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DOE OSTI2025

Portable Distortion Free Large Solid Angle Coverage Detector

Neutron single crystal diffractometers require large solid angle coverage for optimum performance. This can be achieved by tiling flat detectors in a cylindrical or spherical geometry, but results in large gaps in detector coverage and parallax distortion. The detector edges exhibit degraded resolution, distortion, and gamma rejection. Since the detector edge regions are a significant fraction of the detector active area, they must be removed from the experimental data set, requiring extra beam time to collect enough analysis data. A spherical detector with a continuous surface would effectively address this issue while eliminating most boundary ‘dead’ areas. Here we report on the development of a novel hemispherical shaped neutron detector using seamlessly tiled readout modules to form the desired shape. The heart of the detector is a specially developed curved neutron scintillator coupled to high resolution silicon photomultiplier (SiPM) Anger cameras via custom made fiber optic tapers (FOTs). The detector has been assembled and initial tests have been conducted at the High Flux Isotope Reactor (HFIR) beamlines at Oak Ridge National Laboratory (ORNL). Here, in this work, we describe details of the scintillator design, fabrication and characterization, evaluation of individual detector modules, the details of the detector design implementation, and evaluation of the assembled detector at ORNL beamlines.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS1992

Design and testing of the Space Station Freedom Propellant Tank Assembly

Propellant storage and management functions for the Propulsion Module of the U.S. Space Station Freedom are provided by the Propellant Tank Assembly (PTA). The PTA consists of a surface-tension type propellant acquisition device contained within a welded titanium pressure vessel. The PTA design concept was selected with high reliability and low program risk as primary goals in order to meet stringent NASA structural, expulsion, fracture control and reliability requirements. The PTA design makes use of Shuttle Orbital Maneuvering System and Peacekeeper Propellant Storage Assembly design and analysis techniques. This paper summarizes the PTA design solution and discusses the underlying detailed analyses. In addition, design verification and qualification test activities are discussed.

Dudley, D. D.↗

NASA NTRS2008

Failure Analysis Study and Long-Term Reliability of Optical Assemblies with End-Face Damage

In June 2005, the NESC received a multi-faceted request to determine the long term reliability of fiber optic termini on the ISS that exhibited flaws not manufactured to best workmanship practices. There was a lack of data related to fiber optic workmanship as it affects the long term reliability of optical fiber assemblies in a harsh environment. A fiber optic defect analysis was requested which would find and/or create various types of chips, spalls, scratches, etc., that were identified by the ISS personnel. Once the defects and causes were identified the next step would be to perform long term reliability testing of similar assemblies with similar defects. The goal of the defect analysis would be for the defects to be observed and documented for deterioration of fiber optic performance. Though this report mostly discusses what has been determined as evidence of poor manufacturing processes, it also concludes the majority of the damage could have been avoided with a rigorous process in place.

Kichak, Robert A.↗

DOE OSTI2025

Investigating the effect of screen-printed structured graphite electrodes with low tortuosity for high-capacity and fast-charging lithium-ion batteries

A flexible screen-printed graphite electrode was fabricated as an anode for developing fast-charging lithium-ion batteries with low tortuosity. A homogenous anode ink was prepared by mixing graphite as the active material, carbon black (C45) as the conductive additive, and polyvinylidene fluoride (PVDF) as the binder in N-Methyl-2-pyrrolidone (NMP) solvent. The ink was deposited on a flexible copper foil via a stainless-steel screen consisting of an array of pores, that act as secondary pore networks (SPNs), using the screen-printing process. Lithium-ion battery half-cells were assembled using the printed graphite anode, lithium metal foil as the counter electrode, and 1.2 M lithium hexafluorophosphate (LiPF 6 ) in ethyl carbonate: ethyl methyl carbonate (EC: EMC = 3:7) as the electrolyte. The effect of SPNs on the cell performance was investigated by performing formation, rate and cycling tests on the assembled cells, at different C-rates. It was observed that the cells consisting of SPNs with a pore size of 100 μm and edge-to-edge distance of 100 μm between the pores exhibited significantly higher specific capacities of 168 and 129 mAh/g when compared to reference cells without SPNs, which had capacities of 120 and 85 mAh/g, at high C-rates of 4 C and 6 C, respectively. The cells with SPNs also demonstrated excellent cycling performance with ~ 95% capacity retention after 100 cycles at 2 C.

Fast charging lithium-ion battery↗

DOE OSTI2020

Reduction of CO 2 Emissions Through Lightweight Body Panels (Project Final Report)

Lightweight construction is an integral part of Volkswagen’s overall strategy of reducing CO 2 emissions. Due to its low cost, steel is the most commonly used material for automotive exterior body panels today. Unfortunately, steel has a high density, resulting in a relatively low specific strength. Glass fiber based sheet molding compounds (SMC) provide high properties in combination with lower density. The high specific strength of SMC offers an enormous lightweight potential. To unlock the full potential of SMC materials in combination with cutting edge manufacturing processes, Volkswagen Group of America worked together with IACMI (Institute for Advanced Composites Manufacturing Innovation) and the academic partners: University of Tennessee Knoxville, Purdue University and Michigan State University; as well as the industry partners: Ashland, IDI, Owens Corning and Continental Structural Plastics. Leveraging the expertise of all project partners, reaching over the entire supply chain the project demonstrated the potential of these materials. This report will highlight the major steps in the development process on the way to technology readiness for SMC using the example of the Volkswagen Atlas Liftgate. Over the 36-month period of the project, the work focused on three R&D areas: material development, design and simulation, and development of the manufacturing process. Material selection included alternative fibers and resin systems, and accounted for material availability, properties, and cost-efficiency. The work undertaken in the field of design and simulation has pushed the envelope of short fiber reinforced thermoset molding compound process simulation. Design iterations were virtually tested, while the final design was used to validate the simulation software against physical parts. Manufacturing development used cutting-edge technology, while experts along the supply chain were working together to ensure the best possible results. In the final stage of the project, liftgates were molded, trimmed, bonded, painted and assembled before exhaustive testing. The result is an e-coat (electrophoretic dip coating) capable Class-A SMC liftgate, which is ready for high-volume production, and can be used as a technology demonstrator. The prototypes manufactured in the scope of this work have exhibited a mass reduction for the Volkswagen Atlas liftgate of up to 35% compared to the series production steel version, without a degradation of the functionalities.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Test Capabilities of the NASA Langley Direct Connect Supersonic Combustion Test Facility with Historical Perspective

In 1969, a combustion-heated direct-connect test facility was assembled at the NASA Langley Research Center to conduct basic research in ramjet and scramjet propulsion systems. The facility was initially used in assessing the mixing, ignition, flame holding, and combustion characteristics of various ramjet and scramjet combustors. Over the years, the facility was updated and modified to conduct increasingly longer and more complicated tests. Today, the facility is known as the Direct Connect Supersonic Combustion Test Facility and is part of the NASA Langley Scramjet Test Complex. More recently, the facility has been used by external customers to test fuel-cooled and uncooled, flight-like test articles. Tests have been conducted at ramjet flight conditions for up to 15 minutes of continuous operation. Even though the facility is nearly 50 years old, it remains a viable and useful tool in the support of various U.S. hypersonic programs.

direct connect test facility↗

NASA NTRSDate not supplied

SLS First Flight: Assessment of Artemis-I Motor Performance

NASA’s Artemis-I mission, which launched from Kennedy Space Center on November 16, 2022 and lasted 25 days, was the first flight test of the new Space Launch System vehicle as well as its twin solid rocket boosters. This flight test was the culmination of many years of development, testing, construction, and assembly completed by NASA and a large consortium of corporate partners, including Northrop Grumman. The solid rocket boosters are updated five-segment versions of those used during the Space Shuttle program, re-designed to provide enhanced performance and lifting capability. Booster motor performance had been characterized over the course of seven ground static tests conducted between 2009 and 2022, including three development tests, two qualification tests, and two supplemental flight support tests. The Artemis-I flight provided the first opportunity to assess solid rocket motor performance in a flight environment for any potential flight-ground biases and to ensure that measured flight performance was within requirement and analytical model limits and expectations.

Nikolas Ciaston↗

DOE OSTI2024

Microstructural Coarsening Kinetics and Mechanical Property Changes in Long-Term Aged Sn–Pb–Sb Solder Joints

Tin-lead-antimony (50Sn–47Pb–3Sb wt.%) soldered assemblies were mechanically tested approximately 30 years after initial production and found to have solder joints of reduced strength. The microstructure of this solder alloy exhibits a ternary eutectic structure with Sn-rich, Pb-rich, and SnSb phases. Accelerated aging was performed to evaluate solder microstructural coarsening and associated strength of laboratory solder joints to correlate these properties to the “naturally aged” solder joints. Isothermal aging was conducted at room temperature, 55, 70, 100, and 135 °C and aging times that ranged from 0.1 to 365 days. The coarsening kinetics of the Pb-rich phase were determined through optical microscopy and image analysis methods established in previous studies on binary Sn–Pb solder. A kinetic equation was developed with time exponent n of 0.43 and activation energy of 24000 J/mol, suggesting grain boundary diffusion or other fast diffusion pathways controlling the microstructural evolution. Compression testing and Vickers microhardness showed significant strength loss within the first 20–30 days after soldering; then, the microstructure and mechanical properties changed more slowly over long periods of time. Further, by combining accelerated aging data and the microstructure-based kinetics, strength predictions were made that match well with the properties of the actual soldered assemblies naturally aged for 30 years. However, aging at the highest temperature of 135 °C produced anomalous behavior suggesting that extraneous aging mechanisms are active. Therefore, data obtained at this temperature or higher should not be used. Overall, the combined microstructural and mechanical property methods used in this study confirmed that the observed reduction in strength of ~ 30-year-old solder joints can be accounted for by the microstructural coarsening that takes place during long-term solid-state aging.

36 MATERIALS SCIENCE↗

NASA NTRS1973

Fabrication of capsule assemblies, phase 3

Thirteen capsule assemblies were fabricated for evaluation of fuel pin design concepts for a fast spectrum lithium cooled compact space power reactor. These instrumented assemblies were designed for real time test of prototype fuel pins. Uranium mononitride fuel pins were encased in AISI 304L stainless steel capsules. Fabrication procedures were fully qualified by process development and assembly qualification tests. Instrumentation reliability was achieved utilizing specially processed and closely controlled thermocouple hot zone fabrication and by thermal screening tests. Overall capsule reliability was achieved with an all electron beam welded assembly.

Keeton, A. R.↗

NASA NTRSDate not supplied

Test Capabilities of the NASA Langley Direct Connect Supersonic Combustion Test Facility

In 1969 a combustion-heated direct-connect test facility was assembled at the NASA Langley Research Center and used to support NASA’s Hypersonic Research Engine program. Later, the facility was used to support NASA’s generic hypersonic program, assessing the mixing, ignition, flame holding, and combustion characteristics of ramjet and scramjet combustors. Over the years, the facility has been updated and modified to conduct increasingly complicated tests. Today, the facility is known as the Direct Connect Supersonic Combustion Test Facility (DCSCTF) and is part of the NASA Langley Scramjet Test Complex. Recently, the facility has been used by external customers to test fuel-cooled and uncooled, flight-like test articles. Tests have been conducted at nominal Mach 5 flight conditions for up to 15 minutes of continuous operation. The facility remains a viable and useful tool in the support of various Department of Defense projects.

Diego P Capriotti↗

NASA NTRS2014

Power, Avionics and Software - Phase 1.0:

This report describes Power, Avionics and Software (PAS) 1.0 subsystem integration testing and test results that occurred in August and September of 2013. This report covers the capabilities of each PAS assembly to meet integration test objectives for non-safety critical, non-flight, non-human-rated hardware and software development. This test report is the outcome of the first integration of the PAS subsystem and is meant to provide data for subsequent designs, development and testing of the future PAS subsystems. The two main objectives were to assess the ability of the PAS assemblies to exchange messages and to perform audio testing of both inbound and outbound channels. This report describes each test performed, defines the test, the data, and provides conclusions and recommendations.

Communiocations↗

NASA NTRS2017

Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER)

Abstract: NASA is currently investigating methods to reduce the boil-off rate on large cryogenic upper stages. Two such methods to reduce the total heat load on existing upper stages are vapor cooling of the cryogenic tank support structure and integration of thick multilayer insulation systems to the upper stage of a launch vehicle. Previous efforts have flown a 2-layer MLI blanket and shown an improved thermal performance, and other efforts have ground-tested blankets up to 70 layers thick on tanks with diameters between 2 3 meters. However, thick multilayer insulation installation and testing in both thermal and structural modes has not been completed on a large scale tank. Similarly, multiple vapor cooled shields are common place on science payload helium dewars; however, minimal effort has gone into using boil-off to intercept heat on large structural surfaces associated with rocket stages. A majority of the vapor cooling effort focuses on metallic cylinders called skirts, which are the most common structural components for launch vehicles. In order to provide test data for comparison with analytical models, a 4 meter diameter test tank and assembly is currently being designed to include skirt structural systems with integral vapor cooling. In order to give a more representative result for actual applications, the technologies will be designed for an 8.4 m and scaled down to a 4 meter tank. In order to prove that the insulation system and vapor cooling attachment methods are structurally sound, acoustic testing will also be performed on the system. The test tank with insulation and vapor cooled shield installed will be tested thermally in the B2 test facility at NASAs Plum Brook Station both before and after being vibration tested at Plum Brooks Space Power Facility.

Johnson, Wesley↗

NASA NTRSDate not supplied

LISA EDU Status

LISA will be the first space-based gravitational wave observatory, enabling orders of magnitude greater sensitivity than the state-of-the-art LIGO facility. L3Harris is developing an engineering development unit (EDU) telescope in support of NASA, ESA and the LISA Consortium. The LISA EDU telescope validates a flight-like telescope design and reduces risks associated with stability, materials, assembly, integration, and testing. Mission requirements are unlike any other and require picometer-level stability across the entire telescope’s beam path, even in the presence of temperature variation and jitter. As a result, an all-glass telescope design was developed. The brittle structure represents a new state of the art for stable telescopes, but also introduces challenges with managing assembly, manufacturability, and survivability. From 2019-2024, the LISA EDU project has increased manufacturing readiness and technology readiness for the optical telescope element.

Brian VanRensselaer↗

NASA NTRS2022

Pre-Installation Acceptance (PIA) Functional Performance of the Design Verification Test (DVT) Exploration Extra-vehicular Mobility Unit (xEMU)

In an effort that began with technology investment by NASA in a few key components during the Constellation Program and then evolved to demonstrate a packaged Portable Life Support System (PLSS) as part of the Advanced Exploration Systems (AES) Program, the next evolution of the PLSS is now a key component of the Exploration Extra-vehicular Mobility Unit (xEMU) and is assembled as a Design Verification Test (DVT) unit. The xEMU has been detailed with respect to completing a demonstration on the International Space Station (ISS) with support of units for initial lunar capability. The xEMU completed the Preliminary Design Review (PDR) with subsequent Safety Review Panel (SRP) Phase I reviews in 2019-2020. The objectives for DVT are to validate requirements, train the team, learn how to fabricate the hardware with appropriate process controls, assemble the hardware, test the hardware, determine the failure mechanisms/limits of the hardware design and buy down the most risk possible for the qualification and flight phases of the development. With completion of the assembly and initial functional testing of the DVT PLSS in laboratory ambient conditions and vacuum conditions the xEMU has progressed significantly into the DVT objectives. A key part of the test sequences for DVT and all future phases is the Pre-Installation Acceptance (PIA) functional testing which validates the performance of integrated systems including: primary thermal control, auxiliary thermal control, suit ventilation, primary oxygen, secondary oxygen, power distribution, as well as caution and warning all with respect to the applied requirements. This discussion will include an overview of the assembly, summary of the PIA functional testing, lessons learned, and corrective actions implemented moving forward into the remainder of the DVT phase for xEMU.

Colin Campbell↗

DOE OSTI2023

AUP first Pre-Series Cold Mass Installation into the Cryostat

For the HiLumi LHC Upgrade (HL-LHC), new high field and large-aperture quadrupole magnets for the low-beta inner triplets (Q1, Q2, Q3) are being built. These new quadrupole magnets are based on Nb3Sn superconducting technology. As part of the US-HiLumi Accelerator Upgrade Project (AUP), ten Cryostat Assemblies (LQXFA) for Q1 and Q3 replacement will be built, tested, and delivered to CERN. The first LQXFA was assembled and tested at Fermi National Accelerator Laboratory (FNAL) during fall 2022 and spring/summer 2023, respectively. This paper summarizes the assembly process and experience of the first LQXFA Cryostat Assembly at FNAL.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

NASA NTRS2015

Ground Operations Demonstration Unit for Liquid Hydrogen Initial Test Results

NASA operations for handling cryogens in ground support equipment have not changed substantially in 50 years, despite major technology advances in the field of cryogenics. NASA loses approximately 50% of the hydrogen purchased because of a continuous heat leak into ground and flight vessels, transient chill down of warm cryogenic equipment, liquid bleeds, and vent losses. NASA Kennedy Space Center (KSC) needs to develop energy-efficient cryogenic ground systems to minimize propellant losses, simplify operations, and reduce cost associated with hydrogen usage. The GODU LH2 project has designed, assembled, and started testing of a prototype storage and distribution system for liquid hydrogen that represents an advanced end-to-end cryogenic propellant system for a ground launch complex. The project has multiple objectives including zero loss storage and transfer, liquefaction of gaseous hydrogen, and densification of liquid hydrogen. The system is unique because it uses an integrated refrigeration and storage system (IRAS) to control the state of the fluid. This paper will present and discuss the results of the initial phase of testing of the GODU LH2 system.

liquefaction↗

NASA NTRS1990

Detailed modal testing of a solid rocket motor using a portable test system

Modern analytical techniques have expended the ability to evaluate solid rocket motors used in launch vehicles. As more detailed models of solid rocket motors were developed, testing methods were required to verify the models. Experimental modal analysis (modal testing) of space structures and launch vehicles has been a requirement for model validation for many years. However, previous testing of solid rocket motors has not typically involved dynamic modal testing of full scale motors for verification of solid propellant or system assembly properties. Innovative approaches to the testing of solid rocket motors were developed and modal testing of a full scale, two segment Titan 34D Solid Rocket Motor (SRM) was performed to validate detailed computer modeling. Special modifications were made to convert an existing facility into a temporary modal test facility which would accommodate the test article. The assembly of conventional data acquisition equipment into a multiple channel count portable system has made modal testing in the field feasible. Special purpose hydraulic exciters were configured to apply the dynamic driving forces required. All instrumentation and data collection equipment were installed at the test site for the duration of the test program and removed upon completion. Conversion of an existing test facility into a temporary modal test facility, and use of a multiple channel count portable test data acquisition system allowed all test objectives to be met and resulted in validation of the computer model in a minimum time.

Glozman, Vladimir↗

NASA NTRS1983

Cryogenic Fluid Management Experiment (CFME) trunnion verification testing

The Cryogenic Fluid Management Experiment (CFME) was designed to characterize subcritical liquid hydrogen storage and expulsion in the low-g space environment. The CFME has now become the storage and supply tank for the Cryogenic Fluid Management Facility, which includes transfer line and receiver tanks, as well. The liquid hydrogen storage and supply vessel is supported within a vacuum jacket to two fiberglass/epoxy composite trunnions which were analyzed and designed. Analysis using the limited available data indicated the trunnion was the most fatigue critical component in the storage vessel. Before committing the complete storage tank assembly to environmental testing, an experimental assessment was performed to verify the capability of the trunnion design to withstand expected vibration and loading conditions. Three tasks were conducted to evaluate trunnion integrity. The first determined the fatigue properties of the trunnion composite laminate materials. Tests at both ambient and liquid hydrogen temperatures showed composite material fatigue properties far in excess of those expected. Next, an assessment of the adequacy of the trunnion designs was performed (based on the tested material properties).

Bailey, W. J.↗