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DOE OSTI2023

Molten Salt Loop Testing of Sensors and Off-Gas Components: FY23 progress

The Liquid Salt Test Loop (LSTL) at the US Department of Energy’s (DOE’s) Oak Ridge National Laboratory (ORNL) was developed to demonstrate technology for high-temperature fluoride salt systems (Figure 1). The LSTL is primarily constructed using Inconel 600 alloy and operates at temperatures of up to 700°C. The facility is loaded with 165 kg of LiF-NaF-KF salt (FLiNaK). This salt provides a relevant test environment for de-risking technology while avoiding the costs and hazards associated with beryllium-based or uranium-bearing salts. FLiNaK is also an advantageous salt for the secondary side of molten salt reactors. The facility’s major components include a centrifugal pump for salt circulation, an air-based heat exchanger to reject heat, a suite of instrumentation, and trace heating to prevent salt freezing. Additional heating is available through an induction heater rated at 200 kW. The relatively large heating and cooling capability enables the formation of a temperature gradient across the loop (i.e., a hot and a cold side), which is important for chemistry and corrosion studies. The LSTL is a unique US capability for high-temperature molten halide salt testing. Although some efforts are underway at universities, the LSTL’s scale, co-located purification system, and relatively large power differentiates it from other testing systems. Furthermore, unlike efforts within industry, access to the DOE-supported facility and communication of results, which are generally disseminated publicly, result in a broad significance in the molten salt reactor community.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1988

Report of the In Situ Resources Utilization Workshop

The results of a workshop of 50 representatives from the public and private sector which investigated the potential joint development of the key technologies and mechanisms that will enable the permanent habitation of space are presented. The workshop is an initial step to develop a joint public/private assessment of new technology requirements of future space options, to share knowledge on required technologies that may exist in the private sector, and to investigate potential joint technology development opportunities. The majority of the material was produced in 5 working groups: (1) Construction, Assembly, Automation and Robotics; (2) Prospecting, Mining, and Surface Transportation; (3) Biosystems and Life Support; (4) Materials Processing; and (5) Innovative Ventures. In addition to the results of the working groups, preliminary technology development recommendations to assist in near-term development priority decisions are presented. Finally, steps are outlined for potential new future activities and relationships among the public, private, and academic sectors.

Fairchild, Kyle↗

NASA NTRSDate not supplied

Genesis Solar Wind – Capture, Return, Curate and Analyze: Looking Backward and Creating a Timeline

Introduction: In 1997 NASA’S Discovery Program selected the Genesis mission proposal to return solar wind samples to Earth for laboratory analyses. Principal Investigator Donald S. Burnett and the science team defined the purity of collector materials and ability to analyze solar wind composition to the precision required for planetary science. As a small mission, focused on a well-defined science goal, yet needing careful attention to engineering details, the communication among scientists and engineers, nurtured by Don Burnett, was exceptional. Genesis Mission and Curation Legacy: Genesis, as the first U. S. spacecraft to return astromaterial samples since Apollo, not only integrated the mission planning and flight teams, but also the science and sample curation teams during the mission development period. Since Genesis is a sample return mission, the Science Team was essential in certifying the collectors (sample containers for solar atoms). From inception, Genesis established mission funding for returned sample curation. JSC was lead in contamination control during mission preparation, including establishment of an ISO 4 cleanroom facility and use of ultrapure water (UPW) for cleaning flight hardware (and, as it turned out, for cleaning collectors after the mishap). Reliable, fast communication among scientists, engineers and curators at the hands-on level established deep respect among team members and efficient decision-making. JSC’s 50-years of astromaterial sample curation provided experienced sample processors onsite during recovery in Utah (a deep bench for emergency response). Post-recovery curation included iterative collaboration with science sample users to clean or verify cleanliness of samples. The science legacy from Genesis is addressed by Burnett and Jurewicz, this volume. In The Beginning: After Apollo sample return, Burnett and Marcia Neugebauer at JPL began discussing a solar wind sample return, with Neugebauer arguing that separate collection of solar wind regimes was essential science. By 1992 a solar wind sample return mission was presented at a workshop, and by 1994 a mission was proposed named Suess-Urey. The mission was re-proposed under a new name GENESIS and selected in 1997. Susan Niebur captured the Genesis mission history and stories, from high level management documents and from many interviews with participants [2]. Her account lets readers glimpse personality of participants in quotations from interviews. Need and Scope for Detailed Technical Timeline: A timeline constructed from lower level task documents has been initiated to document the resources and skills actually used, as well as task sequence or concurrency. Timelines for high level mission events are captured in two documents [1] [2] and for detailed re-entry events in [3]. A detailed technical timeline for Genesis mission and curation activities will provide data points for lower level tasks, such as ISO 4 curation facility construction time, preparation for nominal sample field recovery, mishap recovery, and UPW expansion. Changes in technology context 1990-2024: Semiconductor technologies were easily accessible in the U.S.A. (1990-1999), and the Genesis team used those resources for cleanroom design and UPW system expansion. Image documentation was changing from film to digital during cleanroom construction and payload cleaning (1997-2001). Engineering design was done using computer aided design proprietary software, making more difficult the archiving of payload configuration and materials. Email of documents, tracked delivery service and virtual meeting capability greatly improved communication efficiency. Information sources – Pre-launch mission preparation: Examples of mission science, engineering and contamination control are collector purity testing, payload design/fabrication and ISO 4 cleanroom construction. Information on timing of these activities comes from facility readiness reviews, management reviews, shipping documents, procurement documents, test reports, travel documents, laboratory logs, Quality Assurance documents, dates on images, participant notebooks and emails. Information sources – Sample return re-entry and field recovery activities: Information comes from event timelines produced by Mid-Air Recovery team, Lockheed team lead notes and from chase video, JPL Quality Assurance. Information also comes from images and logbooks from UTTR cleanroom operations and from curatorial documents. Information sources – Resulting science and sample cleaning processes: Agendas from the annual gatherings of the science team initially trace testing for collector purity/cleanliness, and after sample recovery, include collector cleaning and cleanliness assessment. Post-recovery documents include curatorial orders and procedures, sample allocation documents and LPSC abstracts. Timeline Objectives: A simple spreadsheet timeline with headers DATE, EVENT, PEOPLE, COMMENT, INFORMATION SOURCE has been initiated and currently has over 90 entries. While this is not definitive historical research, it is a quick look at the evolution of Genesis curation with pointers to documents or people with information. Engineers for future missions may find useful points of comparison for development of facilities. References:[1] Genesis Mission Reference Document, (2011) JPL D-62382.[2] Niebur S. M., edited by Brown D. W. (2023) NASA’s Discovery Program: The First 20 Years of Competitive Planetary Exploration, NASA-SP-2023-4238.[3] Genesis Mishap Investigation Board Report, Vol. 1 (July 2005).

solar wind↗

DOE OSTI2023

Stellarator Simplification using Permanent Magnets (PM4Stell)

This Report describes the design and prototyping of an array of rare-Earth permanent magnets to form a stellarator. This effort was motivated by the hypothesis that the usage of permanent magnets, rather than electromagnetic coils with complex geometry, could reduce the cost of stellarator construction and thereby make increase the feasibility of the stellarator as a technology for a fusion-based power plant. In this project, we have developed novel methods for specifying the positions, shapes, and polarizations of the magnets in the array, and have developed designs for mounting structures and tooling for assembly. We have also performed detailed finite-element modeling to qualify the accuracy of the magnetic field produced by the magnet array as designed, and to confirm that the structure can withstand the forces between the magnets. We have also developed techniques for measuring the magnetic field produced by the array once constructed, as well as for correcting errors in the field arising from misalignments and offsets within the tolerances for mounting and fabrication. Finally, we have constructed a tabletop prototype of a section of the array to qualify the concept for assembling and mounting magnets within the array.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1989

Improving transient analysis technology for aircraft structures

Aircraft dynamic analyses are demanding of computer simulation capabilities. The modeling complexities of semi-monocoque construction, irregular geometry, high-performance materials, and high-accuracy analysis are present. At issue are the safety of the passengers and the integrity of the structure for a wide variety of flight-operating and emergency conditions. The technology which supports engineering of aircraft structures using computer simulation is examined. Available computer support is briefly described and improvement of accuracy and efficiency are recommended. Improved accuracy of simulation will lead to a more economical structure. Improved efficiency will result in lowering development time and expense.

Melosh, R. J.↗

NASA NTRS1976

Biomedical technology transfer: Applications of NASA science and technology

The major efforts of the Stanford Biomedical Applications Team Program at the Stanford University School of Medicine for the period from October 1, 1975 to September 31, 1976 are covered. A completed EMG biotelemetry system which monitors the physiological signals of man and animals in space related research is discussed. The results of a pilot study involving lower body negative pressure testing in cardiac patients has been completed as well as the design and construction of a new leg negative pressure unit for evaluating heart patients. This technology utilizes vacuum chambers to stress the cardiovascular system during space flight. Laboratory tests of an intracranial pressure transducer, have been conducted. Extremely stable long term data using capacative pressure sensors has lead to the order of commercially manufactured monitoring systems base. Projects involving commercialization are: flexible medical electrodes, an echocardioscope, a miniature biotelemetry system, and an on-line ventricular contour detector.

Source record↗

NASA NTRS2013

Millimeter-Wave Localizers for Aircraft-to-Aircraft Approach Navigation

Aerial refueling technology for both manned and unmanned aircraft is critical for operations where extended aircraft flight time is required. Existing refueling assets are typically manned aircraft, which couple to a second aircraft through the use of a refueling boom. Alignment and mating of the two aircraft continues to rely on human control with use of high-resolution cameras. With the recent advances in unmanned aircraft, it would be highly advantageous to remove/reduce human control from the refueling process, simplifying the amount of remote mission management and enabling new operational scenarios. Existing aerial refueling uses a camera, making it non-autonomous and prone to human error. Existing commercial localizer technology has proven robust and reliable, but not suited for aircraft-to-aircraft approaches like in aerial refueling scenarios since the resolution is too coarse (approximately one meter). A localizer approach system for aircraft-to-aircraft docking can be constructed using the same modulation with a millimeterwave carrier to provide high resolution. One technology used to remotely align commercial aircraft on approach to a runway are ILS (instrument landing systems). ILS have been in service within the U.S. for almost 50 years. In a commercial ILS, two partially overlapping beams of UHF (109 to 126 MHz) are broadcast from an antenna array so that their overlapping region defines the centerline of the runway. This is called a localizer system and is responsible for horizontal alignment of the approach. One beam is modulated with a 150-Hz tone, while the other with a 90-Hz tone. Through comparison of the modulation depths of both tones, an autopilot system aligns the approaching aircraft with the runway centerline. A similar system called a glide-slope (GS) exists in the 320-to-330MHz band for vertical alignment of the approach. While this technology has been proven reliable for millions of commercial flights annually, its UHF nature limits its ability to operate beyond the 1-to-2-meter precisions associated with commercial runway width. A prototype ILS-type system operates at millimeter-wave frequencies to provide automatic and robust approach control for aerial refueling. The system allows for the coupling process to remain completely autonomous, as a boom operator is no longer required. Operating beyond 100 GHz provides enough resolution and a narrow enough beamwidth that an approach corridor of centimeter scales can be maintained. Two modules were used to accomplish this task. The first module is a localizer/glide-slope module that can be fitted on a refueling aircraft. This module provides the navigation beams for aligning the approaching aircraft. The second module is navigational receiver fitted onto the approaching aircraft to be re fueled that can detect the approach beams. Since unmanned aircraft have a limited payload size and limited electrical power, the receiver portion was implemented in CMOS (complementary metal oxide semiconductor) technology based on a super-regenerative receiver (SRR) architecture. The SRR achieves mW-level power consumption and chip sizes less than l mm2. While super-regenerative techniques have small bandwidths that limit use in communication systems, their advantages of high sensitivity, low complexity, and low power make them ideal in this situation where modulating tones of less than 1 kHz are used.

Tang, Adrian J.↗

NASA NTRSDate not supplied

Designing a Flight Test of a Flight Path Management System for Advanced Air Mobility Research

The National Aeronautics and Space Administration (NASA) has completed a flight test to evaluate the performance of an onboard prototype automation system operating in future high density urban airspace. The test was part of a research investigation of the Urban Air Mobility (UAM) concept, with a focus on a future environment having hundreds of simultaneous operations over a metropolitan area. The complexity of this future UAM airspace may require automation capable of replanning an aircraft’s path in the presence of traffic and other changing constraints. A live-virtual-constructive (LVC) approach was used to conduct the test. Prototype automation technology was integrated into one of the two live aircraft, which were combined with virtual traffic to create a mixed reality environment at the target airspace density. In-flight evaluation enabled verification of the automation’s functions and discovery of any unexpected behaviors resulting from its operation in an actual flight environment. The in-flight evaluation also provided data for validation of air traffic simulations. This paper discusses the design, methodology, and challenges overcome to conduct a successful flight test. Remaining challenges, future work, and recommendations to improve the flight test capability are also discussed.

Advanced Air Mobility↗

NASA NTRS2004

Separation of Carbon Monoxide and Carbon Dioxide for Mars ISRU

The atmosphere of Mars has many resources that can be processed to produce things such as oxygen, fuel, buffer gas, and water for support of human exploration missions. Successful manipulation of these resources is crucial for safe, cost-effective, and self-sufficient long-term human exploration of Mars. In our research, we are developing enabling technologies that require fundamental knowledge of adsorptive gas storage and separation processes. In particular, we are designing and constructing an innovative, low mass, low power separation device to recover carbon dioxide and carbon monoxide for Mars ISRU (in-situ resource utilization). The technology has broad implications for gas storage and separations for gas-solid systems that are ideally suited for reduced gravitational environments. This paper describes our separation process design and experimental procedures and reports results for the separation of CO2 and CO by a four-step adsorption cycle.

Walton, Krista S.↗

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↗

DOE OSTI2025

Hybrid data-driven cement-stabilized soil design: An integration of machine learning, multi-objective optimization, and life cycle assessment

Soil stabilization is crucial in geotechnical engineering, yet conventional methods are often time-consuming, resource-intensive, and environmentally unsustainable. Despite growing interest in Machine Learning (ML) and optimization tools for mix design, few studies integrate these methods with decision-making techniques and environmental assessment to support practical implementation. This study proposes a hybrid data-driven framework for predicting strength, optimizing mix compositions, and evaluating environmental impacts via life cycle assessment of cement-stabilized soft soils. Six ML models were evaluated, and the top-performing eXtreme Gradient Boosting (XGB) model was further improved using the Grey Wolf Optimizer (GWO). The optimized XGB-GWO model, integrated with a polynomial cost function, served as the objective function in a multi-objective optimization problem solved via the Non-Dominated Sorting Genetic Algorithm II (NSGA-II), with final mix selection guided by the entropy-weighted TOPSIS method. Validation through a case study produced mix designs offering superior strength-cost trade-offs, with the optimal mix achieving 2243.2 kPa unconfined compressive strength and a 16.07 % reduction in carbon emissions compared to the highest-cost design. In conclusion, this study offers a sustainable, scalable approach to soil stabilization and supports informed decision-making in construction.

Life cycle assessment↗

NASA NTRS1983

Antenna technology for orbital Very Long Baseline Interferometry (VLBI)

Since it is not economically feasible to construct steerable antennas much larger than 100 meters on Earth (400 meters for fixed telescopes), radio interferometry became a very useful technique for high resolution astronomy observations of quasars, galactic nuclei, and interstellar hydroxyl (OH) and water vapor (H2O) masers. The subsystems necessary to do the space VLBI experiment appear are available but require space qualifications. There are several 50-meter antenna concepts that could be used. Certainly there are problems to be solved. Feed positioning with respect to reflector, pointing such a large structure to accuracy indicated, and integration into the Shuttle control system are all significant engineering challenges. However, there are no problems that are insurmountable in the latter part of this decade.

Hamilton, E. C.↗

DOE OSTI2020

DOE-ART HT(G)R R&D Overview

The US Government currently has no plans to finance or build advanced nuclear reactors. Instead, the DOE performs research and development to raise the technological readiness of new concepts, fuels and component materials so that private industrial partners are more likely to design and build plants. Develop technologies that can enable new concepts and designs to achieve greater levels of safety and resilience, flexibility of use, sustainability and construction or operational affordability. Collaborate with industry to identify and conduct essential research to reduce technical risk associated with advanced reactor technologies. Sustain essential technical expertise and capabilities within national laboratories, universities, and industry to perform needed research. Collaborate with the Nuclear Regulatory Commission and Standards Developing Organizations (ASME, ANS, ANSI, etc.) to address gaps in codes and standards to support advanced reactor designs

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1987

Test results of a 60 volt bipolar nickel-hydrogen battery

In July, l986, a high-voltage nickel-hydrogen battery was assembled at the NASA Lewis Research Center. This battery incorporated bipolar construction techniques to build a 50-cell stack with approximately 1.0 A-hr capacity (C) and an open-circuit voltage of 65 V. The battery was characterized at both low and high current rates prior to pulsed and nonpulsed discharges. Pulse discharges at 5 and 10 C were performed before placing the battery on over 1400, 40% depth-of-discharge, low-earth-orbit cycles. The successful demonstration of a high-voltage bipolar battery in one containment vessel has advanced the technology to where nickel-hydrogen high-voltage systems can be constructed of several modules instead of hundreds of individual cells.

Cataldo, Russell L.↗

NASA NTRS1987

Test results of a 60 volt bipolar nickel-hydrogen battery

In July 1986, a high-voltage nickel-hydrogen battery was assembled at the NASA Lewis Research Center. This battery incorporated bipolar construction techniques to build a 50-cell stack with approximately 1.0 A-hr capacity (C) and an open-circuit voltage of 65 V. The battery was characterized at both low and high current rates prior to pulsed and nonpulsed discharges. Pulse discharges at 5 and 10 C were performed before placing the battery on over 1400, 40-percent depth-of-discharge, low-earth-orbit cycles. The successful demonstration of a high-voltage bipolar battery in one containment vessel has advanced the technology to where nickel-hydrogen high-voltage systems can be constructed of several modules instead of hundreds of individual cells.

Cataldo, Robert L.↗

DOE OSTI2023

Stellarator Simplification using Permanent Magnets (PM4Stell)

47 OTHER INSTRUMENTATION↗

NASA NTRS1972

Application of planetary quarantine methodology and spacecraft sterilization technology to improved health care delivery.

In 1969 the Jet Propulsion Laboratory undertook an investigation to determine which of its space-derived capabilities could make significant contributions to the improvement of health care delivery in the U.S. The area of planetary quarantine was identified as one of high relevance. Two studies were conducted in this connection. The first study, which could contribute to infection reduction and control, was concerned with conversion of infection implicated complex, nonheat sterilizable equipment to dry heat, sterilizable equipment by changes in design and materials of construction. The second study area related to hospital acquired infection is clean room technology. A definite investigation has been performed to demonstrate and statistically evaluate performance under controlled conditions.

Green, R. H.↗

DOE OSTI2025

Nanopore Activity Assays for Detection of Biomarker Protease Activity: Design and Testing of Substrates for Both Nanopore Sequencing and PCR-Based Detection Methods

The work performed in this project has demonstrated the ability to construct proteolytic enzyme substrates that are PCR and sequencing-readable reporter molecules. Specifically, the goal was to detect those reporter molecules via PCR and Oxford Nanopore Technologies MinION sequencing methods following exposure to the biomarker protease thrombin. The assay development focused on binding the constructed peptide-oligonucleotide chimera to immobilized streptavidin. The action of thrombin on the peptide portion of the molecule released the oligonucleotide for detection. Detection of protease activity was demonstrated in a concentration-dependent manner using MALDI-MS, RT-PCR and DNA sequencing. Additional steps to remove background release of reporter molecules during the assay was used to improve the difference in detected oligonucleotide reporter following protease activity. Additional steps in assay development will be to (1) test the assay in an appropriate matrix, (2) investigate detection using additional DNA sequencing platforms and (3) demonstrate multiplexed detection of multiple protease markers in a single reaction.

59 BASIC BIOLOGICAL SCIENCES↗