitable water is biased dry compared to AIRS. AIRS and CrIS Version-6.36 water vapor products are both improved compared to Version-6.28. Version-6.36 AIRS and CrIS total precipitable water also shows improved agreement with each other. AIRS Version-6.36 total ozone agrees even better with OMPS than does AIRS Version-6.28, and gives reasonable results during polar winter where OMPS does not generate products. CrIS and ATMS are high spectral resolution IR and Microwave atmospheric sounders currently flying on the SNPP satellite, and are also scheduled for flight on future NPOESS satellites. CrIS/ATMS have similar sounding capabilities to those of the AIRS/AMSU sounder suite flying on EOS Aqua. The objective of this research is to develop and implement scientifically equivalent AIRS/AMSU and CrIS/ATMS retrieval algorithms with the goal of generating a continuous data record of AIRS/AMSU and CrIS/ATMS level-3 data products with a seamless transition between them in time. To achieve this, monthly mean AIRS/AMSU and CrIS/ATMS retrieved products, and more importantly their interannual differences, should show excellent agreement with each other. The currently operational AIRS Science Team Version-6 retrieval algorithm has generated 14 years of level-3 data products. A scientifically improved AIRS Version-7 retrieval algorithm is expected to become operational in 2017. We see significant improvements in water vapor and ozone in Version-7 retrieval methodology compared to Version-6.We are working toward finalization and implementation of scientifically equivalent AIRS/AMSU and CrIS/ATMS Version-7 retrieval algorithms to be used for the eventual processing of all AIRS/AMSU and CrIS/ATMS data. The latest version of our retrieval algorithm is Verison-6.36, which includes almost all the improvements we want in Version-7. Version-6.28 has been used to process both AIRS and CrIS data for August 2014. This poster compares August 2014 monthly mean Version-6.28 AIRS/AMSU and CrIS/ATMS products with each other, and also with monthly mean products obtained using AIRS Version-6. AIRS and CrIS results using Version-6.36 are presented for April 15, 2016. These demonstrate further improvements since Version-6.28. The new results also show improved agreement of Version-6.36 AIRS and CrIS products with each other. Version-6.36 is not yet optimized for CrIS ozone products.

AIRS↗

DOE OSTI2022

Nuclear Waste Attributes of SMRs Scheduled for Near-Term Deployment

The purpose of this study is to evaluate the nuclear waste attributes of Small Modular Reactors (SMRs) scheduled for deployment within this decade using available data and established nuclear waste metrics, with the results compared to a reference large Pressurized Water Reactor (PWR). The current fleet of commercial nuclear reactors in the U.S. is composed of 92 large Light Water Reactors (LWR) with an average electricity generating capacity of over 1,000 MWe each. These large LWRs built on-site in massive construction projects have been the mainstay of the industry for the last 50 years. However, new construction soon is expected to include several designs of smaller reactors primarily fabricated in factories and installed in the field in modules. Some of these SMRs will also be LWRs, while some will use other coolants such as liquid metals, molten salts or gases, and different types of fuels. The technologies and economics of SMRs have been the focus of many studies, but there has been only minimal information published on the amount of nuclear waste different types of SMRs are expected to generate and no reports focused on near-term-deployable designs. In this study, the nuclear waste attributes of three small reactors scheduled for near-term-deployment, VOYGR TM (from NuScale Power), Natrium TM ab (from TerraPower), and Xe-100 (from X-energy), were assessed by comparing nuclear waste metrics with those of a reference large Pressurized Water Reactor (PWR).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Factors Impacting Nuclear Energy Share in U.S. Energy Markets

The purpose of this report is to collate information and findings from recent studies conducted by national and international bodies/institutes to identify approaches for maintaining/enhancing the role of nuclear energy in the current and future energy mix of the United States. This report shows how nuclear generation grew quickly to provide 20% of U.S. electricity, sustaining that level for three decades without the benefit of new construction, but is now projected to decline going forward. Nuclear construction costs in the U.S. spiraled out of control, ending construction for two decades and the recent resumption of construction has continued the pattern of schedule delays and cost overruns. However, nuclear operations exhibited strong learning, achieving and sustaining the highest capacity factor of any electricity generation technology and license extensions and uprates have sustained nuclear market share. The share of nuclear energy in the U.S. electricity market is projected to decline by ~1/3rd over the next 30 years The report provides an overview of how the markets work in theory and in practice. It indicates how market deregulation and clean energy policies have created conditions where nuclear plants are being retired for economic rather than technical reasons. The report also shows how many of the markets do not in practice have free competition but instead have outcomes that are being determined more and more by policy instead of market forces. While electricity costs from existing nuclear plants are low, electricity from new builds is projected to be too expensive to be competitive head-to-head with natural gas, even for nth-of-a-kind costs. Wind and solar energy have enjoyed an extended period of sustained subsidy. This protected environment has resulted in a sustained reduction in plant level costs to the point that some of these Variable Renewable Energy (VRE) technologies are becoming competitive even if their direct subsidies are removed. But plant level costs underestimate total VRE costs which include a number of system-level externalities. The incremental system value of additional VRE capacity was shown to decline as market share increases, with solar value declining more quickly than wind. The report closes with examination of a possible future for nuclear generation as part of deep decarbonization of the electricity sector. This approach avoids direct competition with natural gas. The two options for achieving 100% decarbonization are to use only renewables or to use all zero emissions technologies, and the report shows the second approach is much less expensive than the first.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS1972

Astronomy sortie missions definition study. Volume 4: Program development requirements

Program development requirements for the selected Astronomy Sortie Missions concept were generated and are presented in four parts as follows: (1)the gross planning requirements that must be considered in subsequent phases of the project; (2)the schedules and logic networks for the design, development, and operation of the overall project; (3)the supporting research and technology required to support the project; and (4)the work breakdown data, from which cost data will be generated. Data reported in each part includes the appropriate rationale with explanations of the guidelines and assumptions that were used in the analyses and estimates.

Source record↗

DOE OSTI2024

Preventive Power Outage Estimation Based on A Novel Scenario Clustering Strategy: Preprint

The increasing occurrence of extreme weather events is challenging the power grid operation. In front of the extreme weather, the system operator is responsible for estimating the power outage and scheduling the restoration resources. This paper proposes an outage evaluation framework to identify the possible unserved load profiles, vulnerable areas, and mobile energy adequacy. The predicted vulnerable lines of an outage prediction model tool are utilized to generate numerous faulted line scenarios. Next, each scenario's nodal unserved load profile is obtained by solving a three-phase restoration model that considers the schedule of repair crews and mobile energy resources. Then, a novel scenario clustering strategy is developed to cluster the unserved load profiles into multiple representative ones for straightforward analysis. Finally, case studies on a distribution system evaluate the damage level brought by extreme weather and verify the effectiveness of the proposed scenario clustering strategy.

mobile energy resources↗

DOE OSTI2021

Secured Reserve Scheduling of Pumped-Storage Hydropower Plants in ISO Day-ahead Market

Due to the fast response ability and high ramping rates, pumped-storage hydropower (PSH) plants are playing an increasingly critical role in mitigating power generation fluctuations induced by the growing proliferation of renewable energy resources. However, because they are energy-limited resources, actual reserve deployment from PSHs would cause the deviation of state-of-charge (SOC) from the scheduled value, which, once accumulated over time, could induce potential violations on SOC limits and cause non-dispatchability of PSHs. In recognizing this potential issue, it can become important to securing the reserve schedule of PSHs and other energy limited resources preventively in the day-ahead market clearing. To ensure reserve dispatchability of PSHs despite SOC deviations, this paper proposes the reserve secure constraints, which are cast as a distributionally robust chance-constrained formulation by judiciously introducing random parameters to describe deployment ratios of scheduled regulation reserve from PSHs. Furthermore, these constraints are converted into tractable second-order cone constraints, and further approximated as linear constraints to be compatible with the current ISO day-ahead market clearing model. A modified IEEE 118-bus system with multiple PSHs is adopted to verify the proposed approach.

13 HYDRO ENERGY↗

NASA NTRS2018

Performance Evaluation of Conflict-Free Trajectory Taxiing in Airport Ramp Area Using Fast-Time Simulations

The German Aerospace Center (DLR) and the National Aeronautics and Space Administration (NASA) have been collaborating to conduct joint research addressing future surface traffic management challenges. The surface management tool from DLR, called Taxi Routing for Aircraft: Creation and Controlling (TRACC), was adapted to be integrated in NASA's fast-time simulation environment called Surface Operations Simulator and Scheduler (SOSS). The research described in this paper 1) applied TRACC to trajectory-based ramp traffic management, where TRACC generates conflict-free aircraft trajectories in a congested ramp area, 2) investigated the feasibility of the concept through the integrated TRACC-SOSS fast-time simulation, and 3) evaluated the performance of the integrated system. For this activity, TRACC was adapted for ramp operations at Charlotte Douglas International Airport, called TRACC_PB (TRACC for pushback optimization). TRACC_PB provides four-dimensional taxi trajectories with a command speed profile for each aircraft following standard taxi routes within the ramp area. In this study, departures are given the Target Movement Area entry Times (TMATs) provided by the baseline surface metering scheduler based on NASA's Spot and Runway Departure Advisor (SARDA). TRACC_PB also calculates optimal pushback times for departures, as well as the times when arrivals shall enter the ramp, the Target Movement area Exit Times (TMETs). The initial results showed that the TRACC_PB successfully generated conflict-free trajectories for the ramp area taxi operations and improved taxiing efficiency compared to the baseline results. TRACC_PB aimed to provide conflict-free taxi routes avoiding any stops while taxiing. This resulted in longer gate hold times for departures and postponed throughput values compared to the baseline simulation without trajectory optimization. Having conflict-free routes without stoppage also created shorter taxi times but required renegotiation of the given TMATs. TRACC_PB also achieved reductions in both fuel consumption and engine emissions (17% for departures and 10% for arrivals), which correlate with the ramp taxi time reduction.

trajectory-based taxi operations↗

NASA NTRS2007

Automatic Command Sequence Generation

Automatic Sequence Generator (Autogen) Version 3.0 software automatically generates command sequences for the Mars Reconnaissance Orbiter (MRO) and several other JPL spacecraft operated by the multi-mission support team. Autogen uses standard JPL sequencing tools like APGEN, ASP, SEQGEN, and the DOM database to automate the generation of uplink command products, Spacecraft Command Message Format (SCMF) files, and the corresponding ground command products, DSN Keywords Files (DKF). Autogen supports all the major multi-mission mission phases including the cruise, aerobraking, mapping/science, and relay mission phases. Autogen is a Perl script, which functions within the mission operations UNIX environment. It consists of two parts: a set of model files and the autogen Perl script. Autogen encodes the behaviors of the system into a model and encodes algorithms for context sensitive customizations of the modeled behaviors. The model includes knowledge of different mission phases and how the resultant command products must differ for these phases. The executable software portion of Autogen, automates the setup and use of APGEN for constructing a spacecraft activity sequence file (SASF). The setup includes file retrieval through the DOM (Distributed Object Manager), an object database used to store project files. This step retrieves all the needed input files for generating the command products. Depending on the mission phase, Autogen also uses the ASP (Automated Sequence Processor) and SEQGEN to generate the command product sent to the spacecraft. Autogen also provides the means for customizing sequences through the use of configuration files. By automating the majority of the sequencing generation process, Autogen eliminates many sequence generation errors commonly introduced by manually constructing spacecraft command sequences. Through the layering of commands into the sequence by a series of scheduling algorithms, users are able to rapidly and reliably construct the desired uplink command products. With the aid of Autogen, sequences may be produced in a matter of hours instead of weeks, with a significant reduction in the number of people on the sequence team. As a result, the uplink product generation process is significantly streamlined and mission risk is significantly reduced. Autogen is used for operations of MRO, Mars Global Surveyor (MGS), Mars Exploration Rover (MER), Mars Odyssey, and will be used for operations of Phoenix. Autogen Version 3.0 is the operational version of Autogen including the MRO adaptation for the cruise mission phase, and was also used for development of the aerobraking and mapping mission phases for MRO.

Fisher, Forest↗

NASA NTRS1987

TDRS Ku band gateway

The Wideband Transport Frame Formatter (WTFF) is the tracking and data relay satellite (TDRS) ku-band return link gateway. The WTFF system is a multiplexing device developed to process and downlink the high rate data generated by a wide variety of users. The WTFF is designed to frame and format high data rate user channels into transport frames and multiplex according to a predefined schedule into two bit streams that are compatible with TDRS Ku I and Q band service. The combined data rate will be 300 Mbps. The WTFF will service up to eight input channels generating data in the range of 10 to 150 Mbps. In addition to these input channels, audio data will be accepted by the WTFF system and inserted in the downlink. A second function of the WTFF is to provide telecommunication coding as assigned to each virtual channel to ensure a given quality of service.

Collins, Cynthia↗

DOE OSTI2025

Computational Performance Bounds Prediction in Quantum Computing With Unstable Noise

Quantum computing has significantly advanced in recent years, boasting devices with hundreds of quantum bits (qubits), hinting at its potential quantum advantage over classical computing. Yet, noise in quantum devices poses significant barriers to realizing this supremacy. Understanding noise’s impact is crucial for reproducibility and application reuse; moreover, the next-generation quantum-centric supercomputing essentially requires efficient and accurate noise characterization to support system management (e.g., job scheduling), where ensuring correct functional performance (i.e., fidelity) of jobs on available quantum devices can even be higher-priority than traditional objectives. However, noise fluctuates over time, even on the same quantum device, which makes predicting the computational bounds for on-the-fly noise is vital. Noisy quantum simulation can offer insights but faces efficiency and scalability issues. Here, in this work, we propose a data-driven workflow, namely QuBound, to predict computational performance bounds. It decomposes historical performance traces to isolate noise sources and devises a novel encoder to embed circuit and noise information processed by a Long Short-Term Memory (LSTM) network. For evaluation, we compare QuBound with a state-of-the-art learning-based predictor, which only generates a single performance value instead of a bound. Experimental results show that the result of the existing approach falls outside of performance bounds, while all predictions from our QuBound with the assistance of performance decomposition better fit the bounds. Moreover, QuBound can efficiently produce practical bounds for various circuits with over 106 speedup over simulation; in addition, the range from QuBound is over 10× narrower than the state-of-the-art analytical approach.

Li, Jinyang [George Mason Univ., Fairfax, VA (Unit↗

DOE OSTI2021

Preparing Distribution Utilities for the Future - Unlocking Demand-Side Management Potential: A Novel Analytical Framework

The balance of supply and demand in the power systems has traditionally been served solely through generation and network capacity planning and operations. However, with increased requirements for flexibility due to the uptake in variable renewable generation sources such as wind and solar there is a need to increased demand-side flexibility. In addition, there are increased communications and flexibility capabilities emerging on the demand-side from the adoption of advanced metering infrastructures and smart meter deployment and intelligent loads such as smart thermostats and schedulable white goods (e.g. dishwashers and washing machines). Unlocking demand-side flexibility can bring system benefits from peak load reduction bringing about generation capacity and network upgrade deferral, to reducing demand and more efficient utilization of generation and network capacity. Unlocking demand-side flexibility is an evolving process for utilities and solutions must be tailored to each specific customer group. Demand-side management (DSM) is a broad set of tools that can include demand response (both dispatchable and non-dispatchable), energy efficiency and distributed energy resources and demand-side technologies. The National Renewable Energy Laboratory (NREL), in collaboration with BSES Rajdhani Power Ltd. (BRPL) and Deloitte, examined the potential of DSM in BRPL’s service territory, developing detailed information on customer classes and willingness to participate in DSM. The study developed modeling frameworks for load analysis and the analysis tools to assess the potential of time-of-use tariffs in motivating customers to reduce their peak period energy consumption. The study shows that BRPL customers, specifically their domestic customers, are willing to participate in DSM programs and that time-of-use pricing can help BRPL reduce their peak demand and help unlock demand-side flexibility.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Route Optimization for Energy Efficient Airport Shuttle Operations - A Case Study from Dallas Fort Worth International Airport

Air travel and requisite surface traffic supporting passenger arrival/departure constitutes a significant portion of travel and emissions in cities with large airports. An airport trip can segment into three parts namely: i) travel from a location in the city to the airport; ii) travel from a parking lot or rental car center to the terminal (i.e., within the airport premises), and iii) travel inside the terminal. Depending on the airport access mode all or a part of these legs comprise a traveler’s journey to the airport. The priority of airport ground transport management teams is to provide passengers with a seamless travel experience within the airport, so it is understandable that within airport shuttle routes might not be optimized for minimizing energy consumption. Solutions that meet the dual objective of reducing energy consumption from airport shuttle operations without compromising on passenger travel experience are key to improving system efficiency. There is currently a dearth of research and tools that can inform airports in making such decisions. Addressing this need, this research effort puts forth an optimization model that generates optimal shuttle routes for a given set of constraints, and a discrete-event simulator that evaluates the optimal solutions in a stochastic environment to understand the tradeoffs between passenger wait times, and within airport shuttle energy consumption. The proposed set of tools are tested in the context of optimizing airport shuttles routes within the Dallas Fort Worth International Airport (DFW). In addition to shuttle spatial positioning, and passenger demand information, high-fidelity vehicle data was collected using data loggers installed on DFW shuttles. Results show that 20% energy reduction in shuttle operations is possible with a modest two-minute increase in average passenger wait times. The tools developed in this research effort are designed to be generalizable and can help optimize shuttle operations planning at any major airport.

air travel↗

DOE OSTI2025

Laser Powder Bed Fusion Additive Manufacture Nb1Zr Development

Next generation fission and fusion nuclear reactors require materials that can withstand operating temperatures greater than 500 °C, neutron irradiation doses of up to 200 displacements per atom (dpa), and potentially corrosive coolants such as the alkali liquid metals sodium, lithium, and NaK (Na33K eutectic alloy). Refractory alloys, such as Nb1Zr (Nb-1wt%Zr) and Molybdenum alloy TZM (Mo-0.5wt%Ti-0.08wt%Zr) have been traditionally considered viable candidates for advanced fission and fusion reactor concepts. However, it is relatively difficult to generate complex geometries of interest from these alloys using traditional manufacturing methods. In addition, there needs to be a concentrated effort to address refractory metal challenges at elevated temperature operation. In order to generate complex geometries of interest, modern manufacturing techniques are considered to increase the technological readiness level (TRL), cost-effectiveness, and schedule savings. This work focused on the continued development of laser powder bed fusion (L-PBF) additive manufacturing (AM) to improve both design flexibility, evaluate microstructure and properties, and ultimately accelerate the TRL and qualification of these processes and alloys for components to potentially be put into service. Niobium alloy Nb1Zr was identified through a down-selection process outlined in previous reports as a candidate to develop in L-PBF AM. Historically, Nb1Zr had been explored for high temperature fast spectrum fission reactors for both terrestrial and space applications. Molybdenum alloy TZM has also been considered for these reactor concepts due to exceptional high-temperature strength, creep resistance, and stability under irradiation. L-PBF AM of TZM has previously been investigated at LANL under the Microreactor program, NASA, ORNL, and in academia. However, due to the crack prone nature of TZM, L-PBF AM of TZM resulted in significant microcracking and additional development is required to pursue viable maturation. Other AM methods have been found to be more successful in printing TZM, and those alternatives approaches are discussed in this effort. The efforts detailed in this report focused on continued development of Nb1Zr through L-PBF and development of TZM via L-PBF and electron powder bed fusion (E-PBF). The objective of this work was to further the development of these AM techniques for the chosen refractory alloys, elucidating and addressing associated challenges through characterization of several demonstration builds. At LANL, Nb1Zr builds were completed using an EOS M290 and M400 machines, and a refractory alloy-dedicated L-PBF system, the Xact Metal XM200G, was installed. The XM200G primary purpose was to do the Nb1Zr parameter development process; however, due to difficulties associated with the machine installation and qualification process, it was decided to pivot development to the larger M400 and M290 machines. Although the supply of Nb1Zr powder was limited, it was sufficient to generate sub-scale metallographic specimens for the purpose of parameter development. This was first accomplished on the EOS M400 then the M290 due to machine schedule availability. Further development of TZM has been initiated at the University of Texas El Paso (UTEP) under contract with LANL to use both a heated build envelope L-PBF machine and E-PBF machine that have been found in the literature to mitigate microcracking. UTEP was provided with TZM powder and build plates to support parallel TZM parameter development across both machines. As part of the contract, UTEP will also be conducting microstructural characterization once optimized process parameters have been identified. The optimized process parameters for each machine will be used to generate a series of metallographic, mechanical, and surface finish specimens for subsequent characterization and testing. In the next section, we provide a detailed discussion of the methodology used for investigating the feasibility of leveraging these alloys for use in advanced reactor applications.

36 MATERIALS SCIENCE↗