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NASA NTRS2015

Quantitative NDE of Composite Structures at NASA

The use of composite materials continues to increase in the aerospace community due to the potential benefits of reduced weight, increased strength, and manufacturability. Ongoing work at NASA involves the use of the large-scale composite structures for spacecraft (payload shrouds, cryotanks, crew modules, etc). NASA is also working to enable the use and certification of composites in aircraft structures through the Advanced Composites Project (ACP). The rapid, in situ characterization of a wide range of the composite materials and structures has become a critical concern for the industry. In many applications it is necessary to monitor changes in these materials over a long time. The quantitative characterization of composite defects such as fiber waviness, reduced bond strength, delamination damage, and microcracking are of particular interest. The research approaches of NASA's Nondestructive Evaluation Sciences Branch include investigation of conventional, guided wave, and phase sensitive ultrasonic methods, infrared thermography and x-ray computed tomography techniques. The use of simulation tools for optimizing and developing these methods is also an active area of research. This paper will focus on current research activities related to large area NDE for rapidly characterizing aerospace composites.

Cramer, K. Elliott↗

NASA NTRS2016

Research Developments in Nondestructive Evaluation and Structural Health Monitoring for the Sustainment of Composite Aerospace Structures at NASA

The use of composite materials continues to increase in the aerospace community due to the potential benefits of reduced weight, increased strength, and manufacturability. Ongoing work at NASA involves the use of the large-scale composite structures for spacecraft (payload shrouds, cryotanks, crew modules, etc). NASA is also working to enable both the use and sustainment of composites in commercial aircraft structures. One key to the sustainment of these large composite structures is the rapid, in-situ characterization of a wide range of potential defects that may occur during the vehicle's life. Additionally, in many applications it is necessary to monitor changes in these materials over their lifetime. Quantitative characterization through Nondestructive Evaluation (NDE) of defects such as reduced bond strength, microcracking, and delamination damage due to impact, are of particular interest. This paper will present an overview of NASA's applications of NDE technologies being developed for the characterization and sustainment of advanced aerospace composites. The approaches presented include investigation of conventional, guided wave, and phase sensitive ultrasonic methods and infrared thermography techniques for NDE. Finally, the use of simulation tools for optimizing and validating these techniques will also be discussed.

Cramer, K. Elliott↗

DOE OSTI2014

The Status of the Construction of MICE Step IV

The International Muon Ionization Cooling Experiment will provide the demononstration ionization cooling. The experiment is being built in a series of Steps. Step IV, which consists of a tracking spectrometer upstream and downstream of an absorber/focus-coil module will be completed in early in 2015. In this configuration, the emittance of the muon beam upstream and downstream of the absorbed will be measured precisely allowing the emittance reduction and the factors that determine the ionization-cooling effect to be studied in detail. Each tracking spectrometer consists of a scintillating-fibre tracker placed within a 4 T field provided by the superconducting spectrometer solenoid. The muon beam is transported to the absorber/focus-coil module: a 22 liter volume of liquid hydrogen placed inside a superconducting focusing coil. The properties of lithium hydride, and possibly other absorber materials, will also be studied. All the components of Step IV have been manufactured and integration of the experiment in the MICE Hall at the Rutherford Appleton Laboratory is underway. The construction and performance of Step IV will be described. A full study of ionization cooling will be carried out with Step V of the experiment which will include a short 201 MHz linac module in which beam transport is achieved with a superconducting “coupling-coil”. The status of the preparation of the components of Step V of the experiment will be described briefly.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

Thermal behaviors of ethylene vinyl acetate encapsulants in fielded silicon photovoltaic modules

Aging of silicon photovoltaic (PV) module packaging is one of the greatest limiters of PV module service lifetimes. Module characterization typically focuses on power degradation metrics, which do not convey the complexities of often simultaneous degradation mechanisms. In this work, PV modules with pristine references and known fielding histories were investigated by non-destructive and destructive methods. Modules from Canadian Solar, Mission Solar, and Hanwha Q-Cells were fielded for up to three years; select modules were removed from fielding each year for coring to allow for characterization of the encapsulant. Modules are commonly encapsulated with two protective layers of partially-crystalline ethylene vinyl acetate (EVA) polymer that must undergo a crosslinking reaction to achieve desired properties. The extent of crystallinity of the encapsulants as studied by differential scanning calorimetry showed differences between manufacturers and over time. Some encapsulants showed different magnitudes of crystal sizes which changed after fielding; encapsulants with the monodisperse crystal sizes did not change with fielding. This is due to differences in thermal history. In conclusion, these results have implications for stress development during module aging, since EVA crystal melting and crosslinking reactions can result in encapsulant density changes.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Advanced Fuel Cycle Cost Basis Report: Module D1-7 Contact-Handled Pelletized Pressurized Heavy Water (PHWR) UOX Fuel Fabrication (Rev.1)

In addition to literature-based pressurized heavy-water reactor (PHWR) fuel price information in the 2017 AFC-CBR, the what-it-takes (WIT) unit cost data in this update is informed by new analysis and escalation of the 1978 PHWR-UOX fuel life cycle cost (LCC) data from ORNL reports prepared for the 1977–1980 Nonproliferation Alternative Systems Assessment Program (NASAP). (These reports are referenced and summarized in detail in Module D1-PR.) The PHWR fuel fabrication LCC data in these reports is scaled from a bottom-up cost estimate for a reference technology pressurized-water reactor (PWR)—uranium oxide (UOX) fuel fabrication plant by using algorithms that consider the manufacturing process complexity, fuel design complexity, plant floor space requirements, and the radiation and health, safety, and environmental (HS&E) regulatory environment of PHWR-UOX fuel production vis-à-vis light-water reactor (LWR)-UOX production (PWR fuel in this case). The module name has been changed from “Canadian Deuterium Uranium (CANDU)” to the more generic PHWR fuel fabrication in recognition that not all power reactors that might use this fuel type are considered. Unfortunately, the detailed algorithms and their design bases were not archived at the end of the NASAP effort of the commercial CANDU concept specifically developed in the middle of the last century by Atomic Energy of Canada Limited (AECL).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Optimized V1G and V2G Electric Vehicle Fleet Management and Grid Transaction at Marine Corps Air Station Miramar in San Diego, CA

The overall technical goal of the project was to demonstrate an all-electric bi-directional non-tactical fleet at Marine Corps Air Station (MCAS) Miramar that was integrated and controlled with other distributed energy resources (DERs) (i.e., PV, stationary battery, and building loads) to provide resilience to critical electric loads in the event of grid outages, to minimize charging costs, and to provide economic energy resources to electricity markets. In this project, the specific, technical objectives were: 1. Demonstrate that bi-directional electric vehicles can provide critical complementary services to fixed storage batteries in microgrid applications while performing function as non-tactical vehicles. 2. Demonstrate participation of bi-directional (V2G) and unidirectional (V1G) PEVs for demand management and minimization of charging costs. 3. Demonstrate integration of multiple DERs for grid service participation. US Marine Corps Air Station (MCAS) Miramar in San Diego was the site of this electric vehicle-to-microgrid-utility grid test and demonstration project. Existing microgrid assets in this study included (1) a public works building; (2) a 30-kW rooftop photovoltaic (PV) system and (3) a separate 250 kW carport PV system. In this project, six bi-directional V2G vans were located at the MCAS Miramar’s showcase building-scale microgrid to develop and test technical capabilities that V2G can provide in microgrid applications (e.g., cost reduction and resiliency). These resources provided aggregated demand management and simulated participation in current retail DR programs. The vehicles used in this demonstration were selected because they provided functionality that MCAS Miramar needed, 15 passenger transport and facilities work cargo carrying capacity, and bi-directional charging capability that the research project required. All vehicles in this study were manufactured and distributed by VIA Motors, Inc. There were six vehicles total and each was VIA’s VTRUX eREV V2G model, a modified General Motors Chevrolet 2500 2WD van. Three of the vans were configured as passenger vans and the other three were configured as cargo vans. Each van had an on-board bi-direcrtional inverter/charger, Bel Power Solutions model 350INVCHGT150-120-240-8G nominally rated at +/-15 kW. The VIA van’s charging connector follows the J1772 charging protocol. The bi-directional EVSEs demonstrated in this study were manufactured by Coritech, Inc. Each VGI-80-AC charging station enabled enhanced V2G charging capability to a Clipper Creek CS-100 charging module. The enhanced capabilities included ethernet communication following the SEP2.0 protocol with a distributed energy resource function set and an operator screen displaying real-time SOC, voltage, and current. The VGI-80-AC charging stations are classified as level 2 with a maximum current output of 80 A or effectively 19 kW. The VIA van’s onboard charger limited the charging and discharging power to 15 kW in each direction. A control computer was installed in the EWOC and connected to an existing monitor. The V2G control communication network was a completely stand-alone closed system that did not have any connection to any other networks on the base. A cybersecure remote communication connection was created with a cellular modem, firewall hardware, and a virtual private network configuration.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1983

A review and summary of cell and module mismatch losses from theoretical and experimental studies

Studies on power loss due to photovoltaic (PV) cell and module parameter mismatch were reviewed. The losses result from the current voltage (I-V) characteristics of cells which vary over a manufactured lot. The peak power and the peak power I-V point vary from cell to cell. The largest parameter variation occurs in the cell photocurrent generation and the most significant loss occurs in series connections since all cells are essentially limited by the lowest photocurrent. Most theoretical studies address only photocurrent variation effects, which consider shunt and series resistance, ideality factor and saturation current to be comparatively insignificant. One study is identified which specifically configured the study of mismatch loss effects. Experimental results consist of estimates based on limited data not taken from specially configured tests.

Lambarski, T. J.↗

NASA NTRS2010

Innovative Techniques Simplify Vibration Analysis

In the early years of development, Marshall Space Flight Center engineers encountered challenges related to components in the space shuttle main engine. To assess the problems, they evaluated the effects of vibration and oscillation. To enhance the method of vibration signal analysis, Marshall awarded Small Business Innovation Research (SBIR) contracts to AI Signal Research, Inc. (ASRI), in Huntsville, Alabama. ASRI developed a software package called PC-SIGNAL that NASA now employs on a daily basis, and in 2009, the PKP-Module won Marshall s Software of the Year award. The technology is also used in many industries: aircraft and helicopter, rocket engine manufacturing, transportation, and nuclear power."

Source record↗

NASA NTRS2004

Development of a Lunar Consumables Storage and Distribution Depot

NASA is in the preliminary planning stages for a future lunar base as a response to President George W. Bush's recent announcement of a new sustained exploration program beyond low earth orbit. Kennedy Space Center engineers are supporting this program by utilizing experience in Spaceport system design and operations to help develop a Lunar Consumables Depot. This depot will store propellants, life support fluids, and other consumables either transported from Earth or manufactured from In Situ resources. The depot will distribute these consumables in an energy efficient manner to end users including spacecraft, habitation modules, and rovers. This paper addresses some of the changes to lunar base architecture design as a result of advances in knowledge of lunar resources over the past 35 years, as well as technology advances in the area of In Situ Resource Utilization and consumable storage and distribution. A general system level description of the depot will be presented, including overall design philosophy and high level requirements. Finally, specific subsystem technologies that have been or will be developed by KSC will be addressed. Examples of these technologies are automated umbilicals, cryogenic refrigerators, novel storage vessels, advanced heat switches and heat exchangers, and self healing gaskets and wires.

Mueller, Robert P.↗

NASA NTRS1992

Anomalous TWTA output power spikes and their effect on a digital satellite communications system

Several 30 GHz, 60 W traveling wave tube amplifiers (TWTA) were manufactured for the NASA Lewis Research Center's High Burst Rate Link Evaluation Terminal Project. An unusual operating problem characterized by anomalous nonperiodic output power spikes, common to all of the TWTAs proved during testing to significantly affect the performance of a digitally-modulated data transmission test system. Modifications made to the TWTAs significantly curtailed the problem and allowed acceptable system performance to be obtained. This paper presents a discussion of the TWTA output power spike problem, possible causes of the problem, and the solutions implemented by the manufacturer which improved the TWTA performance to an acceptable level. The results of the testing done at NASA Lewis on the TWTAs both before and after the improvement made by Hughes are presented, and the effects of the output power spikes on the performance of the test system are discussed.

May, Brian D.↗

NASA NTRS2002

Space and Terrestrial Photovoltaics: Synergy and Diversity

A historical view of the research and development in photovoltaics from the perspective of both the terrestrial and the space communities is presented from the early days through the '70s and '80s and the '90s and beyond. The synergy of both communities in the beginning and once again in the present and hopefully future are highlighted, with examples of the important features in each program. The space community which was impressed by the light-weight and reliability of photovoltaics drove much of the early development. Even up to today, nearly every satellites and other scientific space probe that has been launched has included some solar power. However, since the cost of these power systems were only a small fraction of the satellite and launch cost, the use of much of this technology for the terrestrial marketplace was not feasible. It was clear that the focus of the terrestrial community would be best served by reducing costs. This would include addressing a variety of manufacturing issues and raising the rate of production. Success in these programs and a resulting globalization of effort resulted in major strides in the reduction of PV module costs and increased production. Although, the space community derived benefit from some of these advancements, its focus was on pushing the envelope with regard to cell efficiency. The gap between theoretical efficiencies and experimental efficiencies for silicon, gallium arsenide and indium phosphide became almost non-existent. Recent work by both communities have focused on the development thin film cells of amorphous silicon, CuInSe2 and CdTe. These cells hold the promise of lower costs for the terrestrial community as well as possible flexible substrates, better radiation resistance, and higher specific power for the space community. It is predicted that future trends in both communities will be directed toward advances through the application of nanotechnology. A picture is emerging in which the space and terrestrial solar cell communities shall once again share many common goals and, in fact, companies may manufacture both space and terrestrial solar cells in III-V materials and thin film materials. Basic photovoltaics research including these current trends in nanotechnology provides a valuable service for both worlds in that fundamental understanding of cell processes is still vitally important, particularly with new materials or new cell structures. It is entirely possible that one day we might have one solar array design that will meet the criteria for success in both space and on the Earth or perhaps the Moon or Mars.

Bailey, Sheila↗

DOE OSTI2016

SU-F-T-213: Commissioning Results of the Prototype Active Scanning Irradiation System of Korea Heavy Ion Medical Accelerator

Purpose: A prototype actives scanning beam delivery system was designed, manufactured and installed as a part of the Korea Heavy Ion Medical Accelerator Project. The prototype system includes the most components for steering, modulating, detecting incident beam to patient. The system was installed in MC-50 cyclotron beam line and tested to extract the normal operation conditions. Methods: The commissioning process was completed by using 45 MeV of proton beam. To measure the beam position accuracy along the scanning magnet power supply current, 25 different spots were scanning and measured. The scanning results on GaF film were compared with the irradiation plan. Also, the beam size variation and the intensity reduction using range shifter were measured and analyzed. The results will be used for creating a conversion factors for asymmetric behavior of scanning magnets and a dose compensation factor for longitudinal direction. Results: The results show asymmetry operations on both scanning × and y magnet. In case of scanning magnet × operation, the current to position conversion factors were measured 1.69 mm/A for positive direction and 1.74 mm/A for negative direction. The scanning magnet y operation shows 1.38mm/A and 1.48 mm/A for both directions. The size of incoming beam which was 18 mm as sigma becomes larger up to 55 mm as sigma while using 10 mm of the range shifter plate. As the beam size becomes large, the maximum intensity of the was decreased. In case of using 10 mm of range shifter, the maximum intensity was only 52% compared with no range shifter insertion. Conclusion: For the appropriate operation of the prototype active scanning system, the commissioning process were performed to measure the beam characteristics variation. The obtained results would be applied on the irradiation planning software for more precise dose delivery using the active scanning system.

43 PARTICLE ACCELERATORS↗

NASA NTRS1985

High-density digital recording

The problems associated with high-density digital recording (HDDR) are discussed. Five independent users of HDDR systems and their problems, solutions, and insights are provided as guidance for other users of HDDR systems. Various pulse code modulation coding techniques are reviewed. An introduction to error detection and correction head optimization theory and perpendicular recording are provided. Competitive tape recorder manufacturers apply all of the above theories and techniques and present their offerings. The methodology used by the HDDR Users Subcommittee of THIC to evaluate parallel HDDR systems is presented.

Kalil, F.↗

NASA NTRS1986

Thermoelectric converter for SP-100 space reactor power system

Conductively coupling the thermoelectric converter to the heat source and the radiator maximizes the utilization of the reactor and radiator temperatures and thereby minimizes the power system weight. This paper presents the design for the converter and the individual thermoelectric cells that are the building block modules for the converter. It also summarizes progress on the fabrication of initial cells and the results obtained from the preparation of a manufacturing plan. The design developed for the SP-100 system utilizes thermally conductive compliant pads that can absorb the displacement and distortion caused by the combinations of temperatures and thermal expansion coefficients. The converter and cell designs provided a 100 kWe system which met the system requirements. Initial cells were fabricated and tested.

Terrill, W. R.↗

DOE OSTI2020

Multi-beam resin curing system and method for whole-volume additive manufacturing

A multi-beam volumetric resin curing system and method for whole-volume additive manufacturing of an object includes a bath containing a photosensitive resin, a light source for producing a light beam, and a spatial light modulator which produces a phase- or intensity-modulated light beam by impressing a phase profile or intensity profile of an image onto a light beam received from the light source. The system and method also include projection optics which then produces multiple sub-image beams from the modulated light beam which are projected to intersect each other in the photosensitive resin to cure select volumetric regions of the resin in a whole-volume three-dimensional pattern representing the object.

Shusteff, Maxim↗

DOE OSTI2023

Multi-beam resin curing system and method for whole-volume additive manufacturing

Shusteff, Maxim↗

DOE OSTI2014

SU-E-T-594: Preliminary Active Scanning Results of KHIMA

Purpose: To verify the design criteria on heavy ion beam irradiation, developing a proto type active scanning system was purposed. The active scanning system consists of scanning magnet, power supplies, beam monitors, energy modulation system, and irradiation control system. Methods: Each components of the active scanning system was designed for carbon beam first. For the fast ramping a laminated yoke was purposed. To measure incoming dose and profile, a plate and strip type of ion chambers were designed. Also, ridge filter and range shifter was manufactured. And, the scanning system was modified to adopt 45 MeV of proton beam because of the absence of carbon ion beam in Korea. The system was installed in a beam line at MC-50, KIRAMS. Also, the irradiation control system and planning software was provided. Results: The scanning experiment was performed by drawing KHIMA logo on GaF film. The logo was scanned by 237 scanning points through time normalized intensity modulation. Also, a grid points scanning was performed to measure the scanning resolution and intensity resolution. Conclusion: A prototype active scanning system was successfully designed and manufactured. Also, an initial experiment to print out a drawing on GaF film through the scanning system was completed. More experiments would be required to specify the system performance.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2015

Improved Large Aperture Collector Manufacturing

The parabolic trough is the most established CSP technology and carries a long history of design experimentation dating back to the 1970’s. This has led to relatively standardized collector architectures, a maturing global supply chain, and a fairly uniform cost reduction strategy. Abengoa has deployed more than 1,500MWe of CSP troughs across several countries and has built and tested full-scale prototypes of many R&D concepts. The latest trough R&D efforts involved efforts to internalize non-CSP industry experience including a preliminary DFMA principles review done with Boothroyd Dewhurst, a construction literature review by the Arizona State University School of Construction Management, and two more focused manufacturing engineering subcontracts done by Ricardo Inc. and the nonprofit Edison Welding Institute. The first two studies highlighted strong opportunities in lowering part count, standardizing components and fasteners, developing modular designs to support prefabrication and automation, and devising simple, error-proof manual assembly methods. These principles have delivered major new cost savings in otherwise “mature” products in analogous industries like automotive, truck trailer manufacture, metal building fabrication, and shipbuilding. For this reason, they were core in the design development of the SpaceTube® collector, and arguably key to its early successes. The latter two studies were applied specifically to the first-generation SpaceTube® design and were important in setting the direction of the present SolarMat project. These studies developed a methodology to analyze the costs of manufacture and assembly, and identify new tooling concepts for more efficient manufacture. Among the main opportunities identified in these studies were the automated mirror arm manufacturing concept and the need for a less infrastructure-intensive assembly line, both of which now form central pillars of the SolarMat project strategy. These new designs will be supported by new technology in the area of quality control inspection, in which state of the art photogrammetry and laser CMM inspection methods will be used to qualify parts and assemblies, and in which the recently-developed Absorber Reflection Method will enable in-line quality control inspection of modules produced by the new high-rate production line.

14 SOLAR ENERGY↗