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All sources NASA NTRS DOE OSTI

DOE OSTI2024

Towards engineering the growth morphology of anisotropic bicrystals

Eutectic alloys, such as Pb-free Bi-Sn-Ag or Sn-Ag-Cu, are essential for their low melting points in solder joints but suffer from brittle intermetallic phases, reducing reliability. Traditional solder design relies on equilibrium phase diagrams, often neglecting the kinetic influence of crystalline anisotropy during solidification. This study hypothesizes that the energetics at the solid-solid-liquid trijunction dictate crystalline facet selection. Using the Al-Al 3 Ni alloy as a model, this project combines atomistic simulations and experimental methods to understand interfacial energies and develop predictive models. This approach aims to mitigate the negative effects of intermetallics, enhancing component reliability in electronic applications.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Current Best Practices on Wildfire Risk Reduction for Electric Transmission and Distribution Systems

This report provides a set of best practices in response to Section 4(d) of Executive Order 14308, Empowering Commonsense Wildfire Prevention and Response. The information contained herein is expected to be used in conjunction with other materials at the Federal Energy Regulatory Commission Wildfire Risk Mitigation Technical Conference (Docket No. AD25-16-000), with possible direction to the North American Electric Reliability Corporation to take action. The objective of this report is to provide an overview of existing and emerging best practices currently employed or planned by utilities for wildfire mitigation, demonstrating how these efforts align with the executive order’s emphasis on reducing electric utility–caused wildfires while also balancing cost-effectiveness. Additionally, while most practices in utility-developed wildfire mitigation plans focus on risk reduction through robustness and operational reliability, this report also discusses best practices for resilience. The best practices are adopted from publicly available utility wildfire mitigation plans from the United States and Canada, recent findings from wildfire risk reduction research, and industry engagement.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS2017

Robust Targeting for the Smartphone Video Guidance Sensor

The Smartphone Video Guidance Sensor (SVGS) is a miniature, self-contained autonomous rendezvous and docking sensor developed using a commercial off the shelf Android-based smartphone. It aims to provide a miniaturized solution for rendezvous and docking, enabling small satellites to conduct proximity operations and formation flying while minimizing interference with a primary payload. Previously, the sensor was limited by a slow (2 Hz) refresh rate and its use of retro-reflectors, both of which contributed to a limited operating environment. To advance the technology readiness level, a modified approach was developed, combining a multi-colored LED target with a focused target-detection algorithm. Alone, the use of an LED system was determined to be much more reliable, though slower, than the retro-reflector system. The focused target-detection system was developed in response to this problem to mitigate the speed reduction of using color. However it also improved the reliability. In combination these two methods have been demonstrated to dramatically increase sensor speed and allow the sensor to select the target even with significant noise interfering with the sensor, providing millimeter level precision at a range of two meters with a 1U target.

Carter, C.↗

NASA NTRS2017

Robust Targeting for the Smartphone Video Guidance Sensor

The Smartphone Video Guidance Sensor (SVGS) is a miniature, self-contained autonomous rendezvous and docking sensor developed using a commercial off the shelf Android-based smartphone. It aims to provide a miniaturized solution for rendezvous and docking, enabling small satellites to conduct proximity operations and formation flying while minimizing interference with a primary payload. Previously, the sensor was limited by a slow (2 Hz) refresh rate and its use of retro-reflectors, both of which contributed to a limited operating environment. To advance the technology readiness level, a modified approach was developed, combining a multi-colored LED target with a focused target-detection algorithm. Alone, the use of an LED system was determined to be much more reliable, though slower, than the retro-reflector system. The focused target-detection system was developed in response to this problem to mitigate the speed reduction of using color. However, it also improved the reliability. In combination these two methods have been demonstrated to dramatically increase sensor speed and allow the sensor to select the target even with significant noise interfering with the sensor, providing millimeter level accuracy at a range of two meters with a 1U target.

Carter, Christopher↗

DOE OSTI2026

Identification and mitigation of memory block timing issue in ITk ABCStar during ASIC production

The ABCStar is a mixed-signal front-end readout ASIC for the strips sensor portion of the ATLAS ITk detector being developed as part of the High-Luminosity LHC upgrade. In pre-production testing, a subtle design flaw was uncovered in the ABCStar that was reducing wafer yields in some manufactured lots from the expected 90% to as low as 2%. The root cause was determined to be a timing issue in the logic synthesized to control previously silicon proven memory blocks re-used for this ASIC. The solutions proposed included manufacturing process changes by the wafer foundry, changes to the operating parameters for the ABCStar in the detector, and the possibility that a redesign might be required. The two mitigation efforts were undertaken in parallel, with the process modification route a less desirable solution since already manufactured wafers would need to be scrapped in favour of the new ones. Based on a knowledge of the existing process, and testing done on the worst performing wafers, it was proposed that raising the core operating voltage of the ABCStar from 1.20V to 1.25V could address the timing issue by sufficiently speeding up its transistors. An extensive testing program that included the effects of temperature and radiation expected over the lifetime of the ITk detector was conducted to validate that approach. Those tests and studies proved that even the worst performing wafers would have yields over 80% with the 1.25V core voltage, and neither the modified process nor redesign would be required for ensuring reliable operation of the ITk. Based on testing, a further timing mitigation was implemented to provide an additional margin of reliability by increasing the duty cycle of the clock to the ABCStar. Testing of all ABCStar wafers has been completed and the production of the detector modules using these ASICs is now well underway as a result of the efforts detailed herein.

FOS: Physical sciences↗

DOE OSTI2025

Large scale polymer toughening of two-dimensional materials revealed by in situ TEM fracture tests and multiscale simulations

Two-dimensional (2D) materials offer significant potential for applications in energy-harvesting devices, batteries, sensors, and transistors. However, their intrinsic brittleness makes them prone to mechanical failure, limiting their practical use. In this work, we perform in situ transmission electron microscopy (TEM) fracture tests on monolayer MoSe2 and uncover an extrinsic toughening effect induced by an ultrathin adsorbed polystyrene adlayer. This adlayer substantially enhances the fracture resistance of the 2D flakes. Through a combination of molecular dynamics simulations and finite element analysis, we elucidate the molecular mechanism behind this toughening effect. Further, it arises from the active crack-bridging behavior of entangled polymer chains and the formation of a fracture process zone that stabilizes crack propagation and increases the energy required for crack extension. The proposed toughening mechanism offers a pathway to improving the mechanical reliability of 2D material-based devices by mitigating the risk of sudden failure.

2D materials↗

DOE OSTI2024

Rapid Monitoring and Defense Approach for Resilience Improvement of Grid Cyber Security

Cyber-physical systems and electric utilities significantly depend on the reliability and efficiency of information and operational technology. However, false data injection attacks based on synchrophasor measurement data pose a serious threat to the safe and reliable operation of modern power systems. Here, to mitigate this problem, a rapid monitoring and defense approach is proposed to defend against cyber attacks. Initially, the Time and Frequency based Convolutional neural Network (TFCN) is proposed to detect different types of attacks. Within the TFCN, the advances are that both time and frequency domain information can be fused without extra spectrum analysis methods, and can save detection time to speed the calculation efficiency using the developed time-frequency block. Next, a comprehensive defense strategy is developed for multiple cyber attacks to ensure the stability and resilience of the power system according to the feedback detection results. The advances of this strategy are that different control strategies can be automatically selected to recover the stability to the greatest extent according to the detected attacks. To verify the effectiveness of the proposed approach, the high-speed frequency measurements collected from the wide-area monitoring system are used. The results demonstrate that the cyber attack detection performance can reach 95.57% accuracy, outperforming both traditional and some advanced neural networks. Importantly, the defense strategy is conducted and verified in a modified IEEE 39 bus system as well, which illustrates profound performance in faster stability restoration.

Comprehensive defense strategy↗

NASA NTRS1990

A Unified Statistical Rain-Attenuation Model for Communication Link Fade Predictions and Optimal Stochastic Fade Control Design Using a Location-Dependent Rain-Statistic Database

A static and dynamic rain-attenuation model is presented which describes the statistics of attenuation on an arbitrarily specified satellite link for any location for which there are long-term rainfall statistics. The model may be used in the design of the optimal stochastic control algorithms to mitigate the effects of attenuation and maintain link reliability. A rain-statistics data base is compiled, which makes it possible to apply the model to any location in the continental U.S. with a resolution of 0-5 degrees in latitude and longitude. The model predictions are compared with experimental observations, showing good agreement.

Manning, Robert M.↗

NASA NTRS2003

A Tabletop Tool for Modeling Life Support Systems

This paper describes the development plan for a comprehensive research and diagnostic tool for aspects of advanced life support systems in space-based laboratories. Specifically it aims to build a high fidelity tabletop model that can be used for the purpose of risk mitigation, failure mode analysis, contamination tracking, and testing reliability. We envision a comprehensive approach involving experimental work coupled with numerical simulation to develop this diagnostic tool. It envisions a 10% scale transparent model of a space platform such as the International Space Station that operates with water or a specific matched index of refraction liquid as the working fluid. This allows the scaling of a 10 ft x 10 ft x 10 ft room with air flow to 1 ft x 1 ft x 1 ft tabletop model with water/liquid flow. Dynamic similitude for this length scale dictates model velocities to be 67% of full-scale and thereby the time scale of the model to represent 15% of the full- scale system; meaning identical processes in the model are completed in 15% of the full- scale time. The use of an index matching fluid (fluid that matches the refractive index of cast acrylic, the model material) allows making the entire model (with complex internal geometry) transparent and hence conducive to non-intrusive optical diagnostics. So using such a system one can test environment control parameters such as core flows (axial flows), cross flows (from registers and diffusers), potential problem areas such as flow short circuits, inadequate oxygen content, build up of other gases beyond desirable levels, test mixing processes within the system at local nodes or compartments and assess the overall system performance. The system allows quantitative measurements of contaminants introduced in the system and allows testing and optimizing the tracking process and removal of contaminants. The envisaged system will be modular and hence flexible for quick configuration change and subsequent testing. The data and inferences from the tests will allow for improvements in the development and design of next generation life support systems and configurations.

Ramachandran, N.↗

NASA NTRS2005

Space Laboratory on a Table Top: A Next Generative ECLSS design and diagnostic tool

This paper describes the development plan for a comprehensive research and diagnostic tool for aspects of advanced life support systems in space-based laboratories. Specifically it aims to build a high fidelity tabletop model that can be used for the purpose of risk mitigation, failure mode analysis, contamination tracking, and testing reliability. We envision a comprehensive approach involving experimental work coupled with numerical simulation to develop this diagnostic tool. It envisions a 10% scale transparent model of a space platform such as the International Space Station that operates with water or a specific matched index of refraction liquid as the working fluid. This allows the scaling of a 10 ft x 10 ft x 10 ft room with air flow to 1 ft x 1 ft x 1 ft tabletop model with water/liquid flow. Dynamic similitude for this length scale dictates model velocities to be 67% of full-scale and thereby the time scale of the model to represent 15% of the full- scale system; meaning identical processes in the model are completed in 15% of the full- scale-time. The use of an index matching fluid (fluid that matches the refractive index of cast acrylic, the model material) allows making the entire model (with complex internal geometry) transparent and hence conducive to non-intrusive optical diagnostics. So using such a system one can test environment control parameters such as core flows (axial flows), cross flows (from registers and diffusers), potential problem areas such as flow short circuits, inadequate oxygen content, build up of other gases beyond desirable levels, test mixing processes within the system at local nodes or compartments and assess the overall system performance. The system allows quantitative measurements of contaminants introduced in the system and allows testing and optimizing the tracking process and removal of contaminants. The envisaged system will be modular and hence flexible for quick configuration change and subsequent testing. The data and inferences from the tests will allow for improvements in the development and design of next generation life support systems and configurations. Preliminary experimental and modeling work in this area will be presented. This involves testing of a single inlet-exit model with detailed 3-D flow visualization and quantitative diagnostics and computational modeling of the system.

Ramachandran, N.↗

NASA NTRS2016

Passive Water Assurance Delivery System

This report provides an analysis and evaluation of proposed design improvements to the internal water delivery system of NASA’s passive vegetable growing system. The VEGGIE system is designed to provide fresh vegetables and psychological benefits for astronauts aboard the International Space Station. Preliminary testing conducted by NASA for the VEGGIE system revealed flaws in the water delivery system. In these tests, the interface between the plants and the water reservoir failed to provide passive water delivery through the system both in microgravity experiments and experiments conducted on Earth. Our team’s goal was to fix this interface such that water can be passively delivered from the water reservoir to the plant rooting pillows to grow vegetative crops from seed to harvest. The system requirements outlined by NASA include: minimal total mass, on-demand passive water delivery, same dimensions as existing fixtures, minimal pressure on system to prevent leaking, zero mold growth, minimal swelling or clogging for non-flammable capillary materials, pressure stabilization between the water reservoir and plant pillow bags, even dispersal of water during initial priming, minimal bubble obstruction of capillary interface, maximum gas availability to plant roots, growth in a mixed artificial media (50:50 Arcillite:Fafard #2), and to avoid overwatering and drought conditions for plants. The major proposed design improvements are to use a single-interface capillary cord design to directly connect the water reservoir to the plant-rooting pillows, and to alter the water reservoir to model a propellant management device (PMD) in order to ensure consistent and long term watering for the VEGGIE system. The plant rooting pillow required minimal changes outside of replacing the capillary mat on the bottom of the pillow with O-ring insertion points the single-interface capillary system. - Research was conducted to determine which materials are able to uptake water through capillary action to grow Outredgeous Lettuce plants from seed to harvest. The primary requirements to be met by the team's design and evaluation of the capillary interface were: continuous passive watering for 90 days using non-flammable capillary materials and a peak water delivery rate of 30 mL/hr./0.15 m 2 . The results of the team's experimentation showed that the capillary material Nomex displayed the highest capillary water delivery potential with a maximum flow rate of 3.6 mL/hr. The Nomex capillary systems were the only capillary material to consistently grow Outredgeous Lettuce plants from seed to harvest, and displayed the highest average flow rate for multiple experiment sets. The Nomex material was previously incorporated into the VEGGIE system using a matted version of the capillary material, though the team recommends using a cord configuration in the single-interface capillary system for greater system stability. Nomex has proven to be a promising material, as it has passed both health and fire standards for use aboard the International Space Station. PMDs are made of materials that utilize surface tension and adhesive forces to overcome adverse accelerations to improve stability and ensure fluid delivery. PMDs are typically used in fuel tanks to ensure fuel delivery. The team recommends using a sponge PMD in order to mitigate bubble obstruction, decrease system weight, and ensure reliable water delivery to the capillary interface. The PMD water reservoir requires a rigid water reservoir and a vent tube for pressure stabilization. Since PMD’s cannot be tested in 1-G (Earth conditions), further theoretical modeling and testing is required for the proposed water reservoir design. The intent of this proposed system is to passively water plants in microgravity, though the technology is not limited to microgravity applications. The testing at The Ohio State University has proven that the design is highly effective on Earth, demonstrating that it could serve as a simple water delivery system in home and office applications. This would make vegetative crops more accessible in all indoor applications, thereby improving indoor air quality and occupant comfort. Additionally, this technology has great potential to be utilized in greenhouse plant production, cutting back on more sophisticated watering system energy and time requirements.

Alexandria Jensen↗

NASA NTRS2023

NASA X-HAB Water Delivery System

As part of the eXploration Systems and Habitation (X-HAB) Academic Innovation Challenge program of National Aeronautics and Space Administration (NASA), The Ohio State University was selected to improve the performance of NASA’s existing Vegetable Production System (VEGGIE), which is a deployable plant growth unit for International Space Station (ISS). During the academic year 2015-2016, The Ohio State University student team developed a passive water delivery system using capillary water transport principle (Jenson et al. 2016). The major design improvement made was directly connecting the water reservoir to the plant-rooting pillows using a single-interface capillary cord design. Harvestable plants were successfully grown from seeds using the single interface system. In addition, Nomex®, a fabric material composed of short nylon based fibers, was identified as the material for wicks. Finally, the water reservoir was modeled as a propellant management device (PMD) to ensure consistent and long term watering of the VEGGIE system. The PMDs are made of materials that utilize surface tension and adhesive forces to improve stability and fluid delivery. The team recommended using a sponge PMD in order to mitigate bubble obstruction, decrease system weight, and ensure reliable water delivery to the capillary interface.

Peter Ling↗

NASA NTRS2016

Mass and Reliability System (MaRS)

The Safety and Mission Assurance (S&MA) Directorate is responsible for mitigating risk, providing system safety, and lowering risk for space programs from ground to space. The S&MA is divided into 4 divisions: The Space Exploration Division (NC), the International Space Station Division (NE), the Safety & Test Operations Division (NS), and the Quality and Flight Equipment Division (NT). The interns, myself and Arun Aruljothi, will be working with the Risk & Reliability Analysis Branch under the NC Division's. The mission of this division is to identify, characterize, diminish, and communicate risk by implementing an efficient and effective assurance model. The team utilizes Reliability and Maintainability (R&M) and Probabilistic Risk Assessment (PRA) to ensure decisions concerning risks are informed, vehicles are safe and reliable, and program/project requirements are realistic and realized. This project pertains to the Orion mission, so it is geared toward a long duration Human Space Flight Program(s). For space missions, payload is a critical concept; balancing what hardware can be replaced by components verse by Orbital Replacement Units (ORU) or subassemblies is key. For this effort a database was created that combines mass and reliability data, called Mass and Reliability System or MaRS. The U.S. International Space Station (ISS) components are used as reference parts in the MaRS database. Using ISS components as a platform is beneficial because of the historical context and the environment similarities to a space flight mission. MaRS uses a combination of systems: International Space Station PART for failure data, Vehicle Master Database (VMDB) for ORU & components, Maintenance & Analysis Data Set (MADS) for operation hours and other pertinent data, & Hardware History Retrieval System (HHRS) for unit weights. MaRS is populated using a Visual Basic Application. Once populated, the excel spreadsheet is comprised of information on ISS components including: operation hours, random/nonrandom failures, software/hardware failures, quantity, orbital replaceable units (ORU), date of placement, unit weight, frequency of part, etc. The motivation for creating such a database will be the development of a mass/reliability parametric model to estimate mass required for replacement parts. Once complete, engineers working on future space flight missions will have access a mean time to failures and on parts along with their mass, this will be used to make proper decisions for long duration space flight missions

Barnes, Sarah↗

NASA NTRS2005

An Ultra Reliability for Project for NASA

NASA has embarked on a new program designed to improve the reliability of NASA systems. In this context, the goal for ultra reliability is to ultimately improve the systems by an order of magnitude. The approach outlined in this presentation involves five steps: 1. Divide NASA systems into seven sectors; 2. Establish sector champions and representatives from each NASA center; 3. Develop a challenge list for each sector using a team of NASA experts in each area with the sector champion facilitating the effort; 4. Develop mitigation strategies for each of the sectors' challenge lists and rank their importance by holding a workshop with area experts from government (NASA and non-NASA), universities and industry; 5. Develop a set of tasks for each sector in order of importance for improving the reliability of NASA systems. Several NASA-wide workshops have been held, identifying issues for reliability improvement and providing mitigation strategies for these issues.

ultra-reliability↗

NASA NTRSDate not supplied

Assembly and Integration Status of a High Fidelity Ground Test Bed for the Water Processor Assembly

The Water Recovery System (WRS) is a critical component of life support aboard the International Space Station (ISS) and will play an essential role in future missions beyond Low Earth Orbit (LEO). Its primary functional units – the Urine Processor Assembly (UPA), Brine Processor Assembly (BPA), and Water Processor Assembly (WPA) – must be evaluated for extended operation, dormancy resilience, material obsolescence, and reliability under exploration-driven constraints. Ground testing is vital for developing these technologies and generating statistically relevant reliability assessments, which requires extended runtime under integrated, Flight-like conditions. Currently, no high-fidelity, fully integrated WPA ground test bed exists to support these objectives. To address this gap, NASA is developing a WPA test bed at Marshall Space Flight Center (MSFC) that combines downgraded ISS flight hardware with functionally flight-like components in a cost-effective configuration while maintaining priority hardware investigations. This paper describes the current status of hardware assembly and integration, outlines key challenges such as simulating microgravity effects and mitigating obsolescence, and presents future test objectives including software development, reliability assessments, dormancy studies, and exploration-oriented upgrades.

Mary-Elizabeth Davis↗

NASA NTRSDate not supplied

Assembly and Integration Status of a High Fidelity Ground Test Bed for the Water Processor Assembly

Water Processor Assembly↗

DOE OSTI2025

Bridging the Gap Between Astronomical Datasets: From Proof-of-Concept to AI Model Deployment with Domain Adaptation

Artificial Intelligence is transforming astrophysics, from studying stars and galaxies to analyzing cosmic large-scale structures. However, a critical challenge arises when AI models trained on simulations or past observational data are applied to new observation— leading to domain shifts, reduced robustness, and increased uncertainty of model predictions. This talk will explore these issues, highlighting examples such as galaxy morphology classification and cosmological parameter inference, where AI struggles to adapt across different datasets. We will discuss domain adaptation as a strategy to improve model generalization and mitigate biases—essential for making AI-driven discoveries reliable. Notably, these challenges extend beyond astrophysics, affecting AI applications across physics and other scientific domains. Addressing them is essential for maximizing AI’s impact in advancing scientific research.

Ćiprijanović, Aleksandra [Fermilab]↗

NASA NTRS1986

Orbit Transfer Rocket Engine Technology Program: Advanced engine study, task D.1/D.3

Concepts for space maintainability of OTV engines were examined. An engine design was developed which was driven by space maintenance requirements and by a failure mode and effects (FME) analysis. Modularity within the engine was shown to offer cost benefits and improved space maintenance capabilities. Space operable disconnects were conceptualized for both engine change-out and for module replacement. Through FME mitigation the modules were conceptualized to contain the least reliable and most often replaced engine components. A preliminary space maintenance plan was developed around a controls and condition monitoring system using advanced sensors, controls, and condition monitoring concepts. A complete engine layout was prepared satisfying current vehicle requirements and utilizing projected component advanced technologies. A technology plan for developing the required technology was assembled.

Martinez, A.↗