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All sources NASA NTRS DOE OSTI

DOE OSTI2022

Immersive Industrialized Construction Environments for Energy Efficiency Construction Workforce

The National Renewable Energy Laboratory is actively developing and testing Immersive Industrialized Construction Environments (IICE) for construction automation and worker-machine interaction to investigate possible solutions and increase workforce productivity. At full scope and matured functionality, IICE allows us to accelerate the development of and better explore industrialized construction approaches such as prefabrication. IICE also enables wider adoption of energy-efficient products and Industry 4.0 construction automation through worker-machine interaction pilots. Industry 4.0 and industrialized construction approaches can encourage workforce specialization in energy efficiency construction, address the lack of multi-skilled workers, and increase workforce productivity with construction automation. However, recent attempts to integrate these concepts with the industry have only been moderately successful. To address this, focusing the pedagogy on using a digital twin, its digital models, and virtual reality could make the experience of continuing education on construction automation more affordable, accessible, scalable, immersive, and safer, and could greatly improve the efficiency and robustness of the building and construction industry. IICE accurately represents the realities of construction uncertainties without having to create full scale physical prototypes of machines. In this paper, we address the following research question: How can a digital twin and its models in virtual reality enhance the learning experience and productivity of energy efficiency construction workers to gain the skills in operating Industry 4.0 components such as construction automation and handling energy-efficient products in industrialized construction factories and on-site? We introduce original research on developing IICE and present preliminary findings from time and motion pilot studies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2020

Cross-Calibration of Terra and Aqua MODIS Using RadCalNet

The twin MODIS instruments onboard the Terra and Aqua spacecraft have been successfully operating for nearly two decades and providing complementary observations of the Earth’s land, ocean, and atmosphere. Although the two MODIS instruments view the entire Earth’s surface once every 2-3 days, simultaneous views between them are limited due to their varying orbits. Therefore, the intercomparison between these two instruments has been previously performed using a transfer instrument (such as AVHRR) or using lunar measurements normalized using a common model such as the USGS ROLO. In recent years RadCalNet, a CEOS initiative, has provided SI-traceable Top-of-Atmosphere (TOA) reflectances from a coordinated network of instrumented land-based sites. RadCalNet facilitates a unique mechanism to perform cross-calibration of instruments by minimizing the uncertainties associated with overpass time differences. In this work, the near-simultaneous TOA reflectance measurements from the Railroad Valley, US (RVUS) are used as a transfer to compare the on-orbit observations for the Terra and Aqua MODIS RSB. Near-nadir overpasses from January 2013 to January 2019 are processed and matched up with near-simultaneous RadCalNet measurements. Results show that the VIS/NIR bands agree to within 2% and the SWIR bands agree to within 5%. Also, discussed in this work are the future efforts that will be undertaken to expand this comparison to include other instruments, other sites, and both nadir- and off-nadir views after compensation for BRDF effects.

Amit Angal↗

DOE OSTI2023

An integrated data management and informatics framework for continuous drug product manufacturing processes: A case study on two pilot plants

The pharmaceutical industry continuously looks for ways to improve its development and manufacturing efficiency. In recent years, such efforts have been driven by the transition from batch to continuous manufacturing and digitalization in process development. To facilitate this transition, integrated data management and informatics tools need to be developed and implemented within the framework of Industry 4.0 technology. Here, in this regard, the work aims to guide the data integration development of continuous pharmaceutical manufacturing processes under the Industry 4.0 framework, improving digital maturity and enabling the development of digital twins. This paper demonstrates two instances where a data integration framework has been successfully employed in academic continuous pharmaceutical manufacturing pilot plants. Details of the integration structure and information flows are comprehensively showcased. Approaches to mitigate concerns in incorporating complex data streams, including integrating multiple process analytical technology tools and legacy equipment, connecting cloud data and simulation models, and safeguarding cyber-physical security, are discussed. Critical challenges and opportunities for practical considerations are highlighted.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2025

Risk-informed Graded Approach for Reliability and Performance Assessment of Machine Learning and Artificial Intelligence for Advanced Condition Monitoring Techniques

With the shift away from time-based maintenance and toward condition-based maintenance, and to reduce overall maintenance costs, there has been an upsurge in the usage and development of advanced condition monitoring (ACM) techniques for real-time monitoring of nuclear power plant (NPP) components. ACM is particularly useful in the development of digital twins, which are designed to predict the failure or degradation of plant components. Successful implementation of ACM requires an assessment to inform the development of a risk-informed approach to evaluate the use of ACM to meet Nuclear Regulatory Committee (NRC) regulations for in-service testing (IST) programs. This includes the monitoring and diagnostics of reactor components and systems in current, new, and advanced reactors. A key component in ACM is the usage of machine learning (ML) and artificial intelligence (AI) algorithms that can employ real-time data from instrumentation and sensors to detect and predict reactor component degradations. Such predictive capabilities enable early detection of component degradation so as to help plant personnel plan and execute necessary maintenance. For successful implementation of ML/AI in ACM such that regulatory requirements are met, a risk-informed graded approach is needed to assess the reliability and performance of ML/AI for ACM. The American Society for Mechanical Engineers (ASME) developed their Operations and Maintenance (O&M) Code to provide guidance on safe, reliable O&M of NPPs. The IST section of the O&M Code specifically establishes requirements for IST and examination to gauge operational readiness of components in water-cooled NPPs. This paper presents a state-of-the-art review of how reliability and risk assessment can be integrated with ACM to assess component performance by non-nuclear industries. This is followed by different methodologies and approaches for conducting performance and reliability assessments so as to meet IST requirements for NPP components.

97 - MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Risk-informed Graded Approach for Reliability and Performance Assessment for Advanced Condition Monitoring Techniques

99 - GENERAL AND MISCELLANEOUS↗

NASA NTRS1984

The multipurpose composite flywheel

The twin disk composite flywheel shows that the techniques that were developed at Rocketdyne to successfully design, fabricate, and test high-speed rotating machinery (turbopumps) for rocket engines could be used to develop advanced flywheels. This flywheel not only demonstrates that successful mating of metal flywheel characteristics (high torque and ruggedness) and composite flywheel characteristics (lightweight and high energy density) can be achieved, but the unique design lends itself to easy adaptation to other configurations.

Ginsburg, B. R.↗

DOE OSTI2020

Experimental verification of a crystal plasticity-based simulation framework for predicting microstructure and geometric shape changes: Application to bending and Taylor impact testing of Zr

This paper is concerned with experimental verification of a recently developed multi-scale simulation framework for plastic deformation of metallic materials from quasi-static to impact deformation conditions. The framework is a visco-plastic self-consistent (VPSC) polycrystalline model embedded in an implicit finite element method (FE-VPSC) to provide a microstructure-sensitive constitutive response at each material point. Each material point of the FEM model is a polycrystalline aggregate with crystallographic deformation mechanisms operating at the single crystal scale with their evolving activity based on a dislocation density-based hardening law and texture. Four beams and three cylinders machined in different orientations from a textured plate of high-purity zirconium are tested quasi-statically in 4-point bending and at speeds of 100 m/s, 170 m/s and 243 m/s during Taylor impact tests, respectively. The variation in dimensional changes resulting from different sample orientations in the plate with respect to loading directions is measured for each sample. Moreover, texture and twinning characterization is performed using electron backscattered diffraction (EBSD). The deformation processes and underlying evolution of microstructure are successfully simulated using the FE-VPSC framework. In doing so, the model parameters are optimized and validated across a broad range of strain rates and temperatures. Simulation results in terms of geometrical changes and microstructural evolution are compared with the experimental measurements. The model predicts anisotropic material flow resulting from the hard-to-deform crystallographic directions, the development of gradients in texture and twinning through the geometries, tension–compression asymmetry, as well as the extent of plasticity under impact.

42 ENGINEERING↗

NASA NTRS2012

Gravity Recovery and Interior Laboratory (GRAIL) Mission: Mission Status and Initial Science Results

The Gravity Recovery and Interior Laboratory (GRAIL) Mission is a component of the NASA Discovery Program. GRAIL is a twin-spacecraft lunar gravity mission that has two primary objectives: to determine the structure of the lunar interior, from crust to core; and to advance understanding of the thermal evolution of the Moon. GRAIL launched successfully from the Cape Canaveral Air Force Station on September 10, 2011, executed a low-energy trajectory to the Moon, and inserted the twin spacecraft into lunar orbit on December 31, 2011 and January 1, 2012. A series of maneuvers brought both spacecraft into low-altitude (55-km), near-circular, polar lunar orbits, from which they perform high-precision satellite-to-satellite ranging using a Ka-band payload along with an S-band link for time synchronization. Precise measurements of distance changes between the spacecraft are used to map the lunar gravity field. GRAIL completed its primary mapping mission on May 29, 2012, collecting and transmitting to Earth >99.99% of the possible data. Spacecraft and instrument performance were nominal and has led to the production of a high-resolution and high-accuracy global gravity field, improved over all previous models by two orders of magnitude on the nearside and nearly three orders of magnitude over the farside. The field is being used to understand the thickness, density and porosity of the lunar crust, the mechanics of formation and compensation states of lunar impact basins, and the structure of the mantle and core. GRAIL s three month-long-extended mission will initiate on August 30, 2012 and will consist of global gravity field mapping from an average altitude of 22 km.

Neumann, Gregory A.↗

DOE OSTI2023

Enabling Recycling of Composites: Understanding the Impacts of Multiple Thermal Processing Cycles

When considering the utilization of recycled short carbon fiber feedstock materials for advanced manufacturing, understanding the material degradation behavior is essential in determining how many times a composite material can be effectively reprocessed and remanufactured. This study characterizes the degradation behavior of short carbon fiber acrylonitrile butadiene (CF-ABS) that has been reprocessed five times with twin screw extrusion. Parallel plate rheology was completed to observe the degradation in complex viscosity of the recycled feedstock materials. Gel permeation chromatography (GPC) was utilized to characterize the changes in molecular weight distribution of the recycled materials as a result of thermal and mechanical degradation during the re-processing steps. Rheological characterization, GPC, and twin-screw processing data help inform the process optimizations required to process the recycled feedstock material. Successful characterization of the degradation behavior of short fiber composite feedstock materials aids in increased understanding of the lifespan of high value carbon fiber composite materials and aids in process optimization of recycled composite materials.

Walker, Roo↗

NASA NTRS1998

Synergistic Airframe-Propulsion Interactions and Integrations: A White Paper Prepared by the 1996-1997 Langley Aeronautics Technical Committee

This white paper addresses the subject of Synergistic Airframe-Propulsion interactions and integrations (SnAPII). The benefits of SnAPII have not been as extensively explored. This is due primarily to the separateness of design process for airframes and propulsion systems, with only unfavorable interactions addressed. The question 'How to design these two systems in such a way that the airframe needs the propulsion and the propulsion needs the airframe?' is the fundamental issue addressed in this paper. Successful solutions to this issue depend on appropriate technology ideas. This paper first details some ten technologies that have yet to make it to commercial products (with limited exceptions) and that could be utilized in a synergistic manner. Then these technologies, either alone or in combination, are applied to both a conventional twin-engine transonic transport and to an unconventional transport, the Blended Wing Body. Lastly, combinations of these technologies are applied to configuration concepts to assess the possibilities of success relative to five of the ten NASA aeronautics goals. These assessments are subjective, but they point the way in which the applied technologies could work together for some break-through benefits.

Yaros, Steven F.↗

DOE OSTI2024

Deciphering the crystal structure of a novel nanobody against the NEIL1 DNA glycosylase

Nanobodies (VHHs) are single-domain antibodies with three antigenic CDR regions and are used in diverse scientific applications. Here, an ∼14 kDa nanobody (A5) specific for the endonuclease VIII (Nei)-like 1 or NEIL1 DNA glycosylase involved in the first step of the base-excision repair pathway was crystallized and its structure was determined to 2.1 Å resolution. The crystals posed challenges due to potential twinning and anisotropic diffraction. Despite inconclusive twinning indicators, reprocessing in an orthorhombic setting and molecular replacement in space groupP2 1 2 1 2 enabled the successful modeling of 96% of residues in the asymmetric unit, with finalR work andR free values of 0.199 and 0.229, respectively.

Biochemistry & Molecular Biology↗

NASA NTRS2018

Lessons Learned from the Investigation of an Anomalous Termination of BETTII

The Balloon Experimental Twin Telescope for Infrared Interferometry (BETTII) mission launched from Palestine, Texas in June 2017. After an exciting launch and successful cruise, the BETTII gondola suffered an anomalous event at termination. BETTII separated from its parachute and free-fell 136,000 feet into the west Texas desert. This event was classified as a "close-call" and investigated as such. We present here the recovery effort required to find the payload and extract the payload from its impact site. We also present lessons learned from the event and results from the investigation, the design for the next BETTII gondola, and a path forward for return to flight.

Veach, Todd J.↗

NASA NTRS1983

Models and analysis for twin-lift helicopter systems

The major limitation of a modern helicopter with respect to its employment in transport operations has been a relatively small payload size. Among several ideas for overcoming this limitation are a number of multiple-lift schemes using two or more helicopters to lift payloads too large for a single helicopter. On a number of occasions, pairs of helicopters carrying a single load have been successfully employed. However, a considerable amount of flying skill was required in these cases in connection with the manual control tasks involved. Some form of automatic control will, therefore, be needed until twin-lift operations become generally practical. The present investigation is concerned with the development of models of the Twin-Lift System which can be used as a basis for the design of automatic control.

Lewis, J.↗

NASA NTRS1994

Twin engine afterbody model

This test was originally conducted to determine the effects of several empennage and afterbody parameters on the aft-end aerodynamic characteristics of a twin-engine fighter-type configuration. Model variables were as follows: horizontal tail axial location and incidence, vertical tail axial location and configuration (twin-vs single-tail arrangements), tail booms, and nozzle power setting. Jet propulsion was simulated by exhausting high-pressure, cold-flow air from the nozzles. Following a successful test conducted on a single engine nacelle model to validate a CFD code, this model was chosen to be instrumented with pressure taps on the afterbody and nozzles and used as a follow-on test, providing a more complex geometry for the CFD code validation. A more limited test matrix was run to collect the pressure data, employing only the twin-tail configuration and varying only the horizontal and vertical tail locations. Mach number was varied from 0.6 to 1.2. Nozzle pressure ratio was varied from jet-off to 8. Angle-of-attack varied from 0 to 8 deg.

Wing, David J.↗

DOE OSTI2025

Development of a Multi-Robot System for Autonomous Inspection of Nuclear Waste Tank Pits

This paper introduces the overall design plan, development timeline, and preliminary progress of the Autonomous Pit Exploration System project. This project aims to develop an advanced multi-robot system for the efficient inspection of nuclear waste-storage tank pits. The project is structured into three phases: Phase 1 involves data collection and interface definition in collaboration with Hanford Site experts and university partners, focusing on tank riser geometry and hardware solutions. Phase 2 includes the selection of sensors and robot components, detailed mechanical design, and prototyping. Phase 3 integrates all components into a cohesive system managed by a master control package which also incorporates digital twin and surrogate models, and culminates in comprehensive testing and validation at a simulated tank pit at the Idaho National Laboratory. Additionally, the system’s communication design ensures coordinated operation through shared data, power, and control signals. For transportation and deployment, an electric vehicle (EV) is chosen to support the system for a full 10 h shift with better regulatory compliance for field deployment. A telescopic arm design is selected for its simple configuration and superior reach capability and controllability. Preliminary testing utilizes an educational robot to demonstrate the feasibility of splitting computational tasks between edge and cloud computers. Successful simultaneous localization and mapping (SLAM) tasks validate our distributed computing approach. More design considerations are also discussed, including radiation hardness assurance, SLAM performance, software transferability, and digital twinning strategies.

Nuclear waste management↗

NASA NTRSDate not supplied

NASA’s Safety, Reliability, and Mission Assurance Digital Future

The evolution from “document-centric” to “data-centric” and “model-centric” information leveraging structured data and model-based approaches is at the heart of digital engineering transformational efforts underway across industry and government. It is these approaches that pave the way for data lakes, Authoritative Sources of Truth (ASOTs), and systems- of-systems interoperability and the corresponding transformational benefits thereof. Such benefits include increased data availability, data access equity, data traceability, real-time analytics, batch analytics, and (most importantly) acceleration of the time-to-value and time-to-insights associated with engineering products and analyses. The longer-term benefits of reusability, customization and traceability are even more promising. For Safety and Mission Assurance (SMA), and Mission Success (SMS) activities; realization of such benefits is essential to provide engineers and analysts alike vital information when needed to support critical decision making throughout the entire life cycle. The SMA community often operate in parallel with engineering activities, for which information exchange with relevant context is paramount. Far too often, such information lags key decision points and/or is absent of the robust, integrated, knowledge needed, given inherent barriers associated with traditional document-centric means to data sharing, analysis, and reporting. This paper provides an overview of how NASA’s Office of Safety and Mission Assurance (OSMA) is evolving its policies, standards, guidance, and training to transform to eliminate such barriers, thus realizing the benefits emerging in this new digital era. A roadmap for achieving this digital future is presented along with key building blocks involving use and implementation of concepts such as: Objectives-Hierarchies, Objective-Driven Requirements, Accepted Standards, Safety and Assurance Cases, data digitization (i.e., ontologies, structured data, and model-centric data), FAIR (Findable, Accessible, Interoperable, & Reusable) and/or FAIRUST (Findable, Accessible, Interoperable, Reusable, Understandable, Secure, and Trusted) principles [1]. This paper also describes how OSMA, leveraging the Agency’s overall commitment to Digital Transformation (DT), is using the power of Policy, “Digital” Domain representation, Product Evolution, and Community Outreach and Engagement as part of a strategic vision and roadmap to evolve and transform its SMA organizations to become better able to serve its stakeholders and customers. Future publications will elaborate on these building blocks and deeper concepts.

Authoritative Source of Truth (ASOT),↗

NASA NTRS2018

Attitude Control System for a Balloon Based Telescope

The Balloon Experimental Twin Telescope for Infrared Interferometry (BETTII) is an 8-meter interferometer which operates on a high-altitude balloon. BETTII had its first successful engineering flight in June 2017. In this paper we discuss the design of the control system for BETTII, which includes the coarse pointing loop and the estimator controls algorithm (Extended Kalman Filter) implemented in FPGA. We will also discuss the different system modes that we defined in the controls system loop, which are used in different phases of the flight and are activated in order to acquire a target star in the science detector. The pointing loop uses different sensors and actuators in each phase to keep pointing at the desired target. The main sensors aregyroscopes, star cameras, and auxiliary sensors such as high-altitude GPS and magnetometers. The azimuth control is achieved with Compensated Controlled Moment Gyros (CCMG) and a Momentum Dump motor. For the elevation control, high-precision motors are used, which change the elevation of the siderostat mirrors. The combination of these instruments keep the baseline oriented within few arcseconds from the target star.In this paper, we will also present the software architecture relevant to the control system. This includes the description of the two flight computers present on the payload and the different control loops that are executed on them. Similarly, we will explain the importance of synchronization between all the sensors and actuators, which have to be referenced to a single master clock in order to obtain science data.

Vila Hernandez De Lorenzo, Jordi↗

DOE OSTI2021

Twinning Enhances Efficiencies of Metallic Catalysts toward Electrolytic Water Splitting

Twinning is demonstrated to be an effective way of enhancing efficiencies of metallic catalysts toward electrolytic water splitting. Dendritic Cu possessing dense coherent nanotwin (NT) boundaries (NTCu-5nm) is successfully prepared with an organic-assisted electrodeposition at high pulse current densities. NT boundaries significantly improve electrocatalytic efficiencies and stability of NTCu-5nm over nanocrystalline Cu (NCCu), reducing overpotentials at 10 mA cm -2 for the oxygen evolution reaction (OER) from 378 to 281 mV and from 235 to 88 mV for the hydrogen evolution reaction (HER), with a small chronoamperometric decay of 5% after 100 h continuous overall water splitting at an ultrahigh initial current density of 500 mA cm -2 , largely outperforming the large chronoamperometric decay of 27% for only 1 h operation of the NCCu//NCCu couple. The defective twin boundaries enable formation of active Cu III O 2 - at low overpotentials, thus enhancing OER performance. Furthermore, the synergistic geometric and electronic effects induced by the twin boundaries result in shifts in Gibbs free energies of hydrogen adsorption (ΔG H ) toward the apex of a volcano plot of exchange current density versus ΔG H , leading to the remarkable improvement in HER activity.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗