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At least 649 records · Page 36
All sourcesNASA NTRSDOE OSTI
NASA NTRS2021

Porosity Detection and Localization During Composite Cure Inside an Autoclave Using Ultrasonic Inspection

Composite materials offer unique benefits in aerospace applications such as increased strength-to-weight ratio and improved fatigue properties. They are increasingly being used in major commercial aircraft programs. However, current processing methods can lead to defects in composite parts, which must be detected using post-manufacturing inspection methods. Porosity (i.e., pores, voids) is a critical defect from the cure process that is detrimental to performance of the composite part. It is therefore necessary to understand and eliminate the formation of porosity defects. At NASA Langley Research Center, an in-situ cure monitoring system was developed to detect porosity defects as they form in real-time inside an autoclave. A capability to directly detect and localize porosity within a composite during cure did not exist before. This study is focused on an elevated-temperature ultrasonic inspection system to detect porosity defects in composites during autoclave cure. The ultrasonic inspection system operated inside an autoclave within an enclosure cooled by intermittent liquid nitrogen (LN_2) injections. A high-temperature, 2.25 MHz, transducer transmitted ultrasonic waves through the tool plate and into the composite part and measured the amplitude and time of flight of the reflected waves with a 1 mm × 1 mm step size/areal resolution. Porosity was observed via the ultrasonic reflections, which experienced increased attenuation in regions of high porosity. Distinct regions of increased porosity were present due to uneven pressure across the panel, which was driven by an intentional misfit between the flat caul plate and the tapered composite panel with ply drops. The results were validated by post-cure ultrasonic inspection and micrographs. The in-situ inspection system was able to successfully provide porosity detection and localization in the tapered ply-drop panel. The successful results indicate the promise of this system for future implementation in the manufacturing of composite structures for aerospace applications.

Composites↗
NASA NTRS1992

System model development for nuclear thermal propulsion

A critical enabling technology in the evolutionary development of nuclear thermal propulsion (NTP) is the ability to predict the system performance under a variety of operating conditions. This is crucial for mission analysis and for control subsystem testing as well as for the modeling of various failure modes. Performance must be accurately predicted during steady-state and transient operation, including startup, shutdown, and post operation cooling. The development and application of verified and validated system models has the potential to reduce the design, testing, and cost and time required for the technology to reach flight-ready status. Since Oct. 1991, the U.S. Department of Energy (DOE), Department of Defense (DOD), and NASA have initiated critical technology development efforts for NTP systems to be used on Space Exploration Initiative (SEI) missions to the Moon and Mars. This paper presents the strategy and progress of an interagency NASA/DOE/DOD team for NTP system modeling. It is the intent of the interagency team to develop several levels of computer programs to simulate various NTP systems. The first level will provide rapid, parameterized calculations of overall system performance. Succeeding computer programs will provide analysis of each component in sufficient detail to guide the design teams and experimental efforts. The computer programs will allow simulation of the entire system to allow prediction of the integrated performance. An interagency team was formed for this task to use the best capabilities available and to assure appropriate peer review.

Walton, James T.↗
NASA NTRS2012

Acquisition of Long-Duration, Low-Gravity Slosh Data Utilizing Existing ISS Equipment (SPHERES) for Calibration of CFD Models of Coupled Fluid-Vehicle Behavior

Accurate prediction of coupled fluid slosh and launch vehicle or spacecraft dynamics (e.g., nutation/precessional movement about various axes, attitude changes, ect.) requires Computational Fluid Dynamics (CFD) models calibrated with low-gravity, long duration slosh data. Recently completed investigations of reduced gravity slosh behavior have demonstrated the limitations of utilizing parabolic flights on specialized aircraft with respect to the specific objectives of the experiments. Although valuable data was collected, the benefits of longer duration low-gravity environments were clearly established. The proposed research provides the first data set from long duration tests in zero gravity that can be directly used to benchmark CFD models, including the interaction between the sloshing fluid and the tank/vehicle dynamics. To explore the coupling of liquid slosh with the motion of an unconstrained tank in microgravity, NASA's Kennedy Space Center, Launch Services Program has teamed up with the Florida Institute of Technology (FIT), Massachusetts Institute of Technology (MIT) and the Office of the Chief Technologist (OCT) to perform a series of slosh dynamics experiments on the International Space Station using the SPHERES platform. The Synchronized Position Hold Engage Reorient Experimental Satellites (SPHERES) testbed provides a unique, free-floating instrumented platform on ISS that can be utilized in a manner that would solve many of the limitations of the current knowledge related to propellant slosh dynamics on launch vehicle and spacecraft fuel tanks. The six degree of freedom (6-DOF) motion of the SPHERES free-flyer is controlled by an array of cold-flow C02 thrusters, supplied from a built-in liquid C02 tank. These SPHERES can independently navigate and re-orient themselves within the ISS. The intent of this project is to design an externally mounted tank to be driven inside the ISS by a set of two SPHERES devices (Figure 1 ). The tank geometry simulates a launch vehicle upper stage propellant tank and the maneuvers replicate those of real vehicles. The design includes inertial sensors, data acquisition, image capture and data storage interfaces to the SPHERES VERTIGO computer system on board the flight article assembly. The design also includes mechanical and electronic interfaces to the existing SPHERES hardware, which include self-contained packages that can operate in conjunction with the existing SPHERES electronics.

Schallhorn, Paul↗
NASA NTRS2013

Acquisition of Long-Duration, Low-Gravity Slosh Data Utilizing Existing ISS Equipment (SPHERES) for Calibration of CFD Models of Coupled Fluid-Vehicle Behavior

Accurate prediction of coupled fluid slosh and launch vehicle or spacecraft dynamics (e.g., nutation/precessional movement about various axes, attitude changes, ect.) requires Computational Fluid Dynamics (CFD) models calibrated with low-gravity, long duration slosh data. Recently completed investigations of reduced gravity slosh behavior have demonstrated the limitations of utilizing parabolic flights on specialized aircraft with respect to the specific objectives of the experiments. Although valuable data was collected, the benefits of longer duration low-gravity environments were clearly established. The proposed research provides the first data set from long duration tests in zero gravity that can be directly used to benchmark CFD models, including the interaction between the sloshing fluid and the tank/vehicle dynamics. To explore the coupling of liquid slosh with the motion of an unconstrained tank in microgravity, NASA's Kennedy Space Center, Launch Services Program has teamed up with the Florida Institute of Technology (FIT), Massachusetts Institute of Technology (MIT) and the NASA Game Changing Development Program (GCD) to perform a series of slosh dynamics experiments on the International Space Station using the SPHERES platform. The Synchronized Position Hold Engage Reorient Experimental Satellites (SPHERES) testbed provides a unique, free-floating instrumented platform on ISS that can be utilized in a manner that would solve many of the limitations of the current knowledge related to propellant slosh dynamics on launch vehicle and spacecraft fuel tanks. The six degree of freedom (6-DOF) motion of the SPHERES free-flyer is controlled by an array of cold-flow C02 thrusters, supplied from a built-in liquid C02 tank. These SPHERES can independently navigate and re-orient themselves within the ISS. The intent of this project is to design an externally mounted tank to be driven inside the ISS by a set of two SPHERES devices (Figure 1). The tank geometry simulates a launch vehicle upper stage propellant tank and the maneuvers replicate those of real vehicles. The design includes inertial sensors, data acquisition, image capture and data storage interfaces to the SPHERES VERTIGO computer system on board the flight article assembly. The design also includes mechanical and electronic interfaces to the existing SPHERES hardware, which include self-contained packages that can operate in conjunction with the existing SPHERES electronics

Schallhorn, Paul↗
NASA NTRSDate not supplied

Lunar Dust Effects on Space Mechanism Ball Bearings for Sustained Human Lunar Operations

NASA has plans to send humans back to the moon under the Artemis Mission. In 2024, the first humans will set foot on the lunar surface since Apollo 17 in 1972. Additionally, extended plans include a sustained human presence on the moon for long duration habitation. These lofty goals will require many different kinds of space mechanisms including: life support, mobility, excavation, scientific instrumentation, etc. Many of these types of systems utilize rotating machinery which require rolling element bearings. As such, dust tolerance of bearings is a major concern for long life in these critical systems. A research activity has been undertaken to characterize and reduce the damage lunar soil (called regolith) dust causes to bearings. The present work details some preliminary results of ball bearings running with grease intentionally contaminated with known quantities and sizes of lunar simulant particles to assess damage. Various bearing material combinations were tested to determine how certain typical bearing materials respond.

BEARINGS↗
DOE OSTI2020

Storm Water Pollution Prevention Plan Middle DP Road Recovery Effort, June 26, 2020

The United States Environmental Protection Agency (EPA) has issued a final 2017 Construction General Permit (CGP) that covers discharges of stormwater from construction sites. The 2017 National Pollutant Discharge Elimination System (NPDES) General Permit for Storm Water Discharges from Construction Activity (Appendix D) includes the following requirements:(1) conduct a critical habitat and threatened/endangered species study; (2) develop and implement a Storm Water Pollution Prevention Plan (SWPPP) in accordance with good engineering practices; (3) submit a Notice of Intent (NOI); (4) install and maintain erosion and stormwater controls; (5) perform and document storm water inspections during construction and site stabilization; (6) amend the SWPPP as necessary; and (7) submit a Notice of Termination (NOT) following project completion and final stabilization of disturbed areas. Authorization to discharge storm water is required under this Permit for both large and small construction projects disturbing more than one (1) acre or part of a larger common plan of development that collectively disturbs more than one (1) acre. All parties that meet the definition of Operator must be permitted. Each permittee is not required to develop and implement a separate SWPP Plan. It is required that there be at least one SWPP Plan for a site that incorporates the required elements for all Operators. The 2017 CGP number for New Mexico (Region 6) is NMR100000. This Plan, which has been developed for Triad National Security, LLC (Triad), describes the nature and sequencing of construction activities, potential sources of pollution, and identifies the Best Management Practices (BMPs) to minimize the potential for erosion and storm water pollution. The Plan was developed in accordance with the provisions of the Clean Water Act (33 U.S.C. § §1251 et seq., as amended by the Water Quality Act of 1987, P.L. 100-4), and the regulations established by the U.S. Environmental Protection Agency (EPA) for National Pollutant Discharge Elimination System (NPDES) General Permits for Storm Water Discharges From Construction Activities.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Storm Water Pollution Prevention Plan Middle DP Road Recovery Effort, June 26, 2020 (Copy for Informational Puproses Only)

The United States Environmental Protection Agency (EPA) has issued a final 2017 Construction General Permit (CGP) that covers discharges of stormwater from construction sites. The 2017 National Pollutant Discharge Elimination System (NPDES) General Permit for Storm Water Discharges from Construction Activity (Appendix D) includes the following requirements: (1) conduct a critical habitat and threatened/endangered species study; (2) develop and implement a Storm Water Pollution Prevention Plan (SWPPP) in accordance with good engineering practices; (3) submit a Notice of Intent (NOI); (4) install and maintain erosion and stormwater controls; (5) perform and document storm water inspections during construction and site stabilization; (6) amend the SWPPP as necessary; and (7) submit a Notice of Termination (NOT) following project completion and final stabilization of disturbed areas. Authorization to discharge storm water is required under this Permit for both large and small construction projects disturbing more than one (1) acre or part of a larger common plan of development that collectively disturbs more than one (1) acre. All parties that meet the definition of Operator must be permitted. Each permittee is not required to develop and implement a separate SWPP Plan. It is required that there be at least one SWPP Plan for a site that incorporates the required elements for all Operators. The 2017 CGP number for New Mexico (Region 6) is NMR100000. This Plan, which has been developed for Triad National Security, LLC (Triad), describes the nature and sequencing of construction activities, potential sources of pollution, and identifies the Best Management Practices (BMPs) to minimize the potential for erosion and storm water pollution. The Plan was developed in accordance with the provisions of the Clean Water Act (33 U.S.C. § §1251 et seq., as amended by the Water Quality Act of 1987, P.L. 100-4), and the regulations established by the U.S. Environmental Protection Agency (EPA) for National Pollutant Discharge Elimination System (NPDES) General Permits for Storm Water Discharges From Construction Activities.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRSDate not supplied

Porosity Prediction and Detection During Composite Cure Using Simulation and Ultrasonic In-Situ Inspection Inside and Autoclave

Composite materials offer unique benefits in aerospace applications such as increased strength-to-weight ratio and improved fatigue properties. They are increasingly being used in major commercial aircraft programs. However, current processing methods can lead to defects in composite parts, which are currently identified using post-manufacturing inspection methods. A cure defects process model has been developed to predict the formation of manufacturing defects (e.g., porosity and fiber waviness) in composites based on the cure parameters and part geometry. However, a capability to directly validate porosity during cure did not exist. Validation methods included comparing resin pressure measured during cure with predictions by the process model and inspection/microscopy after cure. This study developed a high-temperature ultrasonic inspection system to detect porosity defects in composites during autoclave cure and experimentally verify the predictions of the model. The system operated inside an autoclave within an enclosure cooled by intermittent liquid nitrogen(LN2) injections. A high-temperature 2.25 MHz ultrasonic transducer was utilized to transmit ultrasonic waves through the tool plate and into the composite material and to measure the amplitude and time of flight of the reflected waves with a 1 mm × 1 mm resolution. Porosity was observed via the ultrasonic reflections, which experienced increased attenuation in regions of high porosity. Distinct regions of increased porosity were present due to uneven pressure across the panel, which was driven by an intentional misfit between the flat caul plate and the tapered composite panel with ply drops. These observations matched the predictions of the model using the inputs from the experiment (e.g., part material and geometry, cure cycle) and were validated by post-cure ultrasonic inspection and micrographs. The in-situ inspection system was able to successfully provide defect detection and localization and can be applied to future manufacturing of composite structure for aerospace applications.

Porosity↗
DOE OSTI2024

Accuracy Enhancement of Nuclear Power Plant Simulators Utilizing High Accuracy Simulation Predictions

More recently, reactor core simulators for core designs associated with commercial nuclear power plants that utilize what is believed to be higher fidelity models have been developed. Features such as neutronics models that utilize transport equation solvers with fine spatial meshes and many energy-groups, thermal-hydraulic models that utilize sub-channel solvers with fine spatial mesh and capable of treating a wide range of fluid conditions, and fuel-coolant chemistry interaction models capable of treating CRUD deposition are to be found in these higher fidelity core simulators. These reactor core simulators require access to higher performance computers, characterized by many processors, cores and large memory. So associated with utilization of these simulators is access to high performance computers and ability to accommodate in one’s workflow longer execution times. By contrast, currently used core simulators by the nuclear industry can execute on engineering workstations and have execution times of seconds to minutes. The desirability for having short execution times is not only desired for support of time critical tasks but supports the mental process of decision making by engineers. The goal of the work reported upon here has the objective of retaining the fidelity of higher fidelity models while retaining the ability to utilize engineering workstations. Beyond the core simulator goal, additional goals of this work include incorporating the just described core simulator capability into a Nuclear Steam Supply System (NSSS) simulator, and to incorporate the resulting capability into an environment supportive of design and operational decision making associated with nuclear power stations. The model selected for the core neutronics model is the NESTLE code, for the core thermal-hydraulic model is the CTF code utilizing coarse mesh, and for the NSSS model is the RELAP5-3D code. WSC’s proprietary 3KEYMASTERTM platform is being used to provide software coupling, user interface, visualization, and reporting. The NESTLE core neutronics simulator was first integrated with the CTF core thermal-hydraulic simulator using CTF developed communication commands which are also used for CTF to communicate with RELAP5-3D under WSC’s proprietary 3KEYMASTERTM platform. To assure NESTLE prediction consistency with higher fidelity core neutronic simulators, buffer codes have been created to automatically generate from output files written by the VERA core simulator the NESTLE nodal neutronic parameter’ library, geometry, and pin-power reconstruction input files, thereby avoiding a number of challenges associated with utilizing lattice physics codes and providing consistency with VERA predictions. To treat absorber rod effects a multi-set library is utilized, where a set refers to a specific absorber rod fully inserted pattern. A coarse spatial mesh CTF model was developed with features added that support using CTF as envisioned in the engineering quality simulator. A hybrid meshing approach was implemented to allow for automated construction of models with mixed levels of refinement. Specifically, a core model could resolve some assemblies at a nodal level (4 subchannels per assembly) and others at a pin-resolution (one subchannel per coolant subchannel in the assembly). The intention is that this will allow for better resolution of limiting conditions such as DNBR and PCT, which are based on local rod and subchannel conditions. Further development was done of features that enhance the capabilities for the envisioned engineering quality simulator that has been developed, but now for RELAP-3D. The RELAP5-3D code development includes ability to model more than 999 components and the addition of the cross-channels turbulence mixing model and the void drift model that are implemented in CTF, aiming to achieve closer prediction agreement of the two codes for transient simulations, specifically, more accurate matches of the overall mass, momentum, and energy exchanges of both the liquid and gas phases between the neighboring core assemblies. Graphics were also developed for the Instructor Station for this project under WSC’s proprietary 3KEYMASTERTM platform to facilitate design and operational decision making.

42 ENGINEERING↗
DOE OSTI2020

Design and Development of Low Weight, Titanium Aluminide Airfoils for High Performance Industrial Gas Turbines meeting 65% Combined Cycle Efficiency (Final Report)

This project funded under DOE-FOA-0001816 was performed with the intent of evaluating the potential of utilizing a low density, high specific strength Titanium Aluminide (TiAl) alloy in a large annulus last stage gas turbine blade with the intent of improving combined cycle gas turbine efficiency toward a goal of reaching 65% efficiency. The project consisted of identifying a potentially suitable TiAl material for manufacture of such a large blade by investment casting. This included estimation of design properties for the selected alloy, trade studies using a baseline design created for a nickel based alloy cast in the TiAl alloy to evaluate potential design changes required for the use of this material and optimization of a prototype design for the same baseline application using the selected TiAl alloy. Several rounds of optimization were completed with the intent of meeting the baseline design targets with a resulting design that showed at least equivalent performance in terms of creep, LCF/TMF, HCF and aerodynamic damping potential. While it was found that significant reductions in blade loading on the disk were possible, the design resulting from the optimization met most lifing targets at the baseline size, but showed a reduction in margins in some areas in comparison to the Ni-based baseline design. Additionally, it was found that the low strain tolerance of the TiAl alloy for temperatures at and below the operational temperature of the attachment resulted in marginal, although still acceptable, creep rupture performance of the design. Due to results indicating the reduced potential for increasing turbine annulus compared to expectations a Phase II award was not proposed and it is not recommended to pursue additional design optimization efforts until further material advances with TiAl materials are achieved.

03 NATURAL GAS↗
NASA NTRS2004

High Resolution Laser Scanning Techniques for Rock Abrasion and Texture Analyses on Mars and Earth

Aeolian abrasion is operative in many arid locations on Earth and is probably the dominant rock erosion process in the current Martian environment. Therefore, understanding the controlling parameters and rates of aeolian abrasion provides 1) insight into the stability of rocks on planetary surfaces and the environments under which the rocks abrade, and 2) a link between ventifact (a rock abraded by windblown particles) morphology and: a) abrasion conditions, b) possible ancient environments under which the rocks were abraded, and c) rock properties. promising and we plan further investigations in the wind tunnel and field. Our intent here is to discuss the basic technique, initial results, and upcoming plans.

Bridges, N. T.↗
NASA NTRS1994

Artificial gravity in space and in medical research

The history of manned space flight has repeatedly documented the fact that prolonged sojourn in space causes physiological deconditioning. Physiological deterioration has raised a legitimate concern about man's ability to adequately perform in the course of long missions and even the possibility of leading to circumstances threatening survival. One of the possible countermeasures of physiological deconditioning, theoretically more complete than others presently used since it affects all bodily systems, is artificial gravity. Space stations and spacecrafts can be equipped with artificial gravity, but is artificial gravity necessary? The term "necessary" must be qualified because a meaningful answer to the question depends entirely on further defining the purpose of space travel. If man intends to stay only temporarily in space, then he must keep himself in good physical condition so as to be able to return to earth or to land on any other planetary surface without undue exposure to major physiological problems resulting from transition through variable gravitational fields. Such a situation makes artificial gravity highly desirable, although perhaps not absolutely necessary in the case of relative short exposure to microgravity, but certainly necessary in interplanetary flight and planetary landings. If the intent is to remain indefinitely in space, to colonize space, then artificial gravity may not be necessary, but in this case the consequences of long term effects of adaptation to weightlessness will have to be weighed against the biological evolutionary outcomes that are to be expected. At the moment, plans for establishing permanent colonies in space seem still remote. More likely, the initial phase of exploration of the uncharted solar system will take place through successive, scope limited, research ventures ending with return to earth. This will require man to be ready to operate in gravitational fields of variable intensity. Equipping spacecrafts or space stations with some means of artificial gravity in this initial phase is, therefore, necessary without question. In a strict sense artificial gravity is conceived as a means of replacing natural gravity in space by the centripetal acceleration generated by some sort of rotating device. Rotating devices create an inertial force which has effects on bodies similar to those caused by terrestrial gravity, but artificial gravity by a rotation device is not the same as terrestrial gravity, as we shall see. Present research in artificial gravity for space exploration is projected in two main directions: artificial gravity for whole space stations and artificial gravity produced by short arm centrifuges designed for human use in space.

Case Reports↗
NASA NTRS2000

Tactile Sensing for Dexterous Robotic Hands

Robotic systems will be used as precursors to human exploration to explore the solar system and expand our knowledge of planetary surfaces. Robotic systems will also be used to build habitats and infrastructure required for human presence in space and on other planetary surfaces . Such robots will require a high level of intelligence and automation. The ability to flexibly manipulate their physical environment is one characteristic that makes humans so effective at these building and exploring tasks . The development of a generic autonomous grasp ing capability will greatly enhance the efficiency and ability of robotics to build, maintain and explore. To tele-operate a robot over vast distances of space, with long communication delays, has proven to be troublesome. Having an autonomous grasping capability that can react in real-time to disturbances or adapt to generic objects, without operator intervention, will reduce the probability of mishandled tools and samples and reduce the number of re-grasp attempts due to dropping. One aspect that separates humans from machines is a rich sensor set. We have the ability to feel objects and respond to forces and textures. The development of touch or tactile sensors for use on a robot that emulates human skin and nerves is the basis for this discussion. We will discuss the use of new piezo-electric and resistive materials that have emerged on the market with the intention of developing a touch sensitive sensor. With viable tacti le sensors we will be one step closer to developing an autonomous grasping capability.

Martin, Toby B.↗
NASA NTRS2023

Runtime Assurance of Aeronautical Products: Preliminary Recommendations

Runtime assurance (RTA) affords an operational layer of protection against safety hazards to aeronautical products that may include less trusted or untrusted functions. However, any RTA scheme must itself be trusted before it can be deployed into use: i.e., it must be fit for its intended purpose, and it must not itself introduce safety hazards. This report contains preliminary recommendations on the application and integration of RTA into aeronautical products intended for use in civil aviation. The main purpose of these recommendations is to inform regulatory guidance and consensus standards that may be used to meet the safety intent of the applicable regulations.

Runtime assurance↗
DOE OSTI2020

Detection and Localization of Damaged Photovoltaic Cells and Modules Using Spread Spectrum Time Domain Reflectometry

The operating efficiency of photovoltaic (PV) plants can be improved if damaged or degraded modules can be detected and identified. Currently, string-level power electronics can detect problems with modules or cabling but not locate them, which would facilitate addressing these issues. Here, we investigate the ability of spread spectrum time domain reflectometry (SSTDR) to both detect and locate/identify damaged cells and modules within a series-connected PV string. We tested the ability of SSTDR to detect and locate single-cell mini-modules and full-sized PV modules, which were intentionally damaged by impacts with a hammer (breaking the glass and damaging the silicon below) or by cutting through some or all busbars. Damage to the glass and silicon of cells was detected and located within a small string of minimodules. Busbar damage was detectable only if an open was created by cutting through all intercell busbars. Furthermore, physical impact damage to the glass and silicon of a full-sized PV module could be detected, but further development of signal processing is needed to achieve localization of such damaged modules within a string.

14 SOLAR ENERGY↗
NASA NTRS2017

A Fuzzy Logic Approach for Separation Assurance and Collision Avoidance for Unmanned Aerial Systems

In the coming years, operations in low altitude airspace will vastly increase as the capabilities and applications of small Unmanned Aerial Systems (sUAS) continue to multiply. Therefore, solutions to managing sUAS in highly congested airspace must be explored. In this study, a Fuzzy Logic based approach was used to help mitigate the risk of collisions between aircraft using separation assurance and collision avoidance techniques. The system was evaluated for its effectiveness to mitigate the risk of mid-air collisions between aircraft. This system utilizes only current state information and can resolve potential conflicts without knowledge of intruder intent. The avoidance logic was verified using formal methods and shown to select the correct action in all instances. Additionally, the Fuzzy Logic Controllers were shown to always turn the vehicles in the correct direction. Numerical testing demonstrated that the avoidance system was able to prevent a mid-air collision between two sUAS in all tested cases. Simulations were also performed in a three-dimensional environment with a heterogenous fleet of sUAS performing a variety of realistic missions. Simulations showed that the system was 99.98 effective at preventing mid-air collisions when separation assurance was disabled (unmitigated case) and 100 effective when enabled (mitigated case).

Verification & Validation of a Fuzzy Logic Control↗
DOE OSTI2024

FORCE Regression Testing

Via programs including the Light Water Reactor Sustainability and Integrated Energy Systems, the U.S. Department of Energy has invested in the Framework for Optimization of ResourCes and Economics (FORCE) software framework (Idaho National Laboratory 2024a) for the technical and economic analysis of nuclear-integrated energy systems (IES). Nuclear IES expand the use of nuclear from traditional baseload electricity generation to a flexible and adaptive source of combined heat and power. Nuclear heat can be used in the production of a variety of energy currencies such as hydrogen and ammonia as well as other heat applications including water desalination and district heating. FORCE is designed with the intent to provide interconnected analysis tools that enable the accurate technical and economic assessment of specific nuclear IES configurations for individual energy markets. FORCE consists of three main analysis pathways: HYBRID (Idaho National Laboratory 2024b), which contains high-resolution physical models for IES; Holistic Energy Resource Optimization Network (HERON) (Idaho National Laboratory 2024c), which analyzes IES long-term economic viability; and Optimization of Real-time Capacity Allocation (ORCA) (Idaho National Laboratory 2024d), designed for real-time control of IES via digital twins and optimal decision making, including autonomous and remote operation research. Development of the FORCE ecosystem is guided by three pillars: capability, which assures that the computational requirements of IES analysis are met by the software tools; reliability, which provides for consistent code performance and expected behaviors; and accessibility, which lowers the barrier to entry for using the software and accelerates analysis by users beyond the FORCE primary developers. Reliability of the FORCE ecosystem is established according to the American Nuclear Society?s Nuclear Quality Assurance (NQA-1) program [American Society of Mechanical Engineers 1982], with specific levels of software quality assurance (SQA) within NQA-1 applied to each software tool in FORCE. As the tools within FORCE have matured, some integration algorithms to accurately connect the software tools for holistic analysis have been developed and deployed within the FORCE software repository. In accordance with NQA-1 standards, regression tests are required to guarantee the software performs consistently even when new capabilities are added to the software. In this report, we document the deployment of both unit tests, which test the consistent behavior of small pieces of the FORCE code base, as well as integration tests, which test the consistent performance of full use cases for the FORCE integration algorithms. We further document the encapsulation of these tests within a test harness, which collectively checks for each successful test completion on demand. Finally, we document the automation of the test harness using GitHub Actions [GitHub 2024], which require all tests succeed before any new capability or other changes can be added to the FORCE integration software

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Development of Low-Cost, High-Performance, Easy-To-Apply, Non-Flammable, Inorganic Phase Change Material (PCM) Technology (Project Final Report)

This report describes a 45-months long research program focused on the development of novel, easy-to-apply, non-flammable, and high-performance inorganic phase change materials (PCMs) for building and industrial applications. The University of Massachusetts Lowell (UML) formed a world-class team consisting of researchers form InsolCorp (only N. American manufacturer of inorganic PCM systems for building applications), and a group of industrial advisors, to develop a universal/multipurpose, simple-to-manufacture and cost-effective PCM technology. The project team expects that the results of this work will spur in the future the adoption of thermal storage materials – a key building energy saving technology as identified by DOE BTO – for a variety of building envelope applications. The main goal of this project was to demonstrate a suite of low-cost, multipurpose, and durable inorganic PCM formulations with phase transition temperatures encompassing typical building applications (between +5 o C and +55 o C). The first objective was to design, fabricate, and experimentally validate a performance of inexpensive, durable, highly efficient, non-flammable, and easy to manufacture PCMs. To allow a variety of building applications, the project team focused on formulations that exhibit repeatable phase transitions between +5 o C and +55 o C. To follow the DOE BTO cost efficiency target without compromising thermal performance, our work was based on inorganic compounds (mostly salt hydrates) and their blends, which represent a fraction of the cost of most of organic PCMs with about twice as high density as well as significantly higher thermal conductivity and phase change enthalpy. The second objective was to develop easy-to-manufacture and -install packaging/encapsulation designs that are 1) a superior barrier to current state-of-the-art macro-packaging, which significantly reduces the risk of loss of hydration water and PCM leak, and 2) optimal in enhancing the heat exchange rates with the surroundings and within the PCM core to ensure complete charging/discharging of the entire PCM within the product. Finally, the project’s intend was to scale-up the fabrication process to demonstrate installation on system-scale applications, and to validate the performance under field conditions. This work aimed at developing low-cost, high-energy storage, and reliable latent heat storage technology for building applications. This development was realized by formulating and integrating the following two technology components: 1) inorganic salt hydrate based PCMs that have high latent enthalpies and are low-cost and durable, and 2) PCM encapsulation (packaging) technology that maximizes PCM concentration and enhances heat transport characteristics in the product and with the external environment/materials. High thermal storage capacity, low cost and fire resistance are key to the building market entry for PCM technology. Therefore, the project’s focus was on salt-hydrate-based formulations which satisfy all these criteria. Packaging and/or encapsulation of PCM is a key processing step. The project team recognized that a low-cost and simple-to-manufacture salt hydrate-based PCM technology holds the best chance to be successful in the building construction market, a market which is traditionally extremely sensitive to cost and where commodity thermal insulations are the benchmark for envelope-related energy saving measures. That is why, in this project, the main intention was to minimize the production cost and maximize the product energy storage density without sacrificing the PCM performance. It was achieved through: 1. Minimizing the non-PCM components (plastics, additives, packaging/encapsulation materials, etc.) because they are significantly more expensive than salt hydrates, 2. Using highly thermally conductive and lightweight PCM carrier (packaging material) to facilitate more complete phase cycling, and 3. Optimizing the thickness and minimizing air spaces in product design (such as in pouched PCM). For this purpose, our approach was to enable an easy system design, including selection of the PCM operating temperatures, optimizing the necessary heat storage capacity (by stacking together several layers of PCM products), and if needed, a synchronized usage of PCM products of different temperatures. A specially designed, robust, highly thermally conducting and highly impermeable packaging (to retain salt hydrate water during phase transition cycles) was designed and tested to increase the overall system thermal performance and durability. All PCM products developed during this project were tested in both lab scale and in full scale field conditions. It is expected that, after further developments and commercialization, the developed PCM technologies may be also applied in space conditioning, energy storage technologies, and heat transfer applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗