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NASA NTRSDate not supplied

Lessons Learned From the Construction of a Portable Cleanroom for NASA OSIRIS-REx Mission Deintegration

NASA Johnson Space Center (JSC) Infrastructure and Astromaterials Acquisition & Curation Office completed construction and commissioning of the OSIRIS-REx (OREx) Deintegration portable cleanroom at the Utah Test and Training Range (UTTR). The new portable cleanroom was designed to receive the OREx sample return capsule from the landing point on the range to an ISO7 environment. Scientists used the portable clean-room to deintegrate the sample canister from the sample return capsule. Once separated, the sample canister was put in a container under nitrogen purge for transportation to B31 at the Johnson Space Center for astromaterial sample extraction, preliminary analysis, and long-term curation. The portable cleanroom was built by a subcontractor at their facility and then deconstructed to be transported to the remote location at UTTR. Since construction was completed in a remote location all tools and materials had to be transported from contractor site in Dallas, TX. The cleanroom was constructed within an existing facility, which provided conditioned air, electric power, and protection from the elements. Careful coordination was required between the host facility, cleanroom contractor, mission scientists, and JSC facilities and curation personnel. An existing anteroom at JSC was transported to UTTR and added to the portable cleanroom after there was concern about contamination without one for personnel entry/exit. The scientific study of organics is critical for the mission, so a stringent contamination control plan was implemented for low organics. Given these mission requirements the cleanroom construction materials were carefully selected to not hinder the scientific search for amino acids and the study of organics in the samples. The same cleanroom contractor that built the long-term astromaterial curation cleanroom back at JSC Houston, TX was selected to build the portable cleanroom and instructed to use the same materials. The cleanroom had double doors to open and allow the sample return capsule to fit into the cleanroom on its stand and be transferred to a clean stand already in the cleanroom. The portable cleanroom successfully completed its mission and the sample canister was safely deintegrated and transported to JSC under nitrogen purge.

astromaterials curation↗

NASA NTRSDate not supplied

Portable Cleanroom for NASA OSIRIS-REx Mission Deintegration

astromaterials curation↗

DOE OSTI2019

Enabling Staged Pressurized Oxy-Combustion: Improving Flexibility and Performance at Reduced Cost

Introduction: The staged pressurized oxy-combustion (SPOC) process, developed by Washington University in St. Louis (WUSTL), is an oxy-combustion carbon capture technology that employs a steam power cycle to generate electricity. As with atmospheric-pressure oxy-combustion processes, carbon dioxide (CO 2 ) capture rates of 90% or higher can be achieved. The staged-combustion approach of the SPOC process, when operated at elevated gas pressure, allows for near elimination of flue gas recycle (FGR) and leads to significant improvements in efficiency and reduced costs. The primary goal of this project was to investigate the potential for SPOC for flexible operation beyond the capabilities of conventional coal-fired power plants, particularly those employing carbon capture and storage (CCS). Oxy-combustion differs from conventional coal combustion in that the combustion of coal is carried out using oxygen as opposed to air. The resultant flue gas is a mixture of primarily CO 2 and water, greatly simplifying CO 2 capture. As SPOC does the oxy-combustion process under pressure, it is higher efficiency and lower cost than atmospheric oxy-combustion. The project was led by the Electric Power Research Institute, Inc., with the assistance of WUSTL, Doosan Babcock (DBL – boiler plant original equipment manufacturer), and Air Liquide (AL – air separation experts). The specific objectives of the project were to: (1) Evaluate the SPOC concept and develop a risk-based approach to the heating surface layout ensuring that performance (gas and steam side), manufacturing, transportation, and plant erection considerations were fully accounted for in the system design. (2) Improve the technology to ensure its performance and cost potential are substantially better than today’s baseline pulverized coal power plant with post-combustion capture (PCC) or atmospheric oxy-combustion, and show progress toward performance commensurate with projected commercial operation, including 90% or more CO 2 capture. (3) Address critical technology gaps and improving overall system performance for the technology. (4) Perform combustion tests at scale under commensurate pressure to the commercial operating system validate combustor and advance the SPOC combustion modeling tools that will facilitate full-scale design. Combustion Testing: Testing was initially carried out at atmospheric pressure with methane to ensure that all systems were correctly operating. Following this, the testing then proceeded to moderate pressure operation at 4 bara, where different stoichiometric conditions were used across an extended heat input range, showing that a stable flame could be maintained. Testing then proceeded at 10 and 15 bara where it was shown that the ignition system needed to be replaced at these operating conditions. When testing recommenced, a similar stable flame shape was achieved, without any methane support, and the full 100 kWth coal oxy-combustion was demonstrated. Heat flux measurements showed 400 kW/m 2 (0.126 MMBtu/hr-ft 2 ) from the flame, within the 450 kW/m 2 (0.142 MMBtu/hr-ft 2 ) preferred limit defined by DBL for the full-scale design case. Carbon monoxide and carbon-in-ash measurements showed that complete combustion was possible with ultra-low excess oxygen at 1 vol % in the product flue gas. This allowed the full-scale models to be calculated based on this level of excess oxygen, improving the performance of the system as lower feed oxygen is produced in the air separation unit (ASU), saving auxiliary power. Full-Scale Design: The full-scale design is sized to deliver 550 MWe net electrical power output to allow direct comparison with the National Energy Technology Laboratory (NETL) baseline cases using the same Montana Powder River Basin (PRB) fuel. The cases used for direct comparison are: Case S12A (supercritical [SC] coal without CO 2 capture), Case S12B (SC coal with PCC at 90% CO 2 capture, and Case S12F (atmospheric oxy-combustion SC coal with 90% CO 2 capture). The SPOC stages were configured to be identical arrangements, allowing for a more straightforward design, construction, and control strategy. Each stage consists of two PVs, the first being the combustor PV module and the second being the convective PV module. The combustor module is the tallest vessel, with local coal feeding equipment and the burner FGR and oxygen plenums at the top and ash management at the bottom. The combustor module is effectively an open cross section with membrane tubes around the circumference – this unobstructed slender profile ensures that the relatively slower burnout mechanism needed for the low-speed turbulent mixing burner can proceed unimpeded and that molten ash will not attach to any surfaces at an angle to the predominant flue gas flow. The steam turbine used in the SPOC design is essentially the same unit utilized in the atmospheric oxy-combustion case except the degree of heat recovery possible allows the low-pressure (LP) feedwater heater train to be eliminated. This is a result of being able to capture the latent heat of evaporation of the moisture produced in the combustion (normally lost to the stack). The SPOC system outperforms the NETL atmospheric oxy-combustion baseline case by 3.3% points and the PCC case by 7.5% points. This performance increase is mainly a result of the improved heat recovery possible from the product flue gas and from the reduced auxiliary power consumption from the ASU and the CO 2 compression and purification unit over the atmospheric equivalent. The combined improvement in boiler efficiency and reduction in the steam turbine heat rate resulted in a net improvement in the overall plant efficiency by 0.61%, to 35.6% on a HHV basis. This relatively small improvement in plant efficiency between sub-bituminous and bituminous coals shows the value of useful moisture latent heat recovery offered by the SPOC system when using low rank fuels. Flexibility and Turndown: The SPOC system has inherent high turndown capabilities because of a demonstrated high range of combustion stability and the ability to bypass stages, thereby reducing steam generation rates proportionally without altering firing rates in operating stages. ASU units do not generally offer significant turndown opportunities as they are limited by the performance of the compression plant. The baseline SPOC design has a 2-train ASU configuration, needed to be able to meet the 10,500 tonnes per day duty, that can deliver efficient turndown points between 85–100% load with both trains operating, and at 45–50% load with a single train operating. Outside these operating points, the flexibility and efficiency are limited and may be uncompetitive at loads below 45% as the ASU systems are unable to turndown beyond 85% for the base case and 70% for the flexible case. The ASU cold box for the flexible case was designed to operate at loads between 40-100%, below this operating range the purity of the produced oxygen cannot be guaranteed, resulting in additional load for the CPU equipment. The additional power consumption of these cases yields an uneconomic operating condition with poor efficiency when operating at low loads such as 25% and 12%. To address this flexibility constraint, AL evaluated how the ASU configuration could be altered to deliver efficient oxygen supply over the load range. This involved integrating the compressor duties across both ASU trains into a shared duty arrangement with multiple compressors, strategically sized to deliver the duty required across all load ranges between 40–100% by enabling different combinations of the main air compressors and the booster air compressors. The oxygen purity cannot be guaranteed below 40% load for each train – the power consumption at 25% and 12% loads were estimated based on the multi-compressor configuration at maximum turndown as these load cases were not considered in the flexible ASU design. With a different cold box configuration, i.e. number of trains, the entire load range could be delivered within oxygen purity specifications. Although there is a small efficiency reduction at full load, there are significant improvements in overall plant performance during low-load operation. The exact ASU configuration needed will therefore be dependent on the expected operating profile of the unit. Economic Analysis: Cost estimates for the baseline and the flexible cases were developed using NETL baseline case data for common BOP items and an Association for the Advancement of Cost Engineering International Class 5 (conceptual/screening study) assessment of key components unique to the SPOC system. The capital, operating, and maintenance costs were assessed along with the first-year power cost, levelized cost of electricity, and CO 2 captured and avoided cost for the SPOC cases were compared against the relevant NETL baseline cases in January 2019 dollars. Both SPOC cases achieve a lower cost that the alternative NETL baseline cases (with the flexible SPOC case being slightly higher than the baseline SPOC case due to the compounded impact of higher capital costs and lower efficiency at full load). The SPOC cases deliver a lower cost of CO 2 avoided than the NETL baseline cases due to greater efficiency in generating low-carbon power. However, the cost of CO 2 captured is higher because the higher efficiency of the SPOC process generates less CO 2 , hence less needs to be captured, resulting in a high capital cost being shared over a reduced CO 2 quantity. The flexible ASU adds 1.6% overall to the plant cost in comparison to the baseline case, but the efficiency improvements at loads below 50% are significant. Subsequently, depending on the plant load-profile expectation, the flexible ASU would be beneficial if the plant spends a significant portion of its operating life below 50% load. This kind of operating profile is likely to be required for all fossil plants when more renewable electricity generators are installed on the local grid, particularly solar power that can be predicted ahead of time, allowing for appropriate pricing signals to be incorporated into the diurnal cycle. R&D Recommendations: SPOC, while a promising technology, is a relatively recent concept and, as such, operability issues of combustor design and steam-side integration for such systems at a scale relevant to commercial deployment have not been evaluated. WUSTL has conducted extensive small pilot-scale (100 kWth) research to understand and advance pressurized oxy-combustion processes, including investigation of combustion and flame characteristics, radiative heat flux, burner operability, turn down, char burnout, ash characteristics, water-wash column operation, etc. for pressurized oxy-combustion systems. Nonetheless, at this stage in the development of the SPOC process, what is needed is a large-scale pilot plant that can serve to study pressurized oxy-combustion systems and components at a scale commensurate with the maturity of the technology. A scale of 10 MWth, which includes steam-side integration and two stages would yield essential information with respect to heat transfer characteristics both in the radiative and convective sections of the pressure vessels, and the ability to operate the fuel staging process. In addition, while modeling results indicate that combustion and flame characteristics improve with scale, direct studies of the combustor at this scale will ensure that the models can be relied upon for scale up to commercial scale. Furthermore, a detailed analysis must be performed to understand the scaling aspects of key components and systems.

20 FOSSIL-FUELED POWER PLANTS↗

NASA NTRS2003

Data Access Tools And Services At The Goddard Distributed Active Archive Center (GDAAC)

As one of the largest providers of Earth Science data from the Earth Observing System, GDAAC provides the latest data from the Moderate Resolution Imaging Spectroradiometer (MODIS), Atmospheric Infrared Sounder (AIRS), Solar Radiation and Climate Experiment (SORCE) data products via GDAAC's data pool (50TB of disk cache). In order to make this huge volume of data more accessible to the public and science communities, the GDAAC offers multiple data access tools and services: Open Source Project for Network Data Access Protocol (OPeNDAP), Grid Analysis and Display System (GrADS/DODS) (GDS), Live Access Server (LAS), OpenGlS Web Map Server (WMS) and Near Archive Data Mining (NADM). The objective is to assist users in retrieving electronically a smaller, usable portion of data for further analysis. The OPeNDAP server, formerly known as the Distributed Oceanographic Data System (DODS), allows the user to retrieve data without worrying about the data format. OPeNDAP is capable of server-side subsetting of HDF, HDF-EOS, netCDF, JGOFS, ASCII, DSP, FITS and binary data formats. The GrADS/DODS server is capable of serving the same data formats as OPeNDAP. GDS has an additional feature of server-side analysis. Users can analyze the data on the server there by decreasing the computational load on their client's system. The LAS is a flexible server that allows user to graphically visualize data on the fly, to request different file formats and to compare variables from distributed locations. Users of LAS have options to use other available graphics viewers such as IDL, Matlab or GrADS. WMS is based on the OPeNDAP for serving geospatial information. WMS supports OpenGlS protocol to provide data in GIs-friendly formats for analysis and visualization. NADM is another access to the GDAAC's data pool. NADM gives users the capability to use a browser to upload their C, FORTRAN or IDL algorithms, test the algorithms, and mine data in the data pool. With NADM, the GDAAC provides an environment physically close to the data source. NADM will benefit users with mining or offer data reduction algorithms by reducing large volumes of data before transmission over the network to the user.

Pham, Long↗

NASA NTRS2002

Active Control of Combustor Instability Shown to Help Lower Emissions

In a quest to reduce the environmental impact of aerospace propulsion systems, extensive research is being done in the development of lean-burning (low fuel-to-air ratio) combustors that can reduce emissions throughout the mission cycle. However, these lean-burning combustors have an increased susceptibility to thermoacoustic instabilities, or high-pressure oscillations much like sound waves, that can cause severe high-frequency vibrations in the combustor. These pressure waves can fatigue the combustor components and even the downstream turbine blades. This can significantly decrease the safe operating life of the combustor and turbine. Thus, suppression of the thermoacoustic combustor instabilities is an enabling technology for lean, low-emissions combustors. Under the Aerospace Propulsion and Power Base Research and Technology Program, the NASA Glenn Research Center, in partnership with Pratt & Whitney and United Technologies Research Center, is developing technologies for the active control of combustion instabilities. With active combustion control, the fuel is pulsed to put pressure oscillations into the system. This cancels out the pressure oscillations being produced by the instabilities. Thus, the engine can have lower pollutant emissions and long life.The use of active combustion instability control to reduce thermo-acoustic-driven combustor pressure oscillations was demonstrated on a single-nozzle combustor rig at United Technologies. This rig has many of the complexities of a real engine combustor (i.e., an actual fuel nozzle and swirler, dilution cooling, etc.). Control was demonstrated through modeling, developing, and testing a fuel-delivery system able to the 280-Hz instability frequency. The preceding figure shows the capability of this system to provide high-frequency fuel modulations. Because of the high-shear contrarotating airflow in the fuel injector, there was some concern that the fuel pulses would be attenuated to the point where they would not be effective for control. Testing in the combustor rig showed that open-loop pulsing of the fuel was, in fact, able to effectively modulate the combustor pressure. To suppress the combustor pressure oscillations due to thermoacoustic instabilities, it is desirable to time the injection of the fuel so that it interferes with the instability. A closed-loop control scheme was developed that uses combustion pressure feedback and a phase-shifting controller to time the fuel-injection pulses. Some suppression of the pressure oscillations at the 280-Hz instability frequency was demonstrated (see the next figure). However, the overall peak-to- peak pressure oscillations in the combustor were only mildly reduced. Improvements to control hardware and control methods are being continued to gain improved closed-loop reduction of the pressure oscillations.pulse the fuel at

DeLaat, John C.↗

NASA NTRS2024

Integrated Simulations of the Sabatier and Carbon Vapor Deposition Reactor to Understand Its Impacts to Operations and Performance

The carbon vapor deposition (CVD) reactor is a technology developed by Honeywell Aerospace to convert methane, at high temperatures, into hydrogen and solid carbon. This element is coupled with a Sabatier reactor to support a closed-loop environmental control and life support system with the aim of achieving nearly complete oxygen recovery (> 95%). Initial open-loop, brassboard CVD reactor tests and simulations have shown the CVD’s ability to achieve moderately high methane conversion and high hydrogen selectivity. However, in an integrated system, additional deficiencies are expected due to recycling of unreacted or extraneous species from the Sabatier reactor (e.g., carbon dioxide, hydrogen, water) and CVD reactor (e.g., hydrocarbons, methane, etc.). Sabatier and CVD reactor models were integrated and simulated to predict potential impacts to individual reactors’ and the overall system’s performance. The simulations showed that increasing the recycle of the CVD effluent hydrogen combined with decreasing the system inlet hydrogen flow rate (i.e., drawing a stoichiometric flow rate from an electrolyzer) can lead to an oxygen recovery of > 95%. However, system integration comes at a detriment to the individual reactors. The simulations show the initial conversion from the integrated system (Sabatier = 87% and CVD = 59%) to be lower than the standalone systems (Sabatier = 91% and CVD = 69%). Furthermore, transient simulations show substrate densification, leading to worsening methane conversion coupled with increasing acetylene production, which is commensurate with soot formation. Simulations predict a shortening of the maintenance interval (i.e., time until CVD methane conversion drops below 50%) in the integrated system, which would increase the consumable substrate mass. These analyses highlight the importance of long-duration, integrated tests to corroborate these findings as well as suggest potential modifications (e.g., intermediate gas separations) to improve performance.

Air Revitalization↗

DOE OSTI2019

R and DE Robotic Sensor Intern Team: Remote 3D Mapping Overview

The Department of Energy (DOE) nuclear complex includes many hazardous and challenging environments that must be inspected remotely and routinely for structural integrity evaluation and long-term planning purposes. The H-Canyon Air Exhaust (HCAEX) Tunnel biannual inspection is an example of such an environment. Presently inspections are performed by teleoperated robotic crawlers provide low resolution video feedback to the structural engineers. Advanced sensors such as Lidar and panospheric hi-res cameras have the potential to provide additional valuable data in future inspections. UT-Austin Lidar work in support of an H-Canyon deployment began with the DOE EM sponsored H-Canyon Integrated Research Project. The R and DE Robotic Sensor intern team includes two of the UT-Austin Masters students working on Lidar development to facilitate the pulling of university developed solutions to the field. The goal of this project is to develop a suite of sensors that could be used to gather advanced data in future HCAEX tunnel inspections. Of particular interest is the ability to map the tunnel walls at an accuracy that will allow for the comparison of two scans performed at different time periods to estimate the concrete erosion rate. Additionally, the development of the 3D point cloud in the GPS denied environment is the first step in being able to collect and overlay other 3D data such as radiation mapping. Project specific goals include: - Design and develop 3D mapping sensor suite. Merge Lidar point cloud with high res camera images Incorporate Inertial Measurement Unit (IMU) to assist with positioning. - Develop sensor software and user GUI Sensor data collection and integration software User GUI for reach back system. - Test solution on crawler in tunnel test bed Use crawler base similar to H-Canyon planned crawler Design and build test bed simulating tunnel conditions. To facilitate rapid sensor integration, software coding and user GUI development, the Robot Operating System (ROS) was employed as the development platform. ROS is a set of open source software libraries and tools that assist with the building of robot applications. ROS includes drivers for many sensors, state-of-the-art algorithms, and powerful developer tools. Sensors selected for the summer intern solution included assessment as to whether they possessed ROS drivers and associated sample code. Additionally, the ROS 3D Robot Visualizer (rviz) tool has been employed.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

Remote Dismantling and Packaging of the RPV and Thermal Shield at the Obrigheim NPP - 16073

The Obrigheim Nuclear Power Plant (KWO) is located in the Federal State of Baden- Wuerttemberg in Germany and was operated by the EnKK-KWO. The Nuclear Power Plant - a light water pressurized water reactor with 357 MW of electrical power - was operated from 1968 to 2005. In June 2009 the Energiewerke Nord GmbH (EWN) was charged with the dismantling planning and dismantling of the reactor. According to the German nuclear and radiation protection law, several licenses will be required for the realisation of this task. This also applies to the disposal of the waste produced by dismantling, which must finally be stored in the German final repository for low and medium-radioactive waste (underground repository 'Konrad'). In spring 2010 EWN completed all application documents for the dismantling of the reactor pressure vessel (RPV) and the RPV internals and EnKK-KWO delivered them to the responsible Environmental Ministry of Baden-Wuerttemberg. Since then it has been worked intensively on the design, construction and manufacturing of the facilities for dismantling. With a separate notification of amendment, it was applied for the license to install and commission the facilities for the dismantling of the RPV and the RPV internals at the Environmental Ministry of Baden-Wuerttemberg in October 2010. This notification of amendment was confirmed in summer 2012. In September 2011 the work process and test plan and the technical information about the campaign for the removal of the radioactive waste resulting from the RPV with internals, peripheral components and secondary waste with the aim of final disposal in the Federal Repository 'Konrad' was submitted to the Federal Office for Radiation Protection. The evaluation and assessment of the work process and test plan was concluded in August 2013, when it was audited by TUV Nord EnSys without any further measures and indications. On September 10 the work process and test plan was released by the Federal Office for radiation protection. The dismantling of the RPV internals upper core and lower core structure started in September 2013 in the wet cutting area in room 01.106/306 and were finished in October 2014. In the presentation 'Dismantling of the Obrigheim NPP Reactor and Waste Management' held on the WM Symposia in Phoenix, 2014, an overview about the remote cutting and packaging of the upper and lower core structure was given. In today's presentation the subsequent dismantling activities will be outlined and evaluated. The presentation will start with the short description of the basic frame conditions for the nuclear licensing procedure, important procedural principles, and necessary plant-specific conditions. After the remote cutting and packing of the reactor internals of the upper and lower core structure was completed, the wet cutting area 'reactor room 01.106/306' was cleaned and the reactor room rebuilt into a cutting area for peripheral components. After the peripheral components were dismantled, all preconditions were set to lift the RPV from its mounting position and to arrange it in the upper reactor room 01.306. After these activities were completed, the lifting of the RPV was prepared and the cutting area 'Dismantling of the RPV insulation in the reactor room 01.106/306' was set up. To carry out this task, a strand jack unit with connection block was installed on the bridge of the reactor building crane. The opening created by the dismantling of the pool plate was closed with a flap door. The manipulators used for the wet cutting of the RPV internals were also used for the remote dismantling of the RPV insulation and mounted in the cutting area. The remote facilities were handled from a control centre and/or control stand. The air-technical housing which has already been used for the remote dismantling of the RPV internals was designed for the dismantling of the RPV insulation and was extended for this dismantling scope with appropriate ventilation systems. A special feature is the fixation of the RPV insulation at the RPV corpus. The RPV insulation consists of insulation wool, wire mesh and metal-sheet insulation. This 'Sandwich Construction' is detached with a steel corset at the RPV corpus and partly tightened. The insulation of the RPV bottom dome is tightened at the supporting frame. Due to the activation of the material in the core area and the resulting high ambient dose rate the RPV insulation can only be dismantled remotely. Additionally, as asbestos fibers are expected to be found in the insulation the dismantling has to be performed according to the Technical Rules for hazardous substances. The demolition, restoration or maintenance works have to be performed remotely according to the Technical Rules for hazardous substances when the RPV is located in the cutting area. But in case of dismantling of a power reactor no such experience can be found. Beginning with the explanation of the technical, radiological and substantial boundary conditions this presentation will not only impart knowledge about the dismantling of the RPV insulation but also about the remote controlled packaging of the metal sheet insulation and the manual conditioning of the RPV insulation. Subsequently, reports on the remotely controlled cutting and packaging of the RDB are given. Here is particularly interesting that cutting methods have been used and how the activity determination of the segments was carried out. On the basis of the evaluation of the realisation the subsequent dismantling activities will be lined out. In parallel to the dismantling tasks, the waste package documentation for the final repository was issued, checked and confirmed for the containers loaded with parts of the RDB internals. The most important stages are exemplified in this presentation. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

COMPASS-FME Terrestrial Ecosystem Manipulation to Probe the Effects of Storm Treatments (TEMPEST) Experiment Level 2 Sensor Data v2-1

This is the version v2-1 Level 2 (L2) data release for COMPASS-FME environmental sensors located at our Terrestrial Ecosystem Manipulation to Probe the Effects of Storm Treatments (TEMPEST) experimental site. This manipulative, ecosystem-scale TEMPEST experiment addresses the potential for freshwater and estuarine-water disturbance events to alter tree function, species composition, and ecosystem processes in a deciduous coastal forest in MD, USA. The experiment uses a large-unit (2000 m2), un-replicated experimental design, with three 50 m × 40 m plots serving as control, freshwater, and estuarine-water treatments. Level 2 (L2) data consist of sensor observations from the COMPASS-FME synoptic sites, TEMPEST, and DELUGE. Compared to the L1 data, these are more consistent (always 15-minute timestamps for the entire year); better QA/QC’d (out of bounds, out of service, and extreme outlier values are removed); and more complete, with a gap-filled time series available alongside the main observations, and additional derived (calculated) variables. L2 data are intended to be rapidly and easily usable in analyses and simulations. However, algorithmic outlier identification always carries the risk of removing valid data, and Level 1 data may be more suitable for analyses that focus on variability or extreme events. This dataset includes: - An overall dataset README file that describes the current version, gives citation and contact information, etc. - Site- and year-specific folders, each holding variable-specific Parquet (a high performance, space efficient format; see https://parquet.apache.org) data files for each site and plot in that year. - Metadata files within each site-year folder provide full information on data units, expected ranges, contact information, detailed flood times, as well as a general description of the site. - Environmental sensor types that appear in the data files include weather (ClimaVUE50, CS, RM Young, and LI instruments in the graphs below); soil conditions (TEROS12); soil redox state (Redox); groundwater variables (AquaTROLL200 and AquaTROLL600); open water sondes (Exo); tree sap velocity (Sapflow); and system voltage and state (Datalogger). Data are reported every 15 minutes. Please see v2-1 TEMPEST L2 Sensor Package Quick Start.pdf for detailed information on data package structure, temporal coverage, and versioning. Data files are in Apache Parquet, a high performance, space efficient format for tabular data. These files can be read using R's `arrow` package (https://arrow.apache.org/docs/r/), with similar tools available in other languages. The TEMPEST flood events occurred on the following dates. They lasted for ~10 hours each day and delivered ~80,000 gallons to each plot; many data streams are available at 1 or 5 minute frequency during these periods. * Tests: Aug 25 (fresh plot) and Sep 9 (salt plot), 2021 * TEMPEST 1: June 22, 2022 * TEMPEST 2: June 6-7, 2023 * TEMPEST 3: June 11-13, 2024

EARTH SCIENCE > ATMOSPHERE > ATMOSPHERIC TEMPERATU↗

DOE OSTI2025

COMPASS-FME Terrestrial Ecosystem Manipulation to Probe the Effects of Storm Treatments (TEMPEST) Experiment Level 1 Sensor Data v2-1

This is the version 2-1 Level 1 (L1) data release for COMPASS-FME environmental sensors located at our Terrestrial Ecosystem Manipulation to Probe the Effects of Storm Treatments (TEMPEST) experimental site. This manipulative, ecosystem-scale TEMPEST experiment addresses the potential for freshwater and estuarine-water disturbance events to alter tree function, species composition, and ecosystem processes in a deciduous coastal forest in MD, USA. The experiment uses a large-unit (2000 m2), un-replicated experimental design, with three 50 m × 40 m plots serving as control, freshwater, and estuarine-water treatments. L1 data are close to raw, but are units-transformed and have out-of-instrument-bounds, out-of-service, and outlier flags added. Duplicates and missing data are removed but otherwise these data are not filtered, and have not been subject to any additional algorithmic or human QA/QC. Any scientific analyses of L1 data should be performed with care. **This dataset will be updated quarterly with new data for the duration of the project** This dataset includes: - An overall dataset README file that describes the current version, gives citation and contact information, etc. - Site- and year-specific folders, each holding variable-specific CSV (comma separated value) data files for each site and plot in that year. - Metadata files within each site-year folder provide full information on data units, expected ranges, contact information, detailed flood times, as well as a general description of the site. - Environmental sensor types that appear in the data files include weather (ClimaVUE50, CS, RM Young, and LI instruments in the graphs below); soil conditions (TEROS12); soil redox state (Redox); groundwater variables (AquaTROLL200 and AquaTROLL600); open water sondes (Exo); tree sap velocity (Sapflow); and system voltage and state (Datalogger). Data are normally logged every 15 minutes. Please see v2-1 TEMPEST L1 Sensor Package Quick Start.pdf for detailed information on data package structure, temporal coverage, and versioning. The TEMPEST flood events occurred on the following dates. They lasted for ~10 hours each day and delivered ~80,000 gallons to each plot; many data streams are available at 1 or 5 minute frequency during these periods. * Tests: Aug 25 (fresh plot) and Sep 9 (salt plot), 2021 * TEMPEST 1: June 22, 2022 * TEMPEST 2: June 6-7, 2023 * TEMPEST 3: June 11-13, 2024 This dataset was updated 2026-03-12: (i) data now go through 2025-12-31 (previous end was 2025-06-30) and (ii) dataset and file names updated to “…v2-1” (previously was “v2-0”).

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS2007

Fabrication of Polyimide-Matrix/Carbon and Boron-Fiber Tape

The term HYCARB denotes a hybrid composite of polyimide matrices reinforced with carbon and boron fibers. HYCARB and an improved process for fabricating dry HYCARB tapes have been invented in a continuing effort to develop lightweight, strong composite materials for aerospace vehicles. Like other composite tapes in this line of development, HYCARB tapes are intended to be used to build up laminated structures having possibly complex shapes by means of automated tow placement (ATP) - a process in which a computer-controlled multiaxis machine lays down prepreg tape or tows. The special significance of the present process for making dry HYCARB for ATP is that it contributes to the reduction of the overall cost of manufacturing boron-reinforced composite-material structures while making it possible to realize increased compression strengths. The present process for making HYCARB tapes incorporates a "wet to dry" process developed previously at Langley Research Center. In the "wet to dry" process, a flattened bundle of carbon fiber tows, pulled along a continuous production line between pairs of rollers, is impregnated with a solution of a poly(amide acid) in N-methyl-2-pyrrolidinone (NMP), then most of the NMP is removed by evaporation in hot air. In the present case, the polyamide acid is, more specifically, that of LaRC. IAX (or equivalent) thermoplastic polyimide, and the fibers are, more specifically, Manganite IM7 (or equivalent) polyacrylonitrile- based carbon filaments that have a diameter of 5.2 m and are supplied in 12,000-filament tows. The present process stands in contrast to a prior process in which HYCARB tape was made by pressing boron fibers into the face of a wet carbon-fiber/ poly(amide acid) prepreg tape . that is, a prepreg tape from which the NMP solvent had not been removed. In the present process, one or more layer(s) of side-by-side boron fibers are pressed between dry prepreg tapes that have been prepared by the aforementioned gwet to dry h process. The multilayer tape is then heated to imidize the matrix material and remove most of the remaining solvent, and is pressed to consolidate the multiple layers into a dense tape. For tests, specimens of HYCARB tapes and laminated composite panels made from HYCARB tape were prepared as follows: HYCARB tapes were fabricated as described above. Each panel was made by laying down ten layers of tape, containing, variously, one, two, or three boron-fiber plies and the remainder carbon- fiber-only plies (see figure). Each panel was made by laying down ten layers of tape. Each panel was then cured by heating to a temperature of 225 C for 15 minutes, then pressing at 200 psi (A1.4 MPa) while heating to 371 C, holding at 371 C for 1 hour, then continuing to hold pressure during cooling. Control specimens that were otherwise identical except that they did not contain boron fibers also were prepared. In room-temperature flexural tests, the HYCARB specimens performed comparably to the control specimens; in room-temperature, open-hole compression tests, the HYCARB specimens performed slightly better, by amounts that increased with boron content.

Belvin, Harry L.↗

DOE OSTI2026

In situ cryogenic characterization of proton damage in thick p-channel skipper CCDs

Skipper charge-coupled devices (CCDs) are an offshoot of standard silicon pixel detectors and are capable of performing repeated non-destructive charge measurements, enabling deeply sub-electron readout noise. This capability has opened the door to single-photon counting from the near-infrared ($\sim$1.1 $μ$m) to the soft X-ray (several keV), making these devices strong candidates for future astronomical instruments operating in the photon-starved limit. Furthermore, the p-channel architecture used to fabricate Skipper CCDs on n-type silicon has been demonstrated to have an increased hardness to the intense radiation environment of space. Building upon previous irradiation campaigns on room-temperature sensors, here we describe the first radiation-hardness tests of p-channel skipper CCDs at their cryogenic operating temperatures. We assess the performance of the floating-gate output stage and global CCD parameters (charge transfer inefficiency, dark current, hot pixels, and charge traps). We find that these devices maintain excellent performance after displacement damage doses equivalent to ${\sim}$10 years at the Earth/Sun L2 Lagrange point, demonstrating for the first time that these sensors remain radiation-hard in realistic deep-space thermal and radiation environments.

Roach, Brandon M. [Chicago U., KICP] (ORCID:000000↗

DOE OSTI2024

Effect of Heat Treatment on Microstructure and Mechanical Property of 316L Stainless Steel Produced by Laser Powder Bed Fusion

The advanced non-light water reactor designs (Gen IV reactors), including molten salt/ very high temperature/ sodium-cooled and lead-cooled fast reactors, typically operate at higher temperatures and more extreme radiation conditions than light water reactors. An intrinsic part of the deployment and progress of Gen IV reactor designs is selecting the most suitable structural material for a specific application. Additive manufacturing (AM), a fairly new process of making physical, three-dimensional objects from a computer design file, is going to completely change the way of design, build and certify nuclear systems. It offers a range of opportunities to produce complex geometries from existing materials, offers new routes for processing of previously difficult to process materials, allows for design of new high-performance materials, and finally facilitates hybridization of dissimilar materials. This emerging technology has successfully produced cars, wind turbine blade molds and even live cells. It could also open up big opportunities for the nuclear industry to quickly deploy technologies at a fraction of the cost. So far, AM techniques have been preliminarily applied in the field of nuclear reactors, including the classical parts such as the pressure vessel of a small reactor with 508-III steel, the bottom nozzle of a fuel assembly with 304L steel, the fuel cladding with zirconium alloy and the integrated impeller of a pump and the multi-channel valve body with 316L steel [6,7]. The AM applications for operating nuclear reactors started in auxiliary plant components and have slowly migrated to metallic reactors and core components, but many of these are not safety critical components. Although many parts used for nuclear reactors have been fabricated by AM techniques, practical applications in engineering are still a long way off due to the uncertainty factors focused on the processing, material properties, analysis methods and application standards, which feeds the safety and life-cycle of the nuclear reactor. Due to rapid, repeated heating and cooling during production, a high dislocation density was present in the AM material. This microstructure feature is unstable at elevated temperature while high temperature is one of the typical operation environments for nuclear reactors. Thus, it is important to understand the thermal effect on the microstructure of AM material. The objectives of this study are to investigate the effect of heat treatment on the microstructure and mechanical properties of 316L stainless steel produced by laser powder bed fusion additive manufacturing, and to determine an appropriate heat treatment practice that will be applied to the lightweight AM lattice-structured material with the same chemistry. The heat treatment study consisted of annealing the samples at a temperature range of 800 to 1200 oC with a 50 oC increment for different times (1-24 hours), followed by vacuum or air cooling. Microstructural characterization was carried out by Scanning Electron Microscope (SEM). Grain size and crystallographic orientation were investigated by Electron Backscatter Diffraction (EBSD). Vickers hardness tests with a 0.5 kg load were employed to determine the hardness of samples after different heat treatments. After heat treatment, the random crystallographic orientation was preserved, and the volume fraction of high-angle grain boundaries (grain boundary misorientation =15 oC) remained the same. The dislocation density decreased with annealing temperature due to recovery. The fine subgrain structures in the as-printed specimen were quite stable up to 1200 oC. Minimal recrystallization was observed up to 1200 oC. Recrystallization initiated only after 8.5 hours at 1200 oC. The SEM images did not show obvious dependence of microstructure on cooling rate. The hardness of the specimens decreased with increasing annealing temperature as a result of the decrease in dislocation density. It is interesting to note that the AM material showed very similar hardness to the wrought material when annealing at similar temperature, although the microstructures are very different. Annealing at 1050 oC for 1 hour followed by air cooling was selected as the heat treatment procedure for the lattice designed lightweight AM 316L material.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Implementation of ANL’s Mechanics Based Evolutionary Fatigue Modeling Through ABAQUS-WARP3D Based High-Performance Computing Framework

This report presents an update on the environmental fatigue research that is being conducted at Argonne National Laboratory in support of the Department of Energy’s Light Water Reactor Sustainability (LWRS) program. Argonne is developing a fully mechanistic fatigue evaluation approach without using empirical fatigue (S~N) curves. This approach is based on the fundamental concept of the time evolution of progressive fatigue damage rather than on the conventional S~N curve approaches using end-of-life data. In FY 2017, we performed extensive validation of this approach with respect to fatigue test data for 316 stainless steel [1]. This validation was performed for different loading cases, including constant, variable, and random amplitude. In the present FY 2018 semi-annual report, we present the further advances of Argonne’s environmental fatigue research work in the context for more practical applications. In this report, we discuss a methodology for fully mechanistic (i.e., not using S~N curves) fatigue life evaluation of reactor components subjected to realistic loading cycles, namely, design-basis loading cycles. The loading cycles include plant heat-up, full-power, and cool-down operations. As a test case, we considered a typical pressurized water reactor surge line, which is made of 316 SS. To perform the fatigue simulation for thousands of fatigue cycles in a computationally cost effective way, we modified our previous desktop-based finite element (FE) modeling approach to work in a high-performance computing (HPC) framework. For the HPC implementation, we developed a hybrid framework based on commercial FE software (ABAQUS), open-source FE software (WARP3D), and Argonne-developed evolutionary cyclic-plasticity modeling methods. We validated this HPC-based cycle-by-cycle damage model for the entire fatigue life of a Pressurized Water Reactor (PWR) surge line (SL) pipe with respect to assumed loading cycles. The simulated fatigue life was found to be 5855 cycles, which is 85% accurate as compared to the corresponding small-specimen-based experimental fatigue life (6914 cycles). Also, the simulated stress history captures the cyclic hardening and softening behavior of the material for entire fatigue cycles. The FE simulation of the PWR SL pipe was conducted in a reasonable time of 12.5 days. These results show the promise that a fully mechanistic (not using S~N curves) fatigue life evaluation of a safety-critical nuclear reactor component (or even other safety critical components like those in aircraft, aero-engines, etc.) is possible. We anticipate that this type of methodology will drastically reduce the uncertainly associated with conventional fatigue life estimates based on empirical S~N curves. We also proposed an FE model that is based on a hybrid full-component and single-element approach and that can readily be used by industry if HPC resources are not available. In this approach, a single-cycle FE simulation has to be performed first for the required loading cycle. Then, the resulting strain/stress profile at the hotspot (highest strain/stress location) is used as input strain/stress loading to the single-element FE model. The single-element FE model is run under multiple fatigue cycles as long as the failure criteria are achieved. The cycle number at failure gives the fatigue life of the component in question. This cost-effective framework does not require expensive HPC hardware and can be performed in a reasonable time by using a desktop computer. We demonstrated this approach with respect to PWR SL fatigue evaluation under two realistic design-basis loading cycles (simple and detailed). The associated results were validated with respect to test data obtained through fatigue testing of uniaxial specimens under the in-air condition at 300 °C. The approach is in the development stage and requires further improvement and validation.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS1996

Rotorcraft Aeromechanics Branch Home Page on the World Wide Web

The tilt rotor aircraft holds great promise for improving air travel in the future. It's benefits include vertical take off and landing combined with airspeeds comparable to propeller driven aircraft. However, the noise from a tilt rotor during approach to a landing is potentially a significant barrier to widespread acceptance of these aircraft. This approach noise is primarily caused by Blade Vortex Interactions (BVI), which are created when the blade passes near or through the vortex trailed by preceding blades. The XV- 15 Aeroacoustic test will measure the noise from a tilt rotor during descent conditions and demonstrate several possible techniques to reduce the noise. The XV- 15 Aeroacoustic test at NASA Ames Research Center will measure acoustics and performance for a full-scale XV-15 rotor. A single XV-15 rotor will be mounted on the Ames Rotor Test Apparatus (RTA) in the 80- by 120-Foot Wind Tunnel. The test will be conducted in helicopter mode with forward flight speeds up to 100 knots and tip path plane angles up to +/- 15 degrees. These operating conditions correspond to a wide range of tilt rotor descent and transition to forward flight cases. Rotor performance measurements will be made with the RTA rotor balance, while acoustic measurements will be made using an acoustic traverse and four fixed microphones. The acoustic traverse will provide limited directionality measurements on the advancing side of the rotor, where BVI noise is expected to be the highest. Baseline acoustics and performance measurements for the three-bladed rotor will be obtained over the entire test envelope. Acoustic measurements will also be obtained for correlation with the XV-15 aircraft Inflight Rotor Aeroacoustic Program (IRAP) recently conducted by Ames. Several techniques will be studied in an attempt to reduce the highest measured BVI noise conditions. The first of these techniques will use sub-wings mounted on the blade tips. These subwings are expected to alter the size, strength, and location of the tip vortex, therefore changing the BVI acoustics of the rotor. The subwings are approximately 20% of the blade chord and increase the rotor radius by about 3 percent. Four different subwing configurations will be tested, including square tipped subwings with different angles of incidence. The ability of active controls to reduce BVI acoustics will also be assessed. The dynamic control system of the RTA will be used to implement open- and closed-loop active control techniques, including individual blade control. Open-loop testing will be conducted using a personal computer based, automated, real-time data acquisition system. This system features combined automated output of open loop control signals and automated data acquisition of the resulting test data. A final technique to alter the noise of the rotor will be examined. This will involve changing the number of blades from three to four. A four-bladed rotor hub has been fabricated on which the XV-15 blades will be mounted. While the solidity of the rotor will increase, much useful information can be gained by examining the changes in the thrust and RPM with four blades.

Peterson, Randall L.↗

NASA NTRSDate not supplied

Transforming any Facility for Meeting Strict Cleanliness Requirements

Over the life of the James Webb Space Telescope (JWST), Integration & Test (I&T) has taken place in areas that needed considerable work to make the facility itself and/or the protocols used while working in the rooms suitable to meet JWST percent area coverage (PAC) and molecular accumulation requirements. In addition to normal particulate matter, JWST had a uniquely significant challenge: fibers! Fibers not only cause much higher PAC levels, but they also risk damaging the angstrom sized Near Infrared Spectrometer (NIRSpec) microshutter array (MSA), which is critical to NIRSpec instrument performance. The primary emphasis of this paper is to address particulate and fiber contamination. The success of the JWST mission required effective cleanrooms, protocols, and mitigations in non-cleanroom areas that were pressed into service to house contamination-sensitive optics and scientific instruments. Some presented profound challenges. These included: NASA’s 60-year-old Johnson Space Center (JSC) Chamber A, which had never been used for anything contamination-sensitive, and the European tropical launch facilities, which were designed to meet International Standard Organization (ISO) Class 8 processing for communication satellites. The final challenge for JWST, as if to stare us in the face and say, “I dare you to try and make me clean enough,” was preparing the 4 areas in the Centre Spatial Guyanais (CSG) Final Assembly Building (BAF) located in French Guiana, a building in which one entire side opens for Ariane 5 rocket ingress and egress. This paper will describe our initial evaluation processes and the actual work undertaken to transform even the most challenging areas into first class cleanrooms that met JWST particulate and fiber requirements.

James Webb Space Telescope↗

DOE OSTI2019

Innovative Approach to SCC Inspection and Evaluation of Canister in Dry Storage

This final report is summarized four years of work of awarded project number DE-NE0008442\IRP-15-9318, title as: “Innovative Approach to SCC Inspection and Evaluation of Canister in Dry” supported by Nuclear Energy University Program\Integrated Research Program, NEUP\IRP, where last year is an extension of no cost project. This research work is focused on the possible degradation of dry storage canister holding used nuclear fuel (UNF), due to exposure of marine atmospheric environment. The canister usually designed from a welded austenitic stainless-steel of types 304 or 316, encased in a concrete shell known as an overpack. This canister designed and licensed for 20 years with an extension period need to be determined, in addition 20 years or more. These casks are located throughout the country in Independent Spent Fuel Storage Installations (IFSFIs) often on the site close to nuclear power plants, that are often located in coastal or lake-side regions where a marine atmospheric salt air environment exist. As a result of several recent decisions, such as not pursuing Yucca Mountain as a long-term geologic repository storage facility for UNF and the cancellation of the construction of a reprocessing facility in the 1980s due to proliferation risks, interim dry storage facilities for long-term storage are vital option for the immediate future of nuclear energy technology. One of the primary concerns with respect to the long-term performance of the storage casks is the potential for corrosion initiation due to deliquescence of salts deposited on the canister surface as aerosols; in regions of high residual weld stresses, this may lead to localized stress corrosion cracking (SCC). Dust and aerosols in the air being drawn though ventilation openings in the overpacks of passively ventilated dry canister storage systems may be deposited on the stainless-steel canister outer surfaces. Under these conditions, localized corrosion attack can occur. Chlorides ions deliquescence on the canister surface, a process by which the salts essentially pull moisture out of the air, creating a concentrated salt brine on the canister surface. Chloride-induced stress corrosion cracking (CISCC) of welded zones is of special concern, as it a well-documented mode of attack for austenitic stainless steels marine environments, and many independent spent fuel storage installations (ISFSIs) are located in coastal areas. Recent canister inspections have shown that chloride salts are present on the surface of in-service canisters at near-marine settings. However, canister surface inspections of satisfactory resolution to detect SCC have never been carried out in details, because access to the canister surfaces through vents in the overpacks is extremely limited, and high radiation fields make removal of the canisters from the overpacks undesirable. Although no significant corrosion damage has not been detected up to date, there is concern that this may lead to pitting corrosion, which could in turn develop into stress corrosion cracking, causing canister structural failure. The initiation and propagation of pitting corrosion has been widely studied in full immersion conditions, but limited studies have been done on marine atmospheric conditions, which is a focus of this work, these includes laboratory and field experimentally and propagation rate modeling of pitting and transition to crack, and crack propagation rate. It is known, however, that the rate of atmospheric corrosion can be affected by variations in relative humidity (RH), salt density, salt type, droplet area, temperature and stainless-steel microstructure and residual stress particularly in welded zones of canisters. The integrated research program has identified potential deterioration mechanisms for the stainless-steel canisters containing the UNF in dry storage that require detailed research and investigation and will have an impact on the performance of long-term interim storage under the normal and extreme environmental conditions experienced during the duration of this storage. The prediction and monitoring of canister corrosion processes while in storage can provide important data for the assessment of interim storage performance and the safety to the public. This report comprises of mainly the published results in different journals and covering a wide range spectrum from susceptible stainless-steel types 304\316 microstructural analysis through the implant test at atmospheric environment, residual stress analysis of mockup canister and simulation, inspection methodology includes nonlinear ultrasound and vibro-thermography and stochastic modeling and simulation of pits propagation rates and transition to cracks. Description of field specimens installed at ISFSI of Main Yankee is given in the following chapters and will be analyzed in the coming future and serves as an important data for a stochastic analysis as it was drawn from the publications and reports described in this report. The purpose of this report is to bring together the project efforts that includes improving in our understanding of structural aging performance at current dry storage casks fleet at ISFSIs in the context of remedial maintenance and inspection applications technologies.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRSDate not supplied

In-Situ Detection of Process-Induced Porosity During Cure of Out-of-Autoclave Composites

Composite materials offer unique benefits in aerospace applications, including high strength-to-weight ratio, and are becoming increasingly used by industry manufacturers. Current manufacturing and processing methods can lead to defects in the composites, which are identified after fabrication using inspection methods. This study utilized a high-temperature ultrasonic inspection system to detect process-induced porosity in an out-of-autoclave (OOA) composite panel during cure. In order to perform ultrasonic scans in-situ during cure, the system needed to be able to operate at oven temperatures up to 200 °C. There are no commercially available ultrasonic scanning systems that can operate continuously at these temperatures, so an enclosure was fabricated to insulate the ultrasonic system in the curing oven. The enclosure housed a MISTRAS® motorized X-Y raster scanner and contact transducer (Olympus® X2002). The Olympus® X2002 contact transducer is a continuous high-temperature delay line transducer with a center frequency of 2.25 MHz. In order to prevent the inside of the enclosure from reaching high temperatures, a sparge pipe inside the cooling enclosure was connected to a liquid nitrogen (LN2) tank outside of the oven via insulated hoses. The cooling system was automatically controlled by a temperature controller that was programmed to open a solenoid valve along the hose at 31 ℃ and close at 28 ℃ inside the cooling enclosure. When the solenoid valve was open, LN2 would flow from the LN2 tank and vaporize prior to reaching cooling enclosure. A U-shaped sparge pipe had holes drilled along its length to uniformly introduce cold nitrogen gas into the cooling enclosure. This prevented the motors from ever reaching the maximum desired operating temperature of 38 ℃. In the bottom of the enclosure, the tool plate was placed with the composite facing the outside of the enclosure, exposing it to the temperatures of the oven. The tool plate was 63.5 mm thick borosilicate glass, which was chosen for its low ultrasonic attenuation and moderate thermal conductivity. A thin layer of ultrasonic couplant was placed on the tool plate. The transducer sent and received ultrasonic waves through the tool plate into the composite. A MISTRAS® Remote UT System performed all wave generation, analog to digital conversion, and data acquisition and processing. The transducer was connected directly to the Remote UT System via a high-temperature BNC cable (CD International, RG-316). Polyimide insulated copper wire was used to connect the scanner to a 2-axis motor drive, which was connected to the Remote UT System. The motor drive and Remote UT System were located outside the industrial oven. A diagram of the ultrasonic system is shown in Figure 1. Figure 1: Diagram of ultrasonic in-situ defect detection system. In this study, a porosity gradient was introduced into the carbon fiber reinforced polymer (CFRP) composite through a misfit of the part and caul plate. A 24-ply quasi-isotropic ([0/90, ±45]12S) composite panel was laid up using Newport® AS4C-M/NB321 out-of-autoclave (OOA) plain weave (PW) prepreg (42% resin content, 195 g/m2). The first 16 plies were 203 mm × 203 mm. Ply drops were incorporated into the panel by decreasing the length of plies 17-24. The sizes of each ply are included in Table 1. All plies were centered along their length (x-axis) creating a trapezoidal type cross-section. Table 1: Ply sizes Plies Length (mm) Width (mm) 1-16 203 203 17-18 102 203 19-20 85 203 21-22 68 203 23-24 51 203 A 15-5 stainless steel caul plate (Size: 203 × 203 × 1.2 mm) was placed on the laminate. The composite and caul plate were vacuum bagged to the tool plate. Per the product datasheet, Newport 321 can be cured between 121 °C and 149 °C, depending on service temperature, with a hold for 90-120 minutes. Based on prior thermal testing of the cooling enclosure, the desired composite temperature cycle could be attained when the air temperature of the oven was ramped to 160 °C at a rate of 1.7 °C/min with a 3 hour hold. The extended hold was not necessary to cure the composite, but did allow for additional scans at the cure temperature during preliminary testing. The composite panel was under vacuum pressure for the entire cure cycle. Under vacuum, the caul plate deformed causing high and low pressure regions. The low-pressure regions formed high porosity in the composite part. The ultrasonic data collected showed that the inspection system was able to monitor the evolution of porosity within the composite throughout the cure cycle. Fifty scans of a 203 mm × 51 mm (8 in. × 2 in.) area of the composite were completed throughout the cure cycle. The scan speed was set to 43 mm/s in the x-direction and 36 mm/s in the y-direction, with a 1.0 mm/pixel resolution in both directions. Each scan took approximately five minutes to complete. Figure 2 shows C-scan amplitude data (top view) from one scan during the cure cycle. The color map indicates the maximum amplitude (%) measured with a time gate that contains reflections from the back surface (furthest from the transducer in contact with the caul plate) of the composite. Because porosity in the composite increases the ultrasonic attenuation in the composite part, a higher amplitude (red) indicates low porosity and a lower amplitude (blue) indicates high porosity. The regions where the caul plate was applying increased pressure (center and ends of the panel) resulted in reduced porosity, whereas the ply drop regions had reduced pressure and thus had higher porosity. Figure 2: Amplitude C-scan (top view) of OOA composite from one scan during the 160 °C temperature hold. Higher amplitude (red) indicates low porosity. Lower amplitude (blue) indicates high porosity. A B-scan is a two-dimensional image plotting the ultrasonic signals from a single y-position at every x-location of the composite panel. The travel time (μs) of the ultrasonic wave (representing the through-thickness location) is plotted along the y-axis, and the ultrasonic wave signal is represented as a contour map. Based on the B-scan data, the location of the defects with respect to the composite thickness was able to be determined. The ply drop regions had high porosity near the front (tool plate) surface of the composite (Figure 3). Figure 3: B-scan (cross-section view) of OOA composite from one scan during the 160 °C temperature hold. Using the data obtained from amplitude C-scans and B-scans throughout the cure cycle, the high and low porosity regions within the composite laminate were detected and localized with high spatial resolution. This paper will discuss the evolution of porosity content in the OOA composite during cure. OOA tests aided the transition of this system to an autoclave, which is the primary method of curing aerospace-grade thermoset composites.

Tyler B. Hudson↗