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NASA NTRS2019

Nasa Centennial Challenge: Three Dimensional (3d) Printed Habitat, Phase 3

NASA's Centennial Challenges program uses prize competitions with the goal of accelerating innovation in the aerospace industry. Competitions in the Centennial Challenges portfolio have previously focused on advancements in space robotics, regolith excavation, bio-printing, astronaut suit design, small satellites, and solar-powered vehicles. NASA's Three Dimensional (3D) Printed Habitat Centennial Challenge represents a partnership between NASA and the non-profit partner: Bradley University, with co-sponsors Caterpillar, Bechtel, Brick and Mortar Ventures, the American Concrete Institute, and the United States Army Corps of Engineers (USACE) Engineer Research and Development Center (ERDC) to spur development in automated additive construction technologies. The challenge asks teams to design and construct a scaled and simulated Martian habitat using indigenous materials and large scale 3D automated printing systems. Phase 1 of the competition, held in 2015, was an architectural design competition for habitat concepts that could be 3D printed. Phase 2, completed in 2017, asked teams to develop feedstocks from indigenous materials and hydrocarbon polymer recyclables, and demonstrate automated printing systems to manufacture these feedstocks into test specimens to assess mechanical strength. This paper will discuss the Phase 3 competition, focusing on technology outcomes that can potentially be infused into both terrestrial and planetary construction applications. The Phase 3 competition was divided into two sub-competitions: 1) virtual construction, where teams created a high fidelity building information model (BIM) of their 3D-printed habitat design and 2) the construction competition, which required teams to 3D print a structural foundation and subject materials samples to freeze/thaw testing and impact testing (level 1), produce a habitat element and complete a hydrostatic test (level 2), and additively manufacture a 1:3 scale habitat onsite in a head to head competition at Caterpillar, inc.'s Edwards Demonstration & Learning Center near Peoria, Illinois over the course of three days (level 3). While the Phase 2 competition focused primarily on the development of novel feedstocks and robotic printing systems, Phase 3 emphasized the scale-up of these systems and autonomous operation (demonstrating the capability to operate systems on precursor missions prior to the arrival of crew, or terrestrially in field operation settings where human tending of a manufacturing system may be limited). The Phase 3 virtual construction levels yielded a number of novel habitat designs, including both modular habitats and vertically-oriented habitat concepts. The Phase 3 construction competition also challenged teams to autonomously place penetrations and interfacing elements in additively manufactured structures. The paper will emphasize potential applications for the new materials and technologies developed under the umbrella of the competition within NASA's portfolio and in Earth-based applications such as disaster response and infrastructure improvement.

Centennial challenge↗

NASA NTRS2018

Impact of Advanced Synoptics and Simplified Checklists During Aircraft Systems Failures

Abstract—Natural human capacities are becoming increasingly mismatched to the enormous data volumes, processing capabilities, and decision speeds demanded in today’s aviation environment. Increasingly Autonomous Systems (IAS) are uniquely suited to solve this problem. NASA is conducting research and development of IAS - hardware and software systems, utilizing machine learning algorithms, seamlessly integrated with humans whereby task performance of the combined system is significantly greater than the individual components. IAS offer the potential for significantly improved levels of performance and safety that are superior to either human or automation alone. A human-in-the-loop test was conducted in NASA Langley’s Integration Flight Deck B-737-800 simulator to evaluate advanced synoptic pages with simplified interactive electronic checklists as an IAS for routine air carrier flight operations and in response to aircraft system failures. Twelve U.S. airline crews flew various normal and non-normal procedures and their actions and performance were recorded in response to failures. These data are fundamental to and critical for the design and development of future increasingly autonomous systems that can better support the human in the cockpit. Synoptic pages and electronic checklists significantly improved pilot responses to non-normal scenarios, but implementation of these aids and other intelligent assistants have barriers to implementation (e.g., certification cost) that must overcome.

Etherington, Timothy J.↗

DOE OSTI2016

Test Data Monitor

The National Security Campus (NSC) collects a large amount of test data used The National Security Campus (NSC) collects a large amount of test data used to accept high value and high rigor product. The data has been used historically to support root cause analysis when anomalies are detected in down-stream processes. The opportunity to use the data for predictive failure analysis however, had never been exploited. The primary goal of the Test Data Monitor (TDM) software is to provide automated capabilities to analyze data in near-real-time and report trends that foreshadow actual product failures. To date, the aerospace industry as a whole is challenged at utilizing collected data to the degree that modern technology allows. As a result of the innovation behind TDM, Honeywell is able to monitor millions of data points through a multitude of SPC algorithms continuously and autonomously so that our personnel resources can more efficiently and accurately direct their attention to suspect processes or features. TDM’s capabilities have been recognized by our U.S. Department of Energy National Nuclear Security Administration (NNSA) sponsor for potential use at other sites within the NNSA. This activity supports multiple initiatives including expectations of the NNSA and broader corporate goals that center around data-based quality controls on production.

Bosas, Joseph↗

DOE OSTI2019

Measuring Mobility Potential: NREL Researchers Develop New Metric that Quantifies Mobility Energy Productivity

Mobility is one of the fundamental aspects of human behavior, governed by factors such as time, cost, convenience, and availability of travel options. A new measurement developed by NREL researchers, called the Mobility Energy Productivity metric, provides an avenue to not only measure the quality of mobility at a specific location in its current configuration, but also to test how various technological advancements (e.g. connected and automated vehicles (CAVs), plug-in electric vehicles, shared mobility) and infrastructure investments (e.g. building an additional highway lane; constructing a new shopping mall) may impact the mobility of that location over time. A location with high quality mobility offers multiple transportation options to a diverse number of opportunities while minimizing time, cost, and energy consumption - all factors which define a high quality of life. Development of the MEP metric is a cornerstone of the U.S. Department of Energy's (DOE) SMART Mobility Laboratory Consortium. The metric will aid in developing new knowledge, insights, tools, and technology solutions about the evolving connected mobility system, thereby informing decision makers about how emerging mobility choices could impact people's lives.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2020

Measuring Mobility Potential: A Novel Metric to Quantify Mobility Energy Productivity (MEP) of Transportation Systems

For nearly a century, the automobile has been the primary mode of personal transportation in American life. This remains true today as millions of people rely heavily on cars to connect suburbs with cities or to travel long distances - often out of routine or convenience. However, advances in technology are fueling an era of transportation transformation, with the potential to transform a system that has remained virtually unchanged for decades. The challenges of interconnecting our cities and creating a cross-continental transportation system for military purposes spawned the interstate highway system, generating the age of the automobile. In this century, congestion and mobility challenges of rising urban populations are spawning ever-evolving mobility and communications technologies to connect people to goods, services, and employment within a metropolitan and national context - all of which define a high quality of life. Aspiring smart cities are wrestling with questions such as: How does mobility impact a person's quality of life? Would people make different travel choices if they were presented with better information about their mobility options? Would businesses make different location decisions if they could assess the quality of mobility in that area? The ability to quantify the quality of mobility at a given location is the first step toward answering these questions. In response, an interdisciplinary team at the National Renewable Energy Laboratory (NREL) has developed the Mobility-Energy Productivity (MEP) metric. The MEP metric provides an avenue to not only measure the quality of mobility at a specific location in its current configuration, but also to test how various technological advances (e.g., connected and automated vehicles, plug-in electric vehicles, shared mobility) and infrastructure investments (e.g., building an additional highway lane, constructing a new shopping mall, implementing a transit-oriented development) impact the mobility of that location over time.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2020

Urban Traveler - Changes and Impacts: Mobility Energy Productivity (MEP) Metric

For nearly a century, the automobile has been the primary mode of personal transportation in American life. This remains true today as millions of people rely heavily on cars to connect suburbs with cities or to travel long distances—often out of routine or convenience. However, advances in technology are fueling an era of transportation transformation, with the potential to transform a system that has remained virtually unchanged for decades. Aspiring smart cities are wrestling with questions such as: How does mobility impact a person’s quality of life? Would people make different travel choices if they were presented with better information about their mobility options? The ability to quantify the mobility potential of a given location is the first step toward answering these questions. In response, an interdisciplinary team at the National Renewable Energy Laboratory (NREL) has developed the Mobility-Energy Productivity (MEP) metric. The MEP metric provides an avenue to not only measure the mobility potential at a specific location in its current configuration, but also to test how various technological advances (e.g., connected and automated vehicles, plug-in electric vehicles, shared mobility) and infrastructure investments (e.g., building an additional highway lane, constructing a new shopping mall, implementing a transit-oriented development) impact the mobility of that location over time. This presentation details the FY19 progress on the MEP metric project funded through DOE VTO's SMART Mobility Consortium.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Integration of the Kromek D3S Detector and Spot Robot For Secondary Inspections

Inspecting vehicles and containers for the presence of nuclear material is a challenging task for border control and security. When performed manually by inspectors, this task also has an associated risk of exposing the inspectors to unknown radiation. With the advent of agile, easy-to-program, quadruped robots like the Boston Dynamics Spot, automation of secondary inspection can improve the efficiency of the inspection process and alleviates the radiation risks to inspectors. In this project, Brookhaven National Laboratory and the University of Massachussetts at Lowell explored how to automate a simple secondary inspection mission. The Spot robot comes with its own software development kit (SDK) that allows clients/users to write custom code in the Python programming language to control the robot. Spot also has a payload computer called Spot-CORE, which runs the Ubuntu Linux operating system and allows users to integrate external sensors, such as a radiation detector, with Spot. In this study, the Kromek D3S detector has been integrated with Spot via the Spot-CORE, allowing Spot to capture gamma spectra and neutron counts for a specified acquisition period. Two custom routines, search and confirmation, have been developed and executed in this specified order. The search routine directs Spot to go around the nearest obstacle, e.g., vehicle and container, in a preset distance and step to collect gamma and neutron gross counts with the D3S detector. The radiation data and the robot location corresponding to each step are stored and fed to the confirmation routine at the end of the search. The confirmation routine then navigates Spot to the locations of the highest gamma or neutron counts to perform a long, e.g., one minute, measurement, and gives the operators the signature gamma spectra and neutron counts at the hotspots. This paper presents a detailed description of this automated system along with results of the preliminary tests in identifying the location and signature of a 137Cs radiation source in a vehicle.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

NASA NTRS2023

CFD Integrated Transition Modeling for High-Speed Flows via Coupled OVERFLOW-LASTRAC Analysis

This work details ongoing efforts at the NASA Langley Research Center to develop and validate a general-use CFD tool that includes built-in predictions of boundary-layer transition in high-speed flows. Existing tools for the coupling of the NASA OVERFLOW structured overset RANS solver and LASTRAC stability analysis code have been extended to capture boundary-layer transition in high-speed flows driven by either Mack’s first-mode or secondmode instabilities and/or crossflow instabilities. The efficacy of this coupled approach has been demonstrated by examining a variety of supersonic and hypersonic test cases for which experimental validation data is available. The intermittency prescription parameters inherited from prior low-speed applications are found to be suitable for some, but not all high-speed flow scenarios. The method is found to be robust for straight cone configurations and improvements necessary to accurately capture transition on geometries with spatially complex amplification factor envelopes with intermediate regions of slow N-factor variation are examined. The automated, coupled analysis is demonstrated for a 3d supersonic test case and found to perform well within the limits of the linear stability analysis on which it relies. Finally, a preliminary investigation of the method’s robustness to non-ideal CFD meshes is conducted.

High-speed flow↗

DOE OSTI2015

Orientation dependent fracture behavior of nanotwinned copper

Columnar grown nanotwinned Cu was tensile tested in-situ inside the TEM in combination with automated crystal orientation mapping scanning transmission electron microscopy to investigate the active deformation mechanisms present in this material. Two tensile directions were applied, one parallel to the twin boundaries and the other perpendicular to the twin boundaries. In case of tensile testing perpendicular to the twin boundaries, the material deformed by detwinning and the formation of new grains, whereas in the parallel case, no new grains were formed and the fracture happened along the twin boundaries and a boundary that has formed during the deformation.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRS1992

SSME Automated Engine Calibration System (AECS)

An algorithm is derived for the real-time calibration of the engine fuel flowmeter and the engine mixture ratio during Space Shuttle Main Engine (SSME) ground testing. Because currently used calibration methods are post-test operations, there exists no fail-safe way of predicting at what mixture ratio a planned test will run. It is proposed that the algorithm developed here be used as part of an Automated Engine Calibration System (AECS) which could ensure that nearly all SSME tests are run at the proper mixture ratio. In this way, AECS has the potential of increasing the efficiency of the SSME ground test program. In addition to the derivation of the algorithm, an overview of this calibration system is presented along with the list of test stand facility instrumentation necessary for AECS implementation.

Greene, William D.↗

DOE OSTI2016

Poster - 09: A MATLAB-based Program for Automated Quality Assurance of a Prostate Brachytherapy Ultrasound System

Purpose: A robust Quality Assurance (QA) program is essential for prostate brachytherapy ultrasound systems due to the importance of imaging accuracy during treatment and planning. Task Group 128 of the American Association of Physicists in Medicine has recommended a set of QA tests covering grayscale visibility, depth of penetration, axial and lateral resolution, distance measurement, area measurement, volume measurement, and template/electronic grid alignment. Making manual measurements on the ultrasound system can be slow and inaccurate, so a MATLAB program was developed for automation of the described tests. Methods: Test images were acquired using a BK Medical Flex Focus 400 ultrasound scanner and 8848 transducer with the CIRS Brachytherapy QA Phantom – Model 045A. For each test, the program automatically segments the inputted image(s), makes the appropriate measurements, and indicates if the test passed or failed. The program was tested by analyzing two sets of images, where the measurements from the first set were used as baseline values. Results: The program successfully analyzed the images for each test and determined if any action limits were exceeded. All tests passed – the measurements made by the program were consistent and met the requirements outlined by Task Group 128. Conclusions: The MATLAB program we have developed can be used for automated QA of an ultrasound system for prostate brachytherapy. The GUI provides a user-friendly way to analyze images without the need for any manual measurement, potentially removing intra- and inter-user variability for more consistent results.

60 APPLIED LIFE SCIENCES↗

NASA NTRS1998

A New Real - Time Fault Detection Methodology for Systems Under Test

The purpose of this research is focussed on the identification/demonstration of critical technology innovations that will be applied to various applications viz. Detection of automated machine Health Monitoring (BM, real-time data analysis and control of Systems Under Test (SUT). This new innovation using a High Fidelity Dynamic Model-based Simulation (BFDMS) approach will be used to implement a real-time monitoring, Test and Evaluation (T&E) methodology including the transient behavior of the system under test. The unique element of this process control technique is the use of high fidelity, computer generated dynamic models to replicate the behavior of actual Systems Under Test (SUT). It will provide a dynamic simulation capability that becomes the reference truth model, from which comparisons are made with the actual raw/conditioned data from the test elements.

Johnson, Roger W.↗

DOE OSTI2017

Semiconductor Reliability Testing Data Management

iT2 Technologies is a startup developing analytical software and creating automated workflow environment in the area of big data in IC reliability. The main beneficiaries of the iT2 software will be the semiconductor companies as they will see significant savings in terms of time and cost. They will be able to efficiently perform the analysis of large amount of reliability data. A better standard of reliability and quality will also lead to the improvement in public safety in consumer, automotive, medical, and military applications. Smarter and thorough testing will reduce the risk of faulty hardware getting into the hands of the end users. The software is being developed and designed within the United States and will help keep the prominence of US in the cutting edge of high tech space. iT2 is establishing strong relations with its potential customers thanks to its key players being involved in this industry for the past several years and, thus, having a deep understanding of the market. The target clients will be all major semiconductor suppliers such as Intel, Qualcomm, Texas Instruments, OnSemi, and Broadcom and their customers including Apple, Cisco, IBM, HP, and Dell. The iT2 software will be used in a business-to-business environment for sharing engineering data and communicating results between these two classes of customers - some of which are participating in the beta testing of the iT2 software.

99 GENERAL AND MISCELLANEOUS↗

NASA NTRS2003

An Automated Cloud-edge Detection Algorithm Using Cloud Physics and Radar Data

An automated cloud edge detection algorithm was developed and extensively tested. The algorithm uses in-situ cloud physics data measured by a research aircraft coupled with ground-based weather radar measurements to determine whether the aircraft is in or out of cloud. Cloud edges are determined when the in/out state changes, subject to a hysteresis constraint. The hysteresis constraint prevents isolated transient cloud puffs or data dropouts from being identified as cloud boundaries. The algorithm was verified by detailed manual examination of the data set in comparison to the results from application of the automated algorithm.

Ward, Jennifer G.↗

DOE OSTI2014

A quality assurance framework for the fully automated and objective evaluation of image quality in cone-beam computed tomography

Purpose: Thousands of cone-beam computed tomography (CBCT) scanners for vascular, maxillofacial, neurological, and body imaging are in clinical use today, but there is no consensus on uniform acceptance and constancy testing for image quality (IQ) and dose yet. The authors developed a quality assurance (QA) framework for fully automated and time-efficient performance evaluation of these systems. In addition, the dependence of objective Fourier-based IQ metrics on direction and position in 3D volumes was investigated for CBCT. Methods: The authors designed a dedicated QA phantom 10 cm in length consisting of five compartments, each with a diameter of 10 cm, and an optional extension ring 16 cm in diameter. A homogeneous section of water-equivalent material allows measuring CT value accuracy, image noise and uniformity, and multidimensional global and local noise power spectra (NPS). For the quantitative determination of 3D high-contrast spatial resolution, the modulation transfer function (MTF) of centrally and peripherally positioned aluminum spheres was computed from edge profiles. Additional in-plane and axial resolution patterns were used to assess resolution qualitatively. The characterization of low-contrast detectability as well as CT value linearity and artifact behavior was tested by utilizing sections with soft-tissue-equivalent and metallic inserts. For an automated QA procedure, a phantom detection algorithm was implemented. All tests used in the dedicated QA program were initially verified in simulation studies and experimentally confirmed on a clinical dental CBCT system. Results: The automated IQ evaluation of volume data sets of the dental CBCT system was achieved with the proposed phantom requiring only one scan for the determination of all desired parameters. Typically, less than 5 min were needed for phantom set-up, scanning, and data analysis. Quantitative evaluation of system performance over time by comparison to previous examinations was also verified. The maximum percentage interscan variation of repeated measurements was less than 4% and 1.7% on average for all investigated quality criteria. The NPS-based image noise differed by less than 5% from the conventional standard deviation approach and spatially selective 10% MTF values were well comparable to subjective results obtained with 3D resolution pattern. Determining only transverse spatial resolution and global noise behavior in the central field of measurement turned out to be insufficient. Conclusions: The proposed framework transfers QA routines employed in conventional CT in an advanced version to CBCT for fully automated and time-efficient evaluation of technical equipment. With the modular phantom design, a routine as well as an expert version for assessing IQ is provided. The QA program can be used for arbitrary CT units to evaluate 3D imaging characteristics automatically.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

NASA NTRS1991

Telerobotic electronic materials processing experiment

The Office of Commercial Programs (OCP), working in conjunction with NASA engineers at the Goddard Space Flight Center, is supporting research efforts in robot technology and microelectronics materials processing that will provide many spinoffs for science and industry. The Telerobotic Materials Processing Experiment (TRMPX) is a Shuttle-launched materials processing test payload using a Get Away Special can. The objectives of the project are to define, develop, and demonstrate an automated materials processing capability under realistic flight conditions. TRMPX will provide the capability to test the production processes that are dependent on microgravity. The processes proposed for testing include the annealing of amorphous silicon to increase grain size for more efficient solar cells, thin film deposition to demonstrate the potential of fabricating solar cells in orbit, and the annealing of radiation damaged solar cells.

Ollendorf, Stanford↗

NASA NTRS2019

Electrical and Thermal Characterization of 3D Printed Thermoplastic Parts with Embedded Wires for High Current-Carrying Applications

Fabrication of parts exhibiting multi-functionality has recently been complemented by hybrid polymer extrusion additive manufacturing in combination with wire embedding technology. While much mechanical characterization has been performed on parts produced with fused deposition modeling, limited characterization has been performed when combined electrical and thermal loads are applied to 3D printed multi-material parts. As such, this work describes the design, fabrication, and testing of 3D printed thermoplastic coupons containing embedded copper wires that carried current. An automated fabrication process was used employing a hybrid additive manufacturing machine that dispensed polycarbonate thermoplastic and embedded bare copper wires. Testing included AC and DC hipot testing as well as thermal testing on as-fabricated and heat treated coupons to determine the effect of porosity in the substrate. The heat-treated parts contained reduced amounts of porosity, as corroborated through scanning electron microscopy, which led to 50 % increased breakdown strength and 30 to 40 % increased heat dissipation capabilities. The results of this research are describing a set of design protocol that can be used as a guideline for 3D printed embedded electronics to predict the electrical and thermal behavior.

Hipot testing↗

NASA NTRS1989

The automation of an inlet mass flow control system

The automation of a closed-loop computer controlled system for the inlet mass flow system (IMFS) developed for a wind tunnel facility at Langley Research Center is presented. This new PC based control system is intended to replace the manual control system presently in use in order to fully automate the plug positioning of the IMFS during wind tunnel testing. Provision is also made for communication between the PC and a host-computer in order to allow total animation of the plug positioning and data acquisition during the complete sequence of predetermined plug locations. As extensive running time is programmed for the IMFS, this new automated system will save both manpower and tunnel running time.

Supplee, Frank↗