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Going beyond reliability to robustness and resilience in space systems

The words reliability, robustness, and resilience, are often used interchangeably to describe tough and dependable systems but the distinctions between them suggest how to design more serviceable space systems. Reliability is simply the quality of consistently performing well. A system that dependably meets its design requirements in the specified environments is reliable. The designers may not consider themselves responsible for failures under unanticipated conditions. Robustness is the capability of performing without failure under a wide range of conditions, which can go beyond the expected range to include possible off-nominal conditions. Resilience is the ability to recover from or adapt to damaging events, such as failures, accidents, external disruptions, and repurposing. Such changes are usually unanticipated. They often invalidate the usual operating assumptions and cause system failure. Reliability, robustness, and resilience describe dependable performance under increasingly difficult conditions, first the specified environment, then a wider possible environment, and finally unanticipated damaging events. These three are increasingly desirable and increasingly difficult to achieve. Engineering for resilience would design systems that can ignore or repair failures, survive accidents, and recover from disruptions. Increasing the resilience of space systems, the ability to perform after unanticipated events, would greatly increase space crew safety. Improving reliability and robustness can be done by dealing with known sources of problems, but improving resilience requires implementing a general approach to reducing the impact of unknown future events. Two contrasting approaches are reducing system complexity and adding supervisory control. The need for resilience has been claimed for decades but little has been accomplished. Systems designers assume that they understand requirements, technologies, designs, architectures, integration, testing, operations, and environments. The potential problems of changes, failures, accidents, unknown environments, and unknown unknowns are ignored. Systems designers are typically overconfident and ignore the need for robustness and resilience.

Harry W Jones↗

DOE OSTI2021

Sensitivity of Riparian Buffer Designs to Climate Change—Nutrient and Sediment Loading to Streams: A Case Study in the Albemarle-Pamlico River Basins (USA) Using HAWQS

Riparian buffer zones (RBZs) provide multiple benefits to watershed ecosystems. We aimed to conduct an extensive sensitivity analysis of the RBZ designs to climate change nutrient and sediment loadings to streams. We designed 135 simulation scenarios starting with the six baselines RBZs (grass, urban, two-zone forest, three-zone forest, wildlife, and naturalized) in three 12-digit Hydrologic Unit Code watersheds within the Albemarle-Pamlico river basin (USA). Using the hydrologic and water quality system (HAWQS), we assessed the sensitivity of the designs to five water quality indicator (WQI) parameters: dissolved oxygen (DO), total phosphorous (TP), total nitrogen (TN), sediment (SD), and biochemical oxygen demand (BD). To understand the climate mitigation potential of RBZs, we identified a subset of future climate change projection models of air temperature and precipitation using EPA’s Locating and Selecting Scenarios Online tool. Analyses revealed optimal RBZ designs for the three watersheds. In terms of watershed ecosystem services sustainability, the optimal Urban RBZ in contemporary climate (1983–2018) reduced SD from 61–96%, TN from 34–55%, TP from 9–48%, and BD from 53–99%, and raised DO from 4–10% with respect to No-RBZ in the three watersheds. The late century’s (2070–2099) extreme mean annual climate changes significantly increased the projected SD and BD; however, the addition of urban RBZs was projected to offset the climate change reducing SD from 28–94% and BD from 69–93% in the watersheds. All other types of RBZs are also projected to fully mitigate the climate change impacts on WQI parameters except three-zone RBZ.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Integrated Sustainable Product Design With Warranty and End-of-Use Considerations

The concept of integrated sustainable product design has recently emerged, aiming to incorporate downstream life cycle performance into the initial product design to enhance sustainability. Various sustainable product design tools based on life cycle assessment or quality function deployment have been established while the impact of reliability on circular practices has received limited attention. Recognizing the critical role of product reliability in post-design performance, this paper develops a product design optimization model that considers the warranty performance and the effect of end-of-use options. The model takes into account the effect of uncertain operating conditions on product reliability. Two optimization goals including the minimization of expected unit life cycle cost and environmental impact are achieved by the model. To demonstrate the benefits of the integrated approach, the model is applied to an electric motor design problem. The results highlight that integrating end-of-use options in the early design phase leads to adjustments in component selection and reliability design. Moreover, the circular utilization of used products enables cost savings throughout the product’s life cycle and contributes to environmental impact reduction. Finally, the study analyzes the effects of operating conditions, warranty policies, and take-back prices for used products on design decisions, providing valuable insights for product designers.

Integrated design↗

NASA NTRS1972

Riding and handling qualities of light aircraft: A review and analysis

Design procedures and supporting data necessary for configuring light aircraft to obtain desired responses to pilot commands and gusts are presented. The procedures employ specializations of modern military and jet transport practice where these provide an improvement over earlier practice. General criteria for riding and handling qualities are discussed in terms of the airframe dynamics. Methods available in the literature for calculating the coefficients required for a linearized analysis of the airframe dynamics are reviewed in detail. The review also treats the relation of spin and stall to airframe geometry. Root locus analysis is used to indicate the sensitivity of airframe dynamics to variations in individual stability derivatives and to variations in geometric parameters. Computer programs are given for finding the frequencies, damping ratios, and time constants of all rigid body modes and for generating time histories of aircraft motions in response to control inputs. Appendices are included presenting the derivation of the linearized equations of motion; the stability derivatives; the transfer functions; approximate solutions for the frequency, damping ratio, and time constants; an indication of methods to be used when linear analysis is inadequate; sample calculations; and an explanation of the use of root locus diagrams and Bode plots.

Smetana, F. O.↗

DOE OSTI2026

Control of Excitonic Energy Transfer in RGB Quantum Dot:Polymer Composites for Tunable White Emission

Tint-controlled white light is crucial for both illumination systems and display applications. Here, in this study, we demonstrate solution-processed quantum-dot light-emitting diodes (QD-LEDs) featuring a red–green–blue (RGB) QD–poly(methyl methacrylate) (PMMA) composite emissive layer (EML) for tunable white electroluminescence (EL). In this composite EML, PMMA functions as a dispersion matrix that modulates the interdot spacing (d), thereby controlling Förster resonance energy transfer (FRET) between QDs. By adjustment of the PMMA content, the balance of R, G, and B emissions is controlled, enabling systematic and continuous tuning of the EL color from greenish to reddish white at a fixed RGB ratio and constant driving bias. Time-resolved photoluminescence measurements confirm that the variation in the exciton lifetime with the PMMA fraction is the primary factor for tuning the EL color. Notably, nearly pure white EL with CIE coordinates close to (0.33, 0.33) is achieved using a diluted PMMA matrix without significant degradation of the electrical properties. Our results demonstrate d as an independent design parameter for decoupling color tuning from RGB composition and electrical operation, providing a versatile design framework for high-quality white- or tint-controlled QD-LEDs toward advanced solid-state lighting and display technologies.

36 MATERIALS SCIENCE↗

DOE OSTI2023

ac susceptibility studies of intra- and intergrain properties of high-$J_c$ Bi-2212 wires

Bi 2 Sr 2 CaCu 2 O x (Bi-2212) is the only high-$T_c$ superconductor (HTS) available as a multifilamentary round wire with multiple architectures and it is a very promising conductor for the realization of high-field applications. Despite their relatively simple wire fabrication by the powder-in-tube technique, Bi-2212 wires require a tightly controlled overpressure heat treatment (HT) with a multi-parameter time-temperature schedule to achieve high critical current density, $J_c$. Further, the variation of these HT parameters, changes in the wire design, wire diameter and powder quality can lead to variations in both the microstructure and the superconducting performance. Particularly noticeable are variations in $J_c$ performance and degree of filament bridging. In this work, we focus on the use of different magnetic characterization techniques to estimate the bridging level and assess the balance of INTER-grain and intra-grain superconducting properties including the irreversibility field ($H_{\text{irr}}$) and the pinning energy ($U_0$) in differently processed wires. Regardless of the actual bridging level, we find that the supercurrent flows at the filament bundle level, not just at the individual filament level. Moreover, using AC susceptibility we identify two distinct supercurrent contributions, one related to the intra-grain and one to the INTER-grain properties, whose irreversibility fields are different but without large sample-to-sample variation. Moreover, an additional component of intra-grain pinning mechanism becomes effective at low temperatures with positive effects also on the INTER-grain performance. The work clearly shows that detailed magnetic characterizations can become valuable tools to investigate the performance of differently processed Bi-2212 wires, correlating their microstructure and overall transport $J_c$, to obtain a deeper understanding of the causes of performance variation and paths to achieve further improvement.

2212↗

DOE OSTI2026

Regularizing INR with Diffusion Prior for Self-Supervised 3D Reconstruction OF Neutron Computed Tomography Data

Recently, generative diffusion priors have made huge strides as inverse problem solvers, including the ability to be adapted for inference on out-of-distribution data. Concurrently, implicit neural representations (INRs) have emerged as fast and lightweight inverse imaging solvers that are amenable to hybrid approaches that combine learned priors with traditional inverse problem formulations. In this paper, we present a diffusive computed tomography (CT) inversion framework for regularizing INRs called Diffusive INR (DINR), designed to enable high-quality reconstruction from sparse-view neutron CT. Pretrained purely on synthetic data, DINR is evaluated on simulated and experimentally obtained observations of concrete microstructures, where traditional reconstruction methods suffer substantial degradation when the number of views is reduced. Our approach delivers superior performance, reduces reconstruction artifacts, and achieves gains in PSNR and SSIM, enabling accurate micro-structural characterization even under extreme data limitations compared to state-of-the-art sparse-view reconstruction techniques.

Hossain, Maliha [ORNL]↗

DOE OSTI2022

Binary pseudo-random array standards for calibration of 3D optical surface profilers used for metrology with aspheric x-ray optics

High-accuracy surface metrology is vitally important in manufacturing ultra-high-quality free-form mirrors designed to manipulate x-ray light with nanometer-scale wavelengths. The current and potential capabilities of x˗ray mirror manufacturing are limited by inherent imperfections of the integrated metrology tools. Metrology tools are currently calibrated with super-polished flat test-standard/reference mirrors. This is acceptable for fabrication of slightly curved x-ray optics. However, for even moderately curved aspherical x-ray mirrors the flat-reference calibration is not sufficiently accurate. For micro-stitching interferometry developed for surface measurements with curved x-ray mirrors, the tool aberration errors are known to be transferred into the optical surface topography of x-ray mirrors. Our approach to improving metrology is to thoroughly calibrate the measuring tool and apply the results of the calibration to deconvolution of the measured data. Here we explore the application of a recently developed technique for calibrating the instrument transfer function (ITF) of 3D optical surface profilers to metrology with significantly curved x-ray optics. The technique, based on test standards patterned with two-dimensional (2D) binary pseudo-random arrays (BPRAs), employs the unique properties of the BPRA patterns in the spatial frequency domain. The inherent 2D power spectral density of the pattern has a deterministic white-noise-like character that allows direct determination of the ITF with uniform sensitivity over the entire spatial frequency range and field of view of an instrument. The high efficacy of the technique has been previously demonstrated in application to metrology with flat and slightly curved optics. Here, we concentrate on development of an efficient fabrication process for production of highly randomized (HR) BPRA test standards on flat and 500-mm spherical optical substrates. We also compare and discuss the results of the ITF calibration of an interferometric microscope when using the HR BPRA standards on flat and curved substrates.

Munechika, Keiko↗

DOE OSTI2023

Binary pseudo-random array (BPRA) for inspection and calibration for cylindrical wavefront interferometry

High-accuracy metrology is vitally important in manufacturing ultra-high-quality free-form mirrors designed to manipulate X-ray light with nanometer-scale wavelengths. However, surface topography measurements are instrument dependent, and without the knowledge of how the instrument performs under the practical usage conditions, the measured data contain some degree of uncertainty. Binary Pseudo Random Array (BPRA) “white noise” artifact are effective and useful for characterizing the Instrument Transfer Function (ITF) of surface topography metrology tools and wavefront measurement instrument. BPRA artifact contains features with all spatial frequencies in the instrument bandpass with equal weight. As a result, power spectral density of the patterns has a deterministic white-noise-like character that allows direct determination of the ITF with uniform sensitivity over the entire spatial frequency range. The application examples include electron microscopes, x-ray microscopes, interferometric microscopes, and large field-of-view Fizeau Interferometers. Furthermore, we will introduce the application of BPRA method to characterizing the ITF of Cylindrical Wavefront Interferometry (CWI), by developing the BPRA artifact which matches the radius of curvature of the cylindrical wavefront. The data acquisition and analysis procedures for different applications of the ITF calibration technique developed are also discussed.

Munechika, K↗

DOE OSTI2024

Binary pseudo-random array standards for calibration of 3D optical surface profilers used for metrology with significantly curved x-ray optics

High-accuracy metrology is vitally important in manufacturing ultra-high-quality free-form mirrors designed to manipulate X-ray light with nanometer-scale wavelengths. The current capabilities and possibility for improvements in X-ray mirror manufacturing are limited by inherent imperfections of the integrated metrology tools. In the case of Fizeau interferometry, metrology tools are currently calibrated with super-polished flat test-standard/reference mirrors. This is acceptable for measuring slightly curved X-ray optics. However, for even moderately curved aspherical X-ray mirrors the flat-reference calibration is not sufficiently accurate and stitching Fizeau interferometer-based surface metrology is used to mitigate the problem. But still, the retrace and aberration errors, as well as the limited spatial resolution, described with the instrument transfer function (ITF), can be transferred into the optical surface topography of X-ray mirrors obtained in stitching metrology. For ITF calibration, we have developed an original technique, based on test standards structured as two-dimensional (2D) highly-randomized (HR) binary pseudo-random arrays (BPRAs). The technique employs the unique properties of the HR BPRA patterns in the spatial frequency domain., i.e. the inherent 2D power spectral density of the HR BPRA pattern has a deterministic white-noise-like character that allows direct determination of the ITF with uniform sensitivity over the entire spatial frequency range and field-of-view of an instrument. Here, we explore technological, metrological, and analytical aspects essential for calibration of the retrace and aberration errors of Fizeau interferometers using different types of tilted test samples, including a super-polished reference mirror for the re-trace calibration and the uniformly redundant array (URA) BPRA standards for the geometrical distortion (aberration) calibration. While the first method was previously demonstrated by researchers at DIAMOND Light Source, a method based on the URA BPRA is described and demonstrated here for the first time. We outline the design and fabrication process used in fabrication of URA BPRA test standards, and present the results of application of the URA BPRA standards demonstrating the high efficacy of our approach to geometrical distortion calibration of Fizeau interferometers. We also discuss the possible sources of unexpected peculiarities of the systematic errors, including an astigmatic character of the retrace error, observed with Fizeau interferometers at the Advanced Light Source X-Ray Optics Laboratory.

Munechika, Keiko↗

DOE OSTI2021

Studies of the Energy Recovery Performance of the PERLE Project

The Powerful Energy Recovery Linac for Experiments (PERLE) is an accelerator facility for the development and application of the energy recovery technique for an intense 500 MeV electron beam. The paper presents the studies that have been performed to assess the quality of the ERL lattice design and beam optics. The studies include the Coherent Synchrotron Radiation (CSR) emission and wakefields in the superconducting radio-frequency structures of the linacs. The lattice design and optics principles of the ERL structure are discussed, involving the vertical deflection system and the 180° arcs. Finally, the results of the front-to-end tracking simulations that consider the complete multi-turn energy recovery process are presented.

Andre, K.D. J.↗

DOE OSTI2020

Predictive Models and Novel Accelerated Tests for the Reliability of Cell Metallization and Solder Joints in Photovoltaic Modules

Interconnect, solder, and metallization-related failures are the primary reason for premature Si-based photovoltaic panel failure [1, 2] and can lead to a cascade of other failures, including thermal events. This combination of high severity and high occurrence means that understanding interconnect-related failures is key to the long-term health of the photovoltaic industry, and it is crucial that the industry adopt efficient and effective tests that aid in design-for-reliability and manufacturing quality control.

14 SOLAR ENERGY↗

DOE OSTI2022

White Paper on Leading-Edge technology And Feasibility-directed (LEAF) Program aimed at readiness demonstration for Energy Frontier Circular Colliders (pp, μμ) by the next decade

In this White Paper for the Snowmass 2021 Process, we propose the establishment of a magnet Leading-Edge technology And Feasibility-directed Program (LEAF Program) to achieve readiness for a future collider decision on the timescale of the next decade. The LEAF Program would rely on, and be synergetic with, generic R&D efforts presently covered - in the US - by the Magnet Development Program (MDP), the Conductor Procurement and R&D (CPRD) Program and other activities in the Office of HEP supported by Early Career Awards (ECA) or Lab Directed R&D (LDRD) funds. Where possible, ties to synergetic efforts in other Offices of DOE or NSF are highlighted and suggested as wider Collaborative efforts on the National scale. International efforts are also mentioned as potential partners in the LEAF Program. We envision the LEAF Program to concentrate on demonstrating the feasibility of magnets for muon colliders as well as next generation high energy hadron colliders, pursuing, where necessary and warranted by the nature of the application, the transition from R&D models to long models/prototypes. The LEAF Program will naturally drive accelerator-quality and experiment-interface design considerations. LEAF will also concentrate, where necessary, on cost reduction and/or industrialization steps.

43 PARTICLE ACCELERATORS↗

DOE OSTI2022

The Open Cluster Chemical Abundances and Mapping Survey. VI. Galactic Chemical Gradient Analysis from APOGEE DR17

The goal of the Open Cluster Chemical Abundances and Mapping (OCCAM) survey is to constrain key Galactic dynamic and chemical evolution parameters by the construction and analysis of a large, comprehensive, uniform data set of infrared spectra for stars in hundreds of open clusters. This sixth contribution from the OCCAM survey presents analysis of SDSS/APOGEE Data Release 17 (DR17) results for a sample of stars in 150 open clusters, 94 of which we designate to be "high-quality" based on the appearance of their color–magnitude diagram. We find the APOGEE DR17-derived [Fe/H] values to be in good agreement with those from previous high-resolution spectroscopic open cluster abundance studies. Using a subset of the high-quality sample, the Galactic abundance gradients were measured for 16 chemical elements, including [Fe/H], for both Galactocentric radius ($R$ GC ) and guiding center radius ($R$ guide ). We find an overall Galactic [Fe/H] versus RGC gradient of -0.073 ± 0.002 dex kpc -1 over the range of 6 > $R$ GC < 11.5 kpc, and a similar gradient is found for [Fe/H] versus $R$ guide . Significant Galactic abundance gradients are also noted for O, Mg, S, Ca, Mn, Na, Al, K, and Ce. Our large sample additionally allows us to explore the evolution of the gradients in four age bins for the remaining 15 elements.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2026

Commercialization of Reflected Target Non-Intrusive Assessment (ReTNA) Tool, for Indoor Optical Analysis of Heliostats

Under HelioCon, NLR began developing a new optical measurement system, called Reflected Target Non-Intrusive Assessment (ReTNA). ReTNA has shown promise towards addressing metrology gaps for heliostat used in concentrated solar thermal (CST) plant. This project is focused on advancing this measurement system from the laboratory into industry, where it can provide valuable information for heliostat developers during research, development, and qualification of a heliostat design, and be used for quality assurance during heliostat manufacture. Over the course of this project, ReTNA was deployed at several commercial heliostat facilities. The system developed and deployed with the primary project partner, Solar Dynamics LLC, is described in detail. The report discusses each project Milestone, the ending status, the achieved value, and how these Milestones improve and qualify the ReTNA measurement tool. Finally, the final report covers the market advancements, path forward, commercial successes, and lessons learned. Final Technical report for TCF Base Technology-Specific project TCF-23-20118, Commercialization of Reflected Target Non-Intrusive Assessment (ReTNA) tool, for indoor optical analysis of Heliostats.

14 SOLAR ENERGY↗

NASA NTRS1971

An inventory of aeronautical ground research facilities. Volume 4: Engineering flight simulation facilities

The general purpose capabilities of government and industry in the area of real time engineering flight simulation are discussed. The information covers computer equipment, visual systems, crew stations, and motion systems, along with brief statements of facility capabilities. Facility construction and typical operational costs are included where available. The facilities provide for economical and safe solutions to vehicle design, performance, control, and flying qualities problems of manned and unmanned flight systems.

Pirrello, C. J.↗

NASA NTRS1972

Television broadcast satellite systems, volume 1

Empirical expressions are derived to account for various components of the television satellite broadcast system. Computer programs are developed to determine the system weight in any general design. The factors of picture quality, propagation losses, and RF power requirements are discussed and determined.

Graf, E. R.↗

NASA NTRS1973

Liquid and gaseous oxygen safety review

Materials used in oxygen systems and allowable oxygen environments are specified for each material. Design criteria, cleaning procedures and quality control methods are covered. Guidelines for protection against hazards involved with production, transportation, storage and use of oxygen are presented. Study also lists extensive references.

Lapin, A.↗