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NASA NTRS2018

Mechanisms of Oxide Formation in the Self-Reacting Friction Stir Weld Process

The initial objective of this study was to evaluate the effect of an extended delay time between preweld cleaning and the completion of a self-reacting friction stir welding (SRFSW) process on the resulting quality of various thickness panels of AA2219-T87. The current NASA standard specifies no more than a 48 hour delay between preweld cleaning and actual welding. The concern is whether increasing the cleaning delay time results in development of the residual oxide defect (ROD) in SRFSW. This concern emanates from the possibility of increased time correlating with increased oxide layer thickness on the faying surfaces. Oxide content on the faying surfaces has been reported to correlate with the occurrence of the ROD which reduces mechanical properties. When the SRFSW process was first adopted by the NASA Marshall Space Flight Center (MSFC), unexpected low tensile values that resulted were attributed to oxides within the weld that appeared to follow the former faying surface contours. Mitigation of the ROD was achieved through a combination of modifications to the processing parameters, tool designs, and incorporation of a weld seam offset. Two operations are involved in preweld cleaning: the first is removal of oil and grease, and the second is removal of surface oxides. In arc welding, improper cleaning of the faying surfaces of aluminum welded joints can increase the sensitivity toward development of defects. As the aluminum is locally melted, these contaminants contribute toward the development of porosity, inclusions, entrapped oxides, and other discontinuities which can degrade the strength of the weld joint. For weldment of large structures, the weld joint is typically cleaned, fit-up, and tack welded prior to the final full penetration welding pass. Because of the stringent joint fit-up requirements for mismatch and peaking for launch vehicle structures, the joint fit-up can sometimes contribute to lengthy delays between cleaning and tack welding, especially for circumferential weld joints on large diameter components. When the conventional friction stir welding (CFSW) process was introduced at the NASA MSFC, there was no procedure for cleaning prior to the solid-state joining process. As the process expanded to include SRFSW, preparation of the faying, crown, and root surfaces were implemented to overcome the ROD. Although the solid-state process is not expected to reach temperatures high enough for dissociation of the native oxide layer, concern remained regarding the redeposition of the native oxide layer within the stir zone. NASA has previously established the allowable time at 48 hours between preweld cleaning and a SRFSW process. The effect of potential 2 contamination resulting from an extended delay to 188 hours was subsequently evaluated for SRFSWs using tensile testing and metallographic imaging. Tensile specimens were tested at room temperature (RT), and at cryogenic conditions of liquid nitrogen (LN2) and liquid hydrogen. No detrimental effect on weld quality, as determined by weld strength, was reported for cleaning delays of 48, 120, 168, 240 or 288 hours. While no trends were established in this study, which extended the delay from 48 to 188 hours, there were a few outliers in terms of ultimate tensile strength (UTS). According to M. Fisher's 2014 Boeing Company Memo no. EYBF-MAF-14-029, all outliers were above the minimum acceptance criteria, but out of family with respect to the average values. As the robustness and reliability of any process ultimately depends on the average values as well as the outliers, an understanding of the cause of these outliers will ultimately improve the process. This report examines those outliers and their possible causes.

Schneider, J. A.↗

DOE OSTI2019

French Innovative Thermal Treatment Processes for The Management Radioactive Organic Liquid Waste - 19017

The nuclear industry as well as hospitals or some research laboratories produce Radioactive Organic Liquid Waste (ROLW) such as scintillation cocktails for medical imaging, labeled molecules for medical research or liquids from former activities. In order to be compatible with disposal facilities requirements, this waste must be inerted and stabilized in solid matrix. The route generally used is incineration in the Centraco facilities at the Marcoule site (Gard, France), ashes produced being cemented downstream. However, liquids whose chemical or radiological characteristics are not compatible with the incinerator operating rules (high level of {sup 14}C or halogen content, corrosive gas production etc.) cannot follow this path. The purpose of the MILOR project is then to propose alternative paths to treat all kinds of ROLW. Initiated in September 2017, this project has the technical objective of developing, over a four-year period, two pilot-scale mineralization processes. Two variants of complementary plasma technologies are evaluated: aerial plasma with the 'IDOHL' process and submerged plasma with the 'ELIPSE' process. Compared with other methods, thermal plasmas have unique characteristics such as rapid decomposition with high throughput, fast startup and shutdown, and high-energy delivery. The process called IDOHL consists of a process involving an induction plasma in which the liquids are directly introduced. It has been designed for organic liquids without mineral load and for treatment rates less than 0.5 l/h. This type of plasma allows the destruction of liquid organohalogens without any prior evaporation or treatment. Specific gas treatment systems have been developed to direct the gas produced to a dry or wet gas treatment system. One aim of the project is to subsequently install the process in a radioactive zone at Saclay DRF. The second called ELIPSE consists of a breakthrough process involving a submerged plasma at the heart of which organic liquids are also introduced. Current research has demonstrated that such a technique may enable the instantaneous and complete destruction of liquids with a wide variety of constituents, such as chlorine, fluorine, or phosphorus. The submersion solution offers many advantages: quenching and cleaning of combustion gases; filtering of the particles they contain; and cooling maintained for the entire process, which guarantees excellent corrosion control. An advantage of this type of design is that the gas treatment system can be reduced to a demister-condenser followed by a simple safety filter, thereby offering the additional advantage of an extremely compact treatment system. This design also allows the ELIPSE process to become by this way an embeddable process if required. The MILOR project, financed by the French State through investment program is a tripartite project bringing together Andra, in charge of radioactive waste management, the CEA in charge of leading scientific and technological researches to propose effective ways of treatment and the company A3i whose role is to ensure the subsequent industrial development. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2017

Spatio-Temporal Data Analysis at Scale Using Models Based on Gaussian Processes

Gaussian processes are the most commonly used statistical model for spatial and spatio-temporal processes that vary continuously. They are broadly applicable in the physical sciences and engineering and are also frequently used to approximate the output of complex computer models, deterministic or stochastic. We undertook research related to theory, computation, and applications of Gaussian processes as well as some work on estimating extremes of distributions for which a Gaussian process assumption might be inappropriate. Our theoretical contributions include the development of new classes of spatial-temporal covariance functions with desirable properties and new results showing that certain covariance models lead to predictions with undesirable properties. To understand how Gaussian process models behave when applied to deterministic computer models, we derived what we believe to be the first significant results on the large sample properties of estimators of parameters of Gaussian processes when the actual process is a simple deterministic function. Finally, we investigated some theoretical issues related to maxima of observations with varying upper bounds and found that, depending on the circumstances, standard large sample results for maxima may or may not hold. Our computational innovations include methods for analyzing large spatial datasets when observations fall on a partially observed grid and methods for estimating parameters of a Gaussian process model from observations taken by a polar-orbiting satellite. In our application of Gaussian process models to deterministic computer experiments, we carried out some matrix computations that would have been infeasible using even extended precision arithmetic by focusing on special cases in which all elements of the matrices under study are rational and using exact arithmetic. The applications we studied include total column ozone as measured from a polar-orbiting satellite, sea surface temperatures over the Pacific Ocean, and annual temperature extremes at a site in New York City. In each of these applications, our theoretical and computational innovations were directly motivated by the challenges posed by analyzing these and similar types of data.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS2022

Pre- and Post-Production Processes Increasingly Dominate Greenhouse Gas Emissions From Agri-Food Systems

We present results from the FAOSTAT emissions shares database, covering emissions from agri-food systems and their shares to total anthropogenic emissions for 196 countries and 40 territories for the period 1990–2019. We find that in 2019, global agri-food system emissions were 16.5 (95 %; CI range: 11–22) billion metric tonnes (GtCO2 eq. yr(exp -1)), corresponding to 31%(range: 19 %–43 %) of total anthropogenic emissions. Of the agri-food system total, global emissions within the farm gate – from crop and livestock production processes including on-farm energy use – were 7.2 GtCO2 eq. yr(exp -1); emissions from land use change, due to deforestation and peatland degradation, were 3.5 GtCO2 eq. yr(exp -1); and emissions from pre- and post-production processes – manufacturing of fertilizers, food processing, packaging, transport, retail, household consumption and food waste disposal – were 5.8 GtCO2 eq. yr(exp -1). Over the study period 1990–2019, agri-food system emissions increased in total by 17 %, largely driven by a doubling of emissions from pre- and post-production processes. Conversely, the FAOSTAT data show that since 1990 land use emissions decreased by 25 %, while emissions within the farm gate increased 9 %. In 2019, in terms of individual greenhouse gases (GHGs), pre- and postproduction processes emitted the most CO2 (3.9 GtCO2 yr(exp -1)), preceding land use change (3.3 GtCO2 yr(exp -1)) and farm gate (1.2 GtCO2 yr(exp -1)) emissions. Conversely, farm gate activities were by far the major emitter of methane (140 MtCH4 yr(exp -1)) and of nitrous oxide (7.8 MtN2Oyr(exp -1)). Pre- and post-production processes were also significant emitters of methane (49 MtCH4 yr(exp -1)), mostly generated from the decay of solid food waste in landfills and open dumps. One key trend over the 30-year period since 1990 highlighted by our analysis is the increasingly important role of food-related emissions generated outside of agricultural land, in pre- and post-production processes along the agri-food system, at global, regional and national scales. In fact, our data show that by 2019, pre- and post-production processes had overtaken farm gate processes to become the largest GHG component of agri-food system emissions in Annex I parties (2.2 GtCO2 eq. yr(exp -1)). They also more than doubled in non-Annex I parties (to 3.5 GtCO2 eq. yr(exp -1)), becoming larger than emissions from land use change. By 2019 food supply chains had become the largest agri-food system component in China (1100 MtCO2 eq. yr(exp -1)), the USA (700 MtCO2 eq. yr(exp -1)) and the EU-27 (600 MtCO2 eq. yr(exp -1)). This has important repercussions for food-relevant national mitigation strategies, considering that until recently these have focused mainly on reductions of non-CO2 gases within the farm gate and on CO2 mitigation from land use change. The information used in this work is available as open data with DOI https://doi.org/10.5281/zenodo.5615082 (Tubiello et al., 2021d). It is also available to users via the FAOSTAT database (https://www.fao.org/faostat/en/#data/EM; FAO, 2021a), with annual updates.

FAOSTAT agri-food systems emissions database↗

DOE OSTI2026

Quantitative characterization of gradient microstructures: A study on friction stir spot processing of pure cobalt

Heterogeneous microstructures in polycrystalline metals can enhance the strength and ductility, outperforming homogeneous structures of similar composition. This study investigates deformed cobalt via friction stir spot processing with varying dwell times to uncover the effects of plastic deformation and heat generation on the formation of morphological, phase, and grain boundary character gradients. A new approach to quantify the morphological gradients in materials, which describes grain morphology in terms of density followed by parametric regression, enables direct quantification of processing depth and gradient sharpness. Results show that longer processing times increase the steepness of morphological gradients and reduce the deformation depth for friction stir spot processing with low plunge depths and high tool rotational speeds. The amount of retained FCC is increased in the shorter processing conditions, primarily due to refined grain size, increased defect content, and reduced heat generation. Crystallographic texture analysis of the HCP phase indicated a dominant B-fiber described by (0001) ∥ shear plane normal in the extreme processing conditions and the formation of a P-fiber, shear direction ∥ ⟨11$\bar2$0⟩ for intermediate dwell times. The texture of the FCC phase for low processing times was a C texture {100}⟨011⟩ where longer processing times were dominated by a [001] fiber texture with a main {110}⟨100⟩ orientation and emergence of a slight [111] fiber in the longest processing condition. The approaches outlined in this work give insight into quantifying gradients and improve the understanding of highly deformed cobalt.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Multi-criteria group decision-making based sustainability measurement of wastewater treatment processes

There are various processes which can be used for wastewater treatment (WT), and the selection of the most sustainable one among different processes is a hard task. This study aims at helping the decision-makers (DM) to address this by developing an intuitionistic fuzzy set (IFS) theory based group multi-attribute decision analysis (MADA) method. Ten criteria in environment, economy, society-politic, and technology dimensions were employed to achieve sustainability measurement (SM) of WT processes. The multi-criteria sustainability assessment method developed in this study allow different experts to attend the SM, and enable the participants to employ the natural language/words to depict their intuitionistic opinions. Accordingly, the proposed method can achieve group SM under uncertainties. An illustrative case including four processes for wastewater treatment, namely Anaerobic-Anoxic-Oxic (AAO) process, Triple Oxidation Ditch (TOD) process, Anaerobic single-ditch oxidation (ASD) process, and Sequencing batch reactor activated sludge process (SBR), has been studied, and the results reveal that this method can determine sustainability sequence of different WT processes.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2017

Municipal solid waste processing and separation employing wet torrefaction for alternative fuel production and aluminum reclamation

Highlights: • The MSW treatment and separation based on wet torrefaction process are proposed. • The organic and plastic fraction of MSW can be separated at a low temperature. • The process can detach the aluminum and plastics layer of laminated aluminum waste. • The addition of acid in the wet torrefaction process enhances aluminum yields. • The calorific values of the both organic and plastics products are increased. - Abstract: This study employs wet torrefaction process (also known as hydrothermal) at low temperature. This process simultaneously acts as waste processing and separation of mixed waste, for subsequent utilization as an alternative fuel. The process is also applied for the delamination and separation of non-recyclable laminated aluminum waste into separable aluminum and plastic. A 2.5-L reactor was used to examine the wet torrefaction process at temperatures below 200 °C. It was observed that the processed mixed waste was converted into two different products: a mushy organic part and a bulky plastic part. Using mechanical separation, the two products can be separated into a granular organic product and a plastic bulk for further treatment. TGA analysis showed that no changes in the plastic composition and no intrusion from plastic fraction to the organic fraction. It can be proclaimed that both fractions have been completely separated by wet torrefaction. The separated plastic fraction product obtained from the wet torrefaction treatment also contained relatively high calorific value (approximately 44 MJ/kg), therefore, justifying its use as an alternative fuel. The non-recyclable plastic fraction of laminated aluminum was observed to be delaminated and separated from its aluminum counterpart at a temperature of 170 °C using an additional acetic acid concentration of 3%, leaving less than 25% of the plastic content in the aluminum part. Plastic products from both samples had high calorific values of more than 30 MJ/kg, which is sufficient to be converted and used as a fuel.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2014

The s-process enrichment of the globular clusters M4 and M22

We investigate the enrichment in elements produced by the slow neutron-capture process (s-process) in the globular clusters M4 (NGC 6121) and M22 (NGC 6656). Stars in M4 have homogeneous abundances of Fe and neutron-capture elements, but the entire cluster is enhanced in s-process elements (Sr, Y, Ba, Pb) relative to other clusters with a similar metallicity. In M22, two stellar groups exhibit different abundances of Fe and s-process elements. By subtracting the mean abundances of s-poor from s-rich stars, we derive s-process residuals or empirical s-process distributions for M4 and M22. We find that the s-process distribution in M22 is more weighted toward the heavy s-peak (Ba, La, Ce) and Pb than M4, which has been enriched mostly with light s-peak elements (Sr, Y, Zr). We construct simple chemical evolution models using yields from massive star models that include rotation, which dramatically increases s-process production at low metallicity. We show that our massive star models with rotation rates of up to 50% of the critical (break-up) velocity and changes to the preferred {sup 17}O(α, γ){sup 21}Ne rate produce insufficient heavy s-elements and Pb to match the empirical distributions. For models that incorporate asymptotic giant branch yields, we find that intermediate-mass yields (with a {sup 22}Ne neutron source) alone do not reproduce the light-to-heavy s-element ratios for M4 and M22, and that a small contribution from models with a {sup 13}C pocket is required. With our assumption that {sup 13}C pockets form for initial masses below a transition range between 3.0 and 3.5 M {sub ☉}, we match the light-to-heavy s-element ratio in the s-process residual of M22 and predict a minimum enrichment timescale of between 240 and 360 Myr. Our predicted value is consistent with the 300 Myr upper limit age difference between the two groups derived from isochrone fitting.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2015

The r-process nucleosynthesis in the various jet-like explosions of magnetorotational core-collapse supernovae

The r-process nucleosynthesis in core-collapse supernovae (CC-SNe) is studied, with a focus on the explosion scenario induced by rotation and strong magnetic fields. Nucleosynthesis calculations are conducted based on magneto-hydrodynamical explosion models with a wide range of parameters for initial rotation and magnetic fields. The explosion models are classified in two different types: prompt-magnetic-jet and delayed-magnetic-jet, for which the magnetic fields of proto-neutron stars (PNSs) during collapse and the core-bounce are strong and comparatively moderate, respectively. Following the hydrodynamical trajectories of each explosion model, we confirmed that r-processes successfully occur in the prompt-magnetic-jets, which produce heavy nuclei including actinides. On the other hand, the r-process in the delayed-magnetic-jet is suppressed, which synthesizes only nuclei up to the second peak (A∼130). Thus, the r-process in the delayed-magnetic-jets could explain only “weak r-process” patterns observed in metal-poor stars rather than the “main r-process,” represented by the solar abundances. Our results imply that CC-SNe are possible astronomical sources of heavy r-process elements if their magnetic fields are strong enough, while weaker magnetic explosions may produce “weak r-process” patterns (A≲130). We show the potential importance and necessity of magneto-rotational SNe for explaining the galactic chemical evolution, as well as abundances of r-process enhanced metal-poor stars. We also examine the effects of the remaining uncertainties in the nature of PNSs due to weak interactions that determine the final neutron-richness of ejecta. Additionally, we briefly discuss radioactive isotope yields in primary jets (e.g., {sup 56}Ni), with relation to several optical observation of SNe and relevant high-energy astronomical phenomena.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2016

TU-FG-209-11: Validation of a Channelized Hotelling Observer to Optimize Chest Radiography Image Processing for Nodule Detection: A Human Observer Study

Purpose: To validate the use of a Channelized Hotelling Observer (CHO) model for guiding image processing parameter selection and enable improved nodule detection in digital chest radiography. Methods: In a previous study, an anthropomorphic chest phantom was imaged with and without PMMA simulated nodules using a GE Discovery XR656 digital radiography system. The impact of image processing parameters was then explored using a CHO with 10 Laguerre-Gauss channels. In this work, we validate the CHO’s trend in nodule detectability as a function of two processing parameters by conducting a signal-known-exactly, multi-reader-multi-case (MRMC) ROC observer study. Five naive readers scored confidence of nodule visualization in 384 images with 50% nodule prevalence. The image backgrounds were regions-of-interest extracted from 6 normal patient scans, and the digitally inserted simulated nodules were obtained from phantom data in previous work. Each patient image was processed with both a near-optimal and a worst-case parameter combination, as determined by the CHO for nodule detection. The same 192 ROIs were used for each image processing method, with 32 randomly selected lung ROIs per patient image. Finally, the MRMC data was analyzed using the freely available iMRMC software of Gallas et al. Results: The image processing parameters which were optimized for the CHO led to a statistically significant improvement (p=0.049) in human observer AUC from 0.78 to 0.86, relative to the image processing implementation which produced the lowest CHO performance. Conclusion: Differences in user-selectable image processing methods on a commercially available digital radiography system were shown to have a marked impact on performance of human observers in the task of lung nodule detection. Further, the effect of processing on humans was similar to the effect on CHO performance. Future work will expand this study to include a wider range of detection/classification tasks and more observers, including experienced chest radiologists.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2017

Processing of Ice Cloud In Situ Data Collected by Bulk Water, Scattering, and Imaging Probes: Fundamentals, Uncertainties, and Efforts toward Consistency

Abstract In situ observations of cloud properties made by airborne probes play a critical role in ice cloud research through their role in process studies, parameterization development, and evaluation of simulations and remote sensing retrievals. To determine how cloud properties vary with environmental conditions, in situ data collected during different field projects processed by different groups must be used. However, because of the diverse algorithms and codes that are used to process measurements, it can be challenging to compare the results. Therefore it is vital to understand both the limitations of specific probes and uncertainties introduced by processing algorithms. Since there is currently no universally accepted framework regarding how in situ measurements should be processed, there is a need for a general reference that describes the most commonly applied algorithms along with their strengths and weaknesses. Methods used to process data from bulk water probes, single-particle light-scattering spectrometers and cloud-imaging probes are reviewed herein, with emphasis on measurements of the ice phase. Particular attention is paid to how uncertainties, caveats, and assumptions in processing algorithms affect derived products since there is currently no consensus on the optimal way of analyzing data. Recommendations for improving the analysis and interpretation of in situ data include the following: establishment of a common reference library of individual processing algorithms, better documentation of assumptions used in these algorithms, development and maintenance of sustainable community software for processing in situ observations, and more studies that compare different algorithms with the same benchmark datasets.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2016

RELATIVE CONTRIBUTIONS OF THE WEAK, MAIN, AND FISSION-RECYCLING r-PROCESS

There has been a persistent conundrum in attempts to model the nucleosynthesis of heavy elements by rapid neutron capture (the r-process). Although the locations of the abundance peaks near nuclear mass numbers 130 and 195 identify an environment of rapid neutron capture near closed nuclear shells, the abundances of elements just above and below those peaks are often underproduced by more than an order of magnitude in model calculations. At the same time, there is a debate in the literature as to what degree the r-process elements are produced in supernovae or the mergers of binary neutron stars. In this paper we propose a novel solution to both problems. We demonstrate that the underproduction of nuclides above and below the r-process peaks in main or weak r-process models (like magnetohydrodynamic jets or neutrino-driven winds in core-collapse supernovae) can be supplemented via fission fragment distributions from the recycling of material in a neutron-rich environment such as that encountered in neutron star mergers (NSMs). In this paradigm, the abundance peaks themselves are well reproduced by a moderately neutron-rich, main r-process environment such as that encountered in the magnetohydrodynamical jets in supernovae supplemented with a high-entropy, weakly neutron-rich environment such as that encountered in the neutrino-driven-wind model to produce the lighter r-process isotopes. Moreover, we show that the relative contributions to the r-process abundances in both the solar system and metal-poor stars from the weak, main, and fission-recycling environments required by this proposal are consistent with estimates of the relative Galactic event rates of core-collapse supernovae for the weak and main r-process and NSMs for the fission-recycling r-process.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2023

HD 222925: A New Opportunity to Explore the Astrophysical and Nuclear Conditions of r-process Sites

Abstract With the most trans-iron elements detected of any star outside the solar system, HD 222925 represents the most complete chemical inventory among metal-poor stars enhanced with elements made by the rapid neutron capture (“ r ”) process. As such, HD 222925 may be a new “template” for the observational r -process, where before the (much higher-metallicity) solar r -process residuals were used. In this work, we test under which conditions a single site accounts for the entire elemental r -process abundance pattern of HD 222925. We found that several of our tests—with the single exception of the black hole–neutron star merger case—challenge the single-site assumption by producing an ejecta distribution that is highly constrained, in disagreement with simulation predictions. However, we found that ejecta distributions that are more in line with simulations can be obtained under the condition that the nuclear data near the second r -process peak are changed. Therefore, for HD 222925 to be a canonical r -process template likely as a product of a single astrophysical source, the nuclear data need to be reevaluated. The new elemental abundance pattern of HD 222925—including the abundances obtained from space-based, ultraviolet (UV) data—call for a deeper understanding of both astrophysical r -process sites and nuclear data. Similar UV observations of additional r -process–enhanced stars will be required to determine whether the elemental abundance pattern of HD 222925 is indeed a canonical template (or an outlier) for the r -process at low metallicity.

79 ASTRONOMY AND ASTROPHYSICS↗

NASA NTRSDate not supplied

Robust Metal Additive Manufacturing Process Selection and Development for Aerospace Components

Metal additive manufacturing (AM) is a generic term that captures a variety of fabrication techniques. Each of these manufacturing process has unique advantages, applications for use, and challenges. The most common AM processes in use include Powder Bed Fusion (PBF) and Directed Energy Deposition (DED) as well as many solid state processes. While detailed research has been conducted among many of the processes including parameters and material properties, navigating which processes are best to select is difficult as it is based on component requirements. The focus of this presentation is to provide an overview of considerations for each of metal AM process selection for aerospace components based on various attributes. These attributes include geometric considerations, metallurgical characteristics, cost basis, post-processing and maturity of the processes. The data for these trade selections are based on studies that NASA as performed internally and with academic and industry partners. These studies include multiple AM build experiments to evaluate (1) geometric variations and constraints within the processes, (2) alloy characterization and mechanical testing, (3) pathfinder component development and hotfire evaluations, and (4) certification approaches. This presentation summarizes these results and meant to introduce various considerations when designing a metal AM component.

Additive Manufacturing↗

NASA NTRSDate not supplied

NASA CARA Prelaunch Analysis and Process

NASA implemented an official Procedural Requirement (NPR) 8079.1 in June 2023, establishing the minimum collision avoidance requirements and associated operational protocols for NASA space flight programs, projects, and spacecraft to protect the space environment by reducing the risk of collision to an acceptable level. Part of the requirement employs a two-fold approach to analyze the satellite design process with conjunction assessment and risk mitigation in mind, during the pre-launch process, led by the Conjunction Assessment Risk Analysis (CARA) Program for non-Human Space Flight (HSF) Missions. This presentation outlines CARA coordination with missions, informed by the NPR, that spans early mission development to operations. CARA is an Agency-level resource that provides support to all NASA non-HSF missions. CARA protects the orbital environment from collision between NASA non-HSF missions and other tracked on-orbit objects. During the pre-formulation and formulation phases, NASA missions undergo a series of conjunction assessment analyses captured in the Orbital Collision Avoidance Plan (OCAP) prior to transitioning to the implementation phase (typically at the Preliminary Design Review (PDR) or equivalent). The OCAP analyses consist of a thorough review of the spacecraft(s) orbit selection and placement, deployment, cataloguing performance, trackability, ephemeris generation, conjunction mitigation options, autonomous maneuvering, and risk assessment parameters which are performed by a dedicated CARA Analysis Team. The results of these analyses, CARA’s formal recommendations, and the mission’s methods for implementing them, are documented in the OCAP. The intent of engaging in this process so early in the mission design phase, is to ensure that conjunction assessment is considered from the outset, thus mitigating costly design changes and operational risks down the road. NASA missions are also required to coordinate their operational processes and conjunction mitigation procedures with CARA in a Conjunction Assessment Operations Implementation Agreement (CAOIA). The aim of this process is to document the conjunction assessment screening process, conjunction risk assessment parameters, conjunction mitigation steps, flight dynamics operations concepts and maneuvers, and the communication and coordination process between the mission’s project manager and CARA. The intent of the CAOIA document is for it to be completed iteratively, and as missions update these elements, corresponding changes are made in the CAOIA. With this process in place, the engagement and coordination between the missions and CARA from early in the design process into mission operations, helps to ensure that missions not only have a robust conjunction assessment concept of operations to reduce conjunction risk for space sustainability, but are also able to achieve their science goals and have a successful mission.

conjunction assessment↗

NASA NTRSDate not supplied

NASA CARA Prelaunch Analysis and Process

conjunction assessment↗

DOE OSTI2021

TEA Modeling to Quantify Economic Implications for Biorefinery Processing of Isolated Anatomical Fractions of Corn Stover

The Feedstock-Conversion Interface Consortium (FCIC; https://www.energy.gov/sites/prod/files/2020/01/f70/beto-fcic-overview-web.pdf), a collaboration of nine national laboratory partners, seeks to understand impacts of feedstock attributes on biorefinery performance. It is hypothesized that different individual anatomical fractions of corn stover vary in composition and recalcitrance, such that processing each fraction on its own through dedicated campaigns may enable better biorefinery economics overall relative to processing the whole stover material. This presentation focuses on techno-economic analysis (TEA) modeling to quantify the yield and cost ramifications for processing isolated anatomical fractions of corn stover through a low-temperature conversion biorefinery, reflecting a biochemical processing pathway consisting of biomass deconstruction through pretreatment and enzymatic hydrolysis, sugar fermentation and upgrading to hydrocarbon fuels, and lignin upgrading to value-added coproducts. Commercial-scale process simulation and economic evaluation leveraged experimental and analytical data from FCIC researchers for conversion of whole corn stover plus three individual anatomical fractions (cobs, husks, and stalks) across key steps of the conversion process. Our assessment found encouraging potential for biorefinery economic gains that may be achieved through this approach. TEA results indicated fuel yields varying from 29-44 gallons gasoline equivalent (GGE)/dry ton for the individual anatomical fractions compared to whole stover at 34 GGE/ton, equating to minimum fuel selling prices (MFSPs) between $6.37-$10.18/GGE for the fractions versus $8.76/GGE for whole stover (when lignin is burned), or $9.15-$15.19/GGE for the fractions versus $13.11/GGE for whole stover (when lignin is upgraded to coproducts, based on current experimental performance levels). Cobs and husks demonstrated the ability to achieve the highest fuel yields and lowest MFSPs, outperforming whole stover, while stalks led to the opposite result, as a composite reflection of compositional differences and process convertibility. Notably, even when taking the weighted average of the results reflecting each anatomical fraction weighted by its corresponding makeup of corn stover, this feasibility TEA screening supports feedstock cost allowances on the order of roughly $22-$29/ton as may reflect accommodating additional biomass fractionation equipment during feedstock pre-processing upstream of the conversion biorefinery gate to separate corn stover into such constituent fractions. Or viewed differently, the weighted average MFSP for the fractions was found to be $0.31-$0.32/GGE lower than the MFSP for the whole stover basis across either lignin scenario, when maintaining a fixed biomass feedstock cost. These findings highlight favorable implications for biorefinery economics as may be achieved by moving to a staged campaign approach for processing different corn stover fractions sequentially. Further opportunities exist for future work to fill in data gaps for remaining anatomical constituents (e.g. leaves) that were not included in the initial experimental studies, though are expected to maintain similar trends.

biochemical processing pathway↗

DOE OSTI2017

Implementation of Glycolic Acid Flowsheet in the Defense Waste Processing Facility (DWPF) - 17348

The disposition of high level waste (HLW) into canistered waste forms began at Savannah River Site (SRS) in 1996. For its entire processing history, DWPF has added formic acid as a pretreatment step in producing acceptable melter feed from incoming waste sludges sent from the HLW Tank Farms. While this process has been used to successfully produce more than 4,000 radioactive canisters, the addition of formic acid and its tendency to catalytically decompose in the presence of trace quantities of noble metals adds substantial process complexity in order to safely accommodate hydrogen generation and pH shifting during batch operations. Research efforts have been in progress for several years to identify a chemical surrogate for formic acid which performs the essential process functions without the associated negative consequences. The final analytical work to demonstrate the effectiveness of glycolic acid in the DWPF is nearly complete and a project team has been created to safely integrate the new acid into the chemical process. The project team is currently executing an implementation schedule which addresses safety basis development, revision to operations procedures and training, facility modifications, chemical procurement, and updated process monitoring. Introduction of glycolic acid into DWPF is currently scheduled to take place in early 2017, beginning with a blended flowsheet of glycolic and formic acid and ultimately transitioning to glycolic-only processing. This paper provides an overview of planned glycolic acid flowsheet implementation in the DWPF. This paper discusses several issues related to implementing such a significant change to the chemical process including: 1) Process chemistry differences between the two flowsheets with quantitative comparison for several properties of interest; 2) Technical approach to hazards analysis and safety basis development strategy; 3) Status of project execution for major deliverables; and 4) Path forward for facility modifications related to legacy formic acid support equipment. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗