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DOE OSTI2024

Data-driven Quasi-static Surrogate Model for Nuclear-powered Integrated Energy Systems

The integration of nuclear power into energy systems presents a promising avenue to address the growing global energy demands while minimizing greenhouse gas emissions. In this paper, we introduce a data-driven quasi-static surrogate model for nuclear-powered Integrated Energy Systems (IES) that comprises various components, including a small modular reactor (SMR), energy manifold (EM), balance of plant (BOP), high-temperature steam electrolysis (HTSE), and district heating (DH) system. Traditional physics-based models for these components often entail significant computational overhead and time consumption, necessitating the development of efficient surrogate models. The development of a complete surrogate model for the IES involves the creation of individual surrogate models for each component, leveraging machine learning techniques and simulated data. These isolated surrogate models are subsequently integrated, enabling a holistic view of the IES and reducing the computational burden associated with detailed physics-based simulations. This paper outlines the development process, validation, and the performance evaluation of the surrogate models. The findings shed light on the accuracy and applicability of the surrogate models in practical scenarios, demonstrating their potential to expedite the analysis of nuclear-powered IES and inform future research and development efforts.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1998

ELIPS: Toward a Sensor Fusion Processor on a Chip

The paper presents the concept and initial tests from the hardware implementation of a low-power, high-speed reconfigurable sensor fusion processor. The Extended Logic Intelligent Processing System (ELIPS) processor is developed to seamlessly combine rule-based systems, fuzzy logic, and neural networks to achieve parallel fusion of sensor in compact low power VLSI. The first demonstration of the ELIPS concept targets interceptor functionality; other applications, mainly in robotics and autonomous systems are considered for the future. The main assumption behind ELIPS is that fuzzy, rule-based and neural forms of computation can serve as the main primitives of an "intelligent" processor. Thus, in the same way classic processors are designed to optimize the hardware implementation of a set of fundamental operations, ELIPS is developed as an efficient implementation of computational intelligence primitives, and relies on a set of fuzzy set, fuzzy inference and neural modules, built in programmable analog hardware. The hardware programmability allows the processor to reconfigure into different machines, taking the most efficient hardware implementation during each phase of information processing. Following software demonstrations on several interceptor data, three important ELIPS building blocks (a fuzzy set preprocessor, a rule-based fuzzy system and a neural network) have been fabricated in analog VLSI hardware and demonstrated microsecond-processing times.

Daud, Taher↗

DOE OSTI2025

Scale up production of carbon fibers from petroleum mesophase pitch

This work investigates the scale-up of pitch precursors for the carbon fiber market using mesophase pitch formulated and produced by Advanced Carbon Products Technologies’ (ACPT’s) patented mesophase pitch processing technology. Through use of its patented process, ACPT developed strategic materials by converting petroleum-based pitch into a high-value, low-cost, carbon-rich feedstock for carbon fiber and other materials critical to our national security. The team successfully developed processing criteria for the tailored mesophase pitch material that can be processed further into precursor and carbon fiber. Processability of the mesophase pitch into precursor and carbon fiber was demonstrated at scale. The resulting materials sequester the carbon that would otherwise be burned and released into the atmosphere, making this an environmentally friendly way to produce these materials in the United States.Pitch-based carbon fibers offer a promising pathway toward cost-effective, high-performance materials for structural and high-modulus composite applications; however, adoption has been limited by challenges in precursor processability and scale-up. In this work, tailored isotropic and mesophase petroleum-derived pitch materials were developed and evaluated for precursor and carbon fiber production through a collaborative effort between Oak Ridge National Laboratory (ORNL) and ACPT. Processing conditions were established at ORNL’s Carbon Fiber Technology Facility to enable stable melt-blowing of pitch-based precursors under continuous operation. Mesophase pitch precursor fibers were produced following oxidation and carbonization, corresponding to a diameter shrinkage of approximately 12%–13% and an estimated mass yield of about 75%–80%. Continuous melt-blowing steady-state operation was demonstrated over time, indicating robust process stability. Melt-blowing was achieved at throughput rates of approximately 20 lb/h⁻¹, validating the commercial viability of petroleum-derived pitch feedstocks for fiber production. Further studies are required to tailor carbon fiber microstructure and properties for specific composite applications.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2024

A Review of Remote Welding and Nondestructive Examination Technologies for the DOE Standard Canister

The U.S. Department of Energy (DOE) manages a wide variety of spent nuclear fuel (SNF) that poses a unique management challenge. To help address this challenge, the DOE Standard Canister (DOESC), designed to remain sealed during handling, storage, transportation, and disposal, was conceptualized as a standardized containment vessel to accommodate DOE-managed SNF. Since 1999, several welding and examination processes have been independently developed for the DOESC’s closure welds. However, neither the DOESC nor these processes have been realized in an operational capacity. This review paper seeks to present and compare previously developed DOESC closure weld, nondestructive examination, and repair processes and technologies. Specific processes developed for the Idaho Spent Fuel Facility, in preparation for the Yucca Mountain geological repository, and the recent Road-Ready Demonstration Project are discussed. Further, specific focus is given to how different operating constraints and the American Society of Mechanical Engineers Boiler and Pressure Vessel Code (BPVC) have driven certain welding and nondestructive examination requirements. Historical DOESC welding and examination strategies are assessed against current regulatory and BPVC requirements. The comparison of welding processes, technologies, and DOESC designs presented in this review paper will inform further construction efforts for other commercial and DOE-managed SNF containments, including the DOESC.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS2010

Maximum Likelihood Time-of-Arrival Estimation of Optical Pulses via Photon-Counting Photodetectors

Many optical imaging, ranging, and communications systems rely on the estimation of the arrival time of an optical pulse. Recently, such systems have been increasingly employing photon-counting photodetector technology, which changes the statistics of the observed photocurrent. This requires time-of-arrival estimators to be developed and their performances characterized. The statistics of the output of an ideal photodetector, which are well modeled as a Poisson point process, were considered. An analytical model was developed for the mean-square error of the maximum likelihood (ML) estimator, demonstrating two phenomena that cause deviations from the minimum achievable error at low signal power. An approximation was derived to the threshold at which the ML estimator essentially fails to provide better than a random guess of the pulse arrival time. Comparing the analytic model performance predictions to those obtained via simulations, it was verified that the model accurately predicts the ML performance over all regimes considered. There is little prior art that attempts to understand the fundamental limitations to time-of-arrival estimation from Poisson statistics. This work establishes both a simple mathematical description of the error behavior, and the associated physical processes that yield this behavior. Previous work on mean-square error characterization for ML estimators has predominantly focused on additive Gaussian noise. This work demonstrates that the discrete nature of the Poisson noise process leads to a distinctly different error behavior.

Erkmen, Baris I.↗

NASA NTRS2011

Development and Demonstration of Sustainable Surface Infrastructure for Moon/Mars Exploration

For long-term human exploration of the Moon and Mars to be practical, affordable, and sustainable, future missions must be able to identify and utilize resources at the site of exploration. The ability to characterize, extract, processes, and separate products from local material, known as In-Situ Resource Utilization (ISRU), can provide significant reductions in launch mass, logistics, and development costs while reducing risk through increased mission flexibility and protection as well as increased mission capabilities in the areas of power and transportation. Making mission critical consumables like propellants, fuel cell reagents and life support gases, as well as in-situ crew/hardware protection and energy storage capabilities can significantly enhance robotic and human science and exploration missions, however other mission systems need to be designed to interface with and utilize these in-situ developed products and services from the start or the benefits will be minimized or eliminated. This requires a level of surface and transportation system development coordination not typically utilized during early technology and system development activities. An approach being utilized by the US National Aeronautics and Space Administration and the Canadian Space Agency has been to utilize joint analogue field demonstrations to focus technology development activities to demonstrate and integrate new and potentially game changing. mission critical capabilities that would enable an affordable and sustainable surface infrastructure for lunar and Mars robotic and human exploration. Two analogue field tests performed in November 2008 and February 2010 demonstrated first generation capabilities for lunar resource prospecting, exploration site preparation, and oxygen extraction from regolith while initiating integration with mobility, science, fuel cell power, and propulsion disciplines. A third analogue field test currently planned for June 2012 will continue and expand the fidelity and integration of these surface exploration and infrastructure capabilities while adding Mars exploration technologies, improving remote operations and control of hardware, and promoting the use of common software, interfaces, & standards for control and operation for surface exploration and science. The next field test will also attempt to include greater involvement by industry, academia, and other countries/space agencies. This paper will provide an overview of the development and demonstration approach utilized to date, the results of the previous two ISRU-focused field analogue tests in Hawaii, and the current objectives and plans for the 3rd international Hawaii analogue field test.

Sanders, Gerald B.↗

NASA NTRS1992

Advanced tow placement of composite fuselage structure

The Hercules NASA ACT program was established to demonstrate and validate the low cost potential of the automated tow placement process for fabrication of aircraft primary structures. The program is currently being conducted as a cooperative program in collaboration with the Boeing ATCAS Program. The Hercules advanced tow placement process has been in development since 1982 and was developed specifically for composite aircraft structures. The second generation machine, now in operation at Hercules, is a production-ready machine that uses a low cost prepreg tow material form to produce structures with laminate properties equivalent to prepreg tape layup. Current program activities are focused on demonstration of the automated tow placement process for fabrication of subsonic transport aircraft fuselage crown quadrants. We are working with Boeing Commercial Aircraft and Douglas Aircraft during this phase of the program. The Douglas demonstration panels has co-cured skin/stringers, and the Boeing demonstration panel is an intricately bonded part with co-cured skin/stringers and co-bonded frames. Other aircraft structures that were evaluated for the automated tow placement process include engine nacelle components, fuselage pressure bulkheads, and fuselage tail cones. Because of the cylindrical shape of these structures, multiple parts can be fabricated on one two placement tool, thus reducing the cost per pound of the finished part.

Anderson, Robert L.↗

DOE OSTI2024

Process Intensification for Nanostructure Aluminum Extrusions

A new technology called Shear Assisted Processing and Extrusion (ShAPE™), pioneered at the Pacific Northwest National Laboratory (PNNL), has the potential to revolutionize the US extrusion industry. Maturation of the ShAPE™ process would create a new cross cutting US manufacturing technology that advances three key the objectives within AMO; namely, nanomaterials processing, process intensification, and materials for extreme and harsh environments. PNNL and SCM Metals Products, Inc. (SCM), a division of Kymera International, will collaborate to mature the ShAPE™ extrusion process beyond TRL 3 to increase the likelihood of its adoption by industry. PNNL’s custom (one-of-a-kind in the world) ShAPE™ machine will be used to extrude round rods of high strength aluminum alloy feedstock powder provided by SCM. As proof-of-concept, PNNL has previously extruded 5 mm diameter rods with SCM aluminum alloy powder AL-12.4TM. This project aims to scale up the process to a diameter of 25 mm while retaining the excellent mechanical properties achieved for the 5 mm diameter rods. The degree of process intensification with ShAPE™ will also be estimated. The primary objectives of this project are as follows. 1) Fabricate 25 mm diameter nanostructured extrusions in bulk, directly from AL-12.4TM aluminum alloy powder without the need for canning, degassing, compaction, and other intermediate steps typical of powder metallurgy extrusion. 2) Achieve a microstructure with an ultrafine grained (UFG <1 µm) aluminum matrix having refined and homogenously distributed nanoscale second phases. 3) Show that the ram force can be significantly reduced compared to conventional powder metallurgy extrusion of the same material and estimate the extent of process intensification that may be possible with ShAPE™. 4) Demonstrate improved high-temperature mechanical properties compared to conventional extrusion of the same material. The following tasks will be undertaken to achieve these objectives. PNNL will develop the die set and process parameters necessary to fabricate Al-12.4TM extrusions with a 25 mm diameter. Microstructural analysis will be performed by PNNL while mechanical testing will be conducted by SCM. With information learned from the process development and characterization, PNNL will perform an estimate of the degree of process intensification that may be possible with ShAPE™.

42 ENGINEERING↗

NASA NTRS2000

A Mixed Finite Analysis of Axial Foreshortening

In previous studies, a mixed finite element was derived and shown to be effective in facilitating accurate modal reduction of rotor blades. This study builds upon that earlier work through the development of algorithms that allow the element's Lagrangian axial displacement degrees of freedom to be eliminated in favor of the axial force degrees of freedom. This reduction process, which had been demonstrated previously for the case of a single mixed finite element, may be viewed as a generalization of the UMARC blade analysis methodology to arbitrary topologies. A unique strength of the method. developed here is that the model may consist of two dimensional or even three dimensional elements.

Ruzicka, Gene↗

DOE OSTI2020

Thermal Image Processing for Feature Extraction from Encapsulated Phase Change Materials

Encapsulated inorganic particles with high melting points (>300 °C) are desired as high-temperature Phase Change Materials (PCMs) for next-generation Latent Heat Thermal Energy Storage (LHTES) systems. One of the many challenges during the development of PCMs is to achieve a high throughput that in turn depends on accurately modeling the relation between process parameters and geometric & thermal properties of the PCMs particle. During the production of the PCMs, a high-speed infrared camera is used to acquire images of the encapsulated material under controlled illumination conditions. This research article focuses on the development of image processing techniques for both geometric and thermal feature extraction during the development of the PCMs. A user-friendly GUI has been designed in MATLAB and preliminary experimental results have demonstrated that the method is fast, accurate and reliable for a high throughput production. The extracted features will be used to develop Machine Learning (ML) models to predict the geometric and thermal properties of the PCM based on the process parameter settings. The ML model will accelerate the search for the optimized process settings to boost the throughput of the production.

25 ENERGY STORAGE↗

DOE OSTI2024

CLimate Impact: Determining Etiology thRough pAthways (CLDERA)

Climate impacts have broad economic, health, political, and national security ramifications. Societally relevant impacts are typically farther downstream, are the product of multiple interacting processes, and can arise over small regions and timeframes because their sources are short-term and localized. Short-term forcings (as can be seen in volcanic eruptions, climatic tipping points (e.g., the collapse of rainforests or the disappearance of sea ice), or in increasingly plausible climate interventions) fundamentally possess low signal-to-noise and could benefit from accounting for the multiple conditional processes through which a downstream impact arises. Under the Grand Challenge LDRD CLDERA (CLimate impacts: Discovering Etiology thRough pAthways), we have developed tools to enable downstream impact attribution from geographically and temporally localized source forcings in the climate. CLDERA developed methods that can distinguish how a localized source drives the climate system to respond with particular impacts. The how is embodied in pathways – the spatio-temporally evolving chain of physical processes that connects a source to a series of increasingly distant impacts. Novel analytic methods in pursuit of downstream impact attribution were developed and demonstrated on simulations and observations of the 1991 eruption of Mt. Pinatubo in the Philippines. As described within this report we have • developed stratospheric expertise and aerosol modeling capabilities in E3SM, • created original methods to detect and model pathways from source-to-impact, and • advanced climate attribution through novel methods, cases, and approaches. Further, CLDERA developed a tiered verification process consisting of controlled datasets to prototype, verify, and refine the original method development. CLDERA increased Sandia’s footprint in the climate analytics community and developed new climate collaborations whilst also creating a cadre of climate analysts at Sandia. The products from CLDERA have been extensive with a total of 9 journal articles published, 12 articles submitted and under review, and an additional 8 articles in preparation. We have produced 1750 simulated years and developed 9 code-bases. This report details these accomplishments and serves as a summary of the work completed during the CLDERA Grand Challenge.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

AI Driven Experiment Calibration and Control

One critical step on the path from data taking to physics analysis is calibration. For many experiments this step is both time consuming and computationally expensive. The AI Experimental Calibration and Control project seeks to address these issues, starting first with the GlueX Central Drift Chamber (CDC). We demonstrate the ability of a Gaussian Process to estimate the gain correction factor (GCF) of the GlueX CDC accurately, and also the uncertainty of this estimate. Using the estimated GCF, the developed system infers a new high voltage (HV) setting that stabilizes the GCF in the face of changing environmental conditions. This happens in near real time during data taking and produces data which are already approximately gain-calibrated, eliminating the cost of performing those calibrations which vary ±15% with fixed HV. We also demonstrate an implementation of an uncertainty aware system which exploits a key feature of a Gaussian process.

Britton, Thomas↗

DOE OSTI2024

Reversible Methane Electrochemical Reactors as Efficient Energy Storage for Fossil Power

The overall objective of the project was to conduct a comprehensive Research & Development (R&D) program to demonstrate the suitability and future advancement and integration of reversible methane protonic ceramic electrochemical reactors (PCERs) as an efficient Energy Storage System (ESS) with fossil fuel power plants. Fundamental process and system models are developed to conduct a preliminary conceptual study and investigate the power plant system integration requirements, performance requirements, and technical and non-technical gaps for eventual implementation at system level. Technology maturation requirements is also investigated through identifying the critical technical elements and networking with industrial technology developers and end-users.

08 HYDROGEN↗

DOE OSTI2023

Predicting Deposition Rate and Closing the Loop on Aerosol Jet Printing with In‐Line Light Scattering Measurements

Aerosol jet printing is a compelling noncontact, digital manufacturing technology for flexible, hybrid, and conformal electronics, but batch‐to‐batch variability and process drift inhibit systematic study and translation to production environments. Emerging measurement techniques for the aerosol volume fraction, a key parameter governing deposition rate, have shown promise for real‐time response, including a recent demonstration of human‐in‐the‐loop control. By integrating improved light scattering measurements with custom software, a robust environment for real‐time monitoring is established and fully automated closed‐loop control over the deposition rate during printing is enabled. The physical basis for scattering measurements as a feedback source is examined and the quantitative insight this provides for ink development and fundamental process studies is highlighted. Three candidate process variables for closed‐loop control, namely the atomizer voltage, carrier gas flow rate, and print speed, are then evaluated. The atomizer voltage demonstrates the best extended duration validity because it addresses atomization variability directly, but carrier gas flow rate and print speed provide faster and more deterministic responses. This methodology is then demonstrated for electrical properties using a silver nanoparticle ink, maintaining 98% of printed patterns within 10% of the mean resistance value over 3 h of printing.

36 MATERIALS SCIENCE↗

NASA NTRS2016

Development Status and Performance Comparisons of Environmental Barrier Coating Systems for SiCSiC Ceramic Matrix Composites

Environmental barrier coatings (EBC) and SiCSiC ceramic matrix composites (CMCs) will play a crucial role in future aircraft turbine engine systems, because of their ability to significantly increase engine operating temperatures, reduce engine weight and cooling requirements. This paper presents current NASA EBC-CMC development emphases including: the coating composition and processing improvements, laser high heat flux-thermal gradient thermo-mechanical fatigue - environmental testing methodology development, and property evaluations for next generation EBC-CMC systems. EBCs processed with various deposition techniques including Plasma Spray, Electron Beam - Physical Vapor Deposition, and Plasma Spray Physical Vapor Deposition (PS-PVD) will be particularly discussed. The testing results and demonstrations of advanced EBCs-CMCs in complex simulated engine thermal gradient cyclic fatigue, oxidizing-steam and CMAS environments will help provide insights into the coating development strategies to meet long-term engine component durability goals.

Processing and Properties↗

NASA NTRSDate not supplied

Weather Guidance for UAS Urban Medical Transport Missions

Unmanned aircraft will revolutionize healthcare services by providing efficient and expeditious delivery of life-saving transplant organs and supplies to hospitals in urban environments, where road traffic and congestion can slow delivery times and endanger lives. Bell has developed the Autonomous Pod Transport (APT) vehicle to serve this market, with entry into service in mid-2020s. Adverse weather conditions can introduce risks and inefficiencies in urban environments leading to flight delays and cancellations. In 2018, National Aeronautics and Space Administration (NASA) and Bell entered into a cooperative agreement, under the Systems Integration and Operationalization (SIO) program to tackle key challenges to enable future commercial unmanned aircraft operations. The Center for Collaborative Adaptive Sensing of the Atmosphere (CASA) at the University of Massachusetts, Amherst, joined this team to demonstrate weather avoidance technologies for remotely piloted and autonomous vehicles. CASA has developed the ‘City Warn’ hazard alerting platform to gather weather information from various weather sensors and models, and based on user (or mission) preferences for alerting and on user (or unmanned aircraft) locations, the platform shares timely weather intelligence with users and the systems used by them for remote operations. This presentation discusses the weather avoidance solution developed during this project, leading up to the demonstration of the end-to-end system in Fall 2020. The presentation will cover the following topics: 1) goals related to weather avoidance 2) the design requirements process, including the results of pilot interviews, 3) weather observation and avoidance needs 4) selection of regional and national weather data sets 5) design of the weather graphical interface and 6) considerations for real-time weather alerting. The end-to-end system that was developed will be discussed, along with the results from the demonstration flight. The presentation will conclude with insights from the project team on lessons learned and best practices on weather avoidance technologies for the industry going ahead.

weather avoidance↗

NASA NTRS2021

Weather Guidance for UAS Urban Medical Transport Missions

weather avoidance↗

NASA NTRS2016

Green Propellant Landing Demonstration at U.S. Range

The Green Propellant Loading Demonstration (GPLD) was conducted December 2015 at Wallops Flight Facility (WFF), leveraging work performed over recent years to bring lower toxicity hydrazine replacement green propellants to flight missions. The objective of this collaboration between NASA Goddard Space Flight Center (GSFC), WFF, the Swedish National Space Board (SNSB), and Ecological Advanced Propulsion Systems (ECAPS) was to successfully accept LMP-103S propellant at a U.S. Range, store the propellant, and perform a simulated flight vehicle propellant loading. NASA GSFC Propulsion (Code 597) managed all aspects of the operation, handling logistics, preparing the procedures, and implementing the demonstration. In addition to the partnership described above, Moog Inc. developed an LMP-103S propellant-compatible titanium rolling diaphragm flight development tank and loaned it to GSFC to act as the GPLD flight vessel. The flight development tank offered the GPLD an additional level of flight-like propellant handling process and procedures. Moog Inc. also provided a compatible latching isolation valve for remote propellant expulsion. The GPLD operation, in concert with Moog Inc. executed a flight development tank expulsion efficiency performance test using LMP-103S propellant. As part of the demonstration work, GSFC and WFF documented Range safety analyses and practices including all elements of shipping, storage, handling, operations, decontamination, and disposal. LMP-103S has not been previously handled at a U.S. Launch Range. Requisite for this activity was an LMP-103S Risk Analysis Report and Ground Safety Plan. GSFC and WFF safety offices jointly developed safety documentation for application into the GPLD operation. The GPLD along with the GSFC Propulsion historical hydrazine loading experiences offer direct comparison between handling green propellant versus safety intensive, highly toxic hydrazine propellant. These described motives initiated the GPLD operation in order to investigate the handling and process safety variances in project resources between LMP-103S and typical in-space propellants. The GPLD risk reduction operation proved successful for many reasons including handling the green propellant at a U.S. Range, loading and pressurizing a flight-like tank, expelling the propellant, measuring the tank expulsion efficiency, and most significantly, GSFC propulsion personnel's new insight into the LMP-103S propellant handling details.

Propellant↗