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At least 73 records · Page 4

Progress of Crew Autonomous Scheduling Test (CAST) On the ISS

The United States space policy is evolving toward missions beyond low Earth orbit. In an effort to meet that policy, NASA has recognized Autonomous Mission Operations (AMO) as a valuable capability. Identified within AMO capabilities is the potential for autonomous planning and replanning during human spaceflight operations. That is allowing crew members to collectively or individually participate in the development of their own schedules. Currently, dedicated mission operations planners collaborate with international partners to create daily plans for astronauts aboard the International Space Station (ISS), taking into account mission requirements, ground rules, and various vehicle and payload constraints. In future deep space operations the crew will require more independence from ground support due to communication transmission delays. Furthermore, crew members who are provided with the capability to schedule their own activities are able to leverage direct experience operating in the space environment, and possibly maximize their efficiency. CAST (Crew Autonomous Scheduling Test) is an ISS investigation designed to analyze three important hypotheses about crew autonomous scheduling. First, given appropriate inputs, the crew is able to create and execute a plan in a reasonable period of time without impacts to mission success. Second, the proximity of the planner, in this case the crew, to the planned operations increases their operational efficiency. Third, crew members are more satisfied when given a role in plan development. This presentation shows the progress done in this study with a single astronaut test subject participating in five CAST sessions. CAST is a technology demonstration payload sponsored by the ISS Research Science and Technology Office, and performed by experts in Mission Operations Planning from the Flight Operations Directorate at NASA Johnson Space Center, and researchers across multiple NASA centers.

Healy, Matthew↗

CAST Safety Enhancement Research on Airplane State Awareness and Prediction Technologies

Loss of control in flight (LOC-I) is the leading cause of fatal aircraft accidents. A study of LOC accidents and incidents, commissioned by the Commercial Aviation Safety Team (CAST) identified a growing trend in loss of Airplane State Awareness (ASA) by the flight crew. This has led to recommended safety enhancements that include flight deck technologies for improving current and predicted energy state awareness. In this talk, we discuss recent CAST motivated efforts to develop new information systems for predicting and assessing the future aircraft energy state and auto-flight configuration. The outputs from these systems can serve multiple purposes, including improved pilot alerting for anticipating and recovering from problematic flight conditions, as well as higher level flight safety assurance for autonomous operations.

Schuet, Stefan↗

Research Campaign: Advanced Manufacturing in Space: Properties, Structure and Simulations to Pioneer New Applications

This topic underpins synthesis of, and in many cases manufacturing of, value-added materials via liquid phase processing. Materials and processes range from cast metals and optical glasses through exploration-relevant technologies such as additive manufacturing, casting and in-situ resource utilization to support human space exploration. A recurring theme is the need for accurate thermophysical property and atomic structure data for relevant materials and the exploitation of reduced convection/sedimentation in microgravity to enhance the quality of data and to develop new and transformative technologies for materials processing.

Michael SanSoucie↗

Effects of Transition Layer on Bending Resistance in Copper-Clad Aluminum Composite Casting

The performance of the transition layer in a Cu/Al composite casting directly affects the quality of subsequent plastic deformation processing; however, there are no universal or standardized measurement indices for the performance of the transition layer. In this study, Cu/Al composite castings were prepared using the pouring aluminum method, and the resulting solidification microstructures on the bending resistance were investigated. The results of this study lay a theoretical foundation for the development of the plastic processing technologies of these composite castings. A thinner transition layer in the Cu/Al composite casting led to improved bending resistance. In addition, for a fixed total thickness of the transition layer, the bending resistance was mainly controlled by the γ/β interface and β + eutectic (α + β) microstructure, and the thickness of the γ phase had a negligible effect on the bending resistance. The γ/β interface cracked first when the transition layer bore the tensile and shear stress during the bending process, which resulted in the transition layer easily separating from the copper. The bending resistance of the transition layer can be feasibly judged by measuring the bending angle of the specimen tip, which can be easily performed when the specimen bends toward the aluminum direction, suggesting that our proposed method has considerable practical significance.

36 MATERIALS SCIENCE↗

Study of Ferrite During Refinement of Prior Austenite Grains in Microalloyed Steel Continuous Casting

The formation of coarse prior austenite grain is a key factor to promote transverse crack, and the susceptibility to the transverse crack can be reduced by refining the austenite grain size. In the present study, the high-temperature confocal laser scanning microscope (CLSM) was used to simulate two types of double phase-transformation technologies. The distribution and morphology of ferrites under different cooling conditions were analyzed, and the effects of ferrite distribution and morphology on the double phase-transformation technologies were explored to obtain the suitable double phase-change technology for the continuous casting process. The results indicate that, under the thermal cycle TH0 [the specimens were cooled down to 913 K (640 °C) at a cooling rate of 5.0 K/s (5.0 °C/s)], the width of prior austenite grain boundaries was thick, and the dislocation density at grain boundaries was high. It had strong inhibition effect on crack propagation; under the thermal cycle TH1 [the specimens were cooled down to 1073 K (800 °C) at a cooling rate of 5.0 K/s (5.0 °C/s) and then to 913 K (640 °C) at a cooling rate of 1.0 K/s (1.0 °C/s)], the width of prior austenite grain boundary was thin, and the dislocation density at grain boundaries was low. It was beneficial to crack propagation. After the first phase change, the developed film-like ferrite along the austenite grain boundaries improved the nucleation conditions of new austenitic grains and removed the inhibition effect of the prior austenite grain boundaries on the austenite grain size.

36 MATERIALS SCIENCE↗

Abstract for CRADA between the National Energy Technology Laboratory and General Motors (AGMT-0876)

Lightweight aluminum shape castings have widespread applications for structural components in the automotive, aerospace, and general engineering industries because of their excellent castability, corrosion resistance, and particularly high strength-to-weight ratio in the heat-treated condition. In the automotive industry, cast aluminum alloys have been increasingly used to replace cast iron and steel in vehicle applications such as engine blocks, cylinder heads, intake manifolds, brackets, housings, chassis, transmission parts, and suspension systems to reduce mass. As many of the aluminum shape castings used in automobiles involve cyclic loading, fatigue properties of the castings are critical to their success. The increasing use of lightweight aluminum cast components in critical structures thus requires improved integrity, with more reliable and quantifiable performance. The objective of this project is to demonstrate and further develop GM’s patent-pending, novel casting process, “Pressure-Assistant Precision Sand Casting (PAPSC) for producing flawless cast aluminum cylinder heads with minimum manufacturing and energy costs”. The approach is to leverage NETL’s experience in producing high-quality metal castings through various microstructure control and defect elimination technologies as well as comprehensive quantification of microstructure characteristics and mechanical properties. A baseline (production) alloy together with the melt treatment will be initially evaluated with the new PAPSC process to develop and validate the process window for producing flawless cast aluminum heads.

36 MATERIALS SCIENCE↗

The Residuum-Those Who Technology Leaves Behind

The introduction of new technologies has direct and indirect advantages and disadvantages on societies. As the relentless pace of technology increases, societies have to adjust, accommodate, integrate or reject the latest invention or innovation. Many people even experience the unintended consequences associated with these technologies. Some technologies appear to have a stabilizing effect on society (where the technology lifts all of society) while other technologies appear disruptive with unsettling effects(benefits are shared by a few with previously established firms being displaced). In this latter case, companies with the most disruptive technologies provide benefits but also gain market share by decimating their competitors. Those in society who have the means or the opportunity to seize the benefits of advanced technologies undoubtedly gain efficiencies of time and effectiveness while those who cannot afford or those who chose not to adopt these same technologies unfortunately fall behind. During the present worldwide pandemic, schools have physically closed their doors causing the mto pursue virtual classrooms. How will the teachers and children without internet access in their homes compare to those who do? In the near future, increased automation will lead to some reduction in the full-time workforce. A co-worker recently improved her skills in a fortuitous technical discipline. Others did not. Who should be held responsible for reskilling? Stated another way, who should be held responsible for finding new employment opportunities?In the distant future, parents who incorporated genetically enhanced benefits during childbirth will have offspring who will probably advance beyond those who cannot afford the technology. In these various ways, who should be held responsible for those who technology leaves behind?Are those left behind simply those who suffer inequality or is there something more?Should the semi-transparent hand of technology be allowed to roam freely through society selecting the survival of the fittest as it chooses? Should the invisible hand of the financial market make the decisions? Or, should governments and companies bear some responsibility by crafting policies to mitigate the consequences to those cast aside by the technology? This paper will endeavor to address some of the underlying issues of this question while attempting to find a set of sensible solutions to this problem.

Residuum↗

Optimization of Tape Casting for Fabrication of Li 6.25 Al 0.25 La 3 Zr 2 O 12 Sheets

Tape casting is an attractive technology for the scalable manufacturing of thin lithium garnet electrolyte (LLZO) layers for solid state battery applications. Processing of LLZO is complicated by many factors including lithium volatilization, abnormal grain growth, and phase instability, which are exacerbated by high surface area to volume ratios. In this work a sintering protocol for commercially available Li 6.25 Al 0.25 La 3 Zr 2 O 12 Sheets (Al-LLZO) powder was developed that requires no mother-powder covering or externally applied pressure. MgO was investigated as a sintering additive to improve density and ionic conductivity of the Al-LLZO sheets and produce a fine-grained microstructure. Al-LLZO sheets with 5 wt % MgO had densities of > 90% and ionic conductivity > 2 × 10 -4 S/cm. The optimized ceramic composition and sintering protocol were used to compare several tape casting binder systems. A "green"water-based system using methylcellulose as a binder was developed with green and final properties comparable to those obtained with solvent-based systems.

25 ENERGY STORAGE↗

High-Resolution Characterization of UMo Alloy Microstructure

This report highlights the capabilities and procedure for high-resolution characterization of UMo fuels in PNNL. Uranium-molybdenum (UMo) fuel processing steps, from casting to forming final fuel, directly affect the microstructure of the fuel, which in turn dictates the in-reactor performance of the fuel under irradiation. In order to understand the influence of processing on UMo microstructure, microstructure characterization techniques are necessary. Higher-resolution characterization techniques like transmission electron microscopy (TEM) and atom probe tomography (APT) are needed to interrogate the details of the microstructure. The findings from TEM and APT are also directly beneficial for developing predictive multiscale modeling tools that can predict the microstructure as a function of process parameters. This report provides background on focused-ion-beam–based TEM and APT sample preparation, TEM and APT analysis procedures, and the unique information achievable through such advanced characterization capabilities for UMo fuels, from a fuel fabrication capability viewpoint.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Ageless Aluminum-Cerium-Based Alloys in High-Volume Die Casting for Improved Energy Efficiency

Strong chemical reactions between Al and Ce lead to the formation of intermetallics with exceptional thermal stability. The rapid formation of intermetallics directly from the liquid phase during solidification of Al-Ce alloys leads to an ultrafine microconstituent structure that effectively strengthens as-cast alloys without further microstructural optimization via thermal processing. Die casting is a high-volume manufacturing technology that accounts for greater than 40% of all cast Al products, whereas Ce is highly overproduced as a waste product of other rare earth element (REE) mining. Reducing heat treatments would stimulate significant improvements in manufacturing energy efficiency, exceeding (megatonnes/year) per large-scale heat-treatment line. In this study, multiple compositions were evaluated with wedge mold castings to test the sensitivity of alloys to the variable solidification rate inherent in high-pressure die casting. Once a suitable composition was determined, it was successfully demonstrated at 800 lbs/h in a 600-ton die caster, after which the as-die cast parts performed similarly to ubiquitous A380 in the same geometry without requiring heat treatment. Furthermore, this work demonstrates the compatibility of Al REE alloys with high-volume die-casting applications with minimal heat treatments.

36 MATERIALS SCIENCE↗

Development of High-Performance Cast Crankshafts. Final Technical Report

The objective of this project was to develop technologies that would enable the production of cast crankshafts that can replace high performance forged steel crankshafts. To achieve this, the Ultimate Tensile Strength (UTS) of the new material needs to be 850 MPa with a desired minimum Yield Strength (YS; 0.2% offset) of 615 MPa and at least 10% elongation. Perhaps more challenging, the cast material needs to be able to achieve sufficient local fatigue properties to satisfy the durability requirements in today’s high performance gasoline and diesel engine applications. The project team focused on the development of cast steel alloys for application in crankshafts to take advantage of the higher stiffness over other potential material choices. The material and process developed should be able to produce high-performance crankshafts at no more than 110% of the cost of current production cast units, perhaps the most difficult objective to achieve. To minimize costs, the primary alloy design strategy was to design compositions that can achieve the required properties with minimal alloying and post-casting heat treatments. An Integrated Computational Materials Engineering (ICME) based approach was utilized, rather than relying only on traditional trial-and-error methods, which has been proven to accelerate alloy development time. Prototype melt chemistries designed using ICME were cast as test specimens and characterized iteratively to develop an alloy design within a stage-gate process. Standard characterization and material testing was done to validate the alloy performance against design targets and provide feedback to material design and manufacturing process models. Finally, the project called for Caterpillar and General Motors (GM) to develop optimized crankshaft designs using the final material and manufacturing processing path developed. A multi-disciplinary effort was to integrate finite element analyses by engine designers and geometry-specific casting simulations with existing materials models to optimize crankshaft cost and performance. Prototype crankshafts of the final design were to be produced and validated using laboratory bench testing and on-engine durability testing. ICME process simulation tools were used to investigate a broad range of processing concepts. These concepts included casting orientation, various mold and core materials, and various filling and feeding strategies. Each crankshaft was first simulated without gating and risers, which is termed natural solidification. The natural solidification results were used as a baseline for strategy development of each concept. Casting process simulations and ICME tools were proven to be reasonable predictors of real world results. Potential alloys were developed that could meet the project material property goals with appropriate normalization and temper treatments. For the alloys considered, post-normalization temper treatments proved to be necessary to achieve the desired yield strengths and elongations and appropriate heat treatments were designed using ICME tools. The experimental data of all the alloys were analyzed in combination with ICME tools to establish chemistry-process-structure relations. Several GM small gas engine (SGE) crankshafts were successfully cast in sand molds using two different sprue, runner, gate, riser, chill designs. These crankshafts were cast in two different steel alloys developed during the project, but casting finishing (e.g. riser removal) remains a cost challenge. A long list of future work was left unfinished when this project was unexpectedly terminated.

36 MATERIALS SCIENCE↗

Development of Cast Valve Bodies For High Temperature Service

Gen 3 Concentrating Solar-Thermal Power (CSP) system components are required to operate at 750°C - 800°C to achieve the Sunshot target of 6 cents/kWh. Haynes ® 282 and IN ® 740H are preferred alloys for the construction of these components due to their high tensile and creep strengths for service at temperatures greater than 750°C. There is significant motivation to lower the cost of materials and components so that the capital costs can be minimized. One approach to reduce costs is to fabricate castings at the lowest possible cost. To obtain the lowest cost in castings, there is a significant need to maximize yields in castings by decreasing rejects due to casting defects and to minimize wastage in material lost in the gating systems. However, very little work has been performed to develop cast products using Haynes ® 282. Although preliminary work has established the feasibility of casting Haynes ® 282 using investment and sand casting, there are no commercial cast components available. In particular, there is significant interest in the development of casting design and process technology for the fabrication of components such as valve bodies using Haynes ® 282.

14 SOLAR ENERGY↗

Help for the Steel Industry

A collaboration between NASA Lewis Research Center (LRC) and Gladwin Engineering resulted in the adaptation of aerospace high temperature metal technology to the continuous casting of steel. The continuous process is more efficient because it takes less time and labor. A high temperature material, once used on the X-15 research plane, was applied to metal rollers by a LRC developed spraying technique. Lewis Research Center also supplied mold prototype of metal composites, reducing erosion and promoting thermal conductivity. Rollers that previously cracked due to thermal fatigue, lasted longer. Gladwin's sales have increased, and additional NASA-developed innovations are anticipated.

Source record↗

Commercialization of NASA's High Strength Cast Aluminum Alloy for High Temperature Applications

In this paper, the commercialization of a new high strength cast aluminum alloy, invented by NASA-Marshall Space Flight Center, for high temperature applications will be presented. Originally developed to meet U.S. automotive legislation requiring low- exhaust emission, the novel NASA aluminum alloy offers dramatic improvement in tensile and fatigue strengths at elevated temperatures (450 F-750 F), which can lead to reducing part weight and cost as well as improving performance for automotive engine applications. It is an ideal low cost material for cast components such as pistons, cylinder heads, cylinder liners, connecting rods, turbo chargers, impellers, actuators, brake calipers and rotors. NASA alloy also offers greater wear resistance, dimensional stability, and lower thermal expansion compared to conventional aluminum alloys, and the new alloy can be produced economically from sand, permanent mold and investment casting. Since 2001, this technology was licensed to several companies for automotive and marine internal combustion engines applications.

Lee, Jonathan A.↗

Inspiring the Next Generation in Space Life Sciences

Competitive summer internships in space life sciences at NASA are awarded to college students every summer. Each student is aligned with a NASA mentor and project that match his or her skills and interests, working on individual projects in ongoing research activities. The interns consist of undergraduate, graduate, and medical students in various majors and disciplines from across the United States. To augment their internship experience, students participate in the Space Life Sciences Summer Institute (SLSSI). The purpose of the Institute is to offer a unique learning environment that focuses on the current biomedical issues associated with human spaceflight; providing an introduction of the paradigms, problems, and technologies of modern spaceflight cast within the framework of life sciences. The Institute faculty includes NASA scientists, physicians, flight controllers, engineers, managers, and astronauts; and fosters a multi-disciplinary science approach to learning with a particular emphasis on stimulating experimental creativity and innovation within an operational environment. This program brings together scientists and students to discuss cutting-edge solutions to problems in space physiology, environmental health, and medicine; and provides a familiarization of the various aspects of space physiology and environments. In addition to the lecture series, behind-the-scenes tours are offered that include the Neutral Buoyancy Laboratory, Mission Control Center, space vehicle training mockups, and a hands-on demonstration of the Space Shuttle Advanced Crew Escape Suit. While the SLSSI is managed and operated at the Johnson Space Center in Texas, student interns from the other NASA centers (Glenn and Ames Research Centers, in Ohio and California) also participate through webcast distance learning capabilities.

Hayes, Judith↗

Cast Glance Near Infrared Imaging Observations of the Space Shuttle During Hypersonic Re-Entry

High resolution calibrated infrared imagery of the Space Shuttle was obtained during hypervelocity atmospheric entries of the STS-119, STS-125 and STS128 missions and has provided information on the distribution of surface temperature and the state of the airflow over the windward surface of the Orbiter during descent. This data collect was initiated by NASA s Hypersonic Thermodynamic Infrared Measurements (HYTHIRM) team and incorporated the use of air- and land-based optical assets to image the Shuttle during atmospheric re-entry. The HYTHIRM objective is to develop and implement a set of mission planning tools designed to establish confidence in the ability of an existing optical asset to reliably acquire, track and return global quantitative surface temperatures of the Shuttle during entry. On Space Shuttle Discovery s STS-119 mission, NASA flew a specially modified thermal protection system tile and instrumentation package to monitor heating effects from boundary layer transition during re-entry. On STS-119, the windward airflow on the port wing was deliberately disrupted by a four-inch wide and quarter-inch tall protuberance built into the modified tile. In coordination with this flight experiment, a US Navy NP-3D Orion aircraft was flown 28 nautical miles below Discovery and remotely monitored surface temperature of the Orbiter at Mach 8.4 using a long-range infrared optical package referred to as Cast Glance. Approximately two months later, the same Navy Cast Glance aircraft successfully monitored the surface temperatures of the Orbiter Atlantis traveling at approximately Mach 14.3 during its return from the successful Hubble repair mission. In contrast to Discovery, Atlantis was not part of the Boundary Layer Transition (BLT) flight experiment, thus the vehicle was not configured with a protuberance on the port wing. In September 2009, Cast Glance was again successful in capturing infrared imagery and monitoring the surface temperatures on Discovery s next flight, STS-128. Again, NASA flew a specially modified thermal protection system tile and instrumentation package to monitor heating effects from boundary layer transition during re-entry. During this mission, Cast Glance was able to image laminar and turbulent flow phenomenology optimizing data collection for Mach 14.7. The purpose of this paper is to describe key elements associated with STS-119/125/128 mission planning and execution from the perspective of the Cast Glance flight crew that obtained the imagery. The paper will emphasize a human element of experience, expertise and adaptability seamlessly coupled with Cast Glance system and sensor technology required to manually collect the required imagery. Specific topics will include a near infrared (NIR) camera upgrade that was implemented just prior to the missions, how pre-flight radiance modeling was utilized to optimize the IR sensor configuration, communications, the development of aircraft test support positions based upon Shuttle trajectory information, support to contingencies such as Shuttle one orbit wave-offs/west coast diversions and then the Cast Glance perspective during an actual Shuttle imaging mission.

Tack, Steve↗

Solid-State Mixed-Potential Electrochemical Sensors for Natural Gas Leak Detection and Quality Control (Final Technical Report)

Mitigation of methane emissions are a critical factor to limiting the impact of the natural gas industry on global climate change. Throughout the period of 2020-2024, the University of New Mexico and its commercialization partner and subcontractor, SensorComm Technologies, Inc. (SCT), have worked together to develop a low-cost Artificial Intelligence (AI)-driven Internet of Things (IoT)-based multi-gas sensor platform for methane emissions detection. In the final year of the project, we extended this work to include hydrogen detection in support of a transition to a hydrogen economy where hydrogen could be transported through existing natural gas infrastructure. Mixed potential electrochemical sensors were first prototyped by ceramic additive manufacturing and then transitioned to conventional ceramic manufacturing tape casting and screen-printing technologies in preparation for mass production. Demonstrated limits of detection of 5 ppm of methane in natural gas and 1 ppm of hydrogen were measured. These limits of detection are among the lowest of solid-state electrochemical sensors that have been reported in the literature or available in the industry. Machine learning algorithms were developed to identify natural gas mixtures with > 98% accuracy level and quantify methane concentrations at 97% accuracy. The presence of hydrogen could also be identified, and its concentration quantified at these accuracy levels. These algorithms were optimized for running on portable computing hardware which enabled > 1 Hz processing rates. A portable packaged IoT system was integrated with the electrochemical sensor in collaboration with SCT. The package consists of readout electronics with < 1 mV resolution, sensor temperature control, and data transmission over cellular wireless and/or Wi-Fi networks. Field testing was performed in two rounds at Colorado State University’s Methane Emissions Technology Evaluation Center (CSU METEC). The first round of testing demonstrated successful measurements of methane from an underground natural gas leak of 20 standard liters per minute (SLPM), which agreed with previously published literature using more sophisticated and expensive analytical equipment. The second round of testing showed that an above ground leak of 2 SLPM of hydrogen could be detected at 32 ft. This project has resulted in six published peer reviewed journal articles, over ten presentations at professional conferences, and one full patent application filed in 2023. Future work on this project includes increased sensitivity, higher production yields, and applications in the hydrogen safety and flare emissions monitoring spaces.

03 NATURAL GAS↗

High-Resolution Electron Microscopy and Kinetic Studies of Precipitation Hardening Reactions in Cast Al-5.8Zn-2.2Mg-2.5Cu

Precipitation age hardening (T6) response of Al-5.8Zn-2.2Mg-2.5Cu alloy in near-net-shaped cast condition was investigated. Cast samples were manufactured using the controlled diffusion solidification (CDS) technology combined with a metallic mold tilt pour gravity casting process. This study was conducted using (1) non-isothermal aging during differential scanning calorimetry (DSC) experiments and (2) isothermal aging during which transient bulk and micro-hardness measurements taken at four aging temperatures of 343, 393, 433 and 473 K. A detailed microstructural investigation combined with a quantitative image analysis was carried out on both DSC and hardness specimens using high-resolution electron microscopy (HREM) and energy-dispersive spectroscopy (EDS) elemental mappings. Hardness measurements were analyzed using a kinetic modeling approach (single state variable combined with a kinetic equation that is valid for the Al-Zn-Mg-Cu alloys). The results confirm the formation of hardening phases of GP zone, intermediate hardening metastable phase η′ and equilibrium phase η. The results of calorimetric measurements, electron microscopy and selected area diffraction patterns are in good agreement and confirm transient precipitation/dissolution sequences. A mean value of activation energy Q{sub A} of 75 kJ/mol was evaluated for combined bulk diffusion rate of alloying elements during precipitation of strengthening phases within Al matrix.

36 MATERIALS SCIENCE↗