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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Assessment of Flow-Enhanced Electrochemical Sensor Testing and Deployments for MSRs

This report serves as the deliverable for Milestone M3RS-23AN0401061 that is part of Work Package RS-23AN040106 (Flow Enhanced Sensors for MSRs – ANL). The goal of this milestone was to determine performance of the flow enhanced electrochemical sensor (FEES) and modular flow instrumentation testbed (MFIT) in safeguards relevant scenarios. Flow enhanced electrochemical sensors are a type of electroanalytical sensor that has been developed at Argonne National Laboratory to be installed directly into MSR flow conduits to make measurements of the salt composition. These sensors represent a significant improvement in capabilities compared to earlier electroanalytical sensors that instead can only be operated in quiescent conditions. Previous work has focused on testing of the FEES in flowing conditions provided by the MFIT to assess the accuracy and precision of the sensor measurements. To further improve this capability, in FY23 we undertook a campaign of safeguards relevant scenarios in molten salt containing a range of uranium chloride concentrations (0 to 3 wt%). All the testing carried out in FY23 was aided by a control system designed to automatically actuate flow conditions and collect data. This new automation system is estimated to have increased experimental throughput by a factor of four and enabled testing in a variety of complex conditions. The advancements in throughput and repeatability led to improved quantification of actinide concentrations using the in-flow sensors, with a reduction of the mean absolute relative error from 5.6% in FY22 to 3.1% in FY23. In addition to safeguards scenarios run in the MFIT, FY23 work included deployment of a FEES at a partner institution where it will be tested in a flowing salt loop. The FEES was successfully integrated into that loop and is being tested prior to loop startup. In FY23, work also continued on the smaller flow system that we have named the mini-MFIT. This smaller system is capable of rapid prototyping of new sensor designs prior to installation in the larger MFIT radiological flow system. Work was carried out to test this new system in non-radiological molten salts in a separate glovebox. This work is helping us to enhance the accuracy of our salt monitoring capabilities through the integration of multiple types of sensors. The high degree of accuracy required by 10 CFR 74 represents a significant challenge, and further design evolution and integration of the sensors into multimodal sensing frameworks will be needed to further push the measurement accuracy to the needed level.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Control of low-mode drive asymmetry in an efficient long-pulse low gas-fill density Hohlraum

Laser-driven Hohlraums filled with gas at lower densities (<0.6 mg/cc) have higher efficiency compared to original ≥ 0.96 mg/cc fill because of reduced backscatter losses [Hall et al., Phys. Plasmas 24, 052706 (2017)]. However, using low-density filled Hohlraums with longer drive required for lower adiabat implosions, and hence potentially higher inertial confinement fusion gain designs, has been challenging since the Hohlraum wall blow-off is less tamped, thus altering the laser beam absorption regions and drive symmetry. A series of NIF experiments using optimized pulse shaping, beam pointing, and temporal phasing have demonstrated, through imaging of the Hohlraum and capsule dynamics, that a symmetric implosion using a 14-ns low-adiabat drive pulse {2× longer than high-density-carbon ablator designs using low gas-fill density Hohlraums [Divol et al., Phys. Plasmas 24, 056309 (2017)]} is possible in a low backscatter loss 0.45 mg/cc He-filled Hohlraum. The ingress of the Hohlraum walls was mitigated by revisiting the adiabat-shaped design [Clark et al., Phys. Plasmas 21, 112705 (2014)] that uses a low-power (1 TW) trough that delays the wall expansion. Low-mode P 2 and P 4 drive asymmetry swings caused by the drift of the laser spots were essentially zeroed out by employing temporal beam phasing between cones of beams [Turner et al., Phys. Plasmas 7, 333 (2000)]. So the results also indicate an improved coupling efficiency of ~30% compared to an earlier design using higher density filled Hohlraums and pave the way for revisiting low-adiabat, high convergence drives using CH ablators.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2016

A Mission Concept to Study Multigenerational Mammalian Reproduction in Partial Gravity

A team at NASA Langley Research Center conducted a study during which a conceptual space mission was designed. In this study, rodents are used as human analogs to gather biological and systems data in a relevant environment applicable to future settlements on Mars. The mission concept uniquely addresses the combined effects of long-durations (one-year or greater), autonomous and robotic operations, and biological responses to partial gravity with an emphasis on reproduction. The objectives of this study were to 1) understand challenges associated with designing an artificial gravity habitat that supports the reproduction and maturation of a large animal colony, 2) identify mission architectures and operational concepts to transport and maintain such a facility, and 3) identify fundamental science considerations for mammalian reproduction studies to inform vehicle design. A model demonstration unit was developed to visualize and test certain design concepts that resulted from these considerations. Three versions of this demonstration unit were built over the course of the study, each taking into account lessons learned from the previous version. This paper presents the updated baseline mission and spacecraft design concepts to achieve these objectives, with a specific emphasis on updates since publication in previous works. Analyses of the integrated system trades among the elements which make up the conceptual vehicle are described to address overall feasibility and identify potential integrated design opportunities. The latest iteration of the habitat robotics design and a conceptual design example for autonomous care of crew and systems are also presented. Finally, the conclusion of this conceptual design study, necessary future analyses to enable such a facility, and comments upon other applications of a similar exploration-focused research facilities are addressed.

Rodgers, Erica M.↗
NASA NTRS2005

Re-Configurable Electronics Characterization under Extreme Thermal Environment

The need for reconfigurable electronics is driven by requirements to survive longer missions and harsher environments. It is possible to compensate for degradations in Extreme Environments (EE). EE has effect on electronics: circuits are designed to exploit device characteristics and when a certain temperature or radiation range is exceeded the circuit function gradually degrades. It is possible to employ Hardening by reconfiguration (HBR) to mitigate drifts, degradation, or damage on electronic devices in EE by using reconfigurable devices and an adaptive self-reconfiguration of circuit topology. In this manner degraded components can be salvaged, and completely damaged components can be bypassed. The challenge of conventional design is replaced with that of designing a recover process that automatically performs the (re) design in place of the designer. The objective of testing a Digital Signal Processor (DSP) under the extreme temperatures was to determine the lowest temperature at which the DAP can operate. The objective of testing a Xilinx VirtexII Pro FPGA board was to initially find our whether the evaluation board and the FPGA would survive and continue at temperature ranges from -180 C, and 120 C. The Virtex II functioned correctly at the temperatures tested. The next test was done on the GM-C filter building block using the same temperature range as the Virtex II. The current lower and upper limits were shown to be reduced as the temperature gets lower. The device function can be recovered by increasing the Vb from .08V to .85V. The negative and positive saturation voltages increases as the temperature gets higher. The function of the device can be recovered by decreasing the Vb from .8V to around .75V. The next test was performed to test the recovery of the GmC low pass filter through Vb in a filter circuit. The test indicate that bias voltage control adjustment is an efficient mechanism for circuit recovery at extreme temperatures.

reliability↗
DOE OSTI2022

Grand Challenges in the Science of Making Torque from Wind: Then and Now

Shifting the electricity supply to renewable sources within the next two decades is the first step in decarbonizing the energy sector, and wind energy will play a central role in enabling this rapid energy transition to clean energy. The international wind energy research community - including NREL researchers - has determined that for wind power to fulfill its expected role as a major global supplier of carbon-free energy, critical challenges around the design, development, and deployment of wind energy must be addressed - quickly. Paul Veers and other NREL researchers joined 100 worldwide wind energy experts in writing a series of 10 articles for publication in Wind Energy Science. With the support and guidance of the European Academy of Wind Energy Publications Committee, the articles synthesize and clarify the most critical wind energy science needs. This presentation introduces the concept of the Grand Challenges and its 10 articles.

decarbonization↗
NASA NTRS2010

Generating a Reduced Gravity Environment on Earth

Since the 1950s several reduced gravity simulators have been designed and utilized in preparing humans for spaceflight and in reduced gravity system development. The Active Response Gravity Offload System (ARGOS) is the newest and most realistic gravity offload simulator. ARGOS provides three degrees of motion within the test area and is scalable for full building deployment. The inertia of the overhead system is eliminated by an active motor and control system. This presentation will discuss what ARGOS is, how it functions, and the unique challenges of interfacing to the human. Test data and video for human and robotic systems will be presented. A major variable in the human machine interaction is the interface of ARGOS to the human. These challenges along with design solutions will be discussed.

Dungan, Larry K.↗
DOE OSTI2024

Enhancement of disposal efficiency for deep geological repositories based on three design factors - Decay heat optimization, increased thermal limit of the buffer and double-layer concept

This study investigates the enhancement of disposal efficiency for deep geological repositories (DGRs) based on three design factors: decay heat optimization, increased thermal limit of the buffer, and double-layer concept using coupled thermo-hydro-mechanical (THM) numerical simulations. Decay heat optimization is achieved by iteratively emplacing spent nuclear fuels having the maximum and minimum decay heat in a canister. Disposal areas can be reduced by 20 % to 40 % compared to the current reference disposal system in Korea (KRS+) in accordance with the combinations of the three design factors, alleviating challenges in site selection for the DGR. This study additionally identifies an optimal layer spacing of 500 m for the double-layer concept in the viewpoint of the buffer temperature, where thermal interaction between the upper and lower layers nearly disappears. However, determining the ultimate disposal and layer spacing requires engineering judgement, considering not only the thermal performance of the DGR but also various factors such as cost and difficulties of the construction and rock mass stability. DGRs designed with an increased thermal limit of the buffer poses a greater probability of rock mass failure around disposal tunnels and deposition holes due to elevated thermal stresses. Densely arranged heat sources for the DGRs with enhanced disposal efficiency lead to larger temperature increase even at the far-field scale, raising a possibility of thermally driven fracture shear activation with associated hydraulic, mechanical, and seismic changes.

58 GEOSCIENCES↗
NASA NTRS2009

Recent Advances in Techniques for Hyperspectral Image Processing

Imaging spectroscopy, also known as hyperspectral imaging, has been transformed in less than 30 years from being a sparse research tool into a commodity product available to a broad user community. Currently, there is a need for standardized data processing techniques able to take into account the special properties of hyperspectral data. In this paper, we provide a seminal view on recent advances in techniques for hyperspectral image processing. Our main focus is on the design of techniques able to deal with the highdimensional nature of the data, and to integrate the spatial and spectral information. Performance of the discussed techniques is evaluated in different analysis scenarios. To satisfy time-critical constraints in specific applications, we also develop efficient parallel implementations of some of the discussed algorithms. Combined, these parts provide an excellent snapshot of the state-of-the-art in those areas, and offer a thoughtful perspective on future potentials and emerging challenges in the design of robust hyperspectral imaging algorithms

Plaza, Antonio↗
NASA NTRSDate not supplied

Affordable Development Strategy for NEP Nuclear Systems

One nuclear electric propulsion (NEP) reactor systems under consideration is a hydride moderated thermal spectrum reactor fueled by high assay low enriched uranium (HALEU). While such a reactor is expected to yield the lightest HALEU reactor design, its development challenges grow exponentially with increasing mission demands, most notably power output, specific weight of the overall system (which may require operation at temperatures exceeding 1200 K), service lifetime, and human-rated reliability. Two of the greatest cost drivers are full-powered nuclear demonstrations and extensive material development campaigns, so it is important to consider options that can minimize the need for or complexity of such tasks. This paper discusses a structured framework being developed for assessing how NEP design choices, such as materials selection, neutronic features, and heat-removal technologies, can translate into project risk and how project performance goals can be traded with development cost.Reactors operating at high temperatures often require cutting-edge heat transfer technologies and creep-resistant materials. Use of new materials in high temperature reactors brings additional complication beyond those common to any new space materials development campaign. For example, such materials may not possess necessary neutronic cross-sectional or neutronic irradiation data. Similarly, use of new materials may significantly influence core neutronics; in some extreme cases, neutronic reactivity feed-back of certain new materials can vary during their service life as radiation damage impacts the scattering cross-section. In an affordable development approach, high fidelity modeling and simulation tools are used to identify and characterize potential ‘knees-in-the-curves’ in the relationship that exists between the mission characteristics and the project risk. Of particular significance is use of modern uncertainty management and variance reduction methods to perform gap analyses that feed into phenomena identification and ranking tables (PIRT) commonly used to communicate nuclear readiness levels. Model-based measurements techniques are used to design sub-scale experiments as a substitute to minimize orcompletely eliminate the need for nuclear demonstrations.This paper will describe the approach and present preliminary results. It will lay the groundwork for developing a set of metrics that can be broadly characterized as system nuclear readiness levels and advancement degree of difficulty for nuclear systems. Equally importantly, a goal of this paper is to initiate a dialogue among stakeholders on what is the sufficient level of maturity that is required for launching a demonstration unit.

Dasari V Rao↗
DOE OSTI2020

Start-up of Silo 130 Waste Retrieval at La Hague: first Step Towards Reducing Legacy Inventory - 20020

On June 25, 2019, the first grapple of waste and debris was lifted from Silo 130, one of the most challenging legacy waste storage silos at La Hague. This was the achievement of more than ten years of studies and efforts focused on solving some very unique technical and safety challenges, and on designing an innovative, efficient solution. The waste is from de-cladding materials from past Gas-Cooled Reactor fuel reprocessing operations. It is an unsorted mixture of magnesium cladding pieces, graphite debris, and various other metallic waste types. These materials can be chemically reactive and therefore need specific dispositions for handling and storing. The building is more than 40 years old and does not meet modern standards. French safety authorities have required the silo to be emptied. After about three years of operation, the bulk of this waste will be removed and placed in safe storage, pending the selection of a final conditioning solution. Removal of bottom debris will then be possible. When finished, this operation will bring a conclusion to a significant legacy-related hazard on the site. The silo will then be available for final cleaning and de-activation. This paper will describe the technical, safety, and economical challenges, and the various decisions and optimizations that led to the definition of the process and technology to be implemented. Several innovative features were developed and implemented, in all sections of the project: project organization, progressive approach for the waste disposition strategy, light building design, customized and robust retrieval technology, processing technologies involving the most modern robotic and sorting techniques, storage method... Several of these first-of-a-kind innovative features have been developed and qualified specifically for this application, using the detailed qualification procedure specified for all La Hague projects. The facility was built in less than five years, overcoming various difficulties along the line. Commissioning is now finished with the combined efforts of the project, engineering, start-up, and operating teams assisted by dedicated suppliers. The facility is now ramping-up. The paper will also report on the commissioning and start-up of the facility and describe the first operational results. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1998

The Role of the Strutjet Engine in New Global and Space Markets

The Strutjet, discussed in previous IAF papers, was originally introduced as an enabling propulsion concept for single stage to orbit applications. Recent design considerations indicate that this systems also provides benefits supportive of other commercial non-space applications. This paper describes the technical progress of the Strutjet since 1997 together with a rationale why Rocket Based Combined Cycle Engines in general, and the Strutjet in particular, lend themselves uniquely to systems having the ability to expand current space and open new global 'rapid delivery' markets. During this decade, Strutjet technology has been evaluated in over 1000 tests. Its design maturity has been continuously improved and desired features, like simple variable geometry and low drag flowpath resulting in high performance, have been verified. In addition, data is now available which allows the designer, who is challenged to maximize system operability and economic feasibility, to choose between hydrogen or hydrocarbon fuels for a variety of application. The ability exists now to apply this propulsion system to various vehicles with a multitude of missions. In this paper, storable hydrocarbon and gaseous hydrogen Strutjet RBCC test data as accomplished to date and as planned for the future is presented, and the degree of required technology maturity achieved so far is assessed. Two vehicles, using cryogenic propane fuel Strutjet engines, and specifically designed for rapid point-to-point cargo delivery between Pacific rim locations are introduced, discussed, and compared.

Siebenhaar, A.↗
DOE OSTI2022

A signal packet router for the upgrade of the Muon spectrometer at the ATLAS experiment

Here, we present the design, characterization, and production of a signal packet router for the upgrade of the ATLAS forward muon detector. The router serves as a packet switch in one of the primary trigger paths. It handles up to 12 serial inputs at 4.8 Gbps/input from on-detector electronics and outputs four 4.8 Gbps to the trigger processing circuits. In the 12-to-4 packet switching process, the input streams are decoded and synchronized to a common clock domain for data packets forwarding and NULL packets suppression. Challenges in the design include operations of multi-giga hertz serial links with low and constant latency (<100 ns) for packet routing, as well as mitigation of radiation-induced effects in the harsh radiation environment over 10 years of detector operation. The Router design has been fully characterized and demonstrated to meet all specifications. In total 256 Routers were installed in the detector. Its design concept can be used in other similar applications, particularly in a radiation environment.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRS2020

Parabolic Deformable Mirror Testbed for the ExoSpec Project

The ExoSpec Project is a NASA Headquarters directed work package that links four different tasks at Goddard Space Flight Center to enable future missions to more efficiently characterize directly imaged exoplanets. One of the tasks is the development of parabolic deformable mirrors to improve on the current state-of-the-art wavefront sensing and control implementations, which are baselined to have two flat deformable mirrors (DMs) with high actuator count. To effectively control both amplitude and phase aberrations, the flat DMs need to have a large separation, which poses packaging challenges to missions designed to image rocky exoplanets. To eliminate this large separation, the parabolic DM architecture makes the off-axis imaging elements in the optical train controllable. Simulations also show performance enhancements with the architecture change; larger bandwidths have been shown to be controllable with the parabolic DMs and the number of required actuators can be reduced. With a 32×32 pupil flat DM and two 16x16 parabolic DMs, we could obtain a 5 - 12λ/D dark hole at 35%bandwidth. In addition to addressing the packaging challenge faced by future coronagraph missions, reducing the number of actuators reduces both cost and risk of having the entire coronagraph instrument’s performance depend on two high-actuator count DMs. To test these simulations, Goddard is building a testbed and has a vendor developing the parabolic DM. Here we present these simulations, the current testbed performance, and the development plan to incorporate and test the parabolic DMs

Coronagraph↗
NASA NTRS2011

Advanced Speckle Sensing for Internal Coronagraphs

A 4-8m telescope carrying a coronagraph instrument is a leading candidate for an anticipated flagship mission to detect and characterize Earth-size exoplanets in the 2020s. Many candidate coronagraph instruments have been proposed, and one has met many of the principal requirements for that mission. But the telescope and instrument will need exquisite stability and precise control of the incoming wavefront to enable detection of faint companions (10(exp -10) of the star) at an angular separation of 2-4 Airy radii. In particular, wavefront errors cause speckles in the image, and variations in those speckles can confound the exoplanet detection. This challenge is compounded by the background light from zodiacal dust around our Sun and the target star, which limits the speed with which we can estimate and correct the speckles. We are working on developing coherent speckle detection techniques that will allow rapid calibration of speckles on the science detector, allowing subtraction in post-processing or correction with deformable mirrors. The expected speed improvement allows a much quicker timeline for measurement & calibration, which reduces the required telescope stability requirement and eases both the flight system design and the challenge of ground testing. We will describe the experiments and summarize progress to date.

Terrestrial Planet Finder↗
NASA NTRSDate not supplied

Motor Configuration Selection for A New Technical Challenge to Develop A 5 MW Cryogenic Motor and Drive

Due to aviation’s appreciable and growing share of humanity’s impact on our environment and estimates that CO2emissions only account for 34% of aviation’s total effective radiative forcing [1], there is a need to reach beyond climate goals that focus only on CO2emissions, such as the US Aviation Climate Action Plan’s [3] goal to reach net-zero carbon emissions by 2050.There is motivation to develop technology that pushes toward future large transport aircraft with net zero climate impact that are highly electrified (i.e., have higher power electrical propulsion system components). This paper describes a new, 6-year technical challenge to address this need by developing a 5 MW superconducting motor and cryogenic drive. Section 1 will detail the motivation for this work. Section 2 will describe the technical challenge and the selected specifications for the motor. Section 3 will present the results of a motor configuration trade study and the down selection of one configuration to develop a detailed design for. The technical challenge focuses on the design of a5 MW superconducting motor and cryogenic drive and demonstration of it at a 2+ MW scale to achieve TRL 3. Both fully superconducting (superconducting stator and rotor) and fully cryogenic (superconducting rotor and cryogenic stator) machine configurations will be explored. An emphasis will be placed on addressing the key tall poles for high power superconducting machines. Further details will be included in the full paper. The requirements and goals of the motor will be detailed. The rated speed (2,000 to 3,000 rpm) is defined to be appropriate for directly driving multi-MW fans or propellers. A range of rated speed is permitted because the motor is not designed for a specific aircraft and to provide design flexibility if AC losses in the stator winding are found to be a significant constraint (i.e., a lower speed can be selected to reduce electrical frequency). Relatively conservative requirements for efficiency (99%) and specific power (20 kW/kg) are defined, because TRL advancement and pushing toward flight readiness is emphasized over performance optimization. However, more aggressive efficiency and specific power goals are specified (99.9% and 40 kW/kg). The 3rd section will present the results of a motor configuration trade study. The study started with a qualitative assessment of sixteen motor configurations based on geometric, mechanical, thermal, and electromagnetic criteria. This assessment has been completed with three evaluators scoring all nine criteria. A configuration down select was made by prioritizing the sixteen configurations into four tiers based on each configuration’s total score and consideration of manufacturability, complexity, and support hardware (e.g., rotary vacuum seals, bearings). Configurations in priority A and B will be further evaluated through quantitative assessments, whereas those in priority C will only be further evaluated if time permits and priority D will not be further evaluated. Eight of the sixteen configurations were down selected for quantitative assessment, which will include analytical calculations and low-to moderate-fidelity finite element analysis to produce a preliminary Pareto front of efficiency versus specific power for each configuration. This assessment emphasizes the calculation of AC losses in the stator winding and an exploration of thermal management approaches to remove that heat and maintain cryogenic temperature. The final paper will include a description of each motor configuration that was considered. The quantitative assessments are underway, and an assessment of one configuration is complete for multiple stator conductor options. The remaining assessments are scheduled to be completed by late March so that the final down select to one configuration can be included in this paper.

Net Zero↗
DOE OSTI2022

Emerging Trends and Systemic Issues Influencing Today’s U.S. Electric Grid

With increasing shifts from vertically integrated to horizontally structured operations and from centralized to distributed electric power delivery, today’s electric power grid (the “grid”) operators and designers face the challenge of creating an architecture that accommodates a host of diverse requirements. The grid’s modes of operation must address concerns of reliability and stability, new deployments of renewable energy sources, threats from cyber-attacks and natural disasters, and increasingly distributed system operations. Grid modernization calls for a reliable, affordable, sustainable, agile, secure, and resilient grid. However, the modernization of the U.S. power grid is hampered by mounting complexity and diverging objectives from owners and operators and is consequently risky and fraught with potential missteps. Flawed architecture, design, and implementation will lead to stranded investments and lost opportunities. A principled approach to minimize risk and develop a robust grid of the future is to begin with a sound architecture for the grid to inform the design process. Architecture development starts with the context of influencing factors that provide constraints as well as driving goals. This report provides the context of emerging trends and cross-cutting systemic issues in the U.S. electric power grid and serves as a vital input for grid architecture development.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Bridging the Void: Halogen Bonding and Aromatic Interactions to Program Luminescence and Electronic Properties of π -Conjugated Materials in the Solid State

π-Conjugated materials are promising candidates for emerging organic optoelectronic devices empowered by molecular design. The unsolved challenges of predicting and controlling their packing as solids, central to their properties and performance, currently limits their practical application. As noncovalent interactions drive packing, control over such interactions are critical to bridging from chemical structure to functional properties. In molecular crystals, halogen bonding and interactions of aromatic rings have emerged as versatile tools for noncovalent control with tailored luminescence and electronic properties. Here, we describe how the interplay of these directional and tunable interactions can engineer properties, including stimuli-responsive behavior. Specifically, halogen bonding can provide robust designs for directing 2D molecular assembly, whereas the intentional interactions of aromatic rings can yield metastable, switchable packing modes, as well as programmed stacking between layers of chromophores. Examples, herein, demonstrate clear relationships between assembly by design and resulting solid-state properties, and strategies presented offer guidance for future designs of π-conjugated molecular materials using specific aromatic interactions and halogen bonding.

36 MATERIALS SCIENCE↗
NASA NTRS2011

Solid Rocket Booster (SRB) Flight System Integration at Its Best

The Solid Rocket Booster (SRB) element integrates all the subsystems needed for ascent flight, entry, and recovery of the combined Booster and Motor system. These include the structures, avionics, thrust vector control, pyrotechnic, range safety, deceleration, thermal protection, and retrieval systems. This represents the only human-rated, recoverable and refurbishable solid rocket ever developed and flown. Challenges included subsystem integration, thermal environments and severe loads (including water impact), sometimes resulting in hardware attrition. Several of the subsystems evolved during the program through design changes. These included the thermal protection system, range safety system, parachute/recovery system, and others. Because the system was recovered, the SRB was ideal for data and imagery acquisition, which proved essential for understanding loads, environments and system response. The three main parachutes that lower the SRBs to the ocean are the largest parachutes ever designed, and the SRBs are the largest structures ever to be lowered by parachutes. SRB recovery from the ocean was a unique process and represented a significant operational challenge; requiring personnel, facilities, transportation, and ground support equipment. The SRB element achieved reliability via extensive system testing and checkout, redundancy management, and a thorough postflight assessment process. However, the in-flight data and postflight assessment process revealed the hardware was affected much more strongly than originally anticipated. Assembly and integration of the booster subsystems required acceptance testing of reused hardware components for each build. Extensive testing was done to assure hardware functionality at each level of stage integration. Because the booster element is recoverable, subsystems were available for inspection and testing postflight, unique to the Shuttle launch vehicle. Problems were noted and corrective actions were implemented as needed. The postflight assessment process was quite detailed and a significant portion of flight operations. The SRBs provided fully redundant critical systems including thrust vector control, mission critical pyrotechnics, avionics, and parachute recovery system. The design intent was to lift off with full redundancy. On occasion, the redundancy management scheme was needed during flight operations. This paper describes some of the design challenges and technical issues, how the design evolved with time, and key areas where hardware reusability contributed to improved system level understanding.

Wood, T. David↗