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DOE OSTI2020

Malleable Thermosets (Vitrimers) from CO 2 and Plants

Fiber-reinforced composite materials are increasingly used to replace heavy metal components in transportation applications for lightweighting purposes. Polymer matrix materials used in automotive parts, such as epoxies, nylons, and polypropylenes, are almost all produced from fossil fuels. Higher performance thermoset composites are generally not repairable and lower-cost thermoplastic composites do not have enough performance to replace steel. Vitrimers are a new class of polymer materials with long shelf life, low waste in production, ease of processing, and repairability that have the potential to break through the high-cost thermoset/low-performance thermoplastic barrier to vehicle light-weighting. Vitrimers also exhibit easier chemical recyclability than conventional thermosets with reversible chemical crosslinking that enables reprocessing of scrap from production and end of life components. Vitrimers are a new class of engineered plastics that are weldable, repairable and recyclable like thermoplastics but have high mechanical properties like thermosets. Bio-based vitrimers have only recently been reported in the academic and patent literature. These materials represent an unusual opportunity to meet both VTO light-weighting targets for low-density, high performance materials and BETO sustainability targets for value-added high-volume applications of bio-fuel byproducts. Also, PNNL researchers have previously demonstrated a process to convert CO 2 into potential vitrimer precursors. Washington State University (WSU) success in demonstration of bio-based vitrimers and recent steps toward commercialization of petroleum-based vitrimers support the opportunity for PNNL success in development of sustainable vitrimer materials for recyclable, high-performance fiber-reinforced composites for the transportation sectors.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Cold Spray Additive Manufacturing For New Pipeline Fabrication In Live, Natural Gas Distribution Mains

ULC Technologies (ULC) and the Penn State University Applied Research Lab (PSU ARL) developed a process and approach for rehabilitating live, natural gas distribution pipelines using Cold Spray Additive Manufacturing (CSAM). Robotic inline fabrication of a new pipe will be performed inside a natural gas main without disrupting customers. The material studied was blended with stainless steel which offers corrosion resistance, high strength and compatibility with hydrogen to enable a robust pipeline system that is future proofed. Stainless steel coatings sprayed and tested in the lab showed excellent strength, ductility, and porosity values. ULC initially sought to use methane as the process gas for compatibility with the host pipe, but after evaluating the field and lab challenges, nitrogen was deemed to be more suitable. Early robotic concepts have been developed that indicate technical feasibility. While the technology development originally targeted natural gas distribution mains, market research showed a broader need. Spot repairs performed in natural gas transmission mains may be a more economical approach for reinforcing distribution and transmission mains compared with full pipe-in-pipe rehabilitation. Additive manufacturing offers custom programming, as well as high accuracy and precision. This means custom contours can be manufactured in situ, offering flexibility in the repair solution, such as fabricating internal full circumferential sleeves. The value of the repair can be high at difficult-to-reach locations and in pipes that need reinforcement before the injection of methane-hydrogen blends.

03 NATURAL GAS↗

DOE OSTI2022

Gamma Spectrometry Code Rodeo for Uranium Enrichment—FY 2021 Report

In FY22, the participating Department of Energy (DOE) laboratories continued the work on the project “Gamma Spectrometry Code Rodeo for Uranium Enrichment”. Oak Ridge National Laboratory (ORNL) and Lawrence Livermore National Laboratory (LLNL) continued their efforts to acquire spectra using uranium sources. A collimator (with side and back shields) was custom designed and constructed at ORNL. Spectra were acquired at ORNL using the uranium enrichment standards supplied by New Brunswick Laboratory (NBL) and the collimated M400 detector. Spectra were also acquired using steel absorbers of different thickness placed between the source and the collimated M400 detector. The plan was to ship the collimator to LLNL so that spectra could be acquired using the LLNL detector in collimated geometries. This activity was suspended since problems were noticed with the performance of the LLNL M400 detector. Also, it was brought to light to the project team that some of the aspects of the M400 detector had been updated by the vendor H3D in response to requests by the IAEA. In February 2021, the ORNL and LLNL M400 detectors were returned to the H3D factory in order to resolve the problems with the LLNL detector and to update ORNL and LLNL detectors to the same configuration as the M400 supplied to the IAEA. H3D repaired the LLNL M400 and performed the IAEA updates on both the ORNL and LLNL detectors. ORNL and LLNL received the detectors in April 2021. Data acquisition was continued using the upgraded detectors. ORNL re-collected the spectra using point sources and the NBL standards in uncollimated and collimated geometries. The collimator was shipped from ORNL to LLNL. Spectra were acquired at LLNL through Q4 of FY22. When the ORNL spectra were examined closely, it became apparent that there were spurious artifacts present in some of the spectra. This rendered suspect the ORNL spectra collected in June/July 2021 time frame. ORNL contacted H3D and per H3D’s advice, the M400 detector was returned to H3D for repairs in mid-August 2021. H3D diagnosed the problem and established that the root cause was the extra tight packaging that created a strain on the CZT crystals, causing one of them to break down. The repaired M400 was returned to ORNL in early September 2021. ORNL re-started data acquisition for the third time. Data was continued to be acquired at ORNL and LLNL through September 2021. The ORNL and LLNL data will be shared with the principal investigators from the analyzing laboratories. The GADRAS code and FRAM have been developed to have the capability to analyze the M400 spectra. Good quality spectra from FY21 have been analyzed using modified versions of GADRAS and FRAM. The spectra have also been analyzed using the GEM code. The analysis results from GADRAS, FRAM and GEM codes are presented and discussed in this report. Some preliminary results from FRAM and GEM analysis were presented in February 2021 at the U-Pu Isotopics Workshop sponsored by the IAEA. CZTU code is being modified to analyze M400 spectra. Data collection, code development and analysis will be continued in FY22 as per the FY22 Project Work Plan (PWP).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2018

Maintaining Genome Integrity during Seed Development in Phaseolus vulgaris L.: Evidence from a Transcriptomic Profiling Study

The maintenance of genome integrity is crucial in seeds, due to the constant challenge of several endogenous and exogenous factors. The knowledge concerning DNA damage response and chromatin remodeling during seed development is still scarce, especially in Phaseolus vulgaris L. A transcriptomic profiling of the expression of genes related to DNA damage response/chromatin remodeling mechanisms was performed in P. vulgaris seeds at four distinct developmental stages, spanning from late embryogenesis to seed desiccation. Of the 14,001 expressed genes identified using massive analysis of cDNA ends, 301 belong to the DNA MapMan category. In late embryogenesis, a high expression of genes related to DNA damage sensing and repair suggests there is a tight control of DNA integrity. At the end of filling and the onset of seed dehydration, the upregulation of genes implicated in sensing of DNA double-strand breaks suggests that genome integrity is challenged. The expression of chromatin remodelers seems to imply a concomitant action of chromatin remodeling with DNA repair machinery, maintaining genome stability. The expression of genes related to nucleotide excision repair and chromatin structure is evidenced during the desiccation stage. An overview of the genes involved in DNA damage response and chromatin remodeling during P. vulgaris seed development is presented, providing insights into the mechanisms used by developing seeds to cope with DNA damage.

seed development↗

NASA NTRS1973

Recovery of recordings from heat damaged magnetic tapes

Damaged tapes can now be repaired at home as long as damage does not extend to layer-to-layer adhesion within tape roll. Splice repaired section into good roll or cassette for copying. Every effort should be made to complete copying on first run, because fidelity in repaired section deteriorates with each repetition.

Melugin, J. F.↗

NASA NTRS1974

The role of manned extravehicular activity in reducing the cost of space payloads

Substantial cost savings and performance improvement will result by the use of Extravehicular Activity (EVA) to supplement or replace automation. Taking an all-pallet version of Langley Research Center's Advanced Technology Laboratory payload as an example, $54.5 million should be saved by EVA over automation, considering deployment and stowing only. Additional savings should accrue when reduced-reliability equipment (where permitted) is substituted for high reliability equipment and EVA is used for repairs. More comprehensively, launch and operation costs could also be reduced by elimination of the need to return to the ground for repairs; and production spending might be reduced when an entire vehicle was saved by manned EVA repair not feasible via automation. Potential disadvantages include increased cost due to development and manufacture of EVA equipment, payload provisions to enable EVA interfaces, training, orbiter modification, and prevention of EVA-caused contamination. Possible applications to the Space Shuttle missions are discussed.

Alton, L. R.↗

NASA NTRS1978

Commercial Fishing Port Development in North Florida

The author has identified the following significant results. Seven major counties were examined: Escambia, Bay, Gulf, Franklin, Wakulla, Nassau, and Duval. Population and economic activity were reviewed, along with commercial fishing and port facilities. Recommendations for five northwest Florida counties were based on interpretation of aerial photographs, satellite imagery, an aerial survey site visit, and published data. Major needs in Pensacola included docking, ice supply, and net and engine repair services. Costs for additional docks, an ice plant, and gear storage were estimated at $3,658,600. Port users in Panama City identified additional docking and gear storage as primary needs, along with gear repair and a marine railway. Estimated costs for dock and gear storage were $2,860,000. Added docking, gear storage, and ice supply, as well as gear electronics and diesel repair were needed in Port St. Joe. Costs were calculated at $1,231,500. Franklin County has three ports (Apalachicola - $1,107,000 for docks and gear storage, Eastpoint - $420,000 for additional docks, and Carrabella - $2,824,100 for docks, gear storage, and ice plant).

Mathis, K.↗

NASA NTRS1981

Study to define an approach for developing a computer-based system capable of automatic, unattended assembly/disassembly of spacecraft, phase 1

The initial set of requirements for additional studies necessary to implement a space-borne, computer-based work system capable of achieving assembly, disassembly, repair, or maintenance in space were developed. The specific functions required of a work system to perform repair and maintenance were discussed. Tasks and relevant technologies were identified and delineated. The interaction of spacecraft design and technology options, including a consideration of the strategic issues of repair versus retrieval-replacement or destruction by removal were considered along with the design tradeoffs for accomplishing each of the options. A concept system design and its accompanying experiment or test plan were discussed.

Nevins, J. L.↗

NASA NTRS1986

Dust collection on serviceable satellites

One rationale for the Space Shuttle program which was dramatically realized during the repair of the Solar Maximum Mission (SMM) is the efficiency of in-orbit satellite servicing. An unexpected benefit of this repair mission was the return of parts of the Solar Max satellite which had been exposed for four years to the space environment. Studies conducted on these parts have yielded valuable data on the micrometeorite flux and composition at shuttle altitudes during this time period. The scientific results from studies of the cosmic dust component of the observed particle impacts are not yet complete but it is clear from the preliminary data available that such studies will be a valuable adjunct to the studies of cosmic dust particles collected in the atmosphere. The success of the initial studies of particles collected during repairs of the SMM spacecraft on a surface not specifically designed as a particle collector nor retrieved in a manner intended to minimize or eliminate local contamination raises the possibility that even more interesting results might be obtained if serviceable satellites were initially designed with these objectives in mind. All designs for modern satellites utilize some form of thermal blanket material in order to minimize thermal stresses inside the spacecraft. It is proposed that all future satellites be designed with standardized removeable sections of thermal blanket material which could be replaced during on-orbit servicing and returned to earth for detailed study.

Nuth, J. A., III↗

NASA NTRS1986

Automation, robotics, and inflight training for manned Mars missions

The automation, robotics, and inflight training requirements of manned Mars missions will be supported by similar capabilities developed for the space station program. Evolutionary space station onboard training facilities will allow the crewmembers to minimize the amount of training received on the ground by providing extensive onboard access to system and experiment malfunction procedures, maintenance procedures, repair procedures, and associated video sequences. Considerable on-the-job training will also be conducted for space station management, mobile remote manipulator operations, proximity operations with the Orbital Maneuvering Vehicle (and later the Orbit Transfer Vehicle), and telerobotics and mobile robots. A similar approach could be used for manned Mars mission training with significant additions such as high fidelity image generation and simulation systems such as holographic projection systems for Mars landing, ascent, and rendezvous training. In addition, a substantial increase in the use of automation and robotics for hazardous and tedious tasks would be expected for Mars mission. Mobile robots may be used to assist in the assembly, test and checkout of the Mars spacecraft, in the handling of nuclear components and hazardous chemical propellent transfer operations, in major spacecraft repair tasks which might be needed (repair of a micrometeroid penetration, for example), in the construction of a Mars base, and for routine maintenance of the base when unmanned.

Holt, Alan C.↗

NASA NTRS1987

Technology advancements for servicing of future spacecraft systems

Problems associated with the in-orbit repair and maintenance of spacecraft systems are examined with reference to experience gained from three servicing missions: in-orbit capture, repair, and reflight of the Solar Maximum Mission satellite, capture and return to earth of the Palapa and Westar communications satellites, and in-orbit repair of Syncom 3. It is then shown how the lessons learned from the three servicing missions are applied to current and future servicing activities. In particular, planned servicing missions for the Hubble Space Telescope, tools and servicing facilities development, and the development of the Explorer Platform are discussed.

Cepollina, F. J.↗

NASA NTRS1989

Information management in an integrated space telerobot

The in-orbit operations, like space structures inspection, servicing and repairing, is expected to be one of the most significant technological area for application and development of Robotics and Automation in Space Station environment. The Italian National Space Plan (PSN) has started up its strategic programme SPIDER (Space Inspection Device for Extravehicular Repairs), which is scheduled in three phases, with the final goal of performing docking and precision repairing in the Space Station environment. SPIDER system is an autonomous integrated space robot, using mature Artificial Intelligence tools and technics for its operational control. The preliminary results of a study on the information architecture of the spacecraft are described.

Dipippo, S.↗

NASA NTRS1991

ETARA PC version 3.3 user's guide: Reliability, availability, maintainability simulation model

A user's manual describing an interactive, menu-driven, personal computer based Monte Carlo reliability, availability, and maintainability simulation program called event time availability reliability (ETARA) is discussed. Given a reliability block diagram representation of a system, ETARA simulates the behavior of the system over a specified period of time using Monte Carlo methods to generate block failure and repair intervals as a function of exponential and/or Weibull distributions. Availability parameters such as equivalent availability, state availability (percentage of time as a particular output state capability), continuous state duration and number of state occurrences can be calculated. Initial spares allotment and spares replenishment on a resupply cycle can be simulated. The number of block failures are tabulated both individually and by block type, as well as total downtime, repair time, and time waiting for spares. Also, maintenance man-hours per year and system reliability, with or without repair, at or above a particular output capability can be calculated over a cumulative period of time or at specific points in time.

Hoffman, David J.↗

NASA NTRS1991

End-effector for robotic assembly of welded truss structures in space

In June 1987, work was initiated at LaRC on end-effectors and preloaded joints for robotic truss assembly. This is part of an on-going research effort centered on a test facility that assembles 1 inch x 2 m identical struts into an 8 m diameter x 1.5 m deep platform truss. A detailed description of the test facility was published. The end-effector being used for the LaRC assembly demonstration is quite suitable for the Precision Segmented Reflector or other precision applications. These require high stiffness provided by mechanical joint preloads. Stiffness obtained in this manner is only required and provided over a load range far less than the ultimate strength of the strut tubes. Beyond this useful range, truss behavior is somewhat unpredictable. Mechanically preloaded joints of this type are less suitable for applications such as the Aero Brake where predictable strength and stiffness are required over a greater fraction of the load bearing capacity of component parts. Preliminary studies of the Aerobrake support truss indicate that struts of at least 3 different diameters and various lengths would improve performance. The double-ended end-effector currently in service is designed for only one diameter and length. Anticipated single-ended versions can accommodate varying lengths but not multiple diameters. Tradeoff considerations for welded joints relative to their mechanically preloaded counterparts are presented. Conclusions from this research are as follows: (1) repair by cut and re-weld on the original weld site should be research; (2) welded joints, though repairable, should not be used where high repair frequencies are anticipated; and (3) welded joints should be considered for an Aero Brake truss.

Brewer, William V.↗

NASA NTRS1991

Constraint-based scheduling

The GERRY scheduling system developed by NASA Ames with assistance from the Lockheed Space Operations Company, and the Lockheed Artificial Intelligence Center, uses a method called constraint-based iterative repair. Using this technique, one encodes both hard rules and preference criteria into data structures called constraints. GERRY repeatedly attempts to improve schedules by seeking repairs for violated constraints. The system provides a general scheduling framework which is being tested on two NASA applications. The larger of the two is the Space Shuttle Ground Processing problem which entails the scheduling of all the inspection, repair, and maintenance tasks required to prepare the orbiter for flight. The other application involves power allocation for the NASA Ames wind tunnels. Here the system will be used to schedule wind tunnel tests with the goal of minimizing power costs. In this paper, we describe the GERRY system and its application to the Space Shuttle problem. We also speculate as to how the system would be used for manufacturing, transportation, and military problems.

Zweben, Monte↗

NASA NTRS1991

Constraint-based scheduling

The GERRY scheduling system developed by NASA Ames with assistance from the Lockheed Space Operations Company, and the Lockheed Artificial Intelligence Center, uses a method called constraint based iterative repair. Using this technique, one encodes both hard rules and preference criteria into data structures called constraints. GERRY repeatedly attempts to improve schedules by seeking repairs for violated constraints. The system provides a general scheduling framework which is being tested on two NASA applications. The larger of the two is the Space Shuttle Ground Processing problem which entails the scheduling of all inspection, repair, and maintenance tasks required to prepare the orbiter for flight. The other application involves power allocations for the NASA Ames wind tunnels. Here the system will be used to schedule wind tunnel tests with the goal of minimizing power costs. In this paper, we describe the GERRY system and its applications to the Space Shuttle problem. We also speculate as to how the system would be used for manufacturing, transportation, and military problems.

Zweben, Monte↗

NASA NTRS1992

Space Shuttle Orbiter Fleet Leader Orbital Maneuvering Engine SN 002A injector replacement

During testing of the Fleet Leader Orbital Maneuvering Engine (OME) Serial Number (SN) 002A at the White Sands Test Facility (WSTF) in 1983 the injector was inadvertently damaged. After testing was completed in 1985, there was a concern that the performance of the engine and its response to specific test conditions might not be sufficiently representative of flight engines to provide valid test results. To correct this damage, the engine was returned to the manufacturer to replace the injector. The task assigned was to evaluate the damage and generate a unique process to repair the Fleet Leader OME while providing minimum impact to the overall life condition of the engine. In addition to successfully performing the repair operation, the as received condition of the engine and its components were documented for Fleet Leader reference. The engine is currently at WSTF where it has accumulated 11,341 seconds of firing time to date, 2615 seconds of which have occurred since the engine repair.

Riccio, Joseph R.↗

NASA NTRS1992

Increasingly automated procedure acquisition in dynamic systems

Procedures are widely used by operators for controlling complex dynamic systems. Currently, most development of such procedures is done manually, consuming a large amount of paper, time, and manpower in the process. While automated knowledge acquisition is an active field of research, not much attention has been paid to the problem of computer-assisted acquisition and refinement of complex procedures for dynamic systems. The Procedure Acquisition for Reactive Control Assistant (PARC), which is designed to assist users in more systematically and automatically encoding and refining complex procedures. PARC is able to elicit knowledge interactively from the user during operation of the dynamic system. We categorize procedure refinement into two stages: diagnosis - diagnose the failure and choose a repair - and repair - plan and perform the repair. The basic approach taken in PARC is to assist the user in all steps of this process by providing increased levels of assistance with layered tools. We illustrate the operation of PARC in refining procedures for the control of a robot arm.

Mathe, Nathalie↗