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At least 1,171 records · Page 65

Manufacturing and Reliability Science for CIGS Photovoltaics

The purpose of this program was to overcome the largest challenges to investor confidence and long product lifetime in CuIn x Ga 1-x Se 2 (CIGS)-based photovoltaic products: metastability, shading-induced hot spots, and potential-induced degradation. Key findings were made in each of these areas by studying CIGS reliability at the cell level, which very few groups are currently doing. Metastability was thought to be a function of the CIGS absorber. We have challenged the state-of-the-art by showing that the metastability seen in commercial products is likely to be caused by the buffer layer. SCAPS device modeling confirmed that the buffer layer has a significant influence on metastability in CIGS devices, and also led to a processing change - the introduction of CdS islands to Zn(O,S) buffer layers - that dramatically reduced metastability in CIGS solar cells. In the reverse-bias shading task, modeling showed us that 19% solar cells are possible with thin CIGS layers of 0.5 µm. We were able to fabricate 15.2% solar cells in this project, which is the highest reported efficiency of devices in the ultra-thin class. We also discovered that the best way to dissipate less power in reverse bias was to eliminate the intrinsic ZnO layer that is often used in CIGS devices. Lower power dissipation led to devices that allowed two times the maximum power point current density in reverse without damage. Potential-induced degradation (PID) is caused by the drift of Na+ ions from the back glass to the CIGS/Mo interface, followed by diffusion into the solar cells and to the CdS region. We found that PID can be slowed by using low-conductivity borosilicate glass that contains higher K and lower Na than soda-lime glass. Based on significant progress in each of the three reliability challenges, the CIGS cell-level reliability project was very successful. We have also proved that module-level degradation mechanisms can be tested and solved at the cell level.

14 SOLAR ENERGY↗

Non-metallic dopant modulation of conductivity in substoichiometric tantalum pentoxide: A first-principles study

Here, we apply density-functional theory calculations to predict dopant modulation of electrical conductivity (σ o ) for seven dopants (C, Si, Ge, H, F, N, and B) sampled at 18 quantum molecular dynamics configurations of five independent insertion sites into two (high/low) baseline references of σo in amorphous Ta 2 O 5 , where each reference contains a single, neutral O vacancy center (V O 0 ). From this statistical population (n = 1260), we analyze defect levels, physical structure, and valence charge distributions to characterize nanoscale modification of the atomistic structure in local dopant neighborhoods. C is the most effective dopant at lowering Ta 2 O x σ o , while also exhibiting an amphoteric doping behavior by either donating or accepting charge depending on the host oxide matrix. Both B and F robustly increase Ta 2 O x σ o , although F does so through elimination of Ta high charge outliers, while B insertion conversely creates high charge O outliers through favorable BO 3 group formation, especially in the low σ o reference. While N applications to dope and passivate oxides are prevalent, we also found that N exacerbates the stochasticity of σ o we sought to mitigate; sensitivity to the N insertion site and some propensity to form N-O bond chemistries appear responsible. Finally, we use direct first-principles predictions of σ o to explore feasible Ta 2 O 5 dopants to engineer improved oxides with lower variance and greater repeatability to advance the manufacturability of resistive memory technologies.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Large Payload Ground Transportation and Test Considerations

During test and verification planning for the Altair lunar lander project, a National Aeronautics and Space Administration (NASA) study team identified several ground transportation and test issues related to the large payload diameter. Although the entire Constellation Program-including Altair-has since been canceled, issues identified by the Altair project serve as important lessons learned for payloads greater than 7 m diameter being considered for NASA's new Space Launch System (SLS). A transportation feasibility study found that Altair's 8.97 m diameter Descent Module would not fit inside available aircraft. Although the Ascent Module cabin was only 2.35 m diameter, the long reaction control system booms extended nearly to the Descent Module diameter, making it equally unsuitable for air transportation without removing the booms and invalidating assembly workmanship screens or acceptance testing that had already been performed. Ground transportation of very large payloads over extended distances is not generally permitted by most states, so overland transportation alone would not be an option. Limited ground transportation to the nearest waterway may be possible, but water transportation could take as long as 66 days per production unit, depending on point of origin and acceptance test facility; transportation from the western United States would require transit through the Panama Canal to access the Kennedy Space Center launch site. Large payloads also pose acceptance test and ground processing challenges. Although propulsion, mechanical vibration, and reverberant acoustic test facilities at NASA's Plum Brook Station have been designed to accommodate large spacecraft, special handling and test work-arounds may be necessary, which could increase cost, schedule, and technical risk. Once at the launch site, there are no facilities currently capable of accommodating the combination of large payload size and hazardous processing such as hypergolic fuels, pyrotechnic devices, and high pressure gasses. Ironically, the limiting factor to a national heavy lift strategy may not be the rocket technology needed to throw a heavy payload, but rather the terrestrial infrastructure-roads, bridges, airframes, and buildings-necessary to transport, acceptance test, and process large spacecraft. Failure to carefully consider where and how large spacecraft are manufactured, tested, and launched could result in unforeseen cost to modify existing (or develop new) infrastructure, or incur additional risk due to increased handling operations or eliminating key verifications.

Rucker, Michelle A.↗

Computational models of direct and indirect X‐ray breast imaging detectors for in silico trials

Abstract Background To facilitate in silico studies that investigate digital mammography (DM) and breast tomosynthesis (DBT), models replicating the variety in imaging performance of the DM and DBT systems, observed across manufacturers are needed. Purpose The main purpose of this work is to develop generic physics models for direct and indirect detector technology used in commercially available systems, with the goal of making them available open source to manufacturers to further tweak and develop the exact in silico replicas of their systems. Methods We recently reported on an in silico version of the SIEMENS Mammomat Inspiration DM/DBT system using an open‐source GPU‐accelerated Monte Carlo x‐ray imaging simulation code (MC‐GPU). We build on the previous version of the MC‐GPU codes to mimic the imaging performances of two other Food and Drug Administration (FDA)‐approved DM/DBT systems, such as Hologic Selenia Dimensions (HSD) and the General Electric Senographe Pristina (GSP) systems. In this work, we developed a hybrid technique to model the optical spread and signal crosstalk observed in the GSP and HSD systems. MC simulations are used to track each x‐ray photon till its first interaction within the x‐ray detector. On the other hand, the signal spread in the x‐ray detectors is modeled using previously developed analytical equations. This approach allows us to preserve the modeling accuracy offered by MC methods in the patient body, while speeding up secondary carrier transport (either electron–hole pairs or optical photons) using analytical equations in the detector. The analytical optical spread model for the indirect detector includes the depth‐dependent spread and collection of optical photons and relies on a pre‐computed set of point response functions that describe the optical spread as a function of depth. To understand the capabilities of the computational x‐ray detector models, we compared image quality metrics like modulation transfer function (MTF), normalized noise power spectrum (NNPS), and detective quantum efficiency (DQE), simulated with our models against measured data. Please note that the purpose of these comparisons with measured data would be to gauge if the model developed as part of this work could replicate commercially used direct and indirect technology in general and not to achieve perfect fits with measured data. Results We found that the simulated image quality metrics such as MTF, NNPS, and DQE were in reasonable agreement with experimental data. To demonstrate the imaging performance of the three DM/DBT systems, we integrated the detector models with the VICTRE pipeline and simulated DM images of a fatty breast model containing a spiculated mass and a calcium oxalate cluster. In general, we found that the images generated using the indirect model appeared more blurred with a different noise texture and contrast as compared to the systems with direct detectors. Conclusions We have presented computational models of three commercially available FDA‐approved DM/DBT systems, which implement both direct and indirect detector technology. The updated versions of the MC‐GPU codes that can be used to replicate three systems are available in open source format through GitHub.

Sengupta, Aunnasha↗

In‐operando thermal transport characterization of moving particle bed heat exchanger

The project aimed to develop modulated photothermal radiometry (MPR) for conducting in-operando measurements of thermal transport in moving particle bed heat exchangers (MPBE) located at Sandia National Laboratory (SNL). The plan was to initially conduct lab-scale measurements on a 1-meter-long particle channel at UCSD, followed by in- operando measurements at SNL on a 20 kWth MPBE prototype built for this project, and if time permitting, potential final deployment on SNL’s 1 MWth G3P3 MPBE. The first two goals were successfully achieved but due to changes with commissioning timeline of the G3P3 MPBE, in-operando measurements on the G3P3 MPBE could not be conducted. The measurement campaigns have resulted in some promising results and the MPR tool has been handed over to trained SNL personnel for future use. MPR measurements on UCSD’s 1-meter-long particle channel showed a peculiar length dependence of the particle bed thermal conductivity and near-wall thermal resistance. The bed thermal conductivity increased, and the near-wall thermal resistance decreased, with increasing distance from the channel inlet, both eventually reaching a plateau. This was found to be due to hydrostatic pressure screening by the channel walls, known as the “Janssen effect”, and is the first experimental study on its role in granular heat transfer. A 20 kWth small-scale MPBE prototype, the first of its kind with 3 mm particle channels and 2 mm sCO2 plates, was designed and manufactured by Vacuum Process Engineering (VPE) for this project. This MPBE prototype was installed in SNL’s HEX test stand and the MPR tool was integrated into the test stand for in-operando measurements. Several modifications have been made to the MPR setup for facile installation and easy operation at SNL. Measurements with Carbo HSP40/70 particles were conducted with various particle and sCO2 temperatures and flow rates. Further, apart from regular MPBE operation, fault scenarios such as plate warping, particle stagnation, and choking were also detected and MPR showed excellent sensitivity to the detection of such conditions. Through the course of this project, MPR has evolved from a sensitive laboratory technique to a rugged industrial tool with various applications in high temperature measurements and diagnostics.

14 SOLAR ENERGY↗

Production and testing of the powerboard for ATLAS ITk Strip barrel modules

The upgrade of the ATLAS ITk strips detector for HL-LHC will employ a custom PCB (powerboard) for on-module DC-DC conversion, HV switching, and monitoring. Production of about 14100 of such PCBs with high reliability is a big challenge. In this paper we will present the production procedure and quality control (QC) testing system for the powerboards to be installed on ITk Strip barrel modules. During production, about 150 powerboards will be produced every week. Each powerboard will need to pass QC tests before they are assembled to module. The QC tests include thermal cycling between -35 °C and 40 °C, soak test (continuous running of DC-DC converter at high load at 20 °C), and basic functionality and characterization electrical tests of the low voltage (LV), high voltage (HV), and monitoring functions of the powerboard. A custom QC test system is described, which is based on a reusable PCB (active board) with all testing circuits, a one-time powerboard carrier card, and a Z-turn SoC board which hosts and runs the testing program. The production procedure and QC test system has been tested with 400 powerboards during pre-production, and the system has been proven ready for production with the desired testing program, speed, safety, and cost. Performance and typical failures of powerboards observed during the QC test of pre-production powerboards is also presented.

47 OTHER INSTRUMENTATION↗

Demonstration of NEAMS Multiphysics Tools for Fast Reactor Applications

The SHARP toolkit is a high-fidelity reactor simulation tool developed under the U.S. Department of Energy, Office of Nuclear Energy Advanced Modeling and Simulation (NEAMS) Campaign. SHARP toolkit is comprised of the neutronics module PROTEUS thermal hydraulics module Nek5000, and structural mechanics module Diablo. During FY17 and FY18, the PROTEUS and Nek5000 components of SHARP were applied to solve challenging sodium-cooled fast reactor (SFR) problems. In particular, selected hot channel factors (HCF) for a prototype metal-fueled SFR design (the AFR-100) were analyzed in high fidelity, and the “SHARP zooming capability” for SFRs was developed and demonstrated to reduce computational expense for full core problems in cases where detailed data is needed in selected fuel assemblies. After the previous success applying SHARP to challenging SFR problems, the focus in FY19 and FY20 expanded to additional fast reactor applications including lead cooled fast reactors (LFR) and sodium cooled fast reactors (SFR). The specific technical tasks were (1) assessment of hot channel factors for LFR, for which no data currently exists, and (2) demonstration of zooming capability in assemblies of the Versatile Test Reactor (VTR). First-of-a-kind hot channel factor (HCF) estimation for LFR with high fidelity codes (PROTEUS/Nek5000) was successfully demonstrated in this study which began in FY19 and continued in FY20. Selected HCF were computed and compared with SFR data (AFR-100, EBR-II). The findings confirm that different reactor types, design parameters and uncertainties lead to different HCFs. Careful estimation of HCF for a specific design is necessary to obtain appropriate HCFs. In addition to improvement in HCF accuracy, high fidelity tools generate data to help the designer better understand the mechanism of the impact from these uncertainties. For example, the impact of cladding thickness manufacturing tolerance resulted in non-intuitive effects in the corner pins of the LFR assembly. This procedure of computing HCF using high fidelity models shows promise and flexibility for being repeated for any arbitrary reactor of choice. Along with the application on SFR and LFR, the capability of the tools has also been matured to deal with different reactor types and designs. Progress was made towards extending the previously demonstrated SHARP zooming capability to non-fueled SFR assemblies. In particular, in FY19 a gamma transport capability was implemented in both high fidelity PROTEUS solvers in order to accurately account for heat deposition caused by gamma particles, which accounts for ~10% of total core power. Neutronics verification cases were carried out for a candidate Versatile Test Reactor (VTR) design using the new gamma transport capability in PROTEUS. Comparisons were made with continuous energy MCNP calculations and shown to agree well. The models for the full core design with heterogeneous control and fuel assemblies is in progress for PROTEUS-SN and completed with MCNP. The MCNP power distributions were transferred to Nek5000 to perform thermal hydraulic calculations of the control and fuel assembly.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Designing a Software Architecture for the Precision Assembly of Space Structures

As NASA’s space exploration and science missions expand in complexity, longevity, anddistance beyond earth’s orbit, Orbital Servicing, Assembly and Manufacturing (OSAM)technologies and concepts have become a critical area of ongoing research and innovation.Artemis’ Moon-to-Mars goals of building sustainable elements on and around the Moon andMars that allow our robots and astronauts to explore and conduct more scientific researchwill demand in situ resource utilization, construction, and maintenance to succeed. In-spaceAssembly (ISA), as a sub-component of OSAM, focuses on the on-orbit building or fabricationof mission infrastructure and payloads. One such ISA application is highlighted by the recentNASA In-Space Assembled Telescope (iSAT) study, which stated that the next generation ofspace observatories will exceed the fairing size of existing or even planned launch vehicles andISA has emerged as a viable approach for observatory assembly. Research efforts at NASALangley Research Center have led to the design of a novel TriTruss structural concept for themodular construction of large complex persistent platforms. The TriTruss design and otherdeveloping OSAM technologies enable larger and persistent space missions that would notbe possible with single-launch-sized structures. For example, 20 meter or larger telescopesor orbital platform applications. However, the increased complexity will require autonomousoperations for the construction and maintenance of long-term infrastructure to achieve missionsuccess. NASA’s Precision Assembly of Space Structures (PASS) project is focused on thestructural and autonomy capabilities required to construct an iSAT in deep space. PASSresearch efforts will develop and validate critical technologies needed for effective efficienton-orbit assembly that can be confidently adopted for future systems. PASS will utilize theTriTruss modules to demonstrate the autonomous modular assembly of a 20m-class iSAT mirrorbackbone structure including simulated mirrors and wiring harness. In this paper, we addressthe software and hardware design considerations, technologies, and challenges of designing arobust robotics framework for assembling modular space structures in support of In SpaceAssembly missions in general as well as for PASS specifically.

Benjamin N Kelley↗

Cathodes Delivered for Space Station Plasma Contactor System

The International Space Station's (ISS) power system is designed with high-voltage solar arrays that typically operate at output voltages of 140 to 160 volts (V). The ISS grounding scheme electrically ties the habitat modules, structure, and radiators to the negative tap of the solar arrays. Without some active charge control method, this electrical configuration and the plasma current balance would cause the habitat modules, structure, and radiators to float to voltages as large as -120 V with respect to the ambient space plasma. With such large negative floating potentials, the ISS could have deleterious interactions with the space plasma. These interactions could include arcing through insulating surfaces and sputtering of conductive surfaces as ions are accelerated by the spacecraft plasma sheath. A plasma contactor system was baselined on the ISS to prevent arcing and sputtering. The sole requirement for the system is contained within a single directive (SSP 30000, paragraph 3.1.3.2.1.8): "The Space Station structure floating potential at all points on the Space Station shall be controlled to within 40 V of the ionospheric plasma potential using a plasma contactor." NASA is developing this plasma contactor as part of the ISS electrical power system. For ISS, efficient and rapid emission of high electron currents is required from the plasma contactor system under conditions of variable and uncertain current demand. A hollow cathode plasma source is well suited for this application and was, therefore, selected as the design approach for the station plasma contactor system. In addition to the plasma source, which is referred to as a hollow cathode assembly, or HCA, the plasma contactor system includes two other subsystems. These are the power electronics unit and the xenon gas feed system. The Rocketdyne Division of Boeing North American is responsible for the design, fabrication, assembly, test, and integration of the plasma contactor system. Because of technical and schedule considerations, the NASA Lewis Research Center was asked to manufacture and deliver the engineering model, the qualification model, and the flight HCA units for the plasma contactor system as government furnished equipment. To date, multiple units have been built. One cathode has demonstrated approximately 28 000-hr lifetime, two development HCA units have demonstrated over 15 000-hr lifetime, and one HCA unit has demonstrated more than 38 000 ignitions. All eight flight HCA's have been manufactured, acceptance tested, and are ready for delivery to the flight contractor.

Patterson, Michael J.↗

Constant Rate Production: DOE Approach to Meeting NASA Needs for RPS for Nuclear-Enabled Launches.

The use of radioisotope power systems (RPS) for nuclear-enabled NASA missions is a long-standing arrangement between DOE and NASA. The requirements for the power system come from NASA, while DOE performs the procurement, fueling, testing and delivery. Recent examples include Mars Science Laboratory and New Horizons. A challenge has been interplay between the schedule for RPS availability from DOE versus the schedule NASA has for competitively selected missions. By mutual agreement, the actual operations to procure an RPS and prepare it for fueling, has always waited until the final selection of a mission. This timeline for a New Frontiers class mission leaves approximately 5-6 years from the time of final mission selection to the actual launch date. The number of RPS used for a Frontier class mission can be 1 to 3 units, i.e., the recent New Frontiers-2025 announcement of opportunity published in December 2016. If 1 or 2 units are needed for a specific mission, the timeline from the decision point to the launch date is a challenge, but doable. The activities taking place in this timeframe would include manufacturing the power system, producing the fuel, and performing the assembly/testing and delivery operations. If the mission selected requires 3 RPS the logistics of accomplishing all activities during the 5-6 years is problematic. The challenge involves appropriate resourcing for plutonium production, heat source production and assembly/testing operations. Typically, the time between RPS-enabled missions involve staffing attrition and reduction at the heat source production and the assembly/testing facilities that can be down to 60-75 percent of peak staffing levels to reduce costs. The duration for increasing staffing in these areas, which includes hiring, nuclear workforce training and obtaining the appropriate security clearance is 2 years. Taking account for this 2 years and the 6 months prior to launch arrival of the RPS at Kennedy Space Center erodes too much of the 5-6 years to comfortably support the use of 3 RPS on a mission and doesn't leave much schedule margin for a 2 RPS unit mission. To provide better support for NASA nuclear-enabled missions a different approach was devised, constant rate production. This involves a higher level of base capability at Los Alamos National Laboratory (LANL), Idaho National Laboratory (INL) and Oak Ridge National Laboratory (ORNL) to provide a stabilized work force. This will enable 10-15 heat sources to be produced annually at LANL, and subsequently shipped to the INL to be placed into a stable intermediate form that enables storage for up to several years that leads to quick production of general purpose heat source modules when a mission is selected. The up-front production of Pu-238 at ORNL is maintained so that there is material constantly in the pipeline. Production of key specialized components at ORNL is also maintained using this model. This allows for a reduction of risk to the nuclear-enabled missions, yet always having quantities of hardware available “on the shelf” to support production of RPS for NASA.

99 GENERAL AND MISCELLANEOUS↗

A Strawman for an HPC PowerStack

The landscape of High-Performance Computing (HPC) is changing as we enter the exascale era and power and energy management are key design points for any next generation of supercomputers. Efficiently utilizing procured power and optimizing performance of scientific applications under power and energy constraints is challenging due to several reasons including dynamic phase behavior, processor manufacturing variability and increasing heterogeneity of node-level components. Extending the scope from the node- and application-level up to the system-level introduces further challenges on top of power-unaware job scheduling, which is known to be NP-hard on its own. While there exists several individual efforts across the community to research automatic techniques for managing power and energy better, the majority of these techniques have been specialized to meet the needs of a specific HPC center or specific optimization goals and provide little support to connect them to each other. Some projects, most notably the PowerAPI efforts [1], discuss interfaces that form a good starting point for full stack integration, but these interfaces still need to be hooked up to the wide range of software components offered by academic partners, developers or vendors. Furthermore, a recent survey conducted by the EE HPC WG concluded that the majority of such techniques have lacked the application-awareness required to achieve the best system performance and throughput. Other observations were that each technique tended to target management of power and energy for a different subset of the site or system hardware and that the different techniques tended to perform management at different (and often conflicting) granularities. Unfortunately, the existing techniques have not been designed to coexist simultaneously on one site and cooperate on management in an integrated manner [2]. The lack of application-awareness, lack of coordinated management across different granularities, and the lack of widely accepted interfaces and consequent limited connectivity between modules, can result in substantially underutilized Watts and FLOPS. To address these gaps, the HPC community needs a holistic stack for power and energy management and none currently exists. In our view, a holistic stack is one that is extensible enough to support the present and anticipated future needs of various different HPC centers, one that achieves best system performance and throughput through application-awareness, one that is designed to coordinate management at different granularities, and one that enables the seamless integration of software components from different developers and vendors. In this seminar, our goal is bring together experts from academia, research laboratories, and industry in order to take stock of existing approaches, design points and power management concepts and requirements at the various participant’s institutions, and to design concepts for a holistic power and energy management stack, which we refer to as the HPC PowerStack. Further, we hope to take steps toward defining the interfaces necessary for providing a complete prototype shared among many groups. The intention is to align development and research efforts across the community so that we may share development resources, avoid duplicating effort, agree on common interfaces and reap the rewards together as a community. The intended final outcome of this collaboration will be a holistic, flexible and extensible concept of a software stack ecosystem that allows us to combine product-grade open-source software components to enable runtime optimization of system power, energy, and performance.

97 MATHEMATICS AND COMPUTING↗

Public Reference Data for Megawatt-Scale Hydrogen Electrolysis - Simulated Marine Hydrokinetic Tidal Turbine

The U.S. Department of Energy and National Laboratory of the Rockies (NLR) demonstrate hydrogen electrolysis, hydrogen compression and storage, and variable hydrogen fuel cell power production using megawatt-scale equipment at NLR’s Flatirons Campus as part of the Advanced Research on Integrated Energy Systems (ARIES) initiative. This dataset is part of that effort and is intended for academic, national laboratory, industrial, and other stakeholders to plan, design, and validate models of megawatt-scale hydrogen technologies and diverse energy infrastructure. These data provide a baseline for how existing hydrogen electrolysis technologies perform when coupled with other energy technologies. This dataset contains inputs and outputs from simulations of a floating marine hydrokinetic turbine over approximately half a tidal cycle (~6.6 hours). Inflow conditions were derived from field measurements in Alaska’s Cook Inlet and represent a tidal environment in which the current speed ramps from near 0 m/s to a peak of 3 m/s and back. The original acoustic doppler current profiler dataset is publicly available on the Marine and Hydrokinetic Data Repository. In a full tidal cycle, the flow reverses and the rotor would reorient; this reversal was not modeled. In the Cook Inlet campaign , turbulence intensity was similar in both directions. Two inflow cases are included. In the first case, labeled “raw” in the files, the measured current time series was used directly in the InflowWind module of OpenFAST. Speed and direction were applied as a function of time and elevation, uniformly in the horizontal direction. With full spatial coherence, this approach captures high turbulent variability and results in pronounced power fluctuations, so it is considered a conservative, near-worst-case representation of loading. In the second case, labeled “average” in the files, a 30-minute moving average was applied to extract the slowly varying mean speed. The residual fluctuations about this mean were used to generate spatially varying, full-field turbulence inputs with TurbSim, giving a more physically realistic representation of the inflow across the rotor disk. Two random realizations were used to produce distinct inflow conditions for two OpenFAST simulations representing a two-turbine array. The same turbulence intensity is applied across the full time series, producing larger fluctuations at the start and end, where the mean speed is low. The second case is the more appropriate framework for performance and power assessment but overpredicts turbulence at lower flow speeds and underpredicts it at higher speeds. As the floating platform moves and the rotor changes its x-position, Taylor’s frozen turbulence hypothesis used by InflowWind assumes a constant rather than a time-varying mean velocity, introducing some inaccuracy in the velocity plane sampling. The turbine modeled is the 500-kW Reference Model 1, a horizontal-axis two-bladed hydrokinetic turbine on a four-column floating semisubmersible substructure . Simulations were performed using OpenFAST v4.1 with the Reference Open Source Controller (ROSCO) v2.10. All input files required to reproduce the simulations are included. The electrolyzer is a 1.25-MW proton exchange membrane type MC250 system manufactured by Nel . This unit supports up to 2.5 MW, but NLR has only a single 1.25-MW stack. The datasets report hydrogen balance-of-plant and system data, all captured at 1 Hz, including hydrogen mass production measured with an Emerson Coriolis flow meter. The system controls hydrogen production by varying direct current applied to the stack, from a maximum of 3,000 A to a minimum safe operating current of 300 A, or 10%. Because the current–voltage characteristic changes as the stack ages and efficiency degrades, the actual minimum safe operating power changes over time. The simulated tidal turbine time series data was translated from power (kilowatts) to current (amperes) using a curve fit with calibration data and sent to the electrolyzer power supply at 1-Hz. Each zip file represents a single tidal electrolysis experiment and is named: {technology}_{inflow method}_{number of 500 kW tidal turbines connected} For instance, “tidal-500kW-RM1_average_2.zip” is a 6-hour experiment using the 500-kW tidal reference model, scaled by 2x (1-MW) to better match the electrolyzer maximum of 1.25MW, fed with the 30-minute moving average current case. Each zip folder contains the following files: A .csv file of raw data. An .xlsx file explaining all the fields in the raw data. A .png plot showing the time series of hydrogen production in kilograms per hour, electrolysis power consumption, and input wave power. A .csv file combines all tidal profiles as "combined_tidal_experiments.csv." A separate experiment, “characterization_200.zip,” shows the MC250 electrolyzer steady-state response with 30-minute load steps over 5 hours and is accessible with this entry.

08 HYDROGEN↗

Projection Microstereolithography for Architected Materials

Stereolithography (SL) is a prominent paradigm in the realm of additive manufacturing (AM) technologies, which refers to fabrication approaches that build “bottom up” by adding material. Pioneered in 1984 by Chuck Hull, SL relies on light-activated solidification of a liquid photosensitive resin in a layer-by-layer fashion, with the geometry of each layer defined by sectioning a three-dimensional (3D) computer model by closely-spaced parallel planes. The maturation of the technology over nearly three subsequent decades has resulted in the wide availability of commercial SL products, such as the ProJet series from 3D Systems, Inc. (which uses the proprietary acronym SLA to refer to SL technology), which routinely produces parts with 50-100 µm resolution in all three axes, and overall dimensions of 0.25-0.5 m. In the most general terms, advancements in SL technology have generally been aimed at achieving four goals: decreasing (1) system cost and (2) minimum feature size (i.e. improving resolution), while (3) increasing overall part size and (4) build speed. SL systems can be broadly categorized into two classes, by the way in which they deliver illumination to produce the shape of each object layer to be fabricated: laser-scanning and mask projection approaches. Commercially-available SL systems incorporate the laser-scanning approach, following the original scheme described by Hull, since digital image projection technology has only emerged relatively recently as a viable alternative. A significant limitation of laser scanning is the relatively slow speed of rastering the laser to form each layer’s pattern, highlighting the need for a dynamic mask-based approach to polymerize larger areas in a single exposure. The recent proliferation of digital display technologies (referred to as spatial light modulators or SLMs) has enabled the implementation of such “dynamic masking,” increasing system throughput by allowing a complete image layer to be cross-linked simultaneously. These mask projection SL systems are gaining greater prominence, and the landscape of some of the parameters available for system design, as implemented in recent work by a variety of investigators, has been reviewed by Lambert et al.

36 MATERIALS SCIENCE↗

Topographically Induced Thermal Effects on Lunar Hydrogen Distributions: Correlated Observations from the LRO LEND and LOLA Instruments

The question of whether water exists on the Moon's surface has long been an enigma to Lunar researchers. Largely, this was due to the thermally extreme lunar surface environment that would seem to preclude any long term maintenance, manufacture, transport or accumulation of hydrogen (H) volatiles over most of the lunar surface. As a result, for many years the cold permanent shadow regions (PSR) in the bottoms of craters near the lunar poles appeared to provide the basic conditions at least for maintenance of lunar hydrogen. Importantly, recent discoveries indicate that there is some hydrogen at the poles. However, the picture of the lunar hydrogen budget may be more complex than the PSR hypothesis has suggested. This evidence comes from observations by the Lunar Exploration Neutron Detector (LEND) onboard the Lunar Reconnaissance Orbiter (LRO) that inclici1te 1) some H concentrations lie outside PSR and 2) though a few of the larger PSR's have high hydrogen, PSR does not appear to be an independent factor influencing the large-scale suppression of polar epithermals observed by LEND and the Lunar Prospector Neutron Spectrometer. In this research we investigate the possibility that the thermal contrast between pole-facing and equator facing-slopes is a factor influencing the surface distributions of lunar H. We perform this bulk correlated observation and study by developing a thermal proxy from slope data of the Lunar Orbiting Laser Altimeter (LOLA) digital elevation model (DEM) which is registered with the collimated LEND epithermal map. From the LOLA transforms we impose a thermal functional decomposition and systematic statistical analysis of the LEND epithermal map. Our hypothesis testing suggests in most high latitude bands studied> +/- 45 deg: Epithermal rates in pole-facing slopes are significantly lower than epithermal rates in equivalent equator-facing slopes. As a control study, we find that there is no statistically significant difference between equivalent east and west facing slopes. This finding suggests topographic modulation of insolation is a factor influencing the lunar H budget. Importantly, this result is consistent with observations in terrestrial, Martian research.

McClanahan, T. P.↗

CACTUS: CO 2 Aerogel Capture Towards Utilization and Sequestration

The CACTUS project aimed to develop a novel solid sorbent and sorption module prototype for direct air capture (DAC) of carbon dioxide, by a moisture-swing adsorption (MSA) mechanism. Because MSA uses changes in humidity, not temperature to switch the sorbent from capturing CO 2 to releasing concentrated CO 2 it is > 4X more energy-efficient than the thermal swing process. The goal was to develop a sorbent with a CO 2 capture capacity of 1 mmol CO 2 /g sorbent (or 0.75 mmol CO 2 /g structured sorbent), at a projected scaled cost of < $\$$15/kg sorbent and demonstration of a path to < $\$$100/ton CO 2 . At the end of the project, we achieved 0.8 mmol CO 2 /g sorbent powders, 0.37 mmol CO 2 /g structured sorbent (50% of target), at a projected cost of $\$$29/kg sorbent and an estimated cost of $\$$160/ton CO 2 . The key innovation was SRI’s patented polymer aerogel synthesis platform, which was adapted to produce a nanoporous aerogel with a high density of CO 2 -adsorbing quaternary ammonium groups. This research discovered a new ammonium polymer sorbent and identified a chemical path for its fabrication. The new process solved the monomer immiscibility challenge encountered with the initial method (ammonium is hydrophilic and the crosslinker is hydrophobic). The team fabricated structured sorbent sheets consisting of a non-woven porous substrate impregnated with ammonium polymer and demonstrated its operation in custom made breakthrough test setup MSA DAC built at SRI, and which operates similarly to the envisioned large-scale CO 2 capture plant, to provide data for techno-economic analysis (TEA). TEA sensitivity analysis indicated that ∼$\$$100/ton CO 2 can be achieved if the target capacity of 0.75 mmol CO 2 /g structured sorbent is met. Also identified routes to decrease sorbent manufacturing cost to ∼$\$$19/kg by reducing amounts and recycling the organic solvents. More work is needed on transitioning process manufacturing from powders (which showed a capacity of up to 0.8 mmol/g sorbent) to structured sheets which showed a capacity of 0.37 mmol CO 2 /g structured sorbent (or 0.44 mmol/g sorbent if one excludes the inert porous substrate). This is likely due to different micro/nano-structure of the sorbent and material processing constraints at the laboratory scale. Sorbent cycling studies (> 100 cycles) are needed to investigate its performance stability over time.

99 GENERAL AND MISCELLANEOUS↗

VOLTTRON-Based System for Providing Ancillary Services with Residential Building Loads

Ancillary services entail controlled modulation of building equipment to maintain a stable balance of generation and load in the power system. Ancillary services include frequency regulation and contingency reserves, whose acting time ranges from several seconds to several minutes. Many pilot studies have been implemented to use industrial loads to provide ancillary services, and some have explored services from commercial building loads or electric vehicle charging loads. Residential loads, such as space conditioning and water heating, represent a largely untapped resource for providing ancillary services. The residential building sector accounts for a significant fraction of the total electricity use in the United States. Many loads in residential buildings are flexible and could potentially be curtailed or shifted at the request of the grid. However, there are many barriers that prevent residential loads being widely used for ancillary services. One of the major technical barriers is the lack of communication capabilities between end-use devices and the grid. End-use devices need to be able to receive the automatic generation control (AGC) signal from the grid operator and supply certain types of telemetry to verify response. With the advance of consumer electronics, communication-enabled, or 'connected,' residential equipment has emerged to overcome the communication barrier. However, these end-use devices have introduced a new interoperability challenge due to the existence of numerous standards and communication protocols among different end devices. In this paper, we present a VOLTTRON-based system that overcomes these technical challenges and provides ancillary services with residential loads. VOLTTRON is an open-source control and sensing platform for building energy management, facilitating interoperability solutions for end devices. We have developed drivers to communicate and control different types of end devices through standard-based interfaces, manufacturer-provided application programming interfaces, and proprietary communication interfaces. We document the ability to manage nine appliances, using four different standards or proprietary communication methods. A hardware-in-the-loop test was performed in a laboratory environment where the loads of a laboratory home and a large number of simulated homes are controlled by an aggregator. Upon receipt of an AGC signal, the VOLTTRON home energy management system (HEMS) of the laboratory home adjusts the end-device controls based on the comfort criteria set by the end users and sends telemetry to the aggregator to verify response. The aggregator then sends the AGC signal to other simulated homes in attempts to match the utility request as closely as possible. Frequency regulation is generally considered a higher value service than other ancillary services but it is also more challenging due to the constraint of short response time. A frequency regulation use case has been implemented with the regulation signals sent every 10 seconds. Experimental results indicate that the VOLTTRON-controlled residential loads are able to be controlled with sufficient fidelity to enable an aggregator to meet frequency regulation requirements. Future work is warranted, such as understanding the impact of this type of control on equipment life, and market requirements needed to open up residential loads to ancillary service aggregators.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Advanced, Energy-Efficient Hybrid Membrane System for Industrial Water Reuse

In the U.S. manufacturing sector, current industrial water use practices are energy-intensive and utilize and discharge high volumes of waters, rendering them not sustainable especially in light of the growing scarcity of suitable water supplies. To help address this problem, the goal of this project was to develop an advanced, cost-effective, hybrid membrane-based water treatment system that can improve the energy efficiency of industrial wastewater treatment while allowing at least 50% water reuse efficiency. This hybrid process would combine emerging Forward Osmosis (FO) and Membrane Distillation (MD) technology components into an integrated FO-MD system that can beneficially utilize low-grade waste heat (i.e., T < 450 °F) in industrial facilities to produce distilled-quality product water for reuse. In this project, laboratory-, bench-, and pilot-scale experiments on the hybrid FO-MD system were conducted for industrial wastewater treatment. It was demonstrated at laboratory, bench, and pilot scales that FO-MD membrane technology can concentrate brine to very high total dissolved solids (TDS) levels (>200,000 ppm) that are at least 2.5 times higher than the TDS level to which RO can achieve. In laboratory testing, currently available FO and MD membranes were tested to select for high-performing membranes with high salt rejection and high water flux. Multiple FO membrane/draw-salt solution combinations that gave high water flux with higher than 98% salt rejection were also identified. Reverse draw-salt fluxes were observed to be much lower for divalent salts than for monovalent salts. MD membranes were identified that had 99.9+% salt rejection and water flux as high as 50-90 L/(m 2 ·h) for flat-sheet membranes and >20 L/(m 2 ·h) for hollow fibers. In bench-scale testing, a single unit of commercially available FO and MD membrane modules were evaluated for continuous, integrated operation. Using the laboratory- and bench-scale test data, numerical modeling was performed on the FO and MD processes to estimate engineering parameters for a larger-scale pilot unit. Based on the experimental studies and modeling results, a pilot-scale, integrated FO-MD prototype unit was designed and built for trailer-mounted operation. This prototype system was fed real industrial wastewater, which could not be further treated by conventional technologies, from an oil production facility and was successfully operated for over 15 weeks without major stoppage. About 90% water recovery was possible, while concentrating the TDS from 12,000 ppm up to 190,500 ppm. The FO-MD prototype rejected most wastewater contaminants while producing water with <300 ppm TDS, even when the feed TDS was higher than 150,000 ppm. No chemical cleaning was necessary during the pilot testing period. Flushing the system with dechlorinated tap water was sufficient to reset the membranes for the next set of test conditions. Pilot performance and membrane autopsy showed that, even though the feed was concentrated more than 10 times, membrane fouling was unnoticeable and no defects were detected on the FO and MD membrane surfaces. This project demonstrated the technical feasibility of the hybrid FO-MD process by taking water already treated to the limit with the highest level of current technologies and further concentrating it 10-fold by using mostly low-cost materials. Because no membranes suitable for full-scale plant applications are available at present, economical feasibility of the hybrid technology is still uncertain, but it is expected that broader industry participation can further reduce FO-MD process costs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

LANDO: Developing Autonomous Payload Offloading Capabilities for Lunar Surface Operations

Introduction: The Lightweight Surface Manipulation System (LSMS) AutoNomy capabilities Development for surface Operations and construction (LANDO) project is an Early Career Initiative selected for funding by NASA Space Technology Mission Directorate. LANDO is developing a general-purpose autonomy framework applicable to serial and tension-actuated manipulation agents, that will be validated using an existing prototype of the LSMS-L35 (35-kg wrist lift capacity on the lunar surface [Fig. 1], sized for a Commercial Lunar Pay-load Services (CLPS) mission). The autonomous LSMS-L35 will be used to demonstrate autonomous payload handling capabilities for Lunar and other planetary surfaces, directly addressing STMD capability gaps in autonomous excavation and construction operations, advanced robotics and spacecraft autonomy technologies, and technologies supporting emerging space industries including the In-Space Servicing, Assembly and Manufacturing national strategy. LSMS: The LSMS is a tension actuated robotic agent that is scalable (reach and lifting capacity in different gravity environments), versatile (types of surface operations), and reusable. Compared to serial arms, the LSMS provides significantly higher structural efficiency and mechanical advantage, enabling a greater payload lift capacity at a lower system mass. The LSMS is envisioned to be a crucial part of the excavation and construction portfolio, capable of supporting a variety of activities on the lunar surface. Autonomous payload handling is one of the first activities the LSMS can support that develops capabilities that are extensible to other surface operations. Payload handling is required to: remove payloads from a lander; place payloads on mobile agents for transport from a lander to construction site/assembly point; emplace payloads in their operational configuration, and aggregate components to create an asset. As an example of this critical gap, manifested CLPS missions do not currently have a ubiquitous payload offloading capability; payloads (excluding rovers) are designed to remain on the lander. Why Autonomy? Autonomous robotic systems capable of carrying out excavation and construction operations are a fundamental and critical capability required for realizing the NASA Artemis program vision to “emplace and build the infrastructure, systems, and robotic missions that can enable a sustained lunar surface presence.” While teleoperation is still feasible for lunar surface operations, increased latency at Mars will require validated supervised autonomous technologies capable of operating with minimal human involvement (human-on-the-loop) unless an unexpected event occurs requiring human intervention. Autonomy reduces operator burden, allows operations to continue during uncrewed periods, in-creases the safety of operations by automatically detecting and handling faults, and allows operating in high latency environments. Development Activities: LANDO is extending critical autonomous operations to the manipulation domain and creating an integrated system, based on reusable software modules, that is capable of planning and executing payload handling and autonomous surface operations without requiring hu-man intervention beyond a supervisory role. The priority features under development are 1) autonomously offload payloads from a tilted lander deck without buckling the LSMS; 2) sensing whether a payload is safe to lift and handle; and 3) integrate with Astrobotic’s CLPS lander. The poster presentation will highlight current development activities over the past year on LSMS-L35 prototype hard-ware design, and autonomy software.

in-space assembly↗