NASA's In-Space Manufacturing Initiative: Initial Results from International Space Station Technology Demonstration and Future Plans
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A generalized dynamical adjustment procedure was applied to a diabatic model to produce balanced initial conditions. Namely, backward adiabatic model integration is followed by forward diabatic model integration, with a high frequency (low pass) filter in the form of the Euler-backward time differencing scheme being applied throughout the whole integration. As a result of the application of such a diabatic dynamic initialization procedure within the Goddard Laboratory for Atmospheres (GLA) 4-D data assimilation system, the following properties of forecasts from initialized fields are achieved right from the beginning of the usual forecast integration: (1) the forecast tendencies (and fields) are free of any noise due to imbalance in initial conditions; (2) the shocks related to an initial imbalance between model physics and dynamics, and especially the substantial initial imbalance of precipitation and evaporation fields, or the initial spin-up effect, are practically removed. Diabatic dynamic initialization has been compared with implicit nonlinear normal mode initialization, and found to be superior in removing the initial spin-up effect, and also in improving the tropical structure. The diabatic dynamic initialization procedure was successfully tested for the GLA system with the use of all conventional data and the GLA satellite data retrievals. It allows a smooth data insertion without any shocks or imbalances, which is highly desirable for efficient functioning of 4-D data assimilation systems. The developed initialization procedure is computationally efficient and in principle easily applicable to different forecast models.
We constructed and analyzed wet and dry soil moisture composites for the mid-latitude GCIP region of the central US using long climate model simulations made with the NCAR CCM3 and reanalysis products from NCEP. Using the diagnostic composites as a guide, we have completed a series of predictability experiments in which we imposed soil water initial conditions in CCM3 for the GCIP region for June 1 from anomalously wet and dry years, with atmospheric initial conditions taken from June 1 of a year with 'near-normal' soil water, and initial soil water from the near-normal year and atmospheric initial conditions from the wet and dry years. Preliminary results indicate that the initial state of the atmosphere is more important than the initial state of soil water determining the subsequent late spring and summer evolution of sod water over the GCIP region. Surprisingly, neither the composites or the predictability experiments yielded a strong influence of soil moisture on the atmosphere. To explore this further, we have made runs with extreme dry soil moisture initial anomalies imposed over the GCIP region (the soil close to being completely dry). These runs did yield a very strong effect on the atmosphere that persisted for at least three months. We conclude that the magnitude of the initial soil moisture anomaly is crucial, at least in CCM3, and are currently investigating whether a threshold exists, below which little impact is seen. In a complementary study, we compared the impact of the initial condition of snow cover versus the initial atmospheric state over the western US (corresponding to the westward extension of the GAPP program follow-on to GCIP). In this case, the initial prescription of snow cover is far more important than the initial atmospheric state in determining the subsequent evolution of snow cover. We are currently working to understand the very different soil water and snow cover results.
Idealized numerical simulations are performed with a coupled atmosphere/land-surface model to identify the roles of initial soil moisture, coastline curvature, and land breeze circulations on sea breeze initiated precipitation. Data collected on 27 July 1991 during the Convection and Precipitation Electrification Experiment (CAPE) in central Florida are used. The 3D Goddard Cumulus Ensemble (GCE) cloud resolving model is coupled with the Goddard Parameterization for Land-Atmosphere-Cloud Exchange (PLACE) land surface model, thus providing a tool to simulate more realistically land-surface/atmosphere interaction and convective initiation. Eight simulations are conducted with either straight or curved coast-lines, initially homogeneous soil moisture or initially variable soil moisture, and initially homogeneous horizontal winds or initially variable horizontal winds (land breezes). All model simulations capture the diurnal evolution and general distribution of sea-breeze initiated precipitation over central Florida. The distribution of initial soil moisture influences the timing, intensity and location of subsequent precipitation. Soil moisture acts as a moisture source for the atmosphere, increases the connectively available potential energy, and thus preferentially focuses heavy precipitation over existing wet soil. Strong soil moisture-induced mesoscale circulations are not evident in these simulations. Coastline curvature has a major impact on the timing and location of precipitation. Earlier low-level convergence occurs inland of convex coastlines, and subsequent precipitation occurs earlier in simulations with curved coastlines. The presence of initial land breezes alone has little impact on subsequent precipitation. however, simulations with both coastline curvature and initial land breezes produce significantly larger peak rain rates due to nonlinear interactions.
This innovation consists of a pyrotechnic initiator and piezoelectric initiation system. The device will be capable of being initiated mechanically; resisting initiation by EMF, RF, and EMI (electromagnetic field, radio frequency, and electromagnetic interference, respectively); and initiating in water environments and space environments. Current devices of this nature are initiated by the mechanical action of a firing pin against a primer. Primers historically are prone to failure. These failures are commonly known as misfires or hang-fires. In many cases, the primer shows the dent where the firing pin struck the primer, but the primer failed to fire. In devices such as "T" handles, which are commonly used to initiate the blowout of canopies, loss of function of the device may result in loss of crew. In devices such as flares or smoke generators, failure can result in failure to spot a downed pilot. The piezoelectrically initiated ignition system consists of a pyrotechnic device that plugs into a mechanical system (activator), which on activation, generates a high-voltage spark. The activator, when released, will strike a stack of electrically linked piezo crystals, generating a high-voltage, low-amperage current that is then conducted to the pyro-initiator. Within the initiator, an electrode releases a spark that passes through a pyrotechnic first-fire mixture, causing it to combust. The combustion of the first-fire initiates a primary pyrotechnic or explosive powder. If used in a "T" handle, the primary would ramp the speed of burn up to the speed of sound, generating a shock wave that would cause a high explosive to go "high order." In a flare or smoke generator, the secondary would produce the heat necessary to ignite the pyrotechnic mixture. The piezo activator subsystem is redundant in that a second stack of crystals would be struck at the same time with the same activation force, doubling the probability of a first strike spark generation. If the first activation fails to ignite, the device is capable of multiple attempts. Another unique aspect is in the design of the pyrotechnic device. There is an electrode that aids the generation of a directed spark and the use of a conductive matrix to support the first-fire material so that the spark will penetrate to the second electrode.
Power flow forms the basis of many power system studies. With the increased penetration of renewable energy, grid planners tend to perform multiple power flow simulations under various operating conditions and not just selected snapshots at peak or light load conditions. Getting a converged AC power flow (ACPF) case remains a significant challenge for grid planners especially in large power grid networks. This paper proposes a two-stage approach to improve Newton-Raphson ACPF convergence and was applied to a 6102 bus Electric Reliability Council of Texas (ERCOT) system. The first stage utilizes a deep learning-based initializer with data re-training. Here a deep neural network (DNN) initializer is developed to provide better initial voltage magnitude and angle guesses to aid in power flow convergence. This is because Newton-Raphson ACPF is quite sensitive to the initial conditions and bad initialization could lead to divergence. The DNN initializer includes a data re-training framework that improves the initializer's performance when faced with limited training data. The DNN initializer successfully solved 3,285 cases out of 3,899 non-converging dispatch and performed better than random forest and DC power flow initialization methods. ACPF cases not solved in this first stage are then passed through a hot-starting algorithm based on homotopy continuation with switched shunt control. The hot-starting algorithm successfully converged 416 cases out of the remaining 614 non-converging ACPF dispatch. In conclusion, the combined two-stage approach achieved a 94.9% success rate, by converging a total of 3,701 cases out of the initial 3,899 unsolved cases.
Polymer-grafted nanoparticles (PGNPs) are versatile hybrid materials whose properties critically depend on brush dimensions, uniformity, and grafting density. Herein, we systematically investigated how initiator density, catalyst concentration, and nanoparticle curvature govern the growth of poly(methyl methacrylate) (PMMA) brushes grafted from spherical SiO 2 nanoparticles via surface-initiated activators regenerated by electron transfer atom transfer radical polymerization (SI-ARGET ATRP). By tuning the initiator density through a combination of “active” and “dummy” silane initiators anchored on the nanoparticles’ surface and controlling the catalyst concentration, we reveal that increased initiator crowding and smaller surface curvature amplify steric hindrance, leading to decreased initiation efficiency and broader molecular weight distributions. Correlation with the corresponding unattached chains by ARGET ATRP suggests the presence of permanently inaccessible (“buried”) initiation sites, which are a characteristic of surface-grafted systems. At sufficient Cu catalyst concentrations, uniform brush growth is attained across different initiator densities, whereas decreased catalyst concentrations accentuate nonconcurrent initiation and propagation. These findings provide mechanistic insights into the interplay of initiator density, catalyst concentration, and surface curvature, offering design principles for tailoring the PGNP architecture. These results can guide the structural engineering of densely grafted surfaces, including nanoparticles and flat substrates, for applications in nanocomposites, photonics, and functional coatings.
Lockheed C-130 Hercules aircraft have during their service life been periodically inspected and growing cracks around rivet holes were recorded. This record has recently been used to determine the statistical distributions of crack initiation times and the distribution of initial crack sizes. When crack initiation times are calculated from such cracks, by backward extrapolation of the growth relation, the resulting distribution of crack initiation times will indicate a preponderance of short times to crack initiation. If however, such distributions are combined with the reliability of the inspection procedure, the statistical distribution of missed initiation times can be estimated. The method used is based on Bayes theorem which permits the calculation of the 'prior' distribution (initiation times before inspection) from a knowledge of the 'posterior' distribution (initiation times obtained from the inspection) and a 'likelihood function' (reliability of the inspection) procedure. The results indicate that during an early inspection a large percentage of initiation times will be missed and that the fraction of located initiation times increases during later inspections.
The Gemini, Apollo and Space Shuttle spacecraft utilized explosive transfer lines (ETL) in a number of applications. In each case the ETL was located behind substantial structure and the risk of impact initiation by micrometeoroids and orbital debris was negligible. A current NASA program is considering an ETL to synchronize the actuation of pyrobolts to release 12 capture latches in a contingency. The space constraints require placing the ETL 50 mm below the 1 mm thick 2024-T72 Whipple shield. The proximity of the ETL to the thin shield prompted analysts at NASA to perform a scoping analysis with a finite-difference hydrocode to calculate impact parameters that would initiate the ETL. The results suggest testing is required and a 12 shot test program with surplused Shuttle ETL is scheduled for February 2012 at the NASA White Sands Test Facility. Explosive initiation models are essential to the analysis and one exists in the CTH library for HNS I, but not the HNS II used in the Shuttle 2.5 gr/ft rigid shielded mild detonating cord (SMDC). HNS II is less sensitive than HNS I so it is anticipated that these results using the HNS I model are conservative. Until the hypervelocity impact test results are available, the only check on the analysis was comparison with the Shuttle qualification test result that a 22 long bullet would not initiate the SMDC. This result was reproduced by the hydrocode simulation. Simulations of the direct impact of a 7 km/s aluminum ball, impacting at 0 degree angle of incidence, onto the SMDC resulted in a 1.5 mm diameter ball initiating the SMDC and 1.0 mm ball failing to initiate it. Where one 1.0 mm ball could not initiate the SMDC, a cluster of six 1.0 mm diameter aluminum balls striking simultaneously could. Thus the impact parameters that will result in initiating SMDC located behind a Whipple shield will depend on how well the shield fragments the projectile and spreads the fragments. An end-to-end simulation of the impact of an aluminum ball onto a Whipple shield covering SMDC is problematic due to the hydrocode fracture models. Regardless, two simulations were performed resulting in a 5 mm ball initiating the SMDC and a 4 mm ball failing to initiate the SMDC.
Mesoscale convective systems (MCSs) frequently occur over the U.S. Great Plains during summer. An analysis using self-organizing map is conducted to identify four types of summer MCS initiation environments during 2004-2017. The first two types feature favorable large-scale environments at both upper and low levels, while Type-3 has favorable lower-level and surface conditions but unfavorable upper-level circulation, and Type-4 features the most unfavorable large-scale environments for MCS initiation. Despite the unfavorable large-scale environment, the convection-centered environments in Type-4 are favorable for MCS initiation and similar to the first two types, suggesting a role of sub-synoptic disturbances as an MCS precursor. All four types of the MCS initiation delineate a clear eastward propagating feature in many fields, such as upper-level potential vorticity/geopotential height, surface pressure and surface equivalent potential temperature, upstream up to 25°-longitude west of and ~36 hours before the MCS initiation. The propagating environments and local, non-propagating low-level moisture are found to be important in MCS initiation at the foothill of the Rocky Mountains, but over the central Great Plains, it is the coupling of dynamical and moisture anomalies associated with propagating waves that results in the MCS initiation. By tracking MCSs and mid-tropospheric perturbations (MPs), a type of sub-synoptic disturbances with Rocky Mountains origin, ~30% of MPs is associated with MCS initiation, mostly in Type-4. Although MPs are related to a small fraction of MCS initiation, MCSs that are associated with MPs tend to produce more rainfall in a larger area with a stronger convective intensity, suggesting MPs to be a source of intense MCSs in summer.
Objectives/Scope: StimuFrac (US Patents 9,873,828 B2 and 9,447,315 B2), a CO2-reactive polymer aqueous solution [polyallylamine (PAA) 1wt% in water] combined with CO2, can be used as a less water-intensive fracturing fluid for enhanced geothermal systems (EGS). Our previous results show that in hot dry rock (HDR), PAA/CO2 fracturing fluids outperformed other fluids such as water, CO2, and CO2/water in generating large fractures with less fluid consumed. The objective of this work is to study the effect of initial water saturation of rock on the performance of StimuFrac fluid in ½ foot cubic rock samples and under representative EGS pressure/temperature conditions using cyclic and constant flow rate injection strategies. The fracturing results are compared with results using different fracturing fluids in terms of controlling fracture propagation rates, fracture hydraulic conductivity, breakdown pressures and volumes of fluids required. Methods/Procedures/Process: In all tests, water was initially injected into the rock to increase the water saturation before the fracturing processes to simulate actual geothermal reservoir conditions. For the cyclic injection, one complete cycle consisted of (1) a PAA slug (or water slug) injection followed by (2) CO2 injection to initiate the fracture. In the second step of the first cycle, the pressure of CO2 is increased until a maximum pressure is reached (fracture is initiated at this moment), and then the injection of CO2 is allowed for another 30 seconds to propagate the fracture. Then, the two-step cycle of PAA followed by CO2 injection (up to 2-4 mL/min) was continued. For the constant flow rate injection strategies, the initial water saturation was increased by injecting water at 1000 psi and 200°C for three days. After that, an initial slug of water, CO2, or PAA was injected and then fracturing was initiated and propagated by injecting CO2 at a constant flow rate. Applications/Significance/Novelty: The results of this study suggest that water saturation, especially near the wellbore region, will significantly affect the fracturing fluid transmission into the rock porous media by changing the relative permeability of CO2 or water, thus affecting the fracture initiation and propagation. In this study, fracturing with cyclic injection or constant flow rate injection methods were performed using three different kinds of fluids systems. These fluids are water, CO2, or CO2 with PAA. Splitting the rock samples in half after fracturing reveals that the fracture propagation is significantly limited under these high water saturated conditions compared to dry initial conditions: The fractures propagate less than 1/3 length of the distance from the wellbore to rock surface, and in some cases no fracture is generated. This may be caused by the fact that leak-off is dominating the fracturing process and the injected fluid flow rate is not high enough to overcome the leak-off even under high flow rate injection conditions. Additionally, CO2 could be leaking off into the wellbore annulus and this may be making it more difficult to generate pressure gradients away from the near-wellbore region.
Objectives/Scope: StimuFrac (US Patents 9,873,828 B2 and 9,447,315 B2), a CO 2 - reactive polymer aqueous solution [polyallylamine (PAA) 1wt% in water] combined with CO 2 , can be used as a potentially less water-intensive fracturing fluid for enhanced geothermal systems (EGS). Our previous results show that in hot dry rock (HDR), PAA/CO 2 fracturing fluids outperformed other fluids such as water, CO 2 , and CO 2 /water in generating large fractures with less fluid consumed. The objective of this work is to investigate the effect of initial water saturation on the performance of StimuFrac by conducting hydraulic fracturing tests with ½ foot cubic rock samples held under representative EGS stress/temperature conditions and by using cyclic injection strategies (under constant injection rate). The resulting fracture hydraulic conductivities, breakdown pressures, and volumes of fluids required are compared. Methods/Procedures/Process: To simulate geothermal reservoir conditions, in all tests, the rock sample was held under triaxial confinement and at 200 °C, and different volumes of water were initially injected into the rock sample before any fracturing processes were initiated. For the single-cycle PAA (or water) alternating CO 2 (PAG or WAG) injection fracturing experiments, one complete cycle consisted of two steps: (1) injecting a PAA slug (or water slug) followed by (2) injecting CO 2 to initiate and propagate the fracture. For experiments involving multiple injection cycles, the CO 2 injection pressure is increased until it peaks and begins to decline (indicating fracture initiation at this moment), and then continued being injected for another 30 seconds to propagate the fracture. Then, these two-step cycles [injection of PAA (or water) followed by CO 2 injection (up to 2-4 mL/min)] are repeated. Applications/Significance/Novelty: The results of this study suggest that water saturation significantly affects the fracturing fluid transmission into the rock pore space, thus affecting the fracture initiation and propagation. In this study, fracturing tests via a single injection cycle or multiple injection cycles were performed. Splitting the rock samples in half after testing reveals that fracture propagation is significantly limited under high water saturation conditions (three-day initial water injection) compared to stimulation experiments performed in hot dry rock. The fractures propagate less than 1/3 of the distance from the wellbore to the outer rock surface, and in some cases, no fracture is generated. This may be caused by leak-off dominating the fracturing process and the fluid injection rate is insufficient to overcome leak-off, even under high injection rate conditions. Additionally, CO 2 could be leaking off into the wellbore annulus and this may be making it more difficult to generate sufficiently high-pressure gradients away from the near-wellbore region. Under low water saturation conditions (dry rock or after 1-day initial water injection), PAA/CO 2 consistently generated significantly larger fractures compared with the other fluids. CO 2 generated large fractures only in the hot dry rock and only when using high injection rates, though data variability is high.
Fatigue cracks in additively manufactured (AMed) Inconel 718 (IN-718) in machined surface condition often initiate from persistent slip bands (PSBs) unlike other popular AM alloys such as 17-4 PH stainless steel or Ti-6Al-4V, where fatigue crack initiation is exclusively from volumetric defects; therefore, a competition between PSB- vs. defect- mediated crack initiation clearly exists. To shed light on the factors governing the competition, this study investigates the characteristics of cyclic strain localization, PSB formation, and crack initiation via crystal plasticity (CP) modeling of cyclic loading on polycrystalline aggregates which are then validated by experiments. In this work, a physics-based, free slip distance (FSD) dependent slip strength evolution law is proposed, which is shown to enable the CP model to simulate the heterogeneous strain distribution in IN-718. Implementing a crack initiation criterion based on strain contrast, the locations and lives for crack initiation can also be calculated. It is shown that both FSD and resolve shear stress influence the strain localization and crack initiation behaviors. The distribution of a localization parameter calculated based on the multiplication of FSD and Schmid factor within a grain is found to correlate well with the locations of PSBs. The maximum values of the localization parameters within a microstructure are shown to correlate well with the experimentally obtained crack initiation lives. The presence of volumetric defects in IN-718 generally do not impact strain localization behavior unless their size is large compared to the grain size.
The effect of initial perturbations on the evolution of the inclined Richtmyer-Meshkov turbulent mixing layer before and after reshock initiated by a shock wave with Mach number 1.55 is investigated through three-dimensional (3D) simulations using the flash code. The 3D simulations aim to reproduce both predominantly single-mode and multimode interfaces between light and heavy gases (N 2 -CO 2 , Atwood number, A≈0.22; amplitude to wavelength ratio of 0.088) which were created in an inclined shock tube facility to analyze the effects of initial conditions on mixing development in the entire flow field. The two-dimensional center slices of 3D simulations are compared with the experimental results to validate the computational code. Mixing width, mixed mass, mixed-mass thickness, and circulation in addition to concentration fields are shown to be in good agreement with the experimental data. The three-dimensional density and vorticity fields are first presented to qualitatively describe the flow behavior before and after reshock. Several measured density/velocity-related quantities indicate that the growth of the mixing material is strongly dependent on initial conditions. Before reshock and at early times after reshock, flow is clearly maintaining the memory of initial perturbations. However, at late time after reshock, although the large wavelength feature still dominates the flow motion, and the morphology of the two different interfaces indicates several differences, by breakdown of large-scale coherent structures to much finer scales, the memory of small scales of the multimode initial perturbation is not as clear as pre-reshock. Regarding three-dimensionality of the flow, before reshock in the multimode case, the baroclinic vorticity production, circulation, turbulent kinetic energy, and turbulent mass flux suggest that the small-scale roll-up features along the large inclined wavelength quickly evolves in all three dimensions. The coherent vortex tubes break down to smaller wormlike vortex structures, and turbulent fluctuations in the out-of-plane dimension are comparable to the spanwise direction. After reshock, this three-dimensionality of mixing growth was observed in the flow for both initial conditions. The results of this work represent a significant extension of previous computational studies performed on this specific topic. A different code with a different numerical method is validated through comparison with the experimental data. The initial perturbations are directly measured from the experimental results. Moreover, the entire three-dimensional experimental shock tube domain is simulated, and more quantities are investigated to understand the mixing mechanism and instability evolution in all three dimensions.
A program has been initiated by NASA Headquarters to validate laser initiated ordnance in flight applications. The primary program goal is to bring together a team of government and industry members to develop a laser initiated ordnance system having the test and analysis pedigree to be flown on launch vehicles. The culmination of this effort was a flight of the Pegasus launch vehicle which had two fin rockets initiated by this laser system. In addition, a laser initiated ordnance squib was fired into a pressure bomb during thrusting flight. The complete ordnance system comprising a laser diode firing unit, fiber optic cable assembly, laser initiated detonator, and laser initiated squib was designed and built by The Ensign Bickford Company. The hardware was tested to the requirements of the Pegasus launch vehicle and integrated into the vehicle by The Ensign Bickford Company and the Orbital Sciences Corporation. Discussions include initial program concept, contract implementation, team member responsibilities, analysis results, vehicle integration, safing architecture, ordnance interfaces, mission timeline and telemetry data. A complete system description, summary of the analyses, the qualification test results, and the results of flight are included.
An effectively strain-rate-free diffusion flame constitutes the most vigorous laminar combustion of initially unmixed reactive gases. Such a diffusion flame is characterized by a relatively long residence time and by a relatively large characteristic length scale. If such a flame were also planar, providing high symmetry, it would be particularly suitable for experimental and theoretical investigations of key combustion phenomena, such as multicomponent diffusion, chemical kinetics, and soot inception, growth, and oxidation. Unfortunately, a planar strain-rate-free diffusion flame is highly disrupted in earth-gravity (e.g., in a counterflow-diffusion-flame apparatus) because of the very rapid onset (approx. 100 ms) of gravity-induced instability. Accordingly, a specially dedicated apparatus was designed, fabricated, and initially checked out for the examination of a planar strain-rate-free diffusion flame in microgravity. Such a diffusion flame may be formed within a hollowed-out squat container (initially configured as 25 cm x 25 cm x 9 cm), with isothermal, noncatalytic, impervious walls. At test initiation, a thin metallic sheet (approx. 1 mm in thickness) that separates the internal volume into two equal portions, each of dimensions 25 cm x 25 cm x 4.5 cm, is withdrawn, by uniform translation (approx. 50 cm/s) in its own plane, through a tightly fitting slit in one side wall. Thereupon, diluted fuel vapor (initially confined to one half-volume of the container) gains access to diluted oxygen (initially with the same pressure, density, and temperature as the fuel, but initially confined to the other half-volume). After a brief delay (approx. 10 ms), to permit limited but sufficient-for-flammability diffusional interpenetration of fuel vapor and oxidizer, burning is initiated by discharge of a line igniter, located along that side wall from which the trailing edge of the separator withdraws. The ignition spawns a triple-flame propagation across the 25 cm x 25 cm centerplane. When a diffusion flame is emplaced in the centerplane, any subsequent travel, and change in temperature, of that planar diffusion flame may be tracked, along with the effectively spatially uniform but temporally evolving pressure within the container. Eventually, nearly complete depletion of the stoichiometrically deficient reactant, along with heat loss to the container surfaces, effects extinction. These data afford an opportunity to check theoretical models of diffusion and chemical kinetics under conditions ranging from intense burning to flame out, or, alternatively, to evolve simple empirical representations of these phenomena. Thus, the project sought to utilize microgravity testing to elucidate commonly encountered phenomenology, arising in the commonly-encountered mode of combustion (whether related to heating, manufacturing, boiling, and propulsion, or to uncontrolled, free-burning fire in structures and wildland vegetation), of those commonly utilized fuels usually categorized as gaseous fuels (such as hydrogen, natural gas, and propane, which are gaseous under atmospheric conditions).