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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Parameter, Post-Processing Sensitivities, and Qualification Approach of Laser Powder Bed Fusion Hydrogen Resistant Alloy NASA HR-1

Metal additive manufacturing (AM) processes are being used to enable economical manufacturing of legacy alloys as well as advancing new alloys. Laser powder bed fusion (L-PBF) is a metal AM process that has high maturity and being used to produce a variety of parts for space applications including complex propulsion components. The National Aeronautics and Space Administration (NASA) has identified the need to develop and advance new materials in unique space applications such as high-pressure hydrogen environments. NASA HR-1 is a high strength Fe-Ni based superalloy designed to resist high pressure hydrogen environment embrittlement (HEE), oxidation, and corrosion that has been successfully adapted to laser powder directed energy deposition (LP-DED). Insights gained from the NASA HR-1 development for LP-DED have guided the development process for L-PBF. However, adapting NASA HR-1 to L-PBF posed new challenges due to the distinct differences between the additive manufacturing processes. During parameter development, sensitivities were observed in post-processing that necessitated additional optimization of heat treatments. Additionally, the variations in thickness and how it influenced the microstructural response during heat treatment was characterized. Understanding these sensitivities is important to qualification of the material in a L-PBF machine. This ensures that the microstructures and properties of the material maintain consistency in production. This presentation will cover parameter development along with post-processing challenges and solutions will be discussed in addition to key material properties as it pertains to application performance and qualification per NASA-STD-6030. Improvements made by developing a derivative alloy, NASA HR-2, will be highlighted through preliminary small scale parameter development, material characterization, and initial property testing.

NASA HR-1↗
DOE OSTI2020

OPTIMUS{sup TM} Packaging for Intermediate Level Wastes and Spent Fuel - 20129

NAC's OPTIMUS{sup TM} packaging is a family of Type B(U)F transportation packages designed for maximum flexibility and cost-efficiency to support shipment of a wide range of challenging wastes and materials. They are small, modular packaging designs meeting DOT weight limits for road transport. OPTIMUS{sup TM} contents include low level waste, mixed low-level waste, irradiated fuel waste and intermediate level waste. Contents can also include aerosol cans with compressed gas and liquefied gas propellants and standard DOT 3E lecture bottles for shipment to treatment facilities. OPTIMUS{sup TM} packaging provides a cost-effective solution for challenging and unique waste contents combined with design simplicity and operational flexibility meeting the requirements of both SSR-6 and 10 CFR 71 for Type B(U)F packaging. The modular design of the packaging components combined with the flexibility to add modified internals for enhanced packaging performance makes OPTIMUS{sup TM} the preferred solution for many radioactive material transportation needs. The OPTIMUS{sup TM} product line currently includes two packaging designs; OPTIMUS{sup TM}-L and OPTIMUS{sup TM}-H. OPTIMUS{sup TM}-L is a lightweight transportation packaging intended for low-activity wastes, whereas OPTIMUS{sup TM}-H is a larger, heavier package intended for high-activities wastes. Due to its small size and weight, six (6) to ten (10) OPTIMUS{sup TM}-L packages can be accommodated on a single legal-weight truck shipment, depending on the weight of the contents. For typical payloads, two (2) OPTIMUS{sup TM}-H packages can be accommodated on a single legal-weight truck shipment. The OPTIMUS{sup TM} packaging share the same cask containment vessel (CCV) in the OPTIMUS{sup TM}-H and OPTIMUS{sup TM}-L. The large cavity size of the CCV, which can accommodate a 416-liter (110-gallon) drum, combined with the small size, low weight and modularity of the OPTIMUS{sup TM} packaging provides unmatched flexibility. In this paper, NAC provides a technical overview of the OPTIMUS{sup TM} packaging and identifies the design features and technology advancements making the OPTIMUS{sup TM} a readily adaptable and flexible solution for packaging processing facilities, reactor and decommissioning wastes. Optimized shielding performance through the addition of internal shielding components and alternative shipping configurations are discussed. In addition, an overview of the first major deployment of the OPTIMUS{sup TM} packaging for the Whiteshell Laboratories Closure Project (WLCP) is discussed. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Cesium Removal and Hydraulic Performance Comparisons of CST Ion Exchange Media Batches in Support of the Tank Closure Cesium Removal Project - 20522

Three batches of Crystalline Silicotitanate (CST) ion exchange media have been evaluated for cesium removal efficiency from a Savannah River Site (SRS) High Level Waste (HLW) supernate simulant in support of the Tank Closure Cesium Removal (TCCR) Project, which involves at-tank column waste treatment. Results will be utilized to select the CST media batch to be added to the next TCCR unit columns. Two of the CST media samples were recent production batches and the third was an archived batch studied extensively at SRS nearly two decades ago. The archived CST batch had a significantly smaller average particle diameter than more recent batches. Small-scale (∼23 mL), side-by-side column tests were conducted at 35 deg. C with each of the CST batches using the same simulant at flow rates near 1.2 mL/min (3.0-3.4 CST bed volumes/hr). The cesium ion exchange column performance results were lower than expected for all three CST batches, but the data indicated that 30% more simulant volume and 40% more equivalent CST bed volumes of solution can be processed with the older CST batch prior to reaching the 50% cesium breakthrough point than can be processed with the newer CST batches. Hydraulic evaluations of the CST columns were also conducted in simulant at 24 deg. C to determine the impact of the different particle size distributions and associated bed porosities on frictional pressure drop under dynamic flow conditions. Higher differential pressure drops were observed with the archived CST batch relative to recent production batches, due to the smaller particle size distribution and the packing characteristics of the archived batch. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Plasma-driven solution electrolysis

Plasmas interacting with liquids enable the generation of a highly reactive interfacial liquid layer due to a variety of processes driven by plasma-produced electrons, ions, photons, and radicals. These processes show promise to enable selective, efficient, and green chemical transformations and new material synthesis approaches. While many differences are to be expected between conventional electrolysis and plasma–liquid interactions, plasma–liquid interactions can be viewed, to a first approximation, as replacing a metal electrode in an electrolytic cell with a gas phase plasma. For this reason, we refer to this method as plasma-driven solution electrochemistry (PDSE). In this Perspective, we address two fundamental questions that should be answered to enable researchers to make transformational advances in PDSE: How far from equilibrium can plasma-induced solution processes be driven? and What are the fundamental differences between PDSE and other more traditional electrochemical processes? Different aspects of both questions are discussed in five sub-questions for which we review the current state-of-the art and we provide a motivation and research vision.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2010

Cascade Distillation Subsystem Development: Early Results from the Exploration Life Support Distillation Technology Comparison Test

In 2009, the Cascade Distillation Subsystem (CDS) wastewater processor (Honeywell International, Torrance, California) was assessed in the National Aeronautics and Space Administration (NASA) Exploration Life Support (ELS) distillation comparison test. The purpose of the test was to collect data to support down-selection and development of a primary distillation technology for application in a lunar outpost water recovery system. The CDS portion of the comparison test was conducted between May 6 and August 19, 2009. The system was challenged with two pretreated test solutions, each intended to represent a feasible wastewater generated in a surface habitat. The 30-day equivalent wastewater loading volume for a crew of four was intended to be processed for each wastewater solution. Test Solution 1 consisted of a mixed stream containing human-generated urine and humidity condensate. Test Solution 2 contained the addition of human-generated hygiene wastewater to the solution 1 waste stream components. Approximately 1500 kg of total wastewater was processed through the CDS during testing. Respective recoveries per solution were 93.4 +/- 0.7 and 90.3 +/- 0.5 percent. The average specific energy of the system during testing was calculated to be less than 120 W-hr/kg. The following paper provides detailed information and data on the performance of the CDS as challenged per the ELS distillation comparison test.

Callahan, Michael R.↗
DOE OSTI2020

Decontamination of urban surfaces contaminated with radioactive materials and consequent onsite recycling of the waste water

Enhancing rapid remediation strategies is paramount for recovery after a large-scale nuclear contamination event in an urban environment. Some current strategies recommend use of readily available equipment, materials, and facilities to expedite recovery. For example, applying pressurized water to contaminated surfaces may effectively remove radioactive contamination. In this study, a commercial power washer removes soluble forms of 152 Eu 3 + , 85 Sr 2 + , and 137 Cs + contamination from common porous building materials, and computer simulations characterize the recycling of the resultant contaminated wash water. Pressure washing the porous building materials under spray conditions typical with do-it-yourself units improved decontamination factors (DFs) for 152 Eu compared to low-pressure application of tap water (majority of two-tailed t-test p-values < 0.1), but pressure did not improve DFs for 137 Cs or 85 Sr. For both pressurized and low-pressure applications, adding potassium ions (K + ) to promote ion exchange reactions produced significantly higher DFs for tested radionuclides on asphalt, brick, and concrete. The resultant contaminated wash water can be processed through self-prepared chemical filtration beds of clay and sand. Modeled in a prior study, the beds yielded linear trends (R 2 > 0.98) in sensitivity analyses between most bed configuration variables and bed performance variables, permitting flexible ad-hoc bed design. The experimental and simulation results led to estimates of the remediation rate and waste generated after cleaning 250 m 2 of cesium-contaminated concrete from the combined deployment of a power washer and two different mobile treatment beds. Furthermore, the first treatment bed was designed to reduce treatment time and processed 1900 L of wash solution in 70 min using 880 kg of clay/sand infill material. Designed to reduce the solid waste generated, the second bed processed the same solution volume in 1040 min (17 h) using 170 kg of clay/sand infill material. The results of this analysis warrant further investigation of power washing with recycled salt solution as an effective rapid decontamination method with manageable waste.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS2001

The Paperless Solution

REI Systems, Inc. developed a software solution that uses the Internet to eliminate the paperwork typically required to document and manage complex business processes. The data management solution, called Electronic Handbooks (EHBs), is presently used for the entire SBIR program processes at NASA. The EHB-based system is ideal for programs and projects whose users are geographically distributed and are involved in complex management processes and procedures. EHBs provide flexible access control and increased communications while maintaining security for systems of all sizes. Through Internet Protocol- based access, user authentication and user-based access restrictions, role-based access control, and encryption/decryption, EHBs provide the level of security required for confidential data transfer. EHBs contain electronic forms and menus, which can be used in real time to execute the described processes. EHBs use standard word processors that generate ASCII HTML code to set up electronic forms that are viewed within a web browser. EHBs require no end-user software distribution, significantly reducing operating costs. Each interactive handbook simulates a hard-copy version containing chapters with descriptions of participants' roles in the online process.

Source record↗
DOE OSTI2021

OPFLearnData: Dataset for Learning AC Optimal Power Flow

The datasets are resulting from OPFLearn.jl, a Julia package for creating AC OPF datasets. The package was developed to provide researchers with a standardized way to efficiently create AC OPF datasets that are representative of more of the AC OPF feasible load space compared to typical dataset creation methods. The OPFLearn dataset creation method uses a relaxed AC OPF formulation to reduce the volume of the unclassified input space throughout the dataset creation process. The dataset contains load profiles and their respective optimal primal and dual solutions. Load samples are processed using AC OPF formulations from PowerModels.jl. More information on the dataset creation method can be found in our publication, "OPF-Learn: An Open-Source Framework for Creating Representative AC Optimal Power Flow Datasets" and in the package website: https://github.com/NREL/OPFLearn.jl.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Staying Competitive in Clean Manufacturing: Insights on Barriers from Industry Interviews

While industrial emissions research has historically focused on energy-intensive sectors like steel, cement, and chemicals, this study addresses a critical gap by examining barriers across all the manufacturing industry in the U.S. Sectors like food processing, retail, plastics, and transportation face unique challenges distinct from heavy industry, operating on thin margins with limited bargaining power while experiencing heightened consumer and stakeholder pressure for improved environmental responsibility. Through structured interview data collection process and using quantitative ratings and qualitative analysis, this research identifies and categorizes emission reduction barriers across four key themes: financial, technical, organizational, and regulatory. Unlike energy-intensive industries that may pursue hydrogen or carbon capture technologies, discrete manufacturing industry like automotive, electrical and electronics, and machine manufacturers typically focus on energy efficiency, electrification of thermal processes, and alternate fuel switching, solutions better aligned with their lower-temperature processes and distributed facility profiles. The study’s primary contribution lies in documenting specific barrier manifestations within organizations and identifying proven mitigation strategies that companies have successfully implemented or observed among peers.

business competitiveness↗
DOE OSTI2023

Cesium Removal from SY-101 Tank Waste Using Crystalline Silicotitanate

The newly operational Tank Side Cesium Removal (TSCR) system removes radioactive cesium-137 ( 137 Cs) and solids from tank waste supernate in the 200 east area of the Hanford site. Efforts to expand the removal capabilities to the 200 west area are underway by a system anticipated to be called the West Area Risk Management (WARM) system. Laboratory-scale ion exchange processing using expected WARM unit operations were conducted to contribute toward Washington River Protection Solutions (WRPS) establishing accurate process flowsheets for the individual feed campaigns planned for the west area supernate pretreatment. This report describes the small-scale ion exchange testing with 8.0 L of filtered supernate from tank 241-SY-101 (referred to as SY-101) at 16 °C (62 °F) to demonstrate processing conditions that would be prototypic of what the WARM system may experience. One of the waste acceptance criteria (WAC) for the Waste Treatment Plant (WTP) Low-Activity Waste Facility is that the waste must contain less than 3.18×10 -5 Ci 137 Cs per mole of Na. For the SY-101 tank waste to meet this criterion, only 0.44% of the influent 137 Cs concentration may be delivered to the WTP; this requires a Cs decontamination factor of 227. Testing with SY-101 matched current TSCR prototypic operations where a lead-lag configuration is used until the lag column reached the WAC limit. Neither the lead nor lag columns reached the WAC, so a polish column was never utilized during this test. Feed was processed at 1.9 bed volumes (BVs) per hour; the flowrate, in terms of contact time with the crystalline silicotitate (CST) bed, matched the current flowrate at TSCR (an expected flowrate to be used at WARM). The lead column only reached 0.09% Cs breakthrough after processing ~1363 BVs of feed. Cesium breakthrough from the lag column was not observed during the entire processing. Table S.1 and Figure S.1 summarize the observed column performance and relevant Cs loading characteristics. Table S.1 and Figure S.1 also summarize the measured SY-101 Cs load performance.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1987

Rapid thermal annealing of indium phosphide compound semiconductors

The rapid thermal annealing (RTA) of indium phosphide (InP) substrates using a proximity contact method and silicon nitride encapsulation is investigated. The surface conditions of the InP substrates following cleaning with procedures A and B are analyzed. Procedure A involves using an iodic acid solution to remove work-damage InP surface layers and B is a degasssing process and hydrofluoric acid solution for native oxide removal. AES, XPS, and SIMS data of the proximity contact and silicon nitride encapsulated annealed samples are examined. The data reveal that RTA using proximity contact with silicon wafers does not provide adequate protection; however, the InP sample is successfully annealed when protected by a silicon nitride encapsulant.

Biedenbender, Michael D.↗
NASA NTRS2005

A Management Model for International Participation in Space Exploration Missions

This paper proposes an engineering management model for NASA's future space exploration missions based on past experiences working with the International Partners of the International Space Station. The authors have over 25 years of combined experience working with the European Space Agency, Japan Aerospace Exploration Agency, Canadian Space Agency, Italian Space Agency, Russian Space Agency, and their respective contractors in the design, manufacturing, verification, and integration of their elements electric power system into the United States on-orbit segment. The perspective presented is one from a specific sub-system integration role and is offered so that the lessons learned from solving issues of technical and cultural nature may be taken into account during the formulation of international partnerships. Descriptions of the types of unique problems encountered relative to interactions between international partnerships are reviewed. Solutions to the problems are offered, taking into consideration the technical implications. Through the process of investigating each solution, the important and significant issues associated with working with international engineers and managers are outlined. Potential solutions are then characterized by proposing a set of specific methodologies to jointly develop spacecraft configurations that benefits all international participants, maximizes mission success and vehicle interoperability while minimizing cost.

George, Patrick J.↗
DOE OSTI2024

Insights into the structure and dynamics of K + ions at the muscovite–water interface from machine learning potential simulations

The surfaces of many minerals are covered by naturally occurring cations that become partially hydrated and can be replaced by hydronium or other cations when the surface is exposed to water or an aqueous solution. These ion exchange processes are relevant to various chemical and transport phenomena, yet elucidating their microscopic details is challenging for both experiments and simulations. Here, in this work, we make a first step in this direction by investigating the behavior of the native K + ions at the interface between neat water and the muscovite mica (001) surface with ab-initio -based machine learning molecular dynamics and enhanced sampling simulations. Our results show that the desorption of the surface K + ions in pure ion-free water has a significant free energy barrier irrespective of their local surface arrangement. In contrast, facile K + diffusion between mica’s ditrigonal cavities characterized by different Al/Si orderings is observed. This behavior suggests that the K + ions may favor a dynamic disordered surface arrangement rather than complete desorption when exposed to deionized water.

Ab-initio molecular dynamics↗
DOE OSTI2020

Robust Online Sequential RVFLNs for Data Modeling of Dynamic Time-Varying Systems with Application of an Ironmaking Blast Furnace

In a world where the increasing complexity of modern industrial processes brings difficulties for accurate mathematical modeling, taking advantage of data has become an efficient solution to complex dynamic process modeling issue. In this paper, we develop a novel robust online sequential version of random vector functional-link networks (RVFLNs) for data-driven modeling of dynamic time-varying system and applied it in a blast furnace (BF) ironmaking process. First, to overcome the time-varying dynamics of process and to enable the RVFLNs to learn online with avoiding data saturation, an improved online sequential version of RVFLNs (OS-RFVLNs) is first presented by online sequential learning with forgetting factor. This improved OS-RVFLNs algorithm is not only suitable for the real-time and large data transfer situation, but also can adjust the sensitivity of the algorithm to different samples with the help of the introduced forgetting factor. Second, since the output weights of the improved OS-RVFLNs as well as other RVFLNs algorithms are obtained by the least squares approach, a robustness problem may occur when the training dataset is contaminated with various outliers. To solve this problem, a Cauchy distribution weighted M-estimator is introduced to improve the robustness of the improved OS- RVFLNs. For this proposed robust OS-RVFLNs (R-OS- RVFLNs), since the weights of different outlier data are properly determined by the Cauchy distribution function, their corresponding contribution on modeling can be properly distinguished. Thus robust and better modeling results can be achieved. Experiments using actual industrial data of BF ironmaking process and comparative studies have demonstrated that the proposed method produces a better estimation accuracy and stronger robustness than other methods.

Blast furnace (BF), Modelling, Dynamic systems↗
NASA NTRS1985

Large deflections of a cantilever beam under arbitrarily directed tip load

The nonlinear beam equation was integrated numerically in a direct fashion to obtain results for large deflections of cantilevers under tip loads of arbitrary direction. A short BASIC computer program for performing this integration is presented. Results for selected load cases are presented. The numerical process is performed rapidly on a modern microcomputer, and comparisons with results from closed form solutions show that the process is accurate.

Mccomb, H. E., Jr.↗
DOE OSTI2021

Saltstone Waste Characterization Analysis - Salt Waste Processing Facility (SWPF) Waste Stream (Q4 CY2020)

The Saltstone Production and Disposal Facility is designed and permitted by the state of South Carolina Department of Health and Environmental Control (SCDHEC) to treat and dispose of low-level radioactive and hazardous liquid waste (salt solution) remaining from the processing of radioactive material at the Savannah River Site (SRS). Low-level waste (LEW) aqueous streams from the Effluent Treatment Project (ETP) and decontaminated solutions from the Tank Closure Cesium Removal Unit (TCCR) and the Salt Waste Processing Facility (SWPF) are stored in Tank 50 until the LEW can be transferred to the Saltstone Facility for treatment and disposal. In the past, decontaminated solution from the Modular Caustic Side Solvent Extraction Unit (MCU) was stored in Tank 50 until the LEW could be transferred to the Saltstone Facility for treatment and disposal. MCU is currently in a suspended operations state. LEW that meets the Waste Acceptance Criteria (WAC) can be transferred, stored, and treated in the Saltstone Production Facility (SPF) for subsequent disposal as saltstone grout in the Saltstone Disposal Facility (SDF). Sampling will be conducted as new waste streams are identified for treatment and disposal at the Saltstone Industrial Wastewater Treatment Facility (IWTF) and Z-Area Industrial Solid Waste Landfill (ISWLF), Facility ID# 025500-1603, General Condition B.9 or every six years in accordance with South Carolina (SC) Regulation 61-107.19 Parti C, “Solid Waste Management: Solid Waste Landfills and Structural Fill - General Requirements.”

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS2006

Precision of Sensitivity in the Design Optimization of Indeterminate Structures

Design sensitivity is central to most optimization methods. The analytical sensitivity expression for an indeterminate structural design optimization problem can be factored into a simple determinate term and a complicated indeterminate component. Sensitivity can be approximated by retaining only the determinate term and setting the indeterminate factor to zero. The optimum solution is reached with the approximate sensitivity. The central processing unit (CPU) time to solution is substantially reduced. The benefit that accrues from using the approximate sensitivity is quantified by solving a set of problems in a controlled environment. Each problem is solved twice: first using the closed-form sensitivity expression, then using the approximation. The problem solutions use the CometBoards testbed as the optimization tool with the integrated force method as the analyzer. The modification that may be required, to use the stiffener method as the analysis tool in optimization, is discussed. The design optimization problem of an indeterminate structure contains many dependent constraints because of the implicit relationship between stresses, as well as the relationship between the stresses and displacements. The design optimization process can become problematic because the implicit relationship reduces the rank of the sensitivity matrix. The proposed approximation restores the full rank and enhances the robustness of the design optimization method.

Patnaik, Surya N.↗