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All sourcesNASA NTRSDOE OSTI
NASA NTRS1999

Diagnostic for Plasma Enhanced Chemical Vapor Deposition and Etch Systems

In order to meet NASA's requirements for the rapid development and validation of future generation electronic devices as well as associated materials and processes, enabling technologies ion the processing of semiconductor materials arising from understanding etch chemistries are being developed through a research collaboration between Stanford University and NASA-Ames Research Center, Although a great deal of laboratory-scale research has been performed on many of materials processing plasmas, little is known about the gas-phase and surface chemical reactions that are critical in many etch and deposition processes, and how these reactions are influenced by the variation in operating conditions. In addition, many plasma-based processes suffer from stability and reliability problems leading to a compromise in performance and a potentially increased cost for the semiconductor manufacturing industry. Such a lack of understanding has hindered the development of process models that can aid in the scaling and improvement of plasma etch and deposition systems. The research described involves the study of plasmas used in semiconductor processes. An inductively coupled plasma (ICP) source in place of the standard upper electrode assembly of the Gaseous Electronics Conference (GEC) radio-frequency (RF) Reference Cell is used to investigate the discharge characteristics and chemistries. This ICP source generates plasmas with higher electron densities (approximately 10(exp 12)/cu cm) and lower operating pressures (approximately 7 mTorr) than obtainable with the original parallel-plate version of the GEC Cell. This expanded operating regime is more relevant to new generations of industrial plasma systems being used by the microelectronics industry. The motivation for this study is to develop an understanding of the physical phenomena involved in plasma processing and to measure much needed fundamental parameters, such as gas-phase and surface reaction rates. species concentration, temperature, ion energy distribution, and electron number density. A wide variety of diagnostic techniques are under development through this consortium grant to measure these parameters. including molecular beam mass spectrometry (MBMS). Fourier transform infrared (FTIR) spectroscopy, broadband ultraviolet (UV) absorption spectroscopy, a compensated Langmuir probe. Additional diagnostics. Such as microwave interferometry and microwave absorption for measurements of plasma density and radical concentrations are also planned.

Cappelli, Mark A.↗
NASA NTRSDate not supplied

NASA’s Moon-to-Mars Planetary Autonomous Construction Technology Project: Overview and Status

NASA plans to land the first woman and next man on the Moon by 2025 through the initial Artemis missions. NASA and its international partners plan to establish a sustainable long-term presence on the lunar surface and build up infrastructure in the subsequent Artemis missions. The Lunar Surface Innovation Initiative (LSII), within NASA’s Space Technology Mission Directorate, aims to spur the creation of novel technologies needed for lunar surface exploration and accelerate the technology readiness of key systems and components. The primary thrust areas of LSII include sustainable power; dust mitigation; in-situ resource utilization; surface excavation, construction, and outfitting; and extreme access/extreme environments. The Moon-to-Mars Planetary Autonomous Construction Technology (MMPACT) project was initiated to address the lunar surface construction thrust area of LSII. The goal of the MMPACT project is to develop, deliver, and demonstrate on-demand capabilities to protect astronauts and create infrastructure on the lunar surface via construction of landing pads, habitats, shelters, roadways, berms and blast shields using lunar regolith-based materials. The MMPACT project is leveraging technology derived from NASA’s 3D Printed Mars Habitat Challenge along with contributions from other Government agencies, and multiple partners within industry and academia. The MMPACT project is comprised of three interrelated elements, construction hardware and process development; feedstock materials development; and microwave structure construction capabilities. These elements are working together to address the multiple challenges of infrastructure construction on the surface of the Moon including increased autonomy of operations, hardware operation and manufacturing under lunar environmental conditions, long-duration operation of mechanisms and parts, scale of construction activities, and material and construction requirements and standards. This presentation will summarize the status of development activities in each of the three elements, including testing of the various candidate materials, preliminary design concepts for future lunar infrastructure elements, and the vision for future technology demonstrations on the lunar surface. These demonstrations, targeting the mid-to-late 2020’s, are expected to enable landing pad construction and habitat construction resulting in commercial capabilities early in the next decade.

Additive construction, regolith processing, lunar ↗
DOE OSTI2023

JUST-R metrics for considering energy justice in early-stage energy research

We report achieving sustainable decarbonization of the energy sector requires implementing and improving energy technologies while simultaneously managing sources of social inequity in the energy system. Centering energy justice, which has "the goal of achieving equity in both the social and economic participation in the energy system, while also remediating social, economic, and health burdens on those historically harmed by the energy system," in the transition to clean energy has become an increasingly urgent priority for social scientists, policymakers, and community activists alike. However, late-stage consideration of social impacts of energy technologies may result in identifying inequities only after substantial time, money, and effort have been expended on research and development (R&D). This issue is exemplified by concerns over environmental and human health impacts related to cobalt in lithium-ion batteries, which has spurred research into alternatives only after decades of R&D and the establishment of supply chains, infrastructure, and markets for cobalt-containing chemistries. Other examples include issues with land use and resource consumption related to first-generation biofuel feedstocks as well as occupational hazards and pollution associated with photovoltaics manufacturing. In all these cases, subsequent R&D to improve technologies or processes cannot undo the effects already experienced. Incorporating energy justice from the earliest stage of R&D will enable more just technology implementation, but integrating justice considerations into early-stage research is a challenge due to a lack of tools to assess and manage them. To fill this gap, we center early-stage research to develop the Justice Underpinning Science and Technology Research (JUST-R) metrics framework - energy justice metrics specifically targeted at early-stage researchers to assess their work on an immediate timescale. By applying these metrics to a case study focused on materials for next-generation photovoltaics, we highlight potential benefits and barriers to implementing this framework in early-stage research and discuss necessary institutional and individual actions needed for researchers to effectively leverage the tool to incorporate justice-focused criteria into R&D decision making.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2023

First-Principles Cost Estimation of a Sodium Fast Reactor Nuclear Plant

A multi-tiered cost analysis is performed to estimate full costs of a nuclear power plant (NPP) based on sodium-cooled fast reactor (SFR) technology. To address the lack of fully transparent cost estimations from past undertakings for NPPs, we have developed a detailed and first-principles-based cost estimate for a generalized SFR NPP. Our intent is to achieve a high degree of transparency with our cost assumptions and develop a cost model that is flexible and easily extendable to variations in NPP design and other nuclear reactor types. Furthermore, we strive to achieve a clear organization of costs and complete identification of key cost drivers based on first principles. To this end, the cost results of our analysis as given in Table 24 and Table 25 are organized and categorized into a code of accounts (COA) under development at Idaho National Laboratory (INL). Varying degrees of first-principles methods are employed, such as design for manufacture and assembly® (DFMA® ), to elucidate costs in all process levels of the plant equipment, buildings and site structures, personnel, and other miscellaneous but significant cost elements. These approaches have been successfully applied in past cost analysis projects and are designed to enable rapid and flexible cost estimation. Application of these techniques for evaluating NPP costs is similar in concept to the full, detailed estimation of construction and fabrication costs determined in a later stage of NPP development. Note that our approach tries to avoid use of other past analysis results and data such as those from the legacy Energy Economic Data Base (EEDB) Program, as these resources are based on historical NPP costs and thus may not be indicative of new reactor technologies or construction and fabrication/manufacturing techniques. However, we provide a comparison of our SFR NPP cost results in Table 90 against those included in the EEDB for a representative pressurized water reactor (PWR).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2011

High-Efficiency Ka-Band Waveguide Two-Way Asymmetric Power Combiner

NASA is planning a number of Space Exploration, Earth Observation and Space Science missions where Ka-band solid-state power amplifiers (SSPAs) could have a role. Monolithic microwave integrated circuit (MMIC) based SSPAs with output powers on the order of 10 W at Ka-band frequencies would be adequate to satisfy the data transmission rate requirements at the distances involved. MMICs are a type of integrated circuit fabricated on a GaAs wafer, which operates at micro wave frequencies and performs the function of signal amplification. The highest power Ka-band (31.8 to 32.3 GHz) SSPA to have flown in space had an output power of 2.6 W with an overall efficiency of 14.3 percent. This SSPA was built around discrete GaAs pHEMT (high electron mobility transistor) devices and flew aboard the Deep Space One spacecraft. State-of-the-art GaAs pHEMT-based MMIC power amplifiers (PAs) can deliver RF power at Ka-band frequencies anywhere from 3 W with a power added efficiency (PAE) of 32 percent to 6 W with a PAE of 26 percent. However, to achieve power levels higher than 6 W, the output of several MMIC PAs would need to be combined using a high-efficiency power combiner. Conventional binary waveguide power combiners, based on short-slot and magic-T circuits, require MMIC PAs with identical amplitude and phase characteristics for high combining efficiency. However, due to manufacturing process variations, the output powers of the MMIC PAs tend to be unequal, and hence the need to develop unequal power combiners. A two-way asymmetric magic-T based power combiner for MMIC power amplifiers, which can take in unequal inputs, has been successfully designed, fabricated, and characterized over NASA s Deep Space Network (DSN) frequency range of 31.8 to 32.3 GHz. The figure is a transparent view of the a sym - metric combiner that shows the 4-port configuration and the internal structure. The rod, post, and iris are positioned by design to achieve the desired asymmetric power ratio, phase equality, and port isolation. Although the combiner was designed for an input power ratio of 2:1, it can be custom-designed for any arbitrary power ratio and frequency range. The manufactured prototype combiner was precision machined from aluminum and is less than 2 in.3 (32.8 cm3). Previously investigated rectangular waveguide unequal power combiners were based on shunt/series coupling slots, E-plane septums, or H-plane T-junctions. All the prior art unequal power combiners operated at or below X-band (10 GHz) frequencies and were primarily used in the feed network of antenna arrays. The only reported asymmetric magic-T was developed as a 2:1 power divider for operation at a much lower frequency, around 500 MHz. The measured power ratio when tested as a power divider was very close to 2 and the phase balance was within 2.6, resulting in near ideal performance. When tested as a combiner using two MMIC SSPAs with a 2:1 power output ratio, an efficiency greater than 90 percent was demonstrated over the 500 MHz DSN frequency range. The return loss at the combiner output port (1) was greater than 18 dB and the input port (2 and 3) isolation was greater than 22 dB. The results show the asymmetric combiner to be a good candidate for high-efficiency power combining of two or more SSPAs needed to achieve the 6 to 10 W required by space communications systems of future NASA missions.

Wintucky, E. G.↗
DOE OSTI2022

Use of novel refractory design and installation techniques for improved energy efficiency in iron and steel and other energy intensive industries

This paper describes the planned work to be performed under a United States Department of Energy funded project to bring together the key players necessary to develop and deploy new technology which could increase the thermal efficiency of the steel industry as well as other energy intensive industries. It is hoped that such improvements in energy efficiency will reduce the overall energy and environmental footprint of domestic industry, as well as provide economic benefit to the individual companies. The described project brings together a vertically integrated collaborative team consisting of the end user (U.S. Steel), material producers/suppliers (Allied Mineral Products and Reno Refractories), raw material suppliers (American Metallurgical Services, Minerals Manufacturing), and research organizations (Oak Ridge National Laboratory, National Energy Technology Laboratory and University of Alabama-Birmingham) with the objective of designing and producing new refractory materials based on novel aggregates, improved particle packing, and engineered surface texture. In addition, the recycling and use of spent refractory materials will be investigated and a novel installation technique will be developed taking advantage of new additive manufacturing technology and existing refractory shotcrete technology. It is hoped that the combination of these new technologies will allow for the improvement of the energy, environmental, and economic efficiency of the steel industry while also reducing the environmental footprint of the refractory and steel industries. Additionally, the developed technology is expected to be applicable to other energy intensive industries such as cement, glass, pulp and paper, and non-ferrous metals processing.

Hemrick, James↗
NASA NTRS1994

Test Plan. GCPS Task 4, subtask 4.2 thrust structure development

The Single Stage To Orbit (SSTO) vehicle is designed to lift off from a vertical position, go into orbit, return to earth for a horizontal landing, and be reusable for the next mission. (NASA baseline only) In order to meet its performance goals, the SSTO relies on light weight structure and the use of 8 tri-propellant engines. These engines are mounted to the thrust structure. This test plan addresses selection of the material for this structure, and the integrity of the design through testing of elements and a full-scale subcomponent. This test plan supports the development of the design for an advanced composite thrust structure for a Single Stage to Orbit manned, heavy launch vehicle. The thrust structure is designed to transmit very high thrust loads from the engines to the rest of the vehicle (see Figure 1 ). The thrust structure will also be used for primary attachment of the twin vertical tails and possibly act as the aft attach point for the wing. The combination of high loading, high vibration, long service life and high acoustic environments will need to be evaluated by tests. To minimize design risk, a building block approach will be used. We will first screen materials to determine which materials show the most promise for this application. Factors in this screening will be the suitability of these materials for chosen design concepts, particularly concerning specific strength, environmental compatibility and applicability to fabrication processes. Next we will characterize two material systems that will be used in the design; the characterization will allow us to generate preliminary design data that will be used for the analysis. Element testing will be performed to evaluate critical structural locations under load. Final testing on the full scale test article will be performed to verify the design and to demonstrate predictability of the analysis. Additionally, risks associated with fabricating full scale thrust structures will be reduced through testing activities. One of the major concerns that stems from full scale fabrication is the realities of size and the associated complexities of handling, manufacturing, and assembly. The need exists to fabricate, assemble and test_representative joint specimens to achieve_confidence in the design and manufacturing technologies being proposed.

Greenberg, H. S.↗
NASA NTRS2015

Development of Additive Construction Technologies for Application to Development of Lunar/Martian Surface Structures Using In-Situ Materials

For long-duration missions on other planetary bodies, the use of in situ materials will become increasingly critical. As human presence on these bodies expands, so must the breadth of the structures required to accommodate them including habitats, laboratories, berms, radiation shielding for natural radiation and surface reactors, garages, solar storm shelters, greenhouses, etc. Planetary surface structure manufacturing and assembly technologies that incorporate in situ resources provide options for autonomous, affordable, pre-positioned environments with radiation shielding features and protection from micrometeorites, exhaust plume debris, and other hazards. The ability to use in-situ materials to construct these structures will provide a benefit in the reduction of up-mass that would otherwise make long-term Moon or Mars structures cost prohibitive. The ability to fabricate structures in situ brings with it the ability to repair these structures, which allows for the self-sufficiency and sustainability necessary for long-duration habitation. Previously, under the auspices of the MSFC In-Situ Fabrication and Repair (ISFR) project and more recently, under the jointly-managed MSFC/KSC Additive Construction with Mobile Emplacement (ACME) project, the MSFC Surface Structures Group has been developing materials and construction technologies to support future planetary habitats with in-situ resources. One such additive construction technology is known as Contour Crafting. This paper presents the results to date of these efforts, including development of novel nozzle concepts for advanced layer deposition using this process. Conceived initially for rapid development of cementitious structures on Earth, it also lends itself exceptionally well to the automated fabrication of planetary surface structures using minimally processed regolith as aggregate, and binders developed from in situ materials as well. This process has been used successfully in the fabrication of construction elements using lunar regolith simulant and Mars regolith simulant, both with various binder materials. Future planned activities will be discussed as well.

Werkheiser, Niki J.↗
NASA NTRS2016

SLS Flight Software Testing: Using a Modified Agile Software Testing Approach

NASA's Space Launch System (SLS) is an advanced launch vehicle for a new era of exploration beyond earth's orbit (BEO). The world's most powerful rocket, SLS, will launch crews of up to four astronauts in the agency's Orion spacecraft on missions to explore multiple deep-space destinations. Boeing is developing the SLS core stage, including the avionics that will control vehicle during flight. The core stage will be built at NASA's Michoud Assembly Facility (MAF) in New Orleans, LA using state-of-the-art manufacturing equipment. At the same time, the rocket's avionics computer software is being developed here at Marshall Space Flight Center in Huntsville, AL. At Marshall, the Flight and Ground Software division provides comprehensive engineering expertise for development of flight and ground software. Within that division, the Software Systems Engineering Branch's test and verification (T&V) team uses an agile test approach in testing and verification of software. The agile software test method opens the door for regular short sprint release cycles. The idea or basic premise behind the concept of agile software development and testing is that it is iterative and developed incrementally. Agile testing has an iterative development methodology where requirements and solutions evolve through collaboration between cross-functional teams. With testing and development done incrementally, this allows for increased features and enhanced value for releases. This value can be seen throughout the T&V team processes that are documented in various work instructions within the branch. The T&V team produces procedural test results at a higher rate, resolves issues found in software with designers at an earlier stage versus at a later release, and team members gain increased knowledge of the system architecture by interfacing with designers. SLS Flight Software teams want to continue uncovering better ways of developing software in an efficient and project beneficial manner. Through agile testing, there has been increased value through individuals and interactions over processes and tools, improved customer collaboration, and improved responsiveness to changes through controlled planning. The presentation will describe agile testing methodology as taken with the SLS FSW Test and Verification team at Marshall Space Flight Center.

Bolton, Albanie T.↗
DOE OSTI2024

Software Quality Assurance Plan ANSYS LSDYNA Version 2023R1

ANSYS Inc. develops and markets engineering simulation software and services used in the aerospace, automotive, manufacturing, electronics, biomedical, energy, defense, and many other industries. ANSYS is dedicated to engineering simulation and is the world’s leading software provider. ANSYS was founded in 1970 and is headquartered in Canonsburg, Pennsylvania. ANSYS provides an engineering analysis tool combining structural, thermal, computational fluid dynamics, acoustic and electromagnetic simulation capabilities. ANSYS LS-DYNA is the most used explicit simulation program capable of simulating the response of materials to short periods of severe loading. Its many elements, contact formulations, material models, and other controls can be used to simulate complex models with control over all the details of the problem. ANSYS LS-DYNA has a vast array of capabilities to simulate extreme deformation problems using its explicit solver. Engineers can tackle simulations involving material failure and look at how the failure progresses through a part or through a system. Models with large amounts of parts or surfaces interacting with each other are also easily handled, and the interactions and load passing between complex behaviors are modeled accurately. Using computers with higher numbers of CPU cores can drastically reduce solution times. In addition, many consulting firms and hundreds of universities use ANSYS for analysis, research, and educational purposes. ANSYS is recognized worldwide as one of the most widely used and capable programs of its type. ANSYS has successfully passed over 100 customer quality system audits against American Society of Mechanical Engineers (ASME) NQA-1 and 10 CFR Part 50, Appendix B, since the company was founded, over 60 of which have been since 1997. ANSYS has successfully passed over 100 International Organization for Standardization (ISO) 9001 assessments. ANSYS design analysis software is the first created within a quality system with ISO 9001 certification, which is the internationally accepted quality standard. Product development, testing, maintenance, and support processes also meet the US Nuclear Regulatory Commission’s (NRC’s) quality requirements, as they have for nearly four decades. ANSYS staff perform more than 60,000 software verification tests before releasing each new product. ASME NQA-1-2012 (Subpart 2.7 is specific to software) is the industry- and NRC-accepted approach (consensus standard) for meeting 10 CFR Part 50, Appendix B, requirements.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Aeroelastic Modeling for Distributed Wind Turbines: March 11, 2021 - November 10, 2021

Aeroelastic modeling (AM) is the primary methodology for structural and performance assessment of any wind turbine whereby providing an understanding of the impact of design parameters on its loading and power response before witnessing it in the field. Despite these advantages, the use of AM in the Distributed Wind Technology (DWT) sector is limited, especially within the less established manufacturers. This project represents an in-depth assessment of the status of AM and its role within the Standards for the DWT industry. The study gathered input and feedback from a large number of national and international stakeholders, reviewed technical strengths and weaknesses of the current edition of the design standards, analyzed recent industry workshops' and meetings' minutes, collected publicly available AM templates, and provided an evaluation of the existing AM codes. The study achieved several goals including providing strategies for the load assessment categorization of turbines based on rotor swept area and archetype, and guidance for AM verification and validation (V&V), which includes discussions of measurement requirements and a sample test-plan useful for future V&V campaigns and design standard development. This document summarizes the different tasks conducted in the course of the project and highlights the steps required to improve the AM adoption based on a multifaceted approach that encompasses: 1) augmenting AM software capabilities, 2) publishing AM best-practices and design-basis, 3) creating new model templates, 4) providing guidance for V&V of codes and specific turbine models leveraging field testing best-practice, and 5) addressing weaknesses in the current standards. Many of the future objectives identified in this study could leverage NREL's upcoming testing campaigns of three modern distributed wind turbines. Recommendations within this study will advance the value and the ease-of-use of AM, thereby allowing the industry to better capitalize this underutilized tool resulting in a more efficient design process, an easier path to certification, and overall better and more distributed reliable wind turbine products.

17 WIND ENERGY↗
DOE OSTI2023

Gamma Spectrometry Code Rodeo for Uranium Enrichment—FY 2022 Report

In the first two quarters of FY22, data acquisition continued at ORNL and LLNL using uranium sources of known enrichments. This was an FY21 task which could not be completed in FY21 because of problems encountered with the ORNL M400 CZT in Q4 of FY21, and the subsequent repairs. The detector was received back from H3D in the first of September 2021 , and the measurements resumed . Measurements using the repaired detector were completed in Q1 of FY22. The spectra were distributed by ORNL to the analyzing labs. Analysis results were received in Q2 of FY2022. The results from the various codes were intercompared and an ANOVA analysis was performed. Random and systematic uncertainties were established for each code. The ANOVA results and discussions were included in a revised version of FY21Annual Report issued in March 2022. A paper was presented at the INMM 2022Annual Conference, with the analysis results from the various isotopic codes, and the ANOVA table with random and systematic uncertainties. The Project Work Plan (PWP) for FY22 included a task to perform field testing of the M400 CZT and the analysis codes using UF 6 cylinder measurements at the Framatome Fuel Fabrication Facility in Richland, WA. PNNL was the lead for the field testing task. PNNL drafted a Field Test Plan, and refined it based on comments received from the team. PNNL coordinated with Framatome facility, the logistics of carrying out the field testing . A collimator and shield made out of TFlex (tungsten impregnated polymer) was designed and professionally manufactured. The collimators were used in the field test measurements. The measurements at Framatome were completed on April 21, 2022. A total of 34 Type 30B cylinders were measured using three M400 detectors (PNNL, LLNL, and ORNL detectors). Measurements using M400 were taken at two locations on the side of each cylinder and from the end-on bottom location. Additionally, HPGe measurements were taken at the end-on location to establish ground truth. Cylinder wall thickness measurements were also made at all three locations. To gain a better understanding of the effect of background from surrounding cylinders, the same five cylinders measured individually in low background locations were measured again in the cylinder storage yards. Due to inclement weather, manufacturer delays, shipping delays, and equipment failure, the measurement campaign spanned twice as long compared to the original timeline. Gamma-ray spectra from M400 and HPGe detectors, along with the cylinder data and photographs were organized and shared with the collaborators for further analysis. Spectra were analyzed by the participating laboratories. FY22 PWP also consists of tasks related to plutonium source measurements, adapting the codes to analyze plutonium spectra, and inter-comparison of the results from various codes. Plutonium spectra are being acquired at LANL, ORNL, and LLNL. LANL, SNL and LLNL are in the process of modifying FRAM, GADRAS, and CZTU, respectively. The plutonium related tasks will be completed in Q2 of FY23.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRS2009

Benefits of Using a Mars Forward Strategy for Lunar Surface Systems

This paper identifies potential risk reduction, cost savings and programmatic procurement benefits of a Mars Forward Lunar Surface System architecture that provides commonality or evolutionary development paths for lunar surface system elements applicable to Mars surface systems. The objective of this paper is to identify the potential benefits for incorporating a Mars Forward development strategy into the planned Project Constellation Lunar Surface System Architecture. The benefits include cost savings, technology readiness, and design validation of systems that would be applicable to lunar and Mars surface systems. The paper presents a survey of previous lunar and Mars surface systems design concepts and provides an assessment of previous conclusions concerning those systems in light of the current Project Constellation Exploration Architectures. The operational requirements for current Project Constellation lunar and Mars surface system elements are compared and evaluated to identify the potential risk reduction strategies that build on lunar surface systems to reduce the technical and programmatic risks for Mars exploration. Risk reduction for rapidly evolving technologies is achieved through systematic evolution of technologies and components based on Moore's Law superimposed on the typical NASA systems engineering project development "V-cycle" described in NASA NPR 7120.5. Risk reduction for established or slowly evolving technologies is achieved through a process called the Mars-Ready Platform strategy in which incremental improvements lead from the initial lunar surface system components to Mars-Ready technologies. The potential programmatic benefits of the Mars Forward strategy are provided in terms of the transition from the lunar exploration campaign to the Mars exploration campaign. By utilizing a sequential combined procurement strategy for lunar and Mars exploration surface systems, the overall budget wedges for exploration systems are reduced and the costly technological development gap between the lunar and Mars programs can be eliminated. This provides a sustained level of technological competitiveness as well as maintaining a stable engineering and manufacturing capability throughout the entire duration of Project Constellation.

Mulqueen, Jack↗
DOE OSTI2025

Nuclear Materials Packaging, Transportation, and Systems Analysis Group Software Quality Assurance Plan: ANSYS Mechanical Finite Element Analysis Software Version 2023R1

ANSYS Inc. develops and markets engineering simulation software and services used in the aerospace, automotive, manufacturing, electronics, biomedical, energy, defense, and many other industries. ANSYS is dedicated to engineering simulation and is the world’s leading software provider. ANSYS was founded in 1970 and is headquartered in Canonsburg, Pennsylvania. ANSYS provides an engineering analysis tool combining structural, thermal, computational fluid dynamics, acoustic, and electromagnetic simulation capabilities. ANSYS has two main programs, which use the same solvers: (1) Mechanical APDL (ANSYS Design Parametric Language), a Fortran-based coding platform, and (2) ANSYS Workbench, which uses a graphical user interface to aid in finite element analysis implementation. This plan covers both APDL and Workbench. The ANSYS computer program is a large-scale, multipurpose finite element program that can be used to solve several classes of engineering analyses. The analysis capabilities of ANSYS include the ability to solve static and dynamic structural analyses, steady-state and transient heat transfer problems, mode-frequency and buckling eigenvalue problems, static or time-varying magnetic analyses, and various types of field and coupled-field applications. The program contains many special features that allow nonlinearities or secondary effects such as plasticity, large strain, hyperelasticity, creep, swelling, large deflections, contact, stress stiffening, temperature dependency, material anisotropy, and radiation to be included in the solution. As ANSYS has been developed, other special capabilities such as substructuring, submodeling, random vibration, kinetostatics, kinetodynamics, free convection fluid analysis, acoustics, magnetics, piezoelectrics, coupled-field analysis, and design optimization have been added to the program. These capabilities contribute further to making ANSYS a multipurpose analysis tool for varied engineering disciplines. The ANSYS program has been in commercial use for over 50 years and has been used extensively in the aerospace, automotive, construction, electronic, energy services, manufacturing, nuclear, plastics, oil, and steel industries. Additionally, many consulting firms and hundreds of universities have used ANSYS for analysis, research, and educational purposes. ANSYS is recognized worldwide as one of the most widely used and capable programs of its type. Ansys design analysis software is the first created within a quality system with ISO 9001 certification, the internationally accepted quality standard. Product development, testing, maintenance and support processes also meet the United States Nuclear Regulatory Commission's quality requirements, as they have for nearly four decades. The Quality Assurance Service Agreement is suitable for the customers working in the nuclear industry who need to meet specific federal regulations including 10CRF50 Appendix B and provisions of 10CFR21. ANSYS has retained its original International Organization for Standardization (ISO) 9001 accreditation certificate since1995-05-04, It’s current certificate is valid until 2027-05-29.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Policy Reforms to Unleash Domestic Critical Minerals Mining and Processing

The United States faces growing strategic and economic risks due to its limited ability to mine, process, and refine the minerals required for national defense, energy systems, advanced manufacturing, and emerging technologies. Although the country possesses significant geological resources, development has been slowed by long and unpredictable permitting timelines, fragmented regulatory responsibilities, limited midstream processing capacity, and a shrinking technical workforce. These structural barriers have created supply chain vulnerabilities that constrain industrial growth and reduce national resilience. This report presents a comprehensive set of reforms intended to modernize the nation’s approach to critical minerals. The recommendations address federal permitting, environmental review processes, the legal framework governing mining activities, interagency coordination, domestic processing and refining capacity, and the education and workforce systems needed to support long term industry development. The analysis emphasizes practical steps to shorten project timelines, improve regulatory clarity, expand processing infrastructure, enable recovery from both conventional and nontraditional sources, and update outdated requirements that hinder the development of essential materials. Taken together, the recommended reforms would strengthen domestic supply chains, improve investment certainty, and reduce dependence on external minerals and processing infrastructure. By aligning policy, regulatory frameworks, and workforce capabilities with national needs, the United States can build a more resilient and secure critical minerals ecosystem that supports long term economic competitiveness and technological leadership.

29 - ENERGY PLANNING, POLICY AND ECONOMY↗
DOE OSTI2023

Techno-Economic Impact of a Smart Battery Sorting System

Create analytical framework to capture costs and benefits of the automated sorting into battery recycling including the development and deployment of various types of battery recycling technologies such as pyrometallurgical, hydrometallurgical, and direct recycling. Li Industries, Inc. is a Virginia startup company focused on reinventing how lithium-ion batteries (LIBs) are recycled. Li Industries is focused on developing direct LIB recycling and automated battery sorting technologies in order to reduce the environmental impact of the LIB lifecycle. This work is to be conducted in support of the American-Made Challenges Lithium-Ion Battery Recycling Prize. Li Industries and NREL will work together to understand how novel technologies, such as those being developed by Li Industries, can impact the development and economics of the battery recycling industry. This voucher is being used to evaluate the profitability of an automated sorting system developed by Li Industries and the potential effect this increased value could have on the domestic lithium-ion battery (LIB) recycling industries in the United States. NREL has developed the Lithium-Ion Battery Resources Assessment (LIBRA) system dynamics model to project the future viability of the US LIB manufacturing and recycling industries under varying technoeconomic conditions and battery adoption scenarios over the coming decades. Additional logic was added to LIBRA to analyze the role automated sorting of recycling feedstock could play in the buildout of the industry and the impacts it has on the recovery of end-of-life (EOL) battery materials. This report summarizes the outcomes of this modeling analysis in the US context through a series of sensitivity analyses run for a range of values of a given input dimension and compared across the unsorted or automated sorting cases for LIB recycling feedstock. For greater detail on the process and analysis, the researchers are publishing a forthcoming journal article titled Techno-Economic Impact of a Smart Battery Sorting System for Lithium-Ion Battery Recycling and Mineral Recovery in the United States by Weigl, et al. In the event the article is not accepted by any currently seeking publication in academic or industry journal, it may be published by NREL. CRADA benefit to DOE, Participant, and US Taxpayer: assists laboratory in achieving programmatic scope competencies, uses the laboratory's core competencies.

25 ENERGY STORAGE↗
DOE OSTI2024

Digital bead modeling for wire-arc directed energy deposition

Prediction of 2D cross-section and full 3D geometry for stacked weld beads is critical for the outcome of wire-arc directed energy deposition (DED) parts; however, most additive path planning software packages model beads as extrusions of a rectangle. Weld beads are not rectangular, and the resulting shape is dependent upon physics effects at the moment of deposition. Physics phenomena such as the geometry of the underlying surface, the heat input of the welding mode, and the direction of gravity contribute to bead shape. Here, this paper presents a novel implicit modeling method that discretizes a 2D area or 3D volume of space into pixels or voxels and constructs fields based on these physics phenomena. The fields are combined using a weighting scheme trained on 3D scan measurements of welds and wire-arc DED prints. Pixels or voxels are added until the known amount of deposited volume has been achieved. Thereby, a strong conservation of mass principle is applied to the process. Utilizing machine learning techniques, the present model can be trained on a database of scans allowing for the representation of a wide variety of prints. Results show that this method can produce predictions with realistic bead morphology and sub-millimeter form error.

Bead geometry modeling↗
NASA NTRSDate not supplied

Size Effects on Laser Powder Bed Fusion and Laser Powder Directed Energy Deposition GRCop-42 Alloy

Additive manufacturing (AM) plays a significant role in the fabrication of regeneratively cooled rocket engine combustion chambers, where internal channels are used to transport high pressure propellants to keep the engine from overheating. Cooling channels are designed with thin walls between the cooling and combustion sides, experiencing high thermal and mechanical stresses from large temperature gradients and internal pressures. Hence, selecting materials suited for this environment and maintaining a high-quality processing for this critical application is of utmost importance. GRCop-alloys (Cu-Cr-Nb) were developed as an ideal material for combustion chambers due to its high conductivity and high strength at temperature, being employed as a structural member for the hotwall with excellent heat transfer capabilities. GRCop-42 (Cu, 4 at% Cr, 2 at% Nb) has significantly matured using the Laser Powder Bed Fusion (L-PBF) process through microstructure, mechanical and thermophysical properties and evaluations using hot-fire testing. Additionally, Laser Powder Directed Energy Deposition (LP-DED) has demonstrated successful deposition and geometry samples using GRCop-42. While the maturation in properties has focused on bulk material properties from standard test specimens, these cannot be extrapolated to be used in thin walls, as different features (i.e., microstructure, porosity, and surface texture) have a greater effect on thin walls, especially on AM structures built using L-PBF and LP-DED. This presentation provides an overview of the effects introduced by reducing the thickness on the fabrication, microstructure, surface metrology and subsequent mechanical properties of GRCop-42 using L-PBF and LP-DED as well as future work planned for this research.

Gabriel Demeneghi↗