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Hybrid piezoelectric/fiber-optic (HyPFO) sensor sheets are undergoing development. They are intended for use in nondestructive evaluation and long-term monitoring of the integrity of diverse structures, including aerospace, aeronautical, automotive, and large stationary ones. It is anticipated that the further development and subsequent commercialization of the HyPFO sensor systems will lead to economic benefits in the form of increased safety, reduction of life-cycle costs through real-time structural monitoring, increased structural reliability, reduction of maintenance costs, and increased readiness for service. The concept of a HyPFO sensor sheet is a generalization of the concept of a SMART Layer(TradeMark), which is a patented device that comprises a thin dielectric film containing an embedded network of distributed piezoelectric actuator/sensors. Such a device can be mounted on the surface of a metallic structure or embedded inside a composite-material structure during fabrication of the structure. There is has been substantial interest in incorporating sensors other than piezoelectric ones into SMART Layer(TradeMark) networks: in particular, because of the popularity of the use of fiber-optic sensors for monitoring the "health" of structures in recent years, it was decided to incorporate fiber-optic sensors, giving rise to the concept of HyPFO devices.
The Orion CSM umbilical retention and release mechanism supports and protects all of the cross-module commodities between the spacecrafts crew and service modules. These commodities include explosive transfer lines, wiring for power and data, and flexible hoses for ground purge and life support systems. The mechanism employs a single separation interface which is retained with pyrotechnically actuated separation bolts and supports roughly two dozen electrical and fluid connectors. When module separation is commanded, either for nominal on-orbit CONOPS or in the event of an abort, the mechanism must release the separation interface and sever all commodity connections within milliseconds of command receipt. There are a number of unique and novel aspects of the design solution developed by the Orion mechanisms team. The design is highly modular and can easily be adapted to other vehiclesmodules and alternate commodity sets. It will be flight tested during Orions Exploration Flight Test 1 (EFT-1) in 2014, and the Orion team anticipates reuse of the design for all future missions. The design packages fluid, electrical, and ordnance disconnects in a single separation interface. It supports abort separations even in cases where aerodynamic loading prevents the deployment of the umbilical arm. Unlike the Apollo CSM umbilical which was a destructive separation device, the Orion design is resettable and flight units can be tested for separation performance prior to flight.Initial development testing of the mechanisms separation interface resulted in binding failures due to connector misalignments. The separation interface was redesigned with a robust linear guide system, and the connector separation and boom deployment were separated into two discretely sequenced events. These changes addressed the root cause of the binding failure by providing better control of connector alignment. The new design was tuned and validated analytically via Monte Carlo simulation. The analytical validation was followed by a repeat of the initial test suite plus test cases at thermal extremes and test cases with imposed mechanical failures demonstrating fault tolerance. The mechanism was then exposed to the qualification vibration environment. Finally, separation testing was performed at full speed with live ordnance.All tests of the redesigned mechanism resulted in successful separation of the umbilical interface with adequate force margins and timing. The test data showed good agreement with the predictions of the Monte Carlo simulation. The simulation proved invaluable due to the number of variables affecting the separation and the uncertainty associated with each. The simulation allowed for rapid assessment of numerous trades and contingency scenarios, and can be easily reconfigured for varying commodity sets and connector layouts.
The Orion Crew-Service Module umbilical retention and release mechanism supports, protects and disconnects all of the cross-module commodities between the spacecraft's crew and service modules. These commodities include explosive transfer lines, wiring for power and data, and flexible hoses for ground purge and life support systems. Initial development testing of the mechanism's separation interface resulted in binding failures due to connector misalignments. The separation interface was redesigned with a robust linear guide system, and the connector separation and boom deployment were separated into two discretely sequenced events. Subsequent analysis and testing verified that the design changes corrected the binding. This umbilical separation design will be used on Exploration Flight Test 1 (EFT-1) as well as all future Orion flights. The design is highly modular and can easily be adapted to other vehicles/modules and alternate commodity sets.
The Orion Crew-Service Module umbilical retention and release mechanism supports, protects and disconnects all of the cross-module commodities between the spacecraft's crew and service modules. These commodities include explosive transfer lines, wiring for power and data, and flexible hoses for ground purge and life support systems. Initial development testing of the mechanism's separation interface resulted in binding failures due to connector misalignments. The separation interface was redesigned with a robust linear guide system, and the connector separation and boom deployment were separated into two discretely sequenced events. Subsequent analysis and testing verified that the design changes corrected the binding. This umbilical separation design will be used on Exploration Flight Test 1 (EFT-1) as well as all future Orion flights. The design is highly modular and can easily be adapted to other vehicles/modules and alternate commodity sets.
Fiber-reinforced Ceramic Matrix Composites (CMCs) are currently being used in high-temperature applications such as jet engine components. In such extreme environment applications, materials are exposed to many mechanical and thermal loading cycles during the life of the component. This exposure can degrade the component, and thus, components need to be monitored and inspected during service. The electrical resistivity nondestructive evaluation technique has been shown to be very sensitive to damage in CMCs, and although its performance is highly dependent on temperature, this temperature-dependence is still not well understood. Therefore, this current study aims to establish the influence of thermal cycles, creep, CVI-SiC matrix cracks and fiber volume fraction on the electrical resistance of Hi Nicalon and Hi-Nicalon Type S SiC fiber-reinforced minicomposites with BN interphases. Minicomposites with 97% CVI-SiC matrix volume fraction were used to characterize the electrical resistivity of the CVI-SiC matrix. Next, models were constructed to calculate fiber resistivity and onset and evolution of damage during tensile testing at room-temperature. The thermal cycles were achieved by heating as-received and precracked specimens to 1200°C and then cooling them to room temperature, with or without applied stress on fibers.
The Exploration Extravehicular Mobility Unit (xEMU) uncrewed 11 foot vacuum chamber testing evaluated the capabilities of the 11 foot vacuum chamber facility to support advanced spacesuit testing. The government reference design xEMU spacesuit provided a high-fidelity test article to demonstrate 11 foot vacuum chamber capabilities which included: gas loading of the chamber at varying simulated metabolic rates and open loop suit abort operations, Intravehicular Activity (IVA) vacuum access, consumables recharge, IVA vehicle-provided thermal loop cooling, and IVA vehicle-provided power. To demonstrate the xEMU airlock operations transitioning from IVA to EVA conditions without a test subject in the suit, test support equipment was developed to remotely actuate both the Exploration, Servicing, and Cooling Umbilical (ESCU) and the vacuum access umbilical. This test also evaluated the performance of the Exploration Portable Life Support System (xPLSS) at vacuum conditions. Data was collected and analyzed for carbon dioxide (CO2) scrubbing performance of the Rapid Cycle Amine (RCA) swingbed, for thermal regulation performance of the Suit Water Membrane Evaporator (SWME), and for sensor performance across the xPLSS. This paper will detail the findings of the testing performed with these upgrades which discussed previously laid out in ICES-2025-342.
The Exploration Extravehicular Mobility Unit (xEMU) uncrewed 11 foot vacuum chamber testing evaluated the capabilities of the 11 foot vacuum chamber facility to support advanced spacesuit testing. The government reference design xEMU spacesuit provided a high-fidelity test article to demonstrate 11 foot vacuum chamber capabilities which included: gas loading of the chamber at varying simulated metabolic rates and open loop suit abort operations, Intravehicular Activity (IVA) vacuum access, consumables recharge, IVA vehicle-provided thermal loop cooling, and IVA vehicle-provided power. To demonstrate the xEMU airlock operations transitioning from IVA to EVA conditions without a test subject in the suit, test support equipment was developed to remotely actuate both the Exploration, Servicing, and Cooling Umbilical (ESCU) and the vacuum access umbilical. This test also evaluated the performance of the Exploration Portable Life Support System (xPLSS) at vacuum conditions. Data was collected and analyzed for carbon dioxide (CO2) scrubbing performance of the Rapid Cycle Amine (RCA) swingbed, for thermal regulation performance of the Suit Water Membrane Evaporator (SWME), and for sensor performance across the xPLSS. This paper will detail the findings of the testing performed with these upgrades which discussed previously laid out in ICES-2025-342.
The words reliability, robustness, and resilience are often used interchangeably to describe tough and dependable systems but the distinctions between them suggest how to design more serviceable space systems. Reliability is simply the quality of consistently performing well. A system that dependably meets its design requirements in the specified environment is reliable. The designers may not consider themselves responsible for failures under unanticipated conditions. Robustness is the capability of performing without failure under a wide range of conditions, which can go beyond the expected range to include possible off-nominal conditions. Resilience is the ability to recover from or adapt to unanticipated damaging events, such as failures, accidents, external disruptions, and repurposing. Such changes can invalidate the usual operating assumptions and cause system failure. Reliability, robustness, and resilience describe dependable performance under increasingly difficult conditions, first the specified environment, then a wider possible environment, and finally unanticipated damaging conditions. These three qualities are increasingly desirable and increasingly difficult to achieve. Engineering for resilience would design systems that can ignore or repair failures, survive accidents, and recover from unanticipated disruptions. Increasing the resilience of space systems would greatly increase space crew safety. Improving reliability and robustness requires dealing with known problems, but improving resilience requires implementing a general approach to reducing the impact of unknown future events. The need for robustness and resilience has been stated for decades but little has been done. Systems designers often assume that they understand everything they need to know. The potential failures caused by changes, failures, accidents, unknown environments, and unknown unknowns can be ignored. Such overconfidence can lead to neglect of reliability, robustness, and resilience.
The words reliability, robustness, and resilience are often used interchangeably to describe tough and dependable systems but the distinctions between them suggest how to design more serviceable space systems. Reliability is simply the quality of consistently performing well. A system that dependably meets its design requirements in the specified environment is reliable. The designers may not consider themselves responsible for failures under unanticipated conditions. Robustness is the capability of performing without failure under a wide range of conditions, which can go beyond the expected range to include possible off-nominal conditions. Resilience is the ability to recover from or adapt to unanticipated damaging events, such as failures, accidents, external disruptions, and repurposing. Such changes can invalidate the usual operating assumptions and cause system failure. Reliability, robustness, and resilience describe dependable performance under increasingly difficult conditions, first the specified environment, then a wider possible environment, and finally unanticipated damaging conditions. These three qualities are increasingly desirable and increasingly difficult to achieve. Engineering for resilience would design systems that can ignore or repair failures, survive accidents, and recover from unanticipated disruptions. Increasing the resilience of space systems would greatly increase space crew safety. Improving reliability and robustness requires dealing with known problems, but improving resilience requires implementing a general approach to reducing the impact of unknown future events. The need for robustness and resilience has been stated for decades but little has been done. Systems designers often assume that they understand everything they need to know. The potential failures caused by changes, failures, accidents, unknown environments, and unknown unknowns can be ignored. Such overconfidence can lead to neglect of reliability, robustness, and resilience.
A solar array segment was recently removed from the Mir core module and returned for ground-based analysis. The segment, which is similar to the ones the Russians have provided for the FGB and Service Modules, was microscopically examined and disassembled by US and Russian science teams. Laboratory analyses have shown the segment to he heavily contaminated by an organic silicone coating, which was converted to an organic silicate film by reactions with atomic oxygen within the. orbital flight environment. The source of the contaminant was a silicone polymer used by the Russians as an adhesive and bonding agent during segment construction. During its life cycle, the array experienced a reduction in power performance from approx. 12%, when it was new and first deployed, to approx. 5%, when it was taken out of service. However, current-voltage measurements of three contaminated cells and three pristine, Russian standard cells have shown that very little degradation in solar array performance was due to the silicate contaminants on the solar cell surfaces. The primary sources of performance degradation is attributed to "thermal hot-spotting" or electrical arcing; orbital debris and micrometeoroid impacts; and possibly to the degradation of the solar cells and interconnects caused by radiation damage from high energy protons and electrons.
"This study report summarizes technological developments in science-required contamination control for cost-capped, life-detection missions in the Solar System. Technology advances focus on developing implementable strategies to restrict contamination of the spacecraft and instruments by the launch vehicle hardware. Secondary bake out operations during cruise further reduce molecular contaminants down to femtomolar levels in the sample path. The study validated a full-spacecraft, deployable barrier design as an effective strategy to isolate the spacecraft from the pre-launch processing and launch environment (e.g., fairing acoustic materials). It accommodates late mounting of RTGs and other required prelaunch activities. A new, high-fidelity physics, contamination-transport model for particles (including cells and their parts) and science-relevant molecules (e.g., possible biomolecules) was developed to validate the barrier concept. Importantly, this model takes into account the physics of extremely clean surfaces achieved by the best traditional contamination engineering. The ability to deal with very low levels of particulate and molecular contamination makes this model unique among standard contamination modeling approaches. Modeling also demonstrated that a high-temperature bake out during interplanetary cruise of the sample collector that comprises the largest surface area in the sample path for an Enceladus orbiter reference mission, was extremely effective. This study included the evaluation of other details necessary for an effective contamination control strategy for life detection missions including feasibility of achieving parts per trillion level cleanliness for semi-volatile hydrocarbons in nitrogen purge gas, identification of launch vehicle services required for the baseline contamination control, and defining additional contamination control measures to be taken during launch operations. Key results of the study are: • New spacecraft barrier design that accommodates RTGs is readily cleanable and repairable. Deployment of a 1/3 scale model was successfully demonstrated. • The barrier reduces particle contamination (likely biological) from fairing to spacecraft by 1e-2 to 1e-3. • On-cruise bake-out of critical surfaces significantly reduced molecular contamination (by as much as 1e-12). Subsequently, the probability of a surface contamination particle being transported to an instrument by an ice particle is less than 5.1e-5 (for microbes specifically, 4.39e-10). The report concludes that a full-spacecraft barrier designed specifically for life-detection missions that require stringent control of particulate and molecular contaminates is an effective means of mitigating risks of false positive and negative results for life signature investigations. Further, secondary cleaning steps for critical sections of the sample path can be highly effective at reducing molecular contaminants to low femtomolar levels."
"This study report summarizes technological developments in science-required contamination control for cost-capped, life-detection missions in the Solar System. Technology advances focus on developing implementable strategies to restrict contamination of the spacecraft and instruments by the launch vehicle hardware. Secondary bake out operations during cruise further reduce molecular contaminants down to femtomolar levels in the sample path. The study validated a full-spacecraft, deployable barrier design as an effective strategy to isolate the spacecraft from the pre-launch processing and launch environment (e.g., fairing acoustic materials). It accommodates late mounting of RTGs and other required prelaunch activities. A new, high-fidelity physics, contamination-transport model for particles (including cells and their parts) and science-relevant molecules (e.g., possible biomolecules) was developed to validate the barrier concept. Importantly, this model takes into account the physics of extremely clean surfaces achieved by the best traditional contamination engineering. The ability to deal with very low levels of particulate and molecular contamination makes this model unique among standard contamination modeling approaches. Modeling also demonstrated that a high-temperature bake out during interplanetary cruise of the sample collector that comprises the largest surface area in the sample path for an Enceladus orbiter reference mission, was extremely effective. This study included the evaluation of other details necessary for an effective contamination control strategy for life detection missions including feasibility of achieving parts per trillion level cleanliness for semi-volatile hydrocarbons in nitrogen purge gas, identification of launch vehicle services required for the baseline contamination control, and defining additional contamination control measures to be taken during launch operations. Key results of the study are: • New spacecraft barrier design that accommodates RTGs is readily cleanable and repairable. Deployment of a 1/3 scale model was successfully demonstrated. • The barrier reduces particle contamination (likely biological) from fairing to spacecraft by 1e-2 to 1e-3. • On-cruise bake-out of critical surfaces significantly reduced molecular contamination (by as much as 1e-12). Subsequently, the probability of a surface contamination particle being transported to an instrument by an ice particle is less than 5.1e-5 (for microbes specifically, 4.39e-10). The report concludes that a full-spacecraft barrier designed specifically for life-detection missions that require stringent control of particulate and molecular contaminates is an effective means of mitigating risks of false positive and negative results for life signature investigations. Further, secondary cleaning steps for critical sections of the sample path can be highly effective at reducing molecular contaminants to low femtomolar levels."
The objective of this DOE-sponsored project was to develop a comprehensive database of mechanical properties, alloy microstructures, and to a lesser extent, the oxidation/corrosion behaviors of coal-fired power plant components, such as boiler tubing, steam headers, and steam piping, which had been in service for at least 100,000 operating hours (preferably more than 200,000 operating hours) under the operating conditions of high temperatures and high mechanical stresses where creep, fatigue, steam-side oxidation, and fireside corrosion were life-limiting factors. The components included in this database consisted of ferritic steels, creep strength enhanced ferritic (CSEF) steels, and 300-series H-grade stainless steels, as well as dissimilar metal welds (DMWs) among these types of materials. As a result of extensive metallurgical characterization and mechanical testing performed in this project, a comprehensive database on mechanical properties and detailed quantitative microstructural information was successfully developed for several long-term serviced EEM components. Such a database can be used by material research communities to develop, calibrate, refine, and validate mechanical behaviors, models, and other assessment tools for accurate prediction of remaining life of major components under similar EEM operating conditions.
Energy codes and energy efficiency policy are primed for significant shifts in the coming decade. Consumers are increasingly asking manufacturers to take responsibility for products over the course of the product lifespan, including at end-of-life. Consumer demand for social and environmental responsibility may push new codes and policies that incentivize the circular economy. Within the lighting sector, for example, rapid innovations have created large energy savings but also created a complex waste stream. Traditional energy code approaches to lighting efficiency have considered only lighting power density or energy-based metrics. Shifting codes and policy to consider environmental impacts of the product lifecycle could include circular economy mechanisms such as product deposits or service-based business models. In this paper we consider the possible structures for both codes and policies, and provide an analysis of the merits of each policy using life cycle assessment and sustainability index (SI).
Existing research primarily uses census data to identify the vulnerability of communities to hazards. These vulnerability indices provide aggregated data and are not hazard-specific nor well-validated with post-event data. In contrast, our study uses household survey data (n=1065) to understand which Texan households suffered the greatest loss of their capabilities due to power outages and other utility service disruptions during Winter Storm Uri. Inspired by the Capabilities Approach, our measures of burden include the number of household capability types disrupted during the outages (e.g., cooking, heating, refrigeration), the severity of impact for each disrupted capability, and the additional time and financial costs of coping with these disruptions. We perform a clustering analysis, and find two distinct groups in our data, consisting of ‘lesser burden' and ‘heavier burden' households. Results indicate that the households experiencing the heaviest capabilities burden were most likely to experience longer power outages and the loss of water services. They were also more likely to have a Hispanic-Latino household member, lack access to a generator, live in a rented home, have larger households with more young children, fewer adults over 65, lower household incomes, been impacted by the COVID-19 pandemic, and more family characteristics that made life harder. We also fit a logistic regression model to assess the role of outage, household, and community characteristics in predicting differences in capabilities burden. Our results offer insights into enumerating the consequences of utility service disruptions on households, which can inform more targeted and equitable resilience strategies.
This paper presents a microstructure-based model for low cycle fatigue (LCF) behavior and life of Nickel-based alloy Hastelloy X manufactured using laser-powder bed fusion (L-PBF) additive manufacturing (AM). AM Hastelloy X, a solution-strengthened alloy, is tested at elevated temperature under fully reversed LCF conditions at different strain levels. A generalized plane strain finite element model is generated from electron backscatter diffraction (EBSD) characterization. The constitutive behavior of the material under fatigue is modeled using crystal plasticity and calibrated with both monotonic tensile and cyclic stress–strain data. The fatigue micro-crack initiation and propagation in the microstructure is modeled using a modified Chaboche fatigue damage model. An embedded boundary condition with a homogenous medium is used to apply the cyclic deformation and prevent numerically introduced over-constraints during fatigue simulation. A ‘cycle-jump’ method is used to accelerate the fatigue simulation and reduce the computational cost. The simulation results are compared to LCF experiments, showing satisfactory matches in cyclic stress behavior and number of cycles to macro-crack initiation for all applied strain ranges. In addition, the model illustrates the potential for quantifying microscale fatigue life impacting factors such as microstructure and surface roughness, which is needed to accurately quantify the reliability of AM components in service.
Purge flow is bled from the upstream compressor and supplied to the under-platform region to prevent hot main gas path ingress that damages vulnerable under-platform hardware components. A majority of turbine rim seal research has sought to identify methods of improving sealing technologies and understanding the physical mechanisms that drive ingress. While these studies directly support the design and analysis of advanced rim seal geometries and purge flow systems, the studies are limited in their applicability to real-time monitoring required for condition-based operation and maintenance. As operational hours increase for in-service engines, this lack of rim seal performance feedback results in progressive degradation of sealing effectiveness, thereby leading to reduced hardware life. To address this need for rim seal performance monitoring, this study utilizes measurements from a one-stage turbine research facility operating with true-scale engine hardware at engine-relevant conditions. Time-resolved pressure measurements collected from the rim seal region are regressed with sealing effectiveness through the use of common machine learning techniques to provide real-time feedback of sealing effectiveness. Two modeling approaches are presented that use a single sensor to predict sealing effectiveness accurately over a range of two turbine operating conditions. Here, the results show that an initial purely data-driven model can be further improved using domain knowledge of relevant turbine operations, which yields sealing effectiveness predictions within 3% of measured values.