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DOE OSTI2025

Iterative Reconstruction for Multimodal Neutron Tomography

Here, we describe a unified framework for model-based iterative 3-D reconstruction of multimodal neutron transmission, hydrogen-scatter, and induced-fission images from low resolution data recorded using 14.1-MeV neutrons and the associated-particle imaging (API) technique. The framework, which was developed to facilitate use in challenging field-deployment scenarios, is centered around physics-based system models and a total variation (TV) constrained implementation of the simultaneous iterative reconstruction technique (SIRT). Modified to solve a statistically weighted least squares (WLS) problem, the SIRT algorithm is accelerated using ordered subsets and Nesterov’s momentum for which we derive a near-optimal value of the governing Lipschitz constant. The approach enables the reconstruction of images that are high resolution compared to the acquired data and is robust to both limited statistics and a limited number of projection angles. Moreover, the framework is fast enough to be practical. Example images are provided that demonstrate both the ability to perform fast-neutron imaging of high-atomic-number materials with low radiation dose and the benefit of multimodal neutron imaging to identify key materials.

Hydrogen scatter↗

NASA NTRS1982

Optimality criteria design and stress constraint processing

Methods for pre-screening stress constraints into either primary or side-constraint categories are reviewed; a projection method, which is developed from prior cycle stress resultant history, is introduced as an additional screening parameter. Stress resultant projections are also employed to modify the traditional stress-ratio, side-constraint boundary. A special application of structural modification reanalysis is applied to the critical stress constraints to provide feasible designs that are preferable to those obtained by conventional scaling. Sample problem executions show relatively short run times and fewer design cycle iterations to achieve low structural weights; those attained are comparable to the minimum values developed elsewhere.

Levy, R.↗

NASA NTRS1985

Space Station man-machine automation trade-off analysis

The man machine automation tradeoff methodology presented is of four research tasks comprising the autonomous spacecraft system technology (ASST) project. ASST was established to identify and study system level design problems for autonomous spacecraft. Using the Space Station as an example spacecraft system requiring a certain level of autonomous control, a system level, man machine automation tradeoff methodology is presented that: (1) optimizes man machine mixes for different ground and on orbit crew functions subject to cost, safety, weight, power, and reliability constraints, and (2) plots the best incorporation plan for new, emerging technologies by weighing cost, relative availability, reliability, safety, importance to out year missions, and ease of retrofit. A fairly straightforward approach is taken by the methodology to valuing human productivity, it is still sensitive to the important subtleties associated with designing a well integrated, man machine system. These subtleties include considerations such as crew preference to retain certain spacecraft control functions; or valuing human integration/decision capabilities over equivalent hardware/software where appropriate.

Zimmerman, W. F.↗

NASA NTRS1987

Robotic vision/sensing for space applications

A review is presented of efforts currently in progress at the NASA/Johnson Space Center and Rice University, the accomplishments to date, and some of the anticipated future developments. Both systems and algorithms are discussed. The evolution of future vision/sensing is projected to included the fusion of multisensors ranging from microwave to optical with multimode capability to include position, attitude, recognition, and motion parameters. The algorithms for information extraction are expected to incorporate aspects of intelligence and knowledge for the interpolation and extrapolation of the needed data. The key features of the overall system design will be small size and weight, fast signal processing, robust algorithms, and accurate parameter determination. These aspects of vision/sensing are also discussed.

Krishen, Kumar↗

NASA NTRS1993

An assessment of mission and configuration variations on multi-role fighter/attack aircraft concepts

This paper presents the results of a series of configuration studies conducted in connection with the NASA agility design study project. The purpose of these in-house studies was to develop a parametric data base of configuration concepts and resulting mission performances for a variety of notional fighter/attack missions. This data base will then be used to assess the impact of the imposition of agility requirements on these configurations. Three vehicle concepts were evaluated, and resulting vehicle sizes, weights, and mission performances were compared. Each configuration was then optimized for varying mission requirements and technology levels. It was found that small variations in mission requirements can have significant impact on the design choices. It was also found that optimization of engine cycle variables results in significant improvements in take-off gross weight and vehicle performance regardless of the concept being explored. Finally, results indicate that signature considerations such as internal vs. external weapons carriage can cause dramatic changes in vehicle size, weight, and mission performance.

Logan, Michael J.↗

NASA NTRS2014

Transit Reconfigurable Exerciser - Intern Exit Abstract

The Transit Resistive Exerciser (TREX) was developed during a 16 week period in which a clutch device filled with smart material was built and began the testing phase. The clutch serves as a passive method of creating resistance. When paired with a series of springs, the device creates a rowing machine also capable of resistive exercise configurations. The device has loading profiles similar to the exercise devices used on the International Space Station today. The prototype created was designed in a modular fashion to support parallel development on various aspects of the project. Hardware and software are currently in development and make use of commercially available parts. Similar technologies have been used in the automotive industry but have never been explored in the context of countermeasure systems for space flight. If the work done leads to successful testing and further development, this technology has the potential to cut the size and weight of exercise devices by an order of magnitude or more.

Gebara, Christine A.↗

NASA NTRS2014

The Use of the STAGS Finite Element Code in Stitched Structures Development

In the last 30 years NASA has worked in collaboration with industry to develop enabling technologies needed to make aircraft more fuel-efficient and more affordable. The focus on the airframe has been to reduce weight, improve damage tolerance and better understand structural behavior under realistic flight and ground loading conditions. Stitched structure is a technology that can address the weight savings, cost reduction, and damage tolerance goals, but only if it is supported by accurate analytical techniques. Development of stitched technology began in the 1990's as a partnership between NASA and Boeing (McDonnell Douglas at the time) under the Advanced Composites Technology Program and has continued under various titles and programs and into the Environmentally Responsible Aviation Project today. These programs contained development efforts involving manufacturing development, design, detailed analysis, and testing. Each phase of development, from coupons to large aircraft components was supported by detailed analysis to prove that the behavior of these structures was well-understood and predictable. The Structural Analysis of General Shells (STAGS) computer code was a critical tool used in the development of many stitched structures. As a key developer of STAGS, Charles Rankin's contribution to the programs was quite significant. Key features of STAGS used in these analyses and discussed in this paper include its accurate nonlinear and post-buckling capabilities, its ability to predict damage growth, and the use of Lagrange constraints and follower forces.

Jegley, Dawn C.↗

NASA NTRS2015

Composite Dry Structure Cost Improvement Approach

This effort demonstrates that by focusing only on properties of relevance, composite interstage and shroud structures can be placed on the Space Launch System vehicle that simultaneously reduces cost, improves reliability, and maximizes performance, thus providing the Advanced Development Group with a new methodology of how to utilize composites to reduce weight for composite structures on launch vehicles. Interstage and shroud structures were chosen since both of these structures are simple in configuration and do not experience extreme environments (such as cryogenic or hot gas temperatures) and should represent a good starting point for flying composites on a 'man-rated' vehicle. They are used as an example only. The project involves using polymer matrix composites for launch vehicle structures, and the logic and rationale behind the proposed new methodology.

Nettles, Alan↗

NASA NTRS2010

Project Management Using Modern Guidance, Navigation and Control Theory

The idea of control theory and its application to project management is not new, however literature on the topic and real-world applications is not as readily available and comprehensive in how all the principals of Guidance, Navigation and Control (GN&C) apply. This paper will address how the fundamental principals of modern GN&C Theory have been applied to NASA's Constellation Space Suit project and the results in the ability to manage the project within cost, schedule and budget. A s with physical systems, projects can be modeled and managed with the same guiding principles of GN&C as if it were a complex vehicle, system or software with time-varying processes, at times non-linear responses, multiple data inputs of varying accuracy and a range of operating points. With such systems the classic approach could be applied to small and well-defined projects; however with larger, multi-year projects involving multiple organizational structures, external influences and a multitude of diverse resources, then modern control theory is required to model and control the project. The fundamental principals of G N&C stated that a system is comprised of these basic core concepts: State, Behavior, Control system, Navigation system, Guidance and Planning Logic, Feedback systems. The state of a system is a definition of the aspects of the dynamics of the system that can change, such as position, velocity, acceleration, coordinate-based attitude, temperature, etc. The behavior of the system is more of what changes are possible rather than what can change, which is captured in the state of the system. The behavior of a system is captured in the system modeling and if properly done, will aid in accurate system performance prediction in the future. The Control system understands the state and behavior of the system and feedback systems to adjust the control inputs into the system. The Navigation system takes the multiple data inputs and based upon a priori knowledge of the input, will develop a statistical-based weighting of the input to determine where the system currently is located. Guidance and Planning logic of the system with the understanding of where it is (provided by the navigation system) will in turn determine where it needs to be and how to get there. Lastly, the system Feedback system is the right arm of the control system to allow it to affect change in the overall system and therefore it is critical to not only correctly identify the system feedback inputs but also the system response to the feedback inputs. And with any systems project it is critical that the objective of the system be clearly defined for not only planning but to be used to measure performance and to aid in the guidance of the system or project.

Hill, Terry↗

NASA NTRSDate not supplied

SIBatt-3D: In-Space/On-Surface 3D Printing of Sodium Ion Batteries from ISRU Materials

Constructed more than 20 years ago, the International Space Station’s primary power system originally used nickel-hydrogen batteries with a lifetime of 6.5 years, until NASA began the process of replacing them in 2016 with lithium-ion batteries with a lifetime of 10 years. The demanding and costly process was accomplished after four flights of the Japanese H-II Transfer Vehicle cargo spacecraft (with a cost of about $10,000 per pound of payload), and 13 different astronauts conducting 14 spacewalks. Besides utilization in the ISS, rechargeable batteries are present in many space applications: they are installed in exploration robots, life support systems and in portable communication devices, to mention some. In this context, this project is focused on the in-space manufacturing of shape-conformable batteries using in-situ resources, and aims to address the NASA’s gaps related to the development of next generation of energy storage devices (TX03), as well as in-space manufacturing and in-situ resource utilization (TX07). The proposed work also tackles the HEOMD’s objectives targeting the in-space additive manufacturing (AM) from Lunar/Martian materials (regolith as AM feedstock) to reinvigorate America’s Human Space Exploration Program (SPD-1). This project is in direct alignment with the STMD’s objectives to demonstrate in-space autonomous manufacturing and assembly of complete systems by 2030, and to enable humans to live and explore in space and on planetary surfaces by 2040 thanks to in-space habitation, infrastructure development and in-situ resource utilization (ST1 and ST5). Manufacturing of shape conformable batteries directly in-space and using in-situ resources would also contribute to reducing the payload weight and volume (TX12) for future missions, thus reducing risk for long term Mars missions where rapid resupply is logistically infeasible. Nowadays, commercial batteries consist of stacked two-dimensional (2D) sheets, which are only manufactured in restricted geometries (cylindrical and coin cell). Evolving from conventional 2D, complex 3D battery architectures have been proven to increase the electrochemical active surface area and ion diffusion path, leading to improved areal energy density and power performance. This tendency was illustrated in our recent in-depth modeling studies by simulating a classical Ragone plot exhibiting the energy-power relationship. Our team demonstrated through modeling that a complex gyroidal 3D printed battery architecture exhibits significantly improved power performances (>150% at the current density of 6C; full discharge in 10 minutes) in comparison to a traditional 3D printed planar geometry. Motivated by these results and as the fabrication of intricate 3D battery design is only possible experimentally thanks to the geometric freedom offered by additive manufacturing (AM), our team has already initiated leveraging thermoplastic material extrusion at the laboratory scale. While 3D printing of batteries is relatively recent (2013), it has witnessed a growing interest during the last recent years, as next-generation shape-conformable 3D batteries can be co-designed with the system. Consequently, dead-volume and mass brought from Earth are minimized, in addition to improved battery performance, in alignment with the aforementioned NASA’s objectives. Further, while this project is specifically dedicated to batteries, it lends itself towards the maturation of in-space manufacturing via 3D printing using in-situ resources, stated in HEOMD and STMD goals.

In-Space Manufacturing↗

DOE OSTI2022

Typological representation of the offshore oceanographic environment along the Alaskan North Slope

Erosion and flooding impacts to Arctic coastal environments are intensifying with nearshore oceanographic conditions acting as a key environmental driver. Robust and comprehensive assessment of the nearshore oceanographic conditions require knowledge of the following boundary conditions: incident wave energy, water level, incident wind energy, ocean temperature and salinity, bathymetry, and shoreline orientation. The number of offshore oceanographic boundary conditions can be large, requiring a significant computational investment to reproduce nearshore conditions. This present study develops location-independent typologies to reduce the number of boundary conditions needed to assess nearshore oceanographic environments in both a Historical (2007–2019) and Future (2020–2040) timespan along the Alaskan North Slope. We used WAVEWATCH III® and Delft3D Flexible Mesh model output from six oceanographic sites located along a constant ~50 m bathymetric line spanning the Chukchi to Beaufort Seas. K-means clustering was applied to the energy-weighted joint-probability distribution of significant wave height (H s ) and peak period (T p ). Distributions of wave and wind direction, wind speed, and water level associated with location-independent centroids were assigned single values to describe a reduced order, typological rendition of offshore oceanographic conditions. Reanalysis data (e.g., ASRv2, ERA5, and GOFS) grounded the historical simulations while projected conditions were obtained from downscaled GFDL-CM3 forced under RCP8.5 conditions. Location-dependence for each site is established through the occurrence joint-probability distribution in the form of unique scaling factors representing the fraction of time that the typology would occupy over a representative year. As anticipated, these typologies show increasingly energetic ocean conditions in the future. They also enable computationally efficient simulation of the nearshore oceanographic environment along the North Slope of Alaska for better characterization of coastal processes (e.g., erosion, flooding, or sediment transport).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Emergence of the temperature–density relation in the low-density intergalactic medium

We examine the evolution of the phase diagram of the low-density intergalactic medium during the Epoch of Reionization in simulation boxes with varying reionization histories from the Cosmic Reionization on Computers project. The probability density function (PDF) of gas temperature at fixed density exhibits two clear modes: a warm and a cold temperature mode, corresponding to the gas inside and outside of ionized bubbles. We find that the transition between the two modes is ‘universal’ in the sense that its timing is accurately parametrized by the value of the volume-weighted neutral fraction for any reionization history. This ‘universality’ is more complex than just a reflection of the fact that ionized gas is warm and neutral gas is cold: it holds for the transition at a fixed value of gas density, and gas at different densities transitions from the cold to the warm mode at different values of the neutral fraction, reflecting a non-trivial relationship between the ionization history and the evolving gas density PDF. Furthermore, the ‘emergence’ of the tight temperature–density relation in the warm mode is also approximately ‘universally’ controlled by the volume-weighted neutral fraction for any reionization history. In particular, the ‘emergence’ of the temperature–density relation (as quantified by the rapid decrease in its width) occurs when the neutral fraction is 10 –4 ≲ X HI ≲ 10 –3 for any reionization history. Our results indicate that the neutral fraction is a primary quantity controlling the various properties of the temperature–density relation, regardless of reionization history.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2022

Scorpius Injector Solenoid Magnet Alignment and Characterization

The Scorpius project consists of a linear induction accelerator (LIA) that will be built in the coming few years at the Nevada test site. Large radius solenoid magnets are used to focus and transport the electron beam through the injector of Scorpius. Typically, solenoid magnets are wrapped directly around the beam pipe. They have an inner radius of about 8 cm and weight approximately 170 lbs. The magnets for the Scorpius injector are much larger, the largest of which extends to an inner radius of 45 cm with a weight of 709 lbs. In addition, the magnet measurement effort is typically time-consuming, taking several months to complete. With 5 different designs of 52 solenoid magnets to measure in under a year, this is a challenging undertaking that requires a systems solution. Due to the size, variability, and quantity of solenoid magnets, as well as the compressed schedule, the process of measuring the solenoid magnets before integrating them into their respective assemblies and shipping them to Nevada is a challenging problem. There is a need for the injector magnets to be characterized and aligned in preparation for the commissioning of Scorpius. This will ensure that the injector magnet installation meets requirements.

42 ENGINEERING↗

DOE OSTI2022

GEN3D Experimental and Numerical Development of GEN3 Durability Models

Understanding of the high temperature durability of particles and the materials that contain them is critical to next generation of concentrating solar power (CSP) technology. Here we studied the durability of particles and their containment materials under extreme UV cycling, thermal cycling, and in low-speed high temperature mechanical wear situations. The optical stability of seven candidate particles has been determined following exposure to the high temperature conditions present in a generation 3 particle-based CSP technology. Particle solar weighted absorptance and emittance measured periodically during 10,000 high solar irradiance exposure cycles and up to 400 hours of isothermal aging has been documented. The particle aging due to repeated exposure to concentrated solar flux represented the 30-year lifetime of a power plant. Models were fit to the absorptivity and emissivity data following the isothermal aging provides the projected optical degradation of the particles as a function of temperature. Mechanical wear was studied through the use of custom developed wear testing facilities for measuring high temperature impact wear, abrasion wear, and particle attrition. Additionally, a novel technique for measuring the high temperature mechanical properties of single particles was developed. Through these tests it was observed that high nickel alloys generally showed lower wear than comparable iron based steels, particularly at elevated temperatures of 800°C. Mechanical wear at these temperatures is a highly complex phenomenon combining both mechanical wear and oxidation. Additionally, the containment materials wear rates are influenced by the particles (both hardness and roundness), making the wear mechanisms complex. The initial wear test conducted in the abrasion test rig revealed a substantial amount of oxide materials in the particle bed after testing (in relative to later tests), and substantially more wear, likely indicating a need for concern in startup operation of particle facilities to not incur high wear from the presence of oxides. Particle attrition experiments have only been conducted for a single material but increase size distribution, reduction in circularity, and particle diameter is observed. Efforts to develop predictive models was limited due to a testing campaign that prioritized testing materials for particle pathway developers over building a comprehensive design of experiments. The results discussed in this report inform future CSP developers and researchers further de risking the technology and assisting in its future development. ParticleBased CSP development provides a path to dispatchable solar power generation with storage at a price competitive in the current energy market. Lowering the cost of CSP technology provides a carbon free power generation solution that can assist in the transition from fossil fuels to renewable sources of electricity.

14 SOLAR ENERGY↗

DOE OSTI2023

Materials (FY 2022 Annual Progress Report)

This document summarizes the progress of VTO Materials R&D projects supported during the fiscal year 2022. The Propulsion Materials portfolio is closely aligned with other VTO subprograms to identify critical materials needs for next-generation high-efficiency powertrains for both heavy- and light-duty vehicles. The Lightweight Materials portfolio works closely with industry through the U.S. DRIVE Partnership to understand light-duty vehicle structural weight-reduction goals and identify technical challenges that prevent the deployment of lightweight materials.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Materials (FR 2023 Annual Progress Report)

This document summarizes the progress of VTO Materials R&D projects supported during the fiscal year 2023. The Propulsion Materials portfolio is closely aligned with other VTO subprograms to identify critical materials needs for next-generation high-efficiency powertrains for both heavy- and light-duty vehicles. The Lightweight Materials portfolio works closely with industry through the U.S. DRIVE Partnership to understand light-duty vehicle structural weight-reduction goals and identify technical challenges that prevent the deployment of lightweight materials.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2000

Low Cost Al-Si Casting Alloy As In-Situ Composite for High Temperature Applications

A new aluminum-silicon (Al-Si) alloy has been successfully developed at NASA- Marshall Space Flight Center (MSFC) that has significant improvement in tensile and fatigue strength at elevated temperatures (500 F-700 F). The alloy offers a number of benefits such as light weight, high hardness, low thermal expansion and high surface wear resistance. In hypereutectic form, this alloy is considered as an in-situ Al-Si composite with tensile strength of about 90% higher than the auto industry 390 alloy at 600 F. This composite is very economically produced by using either conventional permanent steel molds or die casting. The projected material cost is less than $0.90 per pound, and automotive components such as pistons can be cast for high production rate using conventional casting techniques with a low and fully accounted cost. Key Words: Metal matrix composites, In-situ composite, aluminum-silicon alloy, hypereutectic alloy, permanent mold casting, die casting.

Lee, Jonathan A.↗

NASA NTRS2006

Fat-Soluble Vitamin Status in Self-Neglecting Elderly

Elder self-neglect is a form of elder mistreatment. The systematic characterization of self-neglecting individuals is the goal of the CREST project. Reported here is the evaluation of fat-soluble vitamin status. Self-neglect (SN) subjects were recruited and consented following referral from Adult Protective Services. Control (CN) subjects were matched for age, gender, race, and socioeconomic status, as possible. We report here on 47 SN subjects (age 77 plus or minus 7, mean plus or minus SD; body weight 76 kg plus or minus 26) and 40 CN subjects (77 y plus or minus 7, 79 kg plus or minus 20). Blood samples were analyzed for indices of fat-soluble vitamin status. Plasma retinol (p less than 0.01) was lower in SN subjects. Plasma tocopherol tended (p less than 0.06) to be lower in SN subjects, while gamma-tocopherol was unchanged. SN subjects tended to have lower serum 25-OH vitamin D (p less than 0.11), and to be vitamin D deficient (26% below 23 mmol/L). Hypercalcemia occurred more often in SN subjects (23% had values above 2.56 mmol/L), as did elevated parathyroid hormone concentrations (p less than 0.05). These data demonstrate that many nutrients are affected in the self-neglecting elderly, and that long-term deficits are evident by the nature of changes in fat soluble vitamins.

Kala, G.↗