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DOE OSTI2024

Positioning Accuracy in a Concurrent Robot-CNC Hybrid Manufacturing System

Abstract Additive manufacturing (AM) has gained notoriety for offering advantages over traditional manufacturing methods, such as increased design complexity and flexibility. However, it has not found widespread use beyond rapid prototyping. One hindrance to the acceptance of AM processes in industry is the time and cost of fabrication per component. While metal AM by itself can be inexpensive, extra manufacturing steps in the form of subtractive manufacturing (SM) may need to be performed to reach final part tolerances, leading to hybrid additive-subtractive manufacturing (HASM) of a part, which increases time and cost. A potential area to reduce cost is through increasing the efficiency of the HASM process by conducting additive and subtractive manufacturing simultaneously. Usually, HASM is performed in a process where AM is completed in one machine or cell and transferred to another machine or cell for SM in a sequential assembly line process. This efficiency decreases part cost, but high aspect ratio parts or parts with internal geometry that require interleaved additive deposition and machining cannot be produced. One unexplored solution to simultaneous HASM that allows for interleaved operations is to operate the deposition head and machining spindle concurrently within the same machine envelope, known as concurrent HASM (CHASM). In this type of process, both AM and SM occur simultaneously on a batch of small parts or a single large part, maintaining a high efficiency without sacrificing the full range of complex geometries that AM allows for. A potential approach to the single-machine method could be to combine a robot and mill within the same envelope. A challenge to this approach, however, is control of both systems. Most machine controllers have limited external communication or, if a robot has been integrated, only offer movement of either the robot or mill at any given time. As a result, systems must pause either the AM or SM process to switch between them rather than working simultaneously. The present work investigates the positional accuracy of such a CHASM system comprised of a robotic arm and a 3-axis mill. Open-loop tests with limited communication between machines are performed on the system to verify positional error during concurrent robot-mill movements. Under certain conditions, it is demonstrated that position error can stay within 2 mm for the duration of a single layer; however, these tests show that, generally, the open-loop positioning performance of the system is inadequate for CHASM without part-specific hand-tuning of parameters. Based on these results, a set of requirements for successful robot-CNC CHASM is proposed for future integrations.

Goodwin, Jesse↗

NASA NTRS1989

Parallel Eigenvalue extraction

A new numerical algorithm for the solution of large-order eigenproblems typically encountered in linear elastic finite element systems is presented. The architecture of parallel processing is utilized in the algorithm to achieve increased speed and efficiency of calculations. The algorithm is based on the frontal technique for the solution of linear simultaneous equations and the modified subspace eigenanalysis method for the solution of the eigenproblem. Assembly, elimination and back-substitution of degrees of freedom are performed concurrently, using a number of fronts. All fronts converge to and diverge from a predefined global front during elimination and back-substitution, respectively. In the meantime, reduction of the stiffness and mass matrices required by the modified subspace method can be completed during the convergence/divergence cycle and an estimate of the required eigenpairs obtained. Successive cycles of convergence and divergence are repeated until the desired accuracy of calculations is achieved. The advantages of this new algorithm in parallel computer architecture are discussed.

Akl, Fred A.↗

NASA NTRS1995

Developmental problems and their solution for the Space Shuttle main engine alternate liquid oxygen high-pressure turbopump: Anomaly or failure investigation the key

The Space Shuttle main engine (SSME) alternate high-pressure liquid oxygen pump experienced synchronous vibration and ball bearing life problems that were program threatening. The success of the program hinged on the ability to solve these development problems. The design and solutions to these problems are engirded in the lessons learned and experiences from prior programs, technology programs, and the ability to properly conduct failure or anomaly investigations. The failure investigation determines the problem cause and is the basis for recommending design solutions. For a complex problem, a comprehensive solution requires that formal investigation procedures be used, including fault trees, resolution logic, and action items worked through a concurrent engineering-multidiscipline team. The normal tendency to use an intuitive, cut-and-try approach will usually prove to be costly, both in money and time and will reach a less than optimum, poorly understood answer. The SSME alternate high-pressure oxidizer turbopump development has had two complex problems critical to program success: (1) high synchronous vibrations and (2) excessive ball bearing wear. This paper will use these two problems as examples of this formal failure investigation approach. The results of the team's investigation provides insight into the complexity of the turbomachinery technical discipline interacting/sensitivities and the fine balance of competing investigations required to solve problems and guarantee program success. It is very important to the solution process that maximum use be made of the resources that both the contractor and Government can bring to the problem in a supporting and noncompeting way. There is no place for the not-invented-here attitude. The resources include, but are not limited to: (1) specially skilled professionals; (2) supporting technologies; (3) computational codes and capabilities; and (4) test and manufacturing facilities.

Ryan, R.↗

DOE OSTI2025

Synergistic learning with multi-task DeepONet for efficient PDE problem solving

Multi-task learning (MTL) is an inductive transfer mechanism designed to leverage useful information from multiple tasks to improve generalization performance compared to single-task learning. It has been extensively explored in traditional machine learning to address issues such as data sparsity and overfitting in neural networks. In this work, we apply MTL to problems in science and engineering governed by partial differential equations (PDEs). However, implementing MTL in this context is complex, as it requires task-specific modifications to accommodate various scenarios representing different physical processes. To this end, we present a multi-task deep operator network (MT-DeepONet) to learn solutions across various functional forms of source terms in a PDE and multiple geometries in a single concurrent training session. We introduce modifications in the branch network of the vanilla DeepONet to account for various functional forms of a parameterized coefficient in a PDE. Additionally, we handle parameterized geometries by introducing a binary mask in the branch network and incorporating it into the loss term to improve convergence and generalization to new geometry tasks. Our approach is demonstrated on three benchmark problems: (1) learning different functional forms of the source term in the Fisher equation; (2) learning multiple geometries in a 2D Darcy Flow problem and showcasing better transfer learning capabilities to new geometries; and (3) learning 3D parameterized geometries for a heat transfer problem and demonstrate the ability to predict on new but similar geometries. Finally, our MT-DeepONet framework offers a novel approach to solving PDE problems in engineering and science under a unified umbrella based on synergistic learning that reduces the overall training cost for neural operators.

42 ENGINEERING↗

NASA NTRS2017

Structural Design Exploration of an Electric Powered Multi-Propulsor Wing Configuration

Advancements in aircraft electric propulsion may enable an expanded operational envelope for electrically powered vehicles compared to their internal combustion engine counterparts. High aspect ratio wings provide additional lift and drag reduction for a proposed multi-propulsor design, however, the challenge is to reduce the weight of wing structures while maintaining adequate structural and aeroelastic margins. Design exploration using a conventional design-and-build philosophy coupled with a finite element method (FEM)-based design of experiments (DOE) strategy are presented to examine high aspect ratio wing structures that have spanwise distributed electric motors. Multiple leading-edge-mounted engine masses presented a challenge to design a wing within acceptable limits for dynamic and aeroelastic stability. Because the first four primary bending eigenmodes of the proposed wing structure are very sensitive to outboard motor placement, safety-of-flight requirements drove the need for multiple spars, rib attachments, and outboard structural reinforcements in the design. Global aeroelasticity became an increasingly important design constraint during the on-going design process, with outboard motor pod flutter ultimately becoming a primary design constraint. Designers successively generated models to examine stress, dynamics, and aeroelasticity concurrently. This research specifically addressed satisfying multi-disciplinary design criteria to generate fluid-structure interaction solution sets, and produced high aspect ratio primary structure designs for the NASA Scalable Convergent Electric Propulsion Technology and Operations Research (SCEPTOR) project in the Aeronautic Research Mission Directorate at NASA. In this paper, a dynamics-driven, quasi-inverse design methodology is presented to address aerodynamic performance goals and structural challenges encountered for the SCEPTOR demonstrator vehicle. These results are compared with a traditional computer aided design based approach.

Moore, James B.↗

DOE OSTI2025

Greenhouse gas emissions reduction strategies that maximize portfolio-wide life cycle cost reduction, resilience, and environmental justice benefits

While strategies to achieve net-zero emissions at an individual site are well understood, new analysis methods are required for organizations seeking to achieve net-zero across multiple facilities, each with concurrent priority goals. At a portfolio level, distinct locations present varied challenges that cannot be addressed through singular solutions, and competing goals can take precedence with the assumption that net-zero emissions strategies deter from energy resilience and cost savings, therefore negatively impacting nearby communities. This study tests these assumptions by analyzing 16 diverse sites (varying in size, climate, and energy use) to identify strategies that reduce emissions and assess the impact these strategies have on life cycle costs, resilience, and communities with environmental justice concerns. Methods were developed to approximate missing information essential to net-zero evaluation. Established methods were augmented to evaluate life cycle costs, resilience, and environmental justice impacts across a set of strategies and accommodate the multi-criteria analyses. Potential benefits from identified strategies were quantified using site characteristics and a set of corresponding metrics. The net-zero analysis found that 11 sites could use on-site strategies to eliminate all but 2% of emissions generated. The remaining emissions can be offset, for instance through sequestration, executed at the portfolio scale. On-site carbon-free energy was found to reduce 51% of emissions across all sites; efficiency reduced 19% of emissions; sequestration 16%; procured carbon-free energy 15%; fuel switching 1.6%; and fleet electrification 1.3%. Building electrification, however, increased emissions by 4.4%. Different strategies also provide cost, resilience, and/or environmental justice benefits—the degree to which varies with individual site conditions. The findings indicate an advantage to considering the strategies as a comprehensive set, which leads to co-benefits, both in the ability to achieve net-zero goals and in advancing other goals. The results present the case for comprehensive advanced planning at the portfolio level to prioritize investments that will balance the minimization of emissions and life cycle cost with the maximization of resilience and environmental justice benefits. The novel methods for evaluation and integration, valuation of benefits, and consideration at the portfolio scale allow organizations to select investments that simultaneously address multiple key priorities.

Net-Zero Emissions↗

NASA NTRS1980

Automated optical navigation with application to Galileo

This paper presents an overview of an automated optical navigation (AON) system, a lower-cost, faster, earth-based stepping stone to onboard systems. AON provides estimation (orbit determination) and maneuver subsystems which are automatically linked to provide the fast response required by the Galileo mission, AON's first user. A real-time interactive executive schedules the subsystems to run concurrently or sequentially and enables interactive computer-graphics displays designed to speed evaluation and certification of navigation solutions. A compact trajectory integrator provides a favorable combination of speed and accuracy. Resident on a low-cost minicomputer and coded primarily in HAL/S, the NASA standard language for flight software, AON approaches a prototype for autonomous onboard navigation systems of the future.

Klumpp, A. R.↗

NASA NTRS2000

Optimization of Car Body under Constraints of Noise, Vibration, and Harshness (NVH), and Crash

To be competitive on the today's market, cars have to be as light as possible while meeting the Noise, Vibration, and Harshness (NVH) requirements and conforming to Government-man dated crash survival regulations. The latter are difficult to meet because they involve very compute-intensive, nonlinear analysis, e.g., the code RADIOSS capable of simulation of the dynamics, and the geometrical and material nonlinearities of a thin-walled car structure in crash, would require over 12 days of elapsed time for a single design of a 390K elastic degrees of freedom model, if executed on a single processor of the state-of-the-art SGI Origin2000 computer. Of course, in optimization that crash analysis would have to be invoked many times. Needless to say, that has rendered such optimization intractable until now. The car finite element model is shown. The advent of computers that comprise large numbers of concurrently operating processors has created a new environment wherein the above optimization, and other engineering problems heretofore regarded as intractable may be solved. The procedure, shown, is a piecewise approximation based method and involves using a sensitivity based Taylor series approximation model for NVH and a polynomial response surface model for Crash. In that method the NVH constraints are evaluated using a finite element code (MSC/NASTRAN) that yields the constraint values and their derivatives with respect to design variables. The crash constraints are evaluated using the explicit code RADIOSS on the Origin 2000 operating on 256 processors simultaneously to generate data for a polynomial response surface in the design variable domain. The NVH constraints and their derivatives combined with the response surface for the crash constraints form an approximation to the system analysis (surrogate analysis) that enables a cycle of multidisciplinary optimization within move limits. In the inner loop, the NVH sensitivities are recomputed to update the NVH approximation model while keeping the Crash response surface constant. In every outer loop, the Crash response surface approximation is updated, including a gradual increase in the order of the response surface and the response surface extension in the direction of the search. In this optimization task, the NVH discipline has 30 design variables while the crash discipline has 20 design variables. A subset of these design variables (10) are common to both the NVH and crash disciplines. In order to construct a linear response surface for the Crash discipline constraints, a minimum of 21 design points would have to be analyzed using the RADIOSS code. On a single processor in Origin 2000 that amount of computing would require over 9 months! In this work, these runs were carried out concurrently on the Origin 2000 using multiple processors, ranging from 8 to 16, for each crash (RADIOSS) analysis. Another figure shows the wall time required for a single RADIOSS analysis using varying number of processors, as well as provides a comparison of 2 different common data placement procedures within the allotted memories for each analysis. The initial design is an infeasible design with NVH discipline Static Torsion constraint violations of over 10%. The final optimized design is a feasible design with a weight reduction of 15 kg compared to the initial design. This work demonstrates how advanced methodology for optimization combined with the technology of concurrent processing enables applications that until now were out of reach because of very long time-to-solution.

Kodiyalam, Srinivas↗

NASA NTRS1972

Long life assurance study for manned spacecraft long life hardware. Volume 1: Summary of long life assurance guidelines

A long life assurance program for the development of design, process, test, and application guidelines for achieving reliable spacecraft hardware was conducted. The study approach consisted of a review of technical data performed concurrently with a survey of the aerospace industry. The data reviewed included design and operating characteristics, failure histories and solutions, and similar documents. The topics covered by the guidelines are reported. It is concluded that long life hardware is achieved through meticulous attention to many details and no simple set of rules can suffice.

Source record↗

NASA NTRS1985

Study of one- and two-dimensional filtering and deconvolution algorithms for a streaming array computer

The development of vector processing computers of the streaming array architectures has made possible a dramatic decrease in the time required for the solution of problems, i.e., for those algorithms which readily lend themselves to sequential operations on long vectors. There has concurrently been rapid growth in the applications of the techniques generally known as mathematical digital filtering, also called signal analysis, digital signal processing, time series analysis, and digital image processing. The best known applications of these techniques is to seismic data and two-dimensional images, data types consisting of very large collections of numbers. A major limitation for these cases is the size and speed of the computer available. Therefore, a move to the streaming array architecture can result in marked improvement in the data analysis techniques which may be employed.

Ioup, G. E.↗

NASA NTRS1989

A survey on the design of multiprocessing systems for artificial intelligence applications

Some issues in designing computers for artificial intelligence (AI) processing are discussed. These issues are divided into three levels: the representation level, the control level, and the processor level. The representation level deals with the knowledge and methods used to solve the problem and the means to represent it. The control level is concerned with the detection of dependencies and parallelism in the algorithmic and program representations of the problem, and with the synchronization and sheduling of concurrent tasks. The processor level addresses the hardware and architectural components needed to evaluate the algorithmic and program representations. Solutions for the problems of each level are illustrated by a number of representative systems. Design decisions in existing projects on AI computers are classed into top-down, bottom-up, and middle-out approaches.

Wah, Benjamin W.↗

NASA NTRS1991

Model problem

Our purpose in examining this test problem is to measure directly the effect of mesh refinement and the resulting mesh interfaces on a known wave that is sensitive to phase errors, while concurrently being able to visually display a meaningful picture of the effects of the refinement induced error on the solution. The refined mesh must be able to adequately capture the diffraction behavior, so that the plane wave front bends as it passes through the slit. Given that the coarse and refined meshes are sufficiently accurate, the phase errors introduced during the problem solution will be a function of th sound speed on the two grids plus the coarse/refined grid interaction errors.

Perkins, A. Louise↗

NASA NTRS1993

The role of merged interaction regions and drafts in the heliospheric modulation of cosmic rays beyond 20 AU - A computer simulation

Voyager 2 magnetic field measurements are used to simulate merged interaction and rarefaction regions (MIRs and RRs) for 1985-1989 via numerical solutions of the time-dependent, axially symmetric transport equation of cosmic rays in the heliosphere, together with the concurrent use of the wavy neutral sheet as a time-dependent drift parameter. This drift approach was found to be more successful, because it was able to reproduce the intensity levels, the factor modulation, and latitudinal gradients for 1 GeV protons at 23 AU.

Potgieter, M. S.↗

NASA NTRSDate not supplied

Orbit Determination for the James Webb Space Telescope During Launch and Early Orbit

The NASA James Webb Space Telescope (JWST) mission successfully launched on December 25, 2021, at 12:20 UTC. This paper details several novel challenges encountered in the orbit determination (OD) of JWST during the launch and early orbit. The first OD solution used only 6.5 hours of tracking data, much less than the 24 hours of data usually required for libration orbiters on an outbound trajectory. In addition, the observatory area exposed to solar radiation pressure changed through a series of sunshield deployments while concurrent momentum unloads and attitude telemetry outages occurred. This paper covers how the Flight Dynamics Team (FDT) prepared for these challenges, how these challenges were handled on-orbit, and the performance of the resulting OD solutions.

Orbit Determination↗

NASA NTRSDate not supplied

Orbit Determination For The James Webb Space Telescope During Launch And Early Orbit

Orbit Determination↗

DOE OSTI2025

Chemical Functional Groups Regulate Ion Concentrations and pHs in Nanopores

Understanding ion behaviors in functionalized nanopores is essential to deciphering reactions in both natural and engineered systems, such as sediments, biological ion channels, and membranes. While many efforts have shown the modified ion behaviors in the functionalized nanopores, a direct measurement and analysis to show how chemical functional groups affect ion concentrations in nanopores are critically needed. In this work, we present a plasmonic nanosensor that can measure the local concentrations of protons, anions (phosphate, nitrate, sulfate, and arsenate), and cations (mercury, lead, and copper) in functionalized nanopores, and we compare their concentrations in nanopores with the corresponding bulk concentrations. Notably, chemical functional groups induced ion concentrations differently in nanopores. In pristine nanopores and methyl- and phenyl-functionalized nanopores, we discovered an unexpected concurrence of an enhanced anion concentration and a suppressed cation concentration. In addition, the nanopore pH is dependent on bulk solution compositions and can be lower by 2.5 units, even when the bulk solution is well-buffered. In contrast, for hydrophilic (amine, thiol, and carboxyl) nanopores, pH depended on the p K a of the functional groups, and the heavy metal concentrations depended on chemical interactions with the functional groups. Our findings provide a better understanding of water chemistry in nanopores and can help precisely control ions in nanopores to benefit the design of membrane-based desalination techniques, CO 2 storage, and porous catalysts.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1986

Convection zone origins of solar atmospheric heating

Spicules are examined as a means for supplying the corona with mass, energy, and magnetic field. It is suggested that spicules form from the supersonic upward expansion of material on nearly evacuated network flux tubes embedded within the sun's convection zone. This allows supersonic but subescape velocities to be attained by the material as it flows outward through the photosphere. Although supersonic, the kinetic energy (subescape) of the spicule material, as observed, is insufficient for coronal heating. It is suggested that, through buoyancy changes on evacuated flux tubes, the magnetic field first 'wicks' material flow into the solar atmosphere. Subsequently, the magnetic field energizes the gaseous material to form the conventional hot, dynamically expanding, solar corona. This occurs through momentum and energy transport by Alfven waves and associated Maxwell stresses concurrently flowing upward on these 'geysers' (spicules). The vertical momentum equation governing fluid flow is examined, and a particular equipartition solution is presented for the flow velocity along a simple field geometry.

Schatten, Kenneth H.↗

DOE OSTI2024

Technical note: Optimizing the in situ cosmogenic 36 Cl extraction and measurement workflow for geologic applications

Abstract. In situ cosmogenic 36Cl analysis by accelerator mass spectrometry (AMS) is routinely employed to date Quaternary surfaces and assess rates of landscape evolution. However, standard laboratory preparation procedures for 36Cl dating require the addition of large amounts of isotopically enriched chlorine spike solution; these solutions are expensive and increasingly difficult to acquire from commercial sources. In addition, the typical workflow for 36Cl dating involves measuring both 35Cl/37Cl and 36Cl/Cl concurrently on the high-energy (post-accelerator) end of the AMS system, but 35Cl/37Cl determinations using this technique can be complicated by isotope fractionation and system memory during measurement. The traditional workflow also does not provide 36Cl extraction laboratories with the data needed to calculate native Cl concentrations in advance of 36Cl/Cl measurements. In light of these concerns, we present an improved workflow for extracting and measuring chlorine in geologic materials. Our initial step is to characterize 35Cl/37Cl on sample aliquots of up to ∼1 g prepared in Ag(Cl, Br) matrices, which greatly reduces the amount of isotopically enriched spike solution required to measure native Cl content in each sample. To avoid potential issues with isotope fractionation through the accelerator, 35Cl/37Cl is measured on the low-energy, pre-accelerator end of the AMS line. Then, for 36Cl/Cl measurements, we extract Cl as AgCl or Ag(Cl, Br) in analytical batches with a consistent total Cl load across all samples; this step is intended to minimize source memory effects during 36Cl/Cl measurements and allows the preparation of AMS standards that are customized to match known Cl contents in the samples. To assess the efficacy of this extraction and measurement workflow, we compare chlorine isotope ratio measurements on seven geologic samples prepared using standard procedures and the updated workflow. Measurements of 35Cl/37Cl and 36Cl/Cl are consistent between the two workflows, and 35Cl/37Cl values measured using our methods have considerably higher precision than those measured following standard protocols. The chemical preparation and measurement workflow presented here (1) reduces the amount of isotopically enriched chlorine spike used per rock sample by up to 95 %; (2) identifies rocks with high native Cl concentrations, which may be lower priority for 36Cl surface exposure dating, at an early stage of analysis; and (3) allows laboratory users to maintain control over the total chlorine content within and across analytical batches. These methods can be incorporated into existing laboratory and AMS protocols for 36Cl analyses and will increase the accessibility of 36Cl dating for geologic applications.

58 GEOSCIENCES↗