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DOE OSTI2024

Connected and Learning Based Optimal Freight Management for Efficiency

The management of the future heterogenous fleet is a complex decision-making problem. The heterogenous fleet is emerging as decarbonization technologies are deployed by fleets toward lowering the freight operation emissions in Medium and Heavy-duty vehicles. Traditionally, in fleets characterized by a homogeneous Diesel Internal Combustion Engine (ICE) powertrain, the process of fleet planning and operational optimization unfolds sequentially without the necessity to account for powertrain and vehicle-specific characteristics during dispatch decisions. Fleets with trucks less than 5 years old tend to maintain stable vehicle efficiency with minimal operational reliability risks for fleet managers. However, the landscape changes with the incorporation of emerging powertrain technologies, which lack extensive operational data and service experiences. This includes technologies like hybrid, Electric, Fuel Cell, or alternative fuel ICE. Operational decisions for fleets featuring heterogeneous powertrain technologies and facing limited access to alternative fueling and charging stations become intricate, requiring careful consideration and optimization at each dispatch. The difference in efficiency characteristics of emerging technologies, their range limitations, and the restricted availability of charging/alternative fueling infrastructure, coupled with sensitivity to driving conditions (e.g., EV range reduction in low temperatures) and their impact on component aging (such as batteries), become pivotal factors influencing the reliable and efficient freight transportation. To make the path toward low emission freight transportation efficient and reliable, an AI-assisted fleet management software is developed in this project to help fleet managers in optimizing both adoption of emerging powertrain decarbonization, connected and automated technologies and also operating the fleet after such technologies are deployed as schematically. Freight transportation requirements are different depending on the cargos to be shipped, customer requirements and regions of operations. This further highlights the need for software and digital solutions to tailor deployment and operation of emerging powertrain, connectivity, and automation technologies toward the specific fleet operation requirements. The fleet management optimizer was also integrated with a model of the fleet to simulate the operation of the fleet over 1 year of the baseline fleet operation (250,000+ shipments) indicating the significance of day-to-day variations on emissions and energy consumption of a freight transportation fleet. The results demonstrate ≥20% improvement in freight efficiency in terms of WTW CO2 per ton-mile of cargo shipments while all fleet operation constraints are enforced, and the cost (CapEx and OpEx) is minimized.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2002

The Solar-Sail Launched Interstellar Probe: Pre-Perihelion Trajectories and Application of Holography

Design of missions beyond our solar system presents many challenges. Here, we consider certain aspects of the solar-sail launched interstellar probe (ISP), a spacecraft slated for launch in the 2010 time period that is planned to reach the heliopause, at 200 Astronomical Units (AU) from the Sun after a flight of about 20-years duration. The baseline mission under consideration by NASA / JPL has a sail radius of 200 m, a science payload of 25 kg, a spacecraft areal mass thickness of about two grams per square meter and is accelerated out of the solar system at about 14 AU per year after performing a perihelion pass of about 0.25 AU. In current plans, the sail is to be dropped near Jupiter's orbit (5.2 AU from the Sun) on the outbound trajectory leg. One aspect of this study is application of a realistic model of sail thermo-optics to sail kinematics that includes diffuse / specular reflectance and sail roughness. The effects of solar-wind degradation of sail material, based on recent measurements at the NASA MSFC (Marshall Space Flight Center) Space Environment Facility were incorporated in the kinematical model. After setting initial and final conditions for the spacecraft, trajectory was optimized using the provision of variable sail aspect angle. The second phase of the study included consideration of rainbow holography as a medium for a message plaque that would be carried aboard the ISP in the spirit of the message plaques aboard Pioneer 10 /11 and Voyager 1 /2. A prototype holographic message plaque was designed and created by artist C. Bangs with the assistance of Ana Maria Nicholson and Dan Schweitzer of the Center for Holographic Arts in Long Island City, NY. The piece was framed by Simon Liu Inc. of Brooklyn, NY. Concurrent to the creation of the prototype message plaque, we explored the potential of this medium to transmit large amounts of visual information to any extraterrestrial civilization that might detect and intercept ISP. It was also necessary to investigate possible degradation of holograms by the space environment. We developed a new way of characterizing the optical quality of holograms.

Gregory L. Matloff↗

DOE OSTI2024

SMART SiC Power ICs: Scalable, Manufacturable, and Robust Technology for SiC Power Integrated Circuits (Final Technical Report)

This collaborative project was initiated with the goal of developing Scalable, Manufacturable, and Robust Technology for SiC Power Integrated Circuits (SMART SiC Power ICs). In pursuit of this objective, innovative designs and fabrication processes were implemented, enabling the development of large-scale (>1 cm²) SiC Complementary Metal-Oxide-Semiconductor (CMOS) integrated circuits and high-voltage (400–600 V) lateral power MOSFETs (HV-LDMOS) on 150 mm 4H-SiC substrates. The resulting SMART SiC Power ICs are tailored to support a wide range of applications requiring diverse voltage and power levels, including automotive systems, industrial equipment, electronic data processing, energy harvesting, and power conditioning. To achieve the proposed ‘SMART’ technology for SiC ICs, the team focused on 1) the Development of highly scalable CMOS (with high channel mobilities for n-type and p-type MOSFETs), LDMOS (~600V, 10A rated), and IC technologies, 2) Establishment of a manufacturable process baseline in a production-grade-, 150mm, SiC fabrication facility, and 3) Demonstration of SMART SiC ICs. The project initially comprised of fabricating 5 lots. In lot 1 monolithic integration using a single process was achieved. Here, we were able to successfully accomplish Integrated HV NMOSFET with LV CMOS on N-epi/N+ Substrate. The HV NMOS demonstrated a Breakdown Voltage (BV) more than 600V. Circuit demonstration of CMOS was also another achievement from this lot. In lot 2, priority was in place for isolation and integration. Here we addressed the isolation concerns and integrated the HV NMOS and LV CMOS using the N-epi/P-epi/N+ substrate. Similar to the lot 1, we were able to achieve a BV of 600 V for HV NMOS. Optimized gate oxide process with high channel mobilities, better gate oxide reliability, development of SPICE models, successful ohmic process development, novel wafer area saving design layouts, P+ isolation schemes with channeling implantations and high temperature operational circuits demonstrations are some of the key highlights from lot 1 and lot2. In lot 3, discrete device performances of HV NMOS with a BV ~700V and reliable LV CMOS performances were achieved. Also, novel architectural solutions were successfully implemented to suppress the electric field crowding at the gate oxide for reliable operations. In lot 4, half bridge power driver ICs with a conversion efficiency of (target 90% to 95%) in the 1-5MHz switching frequency range for output power between 25 W to 3 kW have been included in. However, due to the unfortunate events of sudden foundry shutdown (SiCamore Semi) the processing of lot 4 wafers came to a complete stop (January 2024). Arrangements have recently been made to shift the fabrication to another foundry, General Electric Aerospace. The fabrication process now on course (as of December 2024). Characterizations are delayed due to this unfortunate circumstance. The proposed trench architectural-based devices and ICs (lot 5) underwent modifications from the original project proposal. This change was necessitated by limitations in the availability of trench-based processes at commercial production-grade fabrication facilities in the US. Apart from above achievements, a Process Development Kit (PDK) was successfully developed for planar type SiC CMOS/LDMOS.

42 ENGINEERING↗

NASA NTRS2020

Calibration of the 11x11-Foot Transonic Wind Tunnel at NASA Ames Research Center

A static pipe calibration characterizing the streamwise static pressure distribution was conducted at the 11-By 11-Foot Transonic Wind Tunnel at NASA Ames Research Center. This data is used to determine the local Mach number within the test section and evaluate buoyancy corrections to axial force measurements. The 60 foot long, 6 inch diameter pipe contained 444 static pressure taps spanning the test section and nozzle regions of the tunnel. The forward end of the pipe extends into the settling chamber and is held by four cables mounting to the tunnel shell, and the aft end is fixed on the institutional model support system. A hydraulic cylinder at the aft end of the pipe provides tension on the system to reduce vibration and to keep the pipe as level as possible throughout the test section. The previous calibration was improved upon by using pressure scanners with greater accuracy, ensuring a uniform pressure tube length for each tap to control pneumatic lag, optically tracking any streamwise movement of the pipe, and more tightly controlling the tunnel condition set points. Typically this calibration is conducted with the pipe on tunnel centerline and 33 inches below centerline for sting-mounted models and semi-span (i.e. floor-mounted) models respectively, however schedule demands permitted only the centerline calibration. The semi-span calibration is planned to be completed in the summer of 2020. Immediately following the static pipe calibration, a shorter, 9 foot static pipe used as the calibration check standard was installed to obtain its first post-calibration pressure dataset. This short static pipe consists of 148 static pressure taps distributed along the pipe section and one total pressure tap at the end of an ogive nose. Performing the calibration test and its check standard back-to-back allows this dataset to establish a reliable baseline for future calibration check standard testing. Over time the use of a calibration check standard offers the ability to assess the stability of the calibration through statistical process control in an efficient and costeffective manner, thereby potentially increasing the time required between full tunnel calibrations.

White, Bethany↗

NASA NTRSDate not supplied

VALENTInE: A Concept for a New Frontiers Class Long Duration In-Situ Balloon Mission to Venus

Venus and Earth are similar in bulk composition, size, density, and approximate distance from the Sun, yet Venus’s modern-day climate and surface geology is distinctly different [1]. Previous missions to Venus revealed unusual volcanic features, possible continental crust, widespread volcanic plains, a weak magnetic field [2], and insights into the Venusian atmosphere [3,4]. Unfortunately, data from these missions were limited in spatial and temporal resolution and global extent. A future mission to Venus is critical to address fundamental questions surrounding the chemical composition and dynamics of the Venusian atmosphere [5], its geologic history [6,7], its internal structure [8,9], and its habitability throughout time [10,11]. We present the Venus Air and Land Expedition: a Novel Trailblazer for In situ Exploration (VALENTInE) mission to meet this need. VALENTInE is a variable altitude balloon that will passively float in Venus’s atmosphere between 45 and 55 km altitude. VALENTInE will acquire atmospheric data at varying latitudes and longitudes in addition to mapping the surface geomorphology and mineralogy across multiple terrains. Mission Objectives: The VALENTInE mission concept is driven by four main science objectives: 1. Determine whether the driving force of the superrotation of Venus’s atmosphere is caused by horizontal or vertical momentum transport. 2. Determine whether the atmospheric composition and noble gas inventory of the Venusian atmosphere is a product of outgassing from the initial protoplanetary source or if there are significant contributions from exogenic sources. 3. Determine whether the tesserae regions (particularly Aphrodite Terra) are felsic and relatively older than surrounding regions. 4. Determine if there is any evidence of a recent dynamo preserved in the rock record of Venus. Mission Overview: A balloon architecture provides a robust system that can survive long-term in the Venusian environment while taking accurate measurements of the lower cloud deck and surface. Two prior balloon missions to Venus, VEGA 1 and VEGA 2 in 1984, have demonstrated the potential for such planetary exploration; however, these missions were short-lived (46 hr), with limited range (54 km). Our spacecraft concept consists of a battery powered balloon with a gondola and flyby carrier stage (Fig. 1). Our novel design allows for at least 15 days of atmospheric exploration, including multiple ascents and descents in the Venus atmosphere. VALENTInE is baselined to launch in 2032, cruise on solar power for 128 days, enter, descend, and inflate (EDI) into Venus’s atmosphere above Aphrodite Terra, and float in Venus’s atmosphere for a total nominal mission duration of 15 days. The balloon, able to control its altitude by changing its buoyancy, will make one full circumnavigation every 4–8 days and move poleward ~1 o latitude per day; it will be passively directed by the horizontal air currents on Venus. The balloon can only be controlled in the z direction, and the expected latitude range is ±10° from EDI. The balloon itself will be a tracer for atmospheric structures such as zonal winds [5, 12]. During the 15-day operational period, there will be five dips to 45 km for a compositional study of the lower atmosphere and geological and magnetic mapping of the surface. Dips are used to take images and measurements closer to the surface and to obtain in situ vertical atmospheric profiles between 45 and 55 km. Instruments: The VALENTInE instrument payload will allow for extensive study of the geology, atmosphere, and interior of Venus. The instrument suite consists of six instruments. The mission profile for each instrument is shown in Fig. 2. Lower Atmosphere Meteorology Analyzer (LAMA) is an atmospheric structure instrument consisting of a thermometer, barometer, and accelerometer to continuously measure temperature and pressure as a function of altitude, longitude, and latitude. TracE and Noble Gas Investigator (TENGI) is aneutral mass spectrometer used to sample the dense atmosphere. TENGI will operate continuously at 45 km and 55 km and will measure D/H ratios, as well as Ne, Ar, and O isotopic ratios. Kilometer Scale Spectral Imager (KSSI) is amultispectral imager (850-1150 nm) used to resolve surface features on the order of km. Near InfraRed Multispectral Photometer (NIRMP) is an Infrared (IR) photometer used to image the surface through the clouds to characterize mineral assemblages at five different areas of the surface. NIRMP will be operated during dwell. ELevation REConnaissance (ELREC) is a light detection and ranging (LIDAR) instrument used for measuring topography at five different areas of the surface. The ELREC data will be combined with those of NIRMP to determine mineral assemblages and how they correlate to topography. Magnetic Exploration and Interior Detective (MEID) is a magnetometer used to detect any near-surface magnetic anomalies. The magnetometer will continuously operate at all altitudes. Mission Design: The spacecraft’s propulsion system will have a wet mass of 930 kg and will be launched on an Atlas V rocket. The spacecraft will jettison the payload upon arrival in Venus’s atmosphere before decelerating to orbital velocity. Figure 2. Notional power-dip profile while the balloon is on the dayside. Risks and Challenges: Raising and lowering the spacecraft to dip beneath the haze layer require a large amount of energy. This issue was partly compensated by limiting the number of dips over the 15 day prime mission. Power needs for pumping helium are reduced by slowing the descent speed, which consequently increases spatial resolution of in situ measurements between 45 and 55 km. The main limitation for the duration of the mission is the need to carry 15 days’ worth of batteries. The bus experiences external Venusian temperatures ranging from ~27°C at 55 km altitude to ~110°C at 45 km altitude. These high atmospheric temperatures require thermal protection for the bus (instruments, electronics, and flight systems) during its descent, dwell at 45 km, and ascent. The bus is maintained at a mechanically safe temperature range of -10°C to 50°C using white external paint, multi-layer insulation (MLI), mechanical/thermal isolation (e.g. Ti, composites), and ~57 kg of Phase Change Materials (PCM). Images and spectra taken below the haze dominate the available data transmission regardless of the time spent at 45 km. Therefore, less time at the lower altitude mainly reduces the coverage of in situ measurements there. Further, we assumed an unrealistically low-density material for the helium storage tanks on the gondola. However, this issue is partially resolved if we were to jettison 75% of the spent helium storage tanks. After the entry process, the balloon volume remains mostly inflated and storage tanks are required only for reducing balloon volume in dipping to 45 km. This mission was planned against an expected New Frontiers 5 (NF5) cost cap of $1B, as the NF5 call had not yet been released. The mission we describe fits within the predicted cost cap if the flyby carrier stage, responsible for powering the spacecraft during cruise and for relaying in situ measurements back to Earth, can be contributed by another space agency. Acknowledgments: We thank the JPL Planetary Science Summer School, especially A. Nash, J. Scully, K. Mitchell, L. Lowes, and J. Armijo, and our mentors from JPL Team X. Thank you to our review panel for their insightful review. References: [1] Kane, S. et al. (2019) JGR:Ps, 124 , 2015–2028. [2] Phillips, J. L., & Russell, C. T. (1987). JGR: Space Physics , 92 (A3), 2253-2263. [3] Nakamura, M. et al. (2018) Earth Planets Space, 70 (1), 144. [4] Svedhem, H. et al. (2009) JGR:P 114 (E5). [5] Limaye et al. (2009) Decadal Survey White Paper . [6] Ivanov, M. and Head, J. (2011) PSS, 59 (13) , 1559-1600. [7] Smrekar, S. et al. (2018) Space Sci Rev, 214 (5), 88. [8] O’Rourke, J. et al. (2018) EPSL, 502 , 46-56. [9] O’Rourke J. et al. (2019) GRL , (46), 5768–5777 [10] Way, M. et al. (2016) GRL, 43 (16), 8376-8383. [11] Way, M. et al. (2020) JGR:P, 125 (5), e2019JE006276. [12] Preston, R. A. et al. (1986) Science, 231 (4744), 1414-1416.

Mission Concept↗

NASA NTRS2022

Analysis of Base Metal Microstructures and Mechanical Properties of a Single-Piece, Spin-Formed Forward Pressure Vessel Bulkhead

In 2012, a pathfinder forward pressure vessel bulkhead (FPVBH) for the Orion Multi-Purpose Crew Vehicle (MPCV) was fabricated using aluminum (Al) alloy 2219. The demonstration article was offered as a replacement for the baseline configuration, which at that time was a multi-piece welded construction using aluminum-lithium (Al-Li) alloy 2195. In 2014, the NASA Engineering and Safety Center (NESC) funded a Phase I effort to explore spin-forming as a manufacturing method to produce a complex-shaped, single-piece FPVBH for the crew module (CM) [1]. The primary focus of the NESC effort was to expand spin-forming technology to the fabrication of an Al-Li 2195 FPVBH. As a result, limited testing and analysis was performed on the original Al 2219 article. In this study, a sufficiently large plate of Al 2219 was not available for the fabrication of a FPVBH. Therefore, the forming blank comprised two plates (from different lots) butt welded together using a single friction stir weld. The welded forming blank was then spin formed into the FPVBH configuration and heat treated to the T62 temper. Mechanical property testing of the spin-formed 2219-T62 FPVBH revealed that the tensile properties were comparable to the Metallic Material Properties Development and Standardization (MMPDS) A-basis allowable for Al 2219-T6 wrought products. However, post-spin forming application of the standard heat treatment produced large, recrystallized grains in the material. The response varied within the two plates; one plate lot exhibited nearly complete recrystallization, while the other lot contained bands of recrystallization. Although no reduction in tensile properties was observed due to these microstructural variations, a more detailed investigation was recommended to better understand the effect of spin forming on the recrystallization mechanism and the impact on other material properties. The current study examined the microstructure and mechanical properties of the fully processed Al 2219-T62 FPVBH with emphasis on comparing differences between the two plates. Testing was limited to the cone region of the FPVBH. The two specific tasks in this study were: a) Characterization of the microstructure and mechanical properties in the two plates used in the FPVBH. b) Isolation of the impact of each step in the thermo-mechanical processing (TMP) sequence of the FPVBH on recrystallization and grain growth. Mechanical property testing sampled regions containing both large, recrystallized and small, unrecrystallized grains. Tensile strengths and elongations were equivalent in both regions and exceeded MMPDS A-basis allowables. Fracture toughness was equivalent in both regions and fracture morphology was typical of aluminum alloys. The fatigue precrack region of the fracture toughness specimens appeared more faceted in the recrystallized plate. This suggests that property testing that is more sensitive to grain size, such as fatigue crack growth rate and stress corrosion cracking, may be warranted. Alcoa reviewed the production records for the two plate lots and confirmed that composition of both plates was within the allowable range for Al 2219 and that plate processing steps were all performed within production limits. However, the Fe content was notably higher in the fully recrystallized plate, resulting in a greater volume fraction of large Fe-bearing inclusions and Al-Cu constituent particles. Alcoa did not provide details regarding plate processing variables for the two plate lots. It was surmised that deformation by hot rolling was the most accurate TMP simulation of commercial spin forming within a laboratory setting. Both hot rolling and spin forming comprise combinations of shear and compressive deformation. The through-thickness strain caused by hot rolling is symmetrical about the mid-plane, as the rollers contact both sides of the material. Shear strains are maximum at the inner and outer surfaces and trend toward zero at the mid-thickness. In contrast, spin forming utilizes a single roller on the outer surface, producing a gradient in shear stress through the thickness. Shear strains in spin-formed material are highest at the outer surface due to direct contact with the roller, and trend toward zero at the inner surface. Consequently, there will undoubtedly be some discrepancies in the mechanical response of hot-rolled and spin-formed products in the through-thickness direction. Interrupted TMP simulations were performed on remnant plate from the FPVBH forming blank in order to isolate the effects of a post-weld anneal, spin-forming deformation/thermal cycling, and solution heat treatment (SHT) on development of the recrystallized microstructures. Analysis confirmed that large, recrystallized grains formed exclusively during SHT and only after a certain deformation level was exceeded. Remnant plate from both lots that received thermal processing only did not exhibit recrystallization but exhibited fully recrystallized microstructures when processed by hot rolling. This indicates that (1) the level of deformation exceeded the critical level for recrystallization in both plates and (2) that the level of deformation during hot rolling was greater than that which accumulated during spin forming of the FPVBH. Comparison of the hot-rolled plate with the spin-formed material showed that the recrystallized grain size was larger in the FPVBH, providing further evidence that deformation levels were lower in the FPVBH. The most plausible explanation for the differing degrees of recrystallization in the two plates is particle stimulated nucleation (PSN) at the Fe-bearing inclusions and large Al-Cu constituent particles. In the plate with higher solute content, the greater volume fraction of these particles reduces the deformation level required to promote recrystallization. During spin forming the critical deformation level was likely exceeded for the higher Fe content plate resulting in a fully recrystallized microstructure. The lower Fe content plate developed a microstructure that exhibited bands of recrystallization due to the combination of a non-uniform distribution of particles and deformation. The critical deformation required for recrystallization was likely only exceeded during spin forming in regions of higher particle content. While there were differences in Fe content between these lots of Al 2219 plate, the composition of both was within defined alloy limits and Alcoa reported no anomalies during plate production. The observed differences in recrystallization after spin forming may reflect the inherent variability between these two lots of plate. The spin-forming vendor, Spincraft, reported that similar variations in recrystallized microstructures have been observed during examination of multiple spin-forming trials of a different 2xxx series aluminum alloy. Hence, tighter chemical specification limits on impurity levels in Al 2219 plate may help ensure uniform, predictable microstructures. Finally, the tensile and fracture toughness properties were not affected by the microstructural variations noted.

single-piece↗

DOE OSTI2020

Evaluation of Changes to the MTR Fuel Dissolution Flowsheet to Increase the Number of L-Bundles Charged to a Dissolver

Material Test Reactor (MTR) fuels are dissolved in the H-Canyon facility using a Hg-catalyzed, HNO₃ dissolution flowsheet. The flowsheet is based on experimental work in which laboratory-scale experiments were used to provide bounding values for both offgas and H₂ generation rates. The generation of H₂ gas, primarily from the dissolution of Al, is controlled by limiting the surface area exposed to the solution. The number of L-Bundles charged and their submergence level defines the exposed surface area which is directly proportional to the H₂ generation rate. For the MTR fuel dissolution flowsheet, the maximum number of L-Bundles which can be charged to a dissolver was specified as a function of the Al concentration in the solution and the submergence level of the bundle. The MTR fuels are currently dissolved in the 6.1D dissolver. To reach the desired terminal Al concentration, a total of 12 L-Bundles of fuel are dissolved per batch. Depending on the submergence level being used in the dissolver, the 12 bundles are dissolved in three charges of four bundles per charge or in a sequence of three, four, and five bundles. However, if six L-Bundles could be dissolved in the initial charge, a dissolver batch could be completed in two dissolutions instead of three. To assess the feasibility of dissolving six bundles in the first charge, the Savannah River National Laboratory evaluated changes to the MTR flowsheet which increase the number of bundles which can be charged to a dissolver. Since the development of the existing MTR fuel dissolution flowsheet, improved offgas measurement methods have been developed to more accurately calculate the offgas composition and generation rate during laboratory-scale dissolutions. In the first part of this study, improvements in the calibration model for the Raman spectrometer (used for offgas characterization) and a more effective data smoothing routine were applied to existing data. The uncertainty in the offgas composition data used to define the MTR fuel dissolution flowsheet were subsequently re-evaluated which resulted in an approximate 50% reduction in the uncertainty of the H₂ gas concentration measurements. The reduced uncertainty was used in new calculations to define the maximum number of L-Bundles which can be charged to either the 6.1D or 6.4D dissolver as a function of the Al concentration. With the reduced uncertainty in the H₂ concentration measurements, a flowsheet was defined which supported initially charging 6 bundles to a dissolver. This flowsheet is based on the use of 0.002 M Hg, an L-Bundle immersion depth of 54 in., an air sparge/purge flowrate of 40 scfm, an iodine reactor operating temperature of 200 °C, and not exceeding 60% of the H₂ LFL in the dissolver offgas. In the second phase of this study, calculations were performed to assess the impact of changing various operating parameters to increase the number of L-Bundles charged to an H-Canyon dissolver. Applying the improved offgas measurement techniques including the reduced uncertainty in the H₂ concentration measurements to the existing data, the number of bundles of MTR fuel which can be charged to either the 6.1D or 6.4D dissolver were calculated based on varying the bundle immersion depth (44-60 in.), air sparge/purge flowrate (40-60 scfm), iodine reactor operating temperature (150-200 °C), and the percentage of the H₂ LFL which must not be exceeded (60-76%). Qualitatively, the percentage of the LFL had the largest influence on the maximum number of bundles which can be charged to a dissolver followed by the air sparge/purge flowrate, L-Bundle immersion depth, and the iodine reactor operating temperature. During the evaluation of each variable, the other variables were held at the baseline flowsheet conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Site Characterization of the Highest-Priority Geologic Formations for CO2 Storage in Wyoming

The project Site Characterization of the Highest-Priority Geologic Formations for CO2 Storage in Wyoming is one of 9 site characterization projects that were implemented as part of ARRA (American Recovery and Reinvestment Act). Data from this project was used to improve resolution of data in NATCARB in the area of study. Data related to this study has already been incorporated in NATCARB Atlas. The Wyoming Carbon Underground Storage Project (WY-CUSP) consisted of CO2 storage site characterization and evaluation, focusing on Wyoming’s most promising CO2 storage reservoirs (the Pennsylvanian Weber/Tensleep Sandstone and Mississippian Madison Limestone) and premier CO2 storage site (Rock Springs Uplift). Results from the WY-CUSP project suggest the two reservoirs could store up to 17,000 million tons of CO2. The WY-CUSP team drilled a stratigraphic test well and acquired a 3-D seismic survey covering 25 square miles of the Rock Springs Uplift site. The team retrieved 916 feet of core from the 12,810-foot-deep well, along with a complete log suite, borehole images, fluid samples, and other data. Project partners (1) provided continuous visual documentation of the core, including grain size, mineralogy, facies distribution, and porosity; (2) performed continuous permeability and velocity scans of selected reservoir intervals; and (3) chemically analyzed the fluid samples. WY-CUSP scientists integrated seismic attributes with observations from log suites, a VSP survey, core, fluid samples, and laboratory analyses, including continuous permeability scans. From these integrations, researchers constructed 3-D spatial distribution volumes of reservoir and seal properties that represent geological heterogeneity at the targeted CO2 storage site. The WY-CUSP team used this data to perform new CO2 plume migration simulations. Baker Hughes, Inc., completed a series of small-scale, in-situ water injectivity measurements. A database was formed when observations, analyses, and experiments from the stratigraphic test well were integrated. Correlation of these data allowed petrophysical parameters to be extrapolated from the test well out into the storage domain (5x5 mile 3-D seismic survey volume). This resulted in an improved, realistic understanding of performance assessments for potential CO2 storage scenarios. The WY-CUSP team worked on (1) improving CO2 storage resource estimates, (2) establishing long-term integrity and permanence of confining layers, (3) designing a profitable strategy for pressure management, and (4) evaluating the utilization of stored CO2 at the Rock Spring Uplift. Finally, Baker Hughes developed a microseismic baseline for the test site using in-bore geophones to complete field operations.

3-D seismic↗

NASA NTRS2016

Pilot Field Test: Performance of a Sit-to-Stand Test After Long-Duration Space Flight

BACKGROUND: Astronauts returning from the International Space Station are met by a team of recovery personnel typically providing physical assistance and medical support immediately upon landing. That is because long-duration spaceflight impacts astronauts' functional abilities. Future expeditions to planets or asteroids beyond the low Earth orbit, however, may require crewmembers to egress the vehicle and perform other types of physical tasks unassisted. It is therefore important to characterize the extent and longevity of functional deficits experienced by astronauts in order to design safe exploration class missions. Pilot Field Test (PFT) experiment conducted with participation of ISS crewmembers traveling on Soyuz expeditions 34S - 41S comprised several tasks designed to study the recovery of sensorimotor abilities of astronauts during the first 24 hours after landing and beyond. METHODS: The first test in the PFT battery sequence, and also the least demanding one from the sensorimotor perspective, was a Sit-to-Stand test. Test subjects were seated in the chair and had to stand up on command and remain standing for ten seconds. The subjects were instructed to stand up unassisted as quickly as they were able to, while maintaining postural control. Synchronized wireless inertial sensors mounted on the head, chest, lower back, wrists, and ankles were used to continuously log body kinematics. Crewmembers' blood pressure and heart rate were monitored and recorded with the Portapres and Polar systems. Each session was recorded with a digital video camera. During data collections occurring within the 24-hour postflight period, crewmembers were also asked to (1) evaluate their perceived motion sickness symptoms on a 20-point scale before and after completion of the test and (2) estimate how heavy they felt compared to their normal (preflight) body weight. Consent to participate in PFT was obtained from 18 crewmembers (11 US Orbital Segment [USOS] astronauts and 7 Russian cosmonauts). For 10 subjects, the first set of data was collected in the medical tent in Soyuz landing zone (1-2 hours after landing); the other 8 subjects were tested at the Kazakhstan deployment airport (4-5 hours after landing). 8 of the 11 astronauts were tested twice more within the first 24 hours postflight, at a refueling stop on the way to Houston (approximately 13 hours after landing) and at the Johnson Space Center (approximately 24 hours after landing). Later postflight data were collected in the first two weeks on some crewmembers. Finally, 6 astronauts were tested 60+ days after landing to establish a delayed baseline. RESULTS/DISCUSSION: Two of the 18 PFT participants felt too ill to attempt any tests in Kazakhstan (at either the landing zone or deployment airport). The remaining test subjects completed the Sit-to-Stand test and their reported motion sickness scores were unaffected by this task. The task completion times and body kinematics data analysis are currently underway. Preliminary analysis of astronaut data shows a steep improvement in the time to complete the task on the second data take, and in some cases, the trend continues through day six postflight. Head and trunk pitch angles and pitch rates were also examined and increases in all measures are evident throughout the observed recovery period (60+ days postflight). Interesting patterns of head and trunk pitch coordination have also emerged. One of the data analysis objectives is comparison of initial postflight performance and recovery of experienced crewmembers and first-time fliers. Another one - possible differences in performance between USOS and Russian crewmembers.

Kofman, I. S.↗

NASA NTRSDate not supplied

Monitoring Airspace Complexity and Determining Contributing Factors

The national airspace has evolved over many years to accommodate increased traffic demand [1] while simultaneously maintaining one of the safest forms of transportation [2], [3]. One of the reasons for this success is the ability of the system and the operators to adapt and accommodate to situations that routinely disrupt optimal operations. These situations may include: adverse weather, delays, early arrivals, equipment outages, and other factors that are outside the operators ability to control. These factors can lead to states where automation is unable to properly handle these issues and therefore air traffic controllers and pilots have to intervene, ultimately increasing communication between operators resulting in higher workload. As controller workload increases to handle sub-optimal operating conditions this can be viewed as an increase in complexity. The reasoning for this is because humans are now required to make tactical decisions in response to external factors, resulting in a departure from the strategic plan where operations would be more efficiently managed. Human operators control airspace complexity under rigid regulations that are constantly changing. The airspace is divided into sectors and the number of aircraft assigned to each controller is limited for safe handling. There has been past work that devised airspace complexity metrics in commercial aviation and related these metrics to controller workload (e.g., [4],[5]). The upper bounds on the system load are pre-determined. Such bounds on complexity make for a safe system, but the system cannot scale and adapt to autonomous, dense, and heterogeneous traffic, including the many types of Unmanned Aerial Vehicles (UAVs) envisioned to be added to the operations. We hypothesize that, as traffic density and heterogeneity grow, and other key metrics change, there will be phase transitions at which the way traffic should be managed changes significantly [6]. We offer a method for in-time detection of contributing factors that lead to phase transitions, characterized by increased complexity. To the best of our knowledge, there is no tool similar to our proposed effort that identifies such contributing factors or precursor patterns. To define the scope we are proposing to measure complexity from the viewpoint of the Terminal Radar Approach Control Facilities (TRACON) controller’s perspective. In particular we are analyzing arrivals into KSFO. With safety as the top concern for airspace operators, it is important to recognize that as density and heterogeneity grow, the focus of the system will change. Times of the day when the airspace has low density and heterogeneity, the flights will follow more efficient paths where the aircraft move on established routes that are more or less directly to the destination. However, when density and heterogeneity increases, the system will begin changing focus to avoiding conflicts and collisions and route the flights in a more flexible way. Higher flexibility requires more communication and coordination between controllers and pilots which the current automation is unable to handle. This paper proposes a novel approach that monitors airspace complexity at multiple scales, uses a Machine Learning-based tool that predicts when operations will transition to a regime of greater complexity, and identifies actions that can reduce the complexity while still maintaining efficient and safe operations. We demonstrate our proposed approach using data from multiple complementary sources. This includes, but is not limited to: historical aircraft surveillance data from NASA’s Sherlock Data Warehouse [7], METAR weather data, and airport configuration data from Aviation System Performance Metrics (ASPM). The surveillance data flight paths are sampled at a variable sample rate — increasing as the aircraft approaches the airport. This is due to how Sherlock manages flight track stitching between different radar facilities which have different sampling rates. The weather and performance data are logged at defined intervals throughout the day at a courser refresh rate. In addition to the logged data and metrics, we leverage pre-defined Standard Terminal Arrival Routes (STARs) procedures to characterize the path of each flight. Each flight files for one of these routes in the flight plan well before entering the terminal airspace, and approximately follows the route until it leaves the STAR, typically on the final fix of a runway transition. However, most flights do not always fly the full STAR procedure to completion [8], but the majority do adhere to the fixes within the common route of the procedure. Our approach leverages fixes in the common route of each of the STARs to build a reference path to the airport. This allows us to characterize the flight paths in what we are defining as the “maneuvering area” (the airspace between the STAR and before the flight is lined up on the runway’s final approach) to determine how off nominal the flights are to calculate its complexity score. Determining airspace complexity is a concept that does not have a concrete answer. In designing this metric, we consider what increases the workload for the air traffic controllers. Consequently more specialized vectoring maneuvers results in higher workload. Accordingly, we start with a theory: each flight has a direct path it takes from the STAR’s common route to the final approach’s outer marker fix for the flight’s landing runway. It is important to note that the direct path is only used as a reference. If the majority of the flights have a large consistent offset as compared to other routes it does not necessarily mean that those flights have higher complexity. We are merely building a distribution based on this direct path for that particular STAR and runway pair to determine the normal mode of operations for that route. Flights that are in the upper tail of these distributions will result in higher complexity scores and flights that fly in the median will represent the normal mode of operations and therefore will have lower complexity scores. Since flights following each STAR route take different paths to the airport, we have a different distribution for each STAR route and therefore can model these distributions to compute a complexity score from their respective normalized distributions. To evaluate the effectiveness of our proposed airspace complexity metric we will compare against an established approach based on trajectory clustering [9]. This unsupervised learning technique consists of the following steps: (1) identify the general maneuvering areas (waypoints) by performing $\kappa$-means or DBSCAN clustering on locations where aircraft frequently turn based on the surveillance radar track data, (2) map flight trajectories onto sequences of waypoints, and (3) cluster the sequences based on their common subsequences. From a high-level perspective, this baseline model learns nominal operations in the airspace through the sequence of waypoints that are representative of where aircraft change direction and defines deviations from the nominal operations as “complex.” Therefore, more deviations from the nominal operations correspond to higher complexity values. For our validation, we re-implemented this technique and tune model hyper-parameters to correctly detect waypoints for the arrival traffic into the San Francisco bay area. We will compute the complexity measure over a one-year period using our proposed technique as well as the baseline. Our validation will be based on each technique’s ability to detect a set of undesirable outcomes (e.g., go-arounds, holding patterns, average time in the airspace, etc.). Since our current complexity metric is derived from the offset from the direct reference path, it’s important to understand what causes these offsets. In many of the flights with high offset distance, flights performing holding patterns and S turns can be observed. These maneuvering tactics are utilized to add distance between the aircraft and the destination runway to prevent multiple flights from having conflicting arrival times. In order to predict a rise in complexity (or the precursor to complexity), it’s necessary to be able to identify these potential conflicts (which in turn, result in higher offsets). To do this, we define a “representative flight” for each STAR route and runway pair. This flight is approximately the path the flight would take if there was a clear path with no other flights in the airspace — including the time remaining to the airport. We first identify the flights for a given STAR runway pair using the offset to the reference path distributions that fall between the 44-55 percentiles. This yields the flights that conform to the most normal mode of operation. Each of these flights is partitioned based on the percent complete from the entry point into the maneuvering areas from 0\% – 100\% complete. Then for each percent “bin”, we take the median value of the flight’s latitude/longitude coordinates, airspeed, and (non causal) time remaining to the airport to construct a lookup table for each percent complete bin on a given route. As a flight enters the maneuvering area, we can find the estimated arrival time of a flight to the airport by finding the closest point to the representative path’s percent complete bin (relative to the flight’s current position at any snapshot in the airspace) and therefore retrieve the corresponding remaining time left on the “representative path”. We assume that the flight will follow the representative path to completion when deriving these estimates. We can then compare these estimated arrival times against other flights for the same snapshot in time to identify potential conflicts. If more flights are estimated to arrive within a tolerance window than there are runways available, then we have a potential conflict. We can use this derived measure along with other factors expected to add disruption to the operation such as weather and runway configuration changes as an input to machine learning tools to detect precursors that increases in our complexity measure. This novel method will assist in uncovering insights into the contributing factors that lead to increased complexity that may allow for in-time responses to avoid reaching a high complexity state in the airspace.

complexity↗

DOE OSTI2025

Design of Novel Hot Gas Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This CRADA project was the result of a project award under FOA-DOE-0001980. The overarching FOA project team consisted of researchers from Carpenter Technology Corporation (CTC), Solar Turbines Incorporated (Solar), Pennsylvania State University (PSU), University of California-Santa Barbara (UCSB), and Oak Ridge National Laboratory (ORNL). Evaluations were conducted on two high-γ’ superalloys that were designed by CTC and the UCSB. One alloy named GammaPrint-700 (GP-700) is a cobalt-base superalloy. The other alloy named GammaPrint-1100 (GP-1100) is a nickel-base (Ni-base) superalloy. PSU provided expertise and experimental testing of the thermal performance of AM micro-cooling architectures. ORNL provided expertise with the AM superalloy materials characterization and AM processing science. Solar provided turbine component design expertise. The focus of this CRADA report is to document the efforts between ORNL and CTC towards the development of superalloys designed for AM. The project goal was to use an AM processable high-temperature superalloy and design for Additive Manufacturing (DfAM) techniques to design an efficient turbine component (i.e. a turbine tip shoe) with enhanced cooling features that can only be fabricated through additive manufacturing (AM). The efficiencies of existing combined heat and power (CHP) engines are capped by both component design and materials limitations. However, AM of a tip shoe component from a γ’strengthened superalloy offers the design flexibility to increase the efficiency and power of an industrial gas turbine. This project brought about advancements in the DfAM tip shoe design space and in the area of high temperature superalloys processable through laser powder bed fusion (LPBF) AM. State of art computation design tools were utilized to optimize unique cooling features into a tip shoe component design. A two-prong materials development approach was taken to support development of the AM tip shoe geometry. The first approach centered on investigating the processability and the appropriate process science for the industry standard high-γ’ nickel-base (Ni-base) superalloy Mar-M247. This superalloy is typically cast and considered non-weldable by traditional welding standards. In the course of this work, the alloy was not deemed feasible for process scale-up due to significant cracking issues during printing. The second approach focused on the development and evaluation of a novel cobalt-base superalloy, GammaPrint™-700 (GP-700 and a Ni-base superalloy, GammaPrint™-1100 (GP-1100) designed to mitigate the significant AM processing issues with Mar-M247. The processability of these two alloys were investigated through electron beam melting (EBM) binder-jet AM (BJAM), and LPBF as a risk mitigation for manufacturability. To be considered a candidate material for down-selection to proceed to fullscale AM tip shoe engine testing trials, the high temperature creep rupture strength was required to achieve at a minimum, a Larsen Miller Parameter (LMP) increase of 10.9% over the baseline material LPBF AM Hastelloy X.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Design of Novel Hot Gas Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This CRADA project was the result of a project award under FOA-DOE-0001980. The overarching FOA project team consisted of researchers from Carpenter Technology Corporation (CTC), Solar Turbines Incorporated (Solar), Pennsylvania State University (PSU), University of California-Santa Barbara (UCSB), and Oak Ridge National Laboratory (ORNL). Evaluations were conducted on two high-γ’ superalloys that were designed by CTC and the UCSB. One alloy named GammaPrint-700 (GP-700) is a cobalt-base superalloy. The other alloy named GammaPrint-1100 (GP-1100) is a nickel-base (Ni-base) superalloy. PSU provided expertise and experimental testing of the thermal performance of AM micro-cooling architectures. ORNL provided expertise with the AM superalloy materials characterization and AM processing science. Solar provided turbine component design expertise. The focus of this CRADA report is to document the efforts between ORNL and CTC towards the development of superalloys designed for AM. The project goal was to use an AM processable high-temperature superalloy and design for Additive Manufacturing (DfAM) techniques to design an efficient turbine component (i.e. a turbine tip shoe) with enhanced cooling features that can only be fabricated through additive manufacturing (AM). The efficiencies of existing combined heat and power (CHP) engines are capped by both component design and materials limitations. However, AM of a tip shoe component from a γ’strengthened superalloy offers the design flexibility to increase the efficiency and power of an industrial gas turbine. This project brought about advancements in the DfAM tip shoe design space and in the area of high temperature superalloys processable through laser powder bed fusion (LPBF) AM. State of art computation design tools were utilized to optimize unique cooling features into a tip shoe component design. A two-prong materials development approach was taken to support development of the AM tip shoe geometry. The first approach centered on investigating the processability and the appropriate process science for the industry standard high-γ’ nickel-base (Ni-base) superalloy Mar-M247. This superalloy is typically cast and considered non-weldable by traditional welding standards. In the course of this work, the alloy was not deemed feasible for process scale-up due to significant cracking issues during printing. The second approach focused on the development and evaluation of a novel cobalt-base superalloy, GammaPrint™-700 (GP-700 and a Ni-base superalloy, GammaPrint™-1100 (GP-1100) designed to mitigate the significant AM processing issues with Mar-M247. The processability of these two alloys were investigated through electron beam melting (EBM) binder-jet AM (BJAM), and LPBF as a risk mitigation for manufacturability. To be considered a candidate material for down-selection to proceed to full-scale AM tip shoe engine testing trials, the high temperature creep rupture strength was required to achieve at a minimum, a Larsen Miller Parameter (LMP) increase of 10.9% over the baseline material LPBF AM Hastelloy X.

99 GENERAL AND MISCELLANEOUS↗

NASA NTRS1993

LOITA: Lunar Optical/Infrared Telescope Array

LOITA (Lunar Optical/Infrared Telescope Array) is a lunar-based interferometer composed of 18 alt-azimuth telescopes arranged in a circular geometry. This geometry results in excellent uv coverage and allows baselines up to 5 km long. The angular resolution will be 25 micro-arcsec at 500 nm and the main spectral range of the array will be 200 to 1100 nm. For infrared planet detection, the spectral range may be extended to nearly 10 mu m. The telescope mirrors have a Cassegrain configuration using a 1.75 m diameter primary mirror and a 0.24 m diameter secondary mirror. A three-stage (coarse, intermediate, and fine) optical delay system, controlled by laser metrology, is used to equalize path lengths from different telescopes to within a few wavelengths. All instruments and the fine delay system are located within the instrument room. Upon exiting the fine delay system, all beams enter the beam combiner and are then directed to the various scientific instruments and detectors. The array instrumentation will consist of CCD detectors optimized for both the visible and infrared as well as specially designed cameras and spectrographs. For direct planet detection, a beam combiner employing achromatic nulling interferometry will be used to reduce star light (by several orders of magnitude) while passing the planet light. A single telescope will be capable of autonomous operation. This telescope will be equipped with four instruments: wide field and planetary camera, faint object camera, high resolution spectrograph, and faint object spectrograph. These instruments will be housed beneath the telescope. The array pointing and control system is designed to meet the fine pointing requirement of one micro-arcsec stability and to allow precise tracking of celestial objects for up to 12 days. During the lunar night, the optics and the detectors will be passively cooled to 70-80 K temperature. To maintain a continuous communication with the earth a relay satellite placed at the L4 libration point will be used in conjunction with the Advanced Tracking and Data Relay Satellite System (ATDRSS). Electrical power of about 10 kW will be supplied by a nuclear reactor based on the SP-100 technology. LOITA will be constructed in three phases of six telescopes each. The total mass of the first operational phase is estimated at 58,820 kg. The cost of the fully operational first phase of the observatory is estimated at $8.9 billion. LOITA's primary objectives will be to detect and characterize planets around nearby stars (up to ten parsec away), study physics of collapsed stellar objects, solar/stellar surface features and the processes in nuclear regions of galaxies and quasars. An interferometric array such as LOITA will be capable of achieving resolutions three orders of magnitude greater than Hubble's design goal. LOITA will also be able to maintain higher signal to noise ratios than are currently attainable due to long observation times available on the moon.

Source record↗

DOE OSTI2024

Fatigue Testing and Characterization of Pre-hydrided Zircaloy-4 Cladding Tubes

The solubility of hydrogen in Zircaloy-4 (Zry-4) at the cladding operating temperature is near 100 wt. ppm. Above this solubility limit, excess hydrogen precipitates as δ-hydride platelets in the cladding material. Because of the effect of the thermal gradient across the cladding thickness on the migration and precipitation of hydrogen, hydride rims are often observed at the cladding outer surface; under excessive corrosion conditions hydride blisters are possible. It is well known that the fatigue of metal alloys, especially high cycle fatigue, is sensitive to the status of surface including the microstructure, roughness, and residual stress. Thus, the question considered herein, is whether excessive hydrogen pickup modifies the microstructure such that it has a degradation effect on the fatigue performance of cladding during operation. This report describes the evaluation of fatigue performance of a pre-hydrided Zry-4 cladding. A commercial Zry-4 was polished and pre-hydrided to 800 ppm and 1300 ppm H contents. The fatigue testing was conducted under strain control at 5 Hz with fully-reversed bending by using a cyclic integrated reversible bending fatigue tester (CIRFT). Six specimens with 1300 ppm and one specimen with 800 ppm were tested. Significant variation in test results were observed. While two of the 1300 ppm specimens failed with less than 1 ×10 5 cycles (at 0.32% and 0.41%), the four other samples did not fail over the strain amplitude range of 0.25% to 0.38%. Interestingly, the fracture initiation site of the failed samples was on the outside diameter (OD) surface rather than on the inside diameter (ID) surface as is typical for the as-polished cladding. This suggested a degrading effect of the hydriding process. Subsequently, three of the unfailed specimens were then further tested at ~0.43% to observe where failure initiation occurred. Significant variation was also observed in these three specimens. One specimen failed at ~9000 cycles while the two others failed at 43000 and 1.06 ×10 5 cycles. The performance here correlated to the location of failure initiation; failure initiated on the OD in the sample that failed after 9000 cycles while it initiated on the ID in the sample that failed after 43000 and 1.06 ×10 5 cycles. Flat features at the OD initiation sites suggest a brittle hydride feature on the surface of those samples was the cause of the degradation in fatigue performance, though the overall hydrogen levels in all samples was similar. A summary of all the observations is provided below: • The un-failed specimens with 1300 ppm H were cycled to failure with a higher amplitude near 0.43%. In addition, the fatigue-treated specimen tended to have a longer fatigue at the same induced amplitude. • Fractography revealed a mixed failure mode for the pre-hydrided specimen. Particularly, the specimen with fracture initiation site (FIS) located on the outer diameter surface of tube tended to have a shorter fatigue life than that of FIS on the inner diameter surface. • Etched cross section was shown to have hydride platelets aligned with tube longitudinal axis as expected, and the density of hydrides is at the similar level as in literature data. Meanwhile, a LECO procedure was applied for hydrogen concentration measurement, which showed the measured hydrogen contents are close to the nominal value. • With the polished cladding tube as baseline, O’Donnell-Lager (O-L) analysis showed that a decrease of about 50% in reduction-of-area (RA) would be needed for the O-L fitting to the fatigue data of 1300 ppm cladding. The suggestion for the next steps is provided.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2016

Fluid Shifts: Otoacoustical Emission Changes in Response to Posture and Lower Body Negative Pressure

INTRODUCTION: The purpose of the NASA Fluid Shifts Study is to characterize fluid distribution and compartmentalization associated with long-duration spaceflight and to correlate these findings with vision changes and other elements of the visual impairment and intracranial pressure (VIIP) syndrome. VIIP signs and symptoms, as well as postflight lumbar puncture data, suggest that elevated intracranial pressure (ICP) may be associated with spaceflight-induced cephalad fluid shifts, but this hypothesis has not been tested. Due to the invasive nature of direct measures of ICP, a noninvasive technique of monitoring ICP is desired for use during spaceflight. The phase angle and amplitude of otoacoustic emissions (OAEs) have been shown to be sensitive to posture change and ICP (1, 2), therefore use of OAEs is an attractive option. OAEs are low-level sounds produced by the sensory cells of the cochlea in response to auditory stimulation. These sounds travel peripherally from the cochlea, through the oval window, to the ear canal where they can be recorded. OAE transmission is sensitive to changes in the stiffness of the oval window, occurring as a result of changes in cochlear pressure. Increased stiffness of the oval window largely affects the transmission of sound from the cochlea at frequencies between 800 Hz and 1600 Hz. OAEs can be self-recorded in the laboratory or on the ISS using a handheld device. Our primary objectives regarding OAE measures in this experiment were to 1) validate this method during preflight testing of each crewmember (while sitting, supine and in head-down tilt position), and 2) determine if OAE measures (and presumably ICP) are responsive to lower body negative pressure and to spaceflight. METHODS: Distortion-product otoacoustic emissions (DPOAEs) and transient evoked otoacoustic emissions (TEOAEs) were recorded preflight using the Otoport Advance OAE system (Otodynamics Ltd., Hatfield, UK). Data were collected in four conditions (seated, supine, 15 degrees head down tilt (HDT), and 15 degrees HDT with lower body negative pressure (LBNP)) to produce a range of ICP in each subject and test the susceptibility of OAEs to LBNP. LBNP was induced using the Russian Chibis suit to produce the same fit and pressures that would be experienced inflight during Chibis LBNP trials. Similar trials have occurred inflight on the ISS. A comparative analysis of preflight and inflight phase measurements and magnitudes was completed in both broad and narrow band frequency ranges. RESULTS: TEOAE data demonstrated notable phase shifts from 859-1640 Hz when the seated baseline condition is compared to supine, HDT, and HDT plus Chibis conditions. Changes were particularly pronounced at low frequencies and were consistent with the expected ICP changes. Preflight DPOAE magnitude data revealed changes consistent with increased ICP in two conditions at 1414 Hz, where a magnitude change (relative to the seated condition) was seen in the HDT position and in HDT plus Chibis. DISCUSSION: OAEs revealed systematic changes in phase and magnitude throughout all test conditions (including use of Chibis LBNP) that were consistent with ICP changes. Results indicate that OAEs may provide a rapid noninvasive means of monitoring ICP changes. The first two subjects are projected to complete inflight testing on the ISS in early 2016, with the full complement of 10 subjects scheduled to be complete in 2018.

Melgoza, R.↗

DOE OSTI2021

Preprocessing for Unintended Conducted Emissions Classification with ResNet

Characterization of Unintended Conducted Emissions (UCE) from electronic devices is important when diagnosing electromagnetic interference, performing nonintrusive load monitoring (NILM) of power systems, and monitoring electronic device health, among other applications. Prior work has demonstrated that UCE analysis can serve as a diagnostic tool for energy efficiency investigations and detailed load analysis. While explaining the feature selection of deep networks with certainty is often not fully comprehensive, or in other applications, quite lacking, additional tools/methods for further corroboration and confirmation can help further the understanding of the researcher. This is true especially in the subject application of the study in this paper. Often the focus of such efforts is the selected features themselves, and there is not as much understanding gained about the noise in the collected data. If selected feature and noise characteristics are known, it can be used to further shape the design of the deep network or associated preprocessing. This is additionally difficult when the available data are limited, as in the case which the authors investigated in this study. Here, the authors present a novel work (which is a proposed complementary portion of the overall solution to the deep network classification explainability problem for this application) by applying a systematic progression of preprocessing and a deep neural network (ResNet architecture) to classify UCE data obtained via current transformers. By using a methodical application of preprocessing techniques prior to a deep classifier, hypotheses can be produced concerning what features the deep network deems important relative to what it perceives as noise. For instance, it is hypothesized in this particular study as a result of execution of the proposed method and periodic inspection of the classifier output that the UCE spectral features are relatively close to each other or to the interferers, as systematically reducing the beta parameter of the Kaiser window produced progressively better classification performance, but only to a point, as going below the Beta of eight produced decreased classifier performance, as well as the hypothesis that further spectral feature resolution was not as important to the classifier as rejection of the leakage from a spectrally distant interference. This can be very important in unpredictable low-FNR applications, where knowing the difference between features and noise is difficult. As a side-benefit, much was learned regarding the best preprocessing to use with the selected deep network for the UCE collected from these low power consumer devices obtained via current transformers. Baseline rectangular windowed FFT preprocessing provided a 62% classification increase versus using raw samples. After performing a more optimal preprocessing, more than 90% classification accuracy was achieved across 18 low-power consumer devices for scenarios in which the in-band features-to-noise ratio (FNR) was very poor.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

System Configuration Evaluation for Process Settling of Hanford Waste Solid Particles

Direct Feed High-Level Waste (DFHLW) is a potential flowsheet operations approach to initiating high-level waste (HLW) vitrification prior to completion of the Hanford Waste Treatment and Immobilization Plant (WTP) Pretreatment Facility. A settle/decant process has been proposed to concentrate solids prior to delivery to the WTP HLW Facility during DFHLW operations, wherein the solids in a settled layer would be remixed with the supernatant liquid remaining after decanting operations to provide the feed at required solids concentrations. Settling would be used in lieu of purpose-built filtration or other solids separation equipment. Pacific Northwest National Laboratory (PNNL) is providing baseline technical support to the Washington River Protection Solutions (WRPS) Flowsheet Integration group. To support planning for DFHLW, WRPS previously requested that PNNL evaluate the current data set available to predict the time needed for HLW solids to settle and the solids concentration and strength of that settled layer, to identify gaps in the understanding and predictive capability of HLW solids waste settling times, and to provide scoping estimates of the potential settling times. Eight technical gaps were identified for predicting settling times and characteristics of the formed sediment layers. In addition to the data gaps, an overarching observation was made that there is significant variation in behavior of settling rate and settled layer data. The settling time required to concentrate solids via a settle/decant process was determined from the limited data to have a difference of potentially more than a factor of 5,000 in the estimated settling times, varying from 0.2 to 1,060 days for example depending on process vessel depth and final sediment solids concentration. In contrast, successful processes of liquid-forward output streams resulting from in-tank settling and decanting forward liquid have been reported for operations conducted at the Hanford Site. The purpose of this current report is to further support DFHLW planning by evaluating double-shell tank (DST) and alternate vessel equipment and operational configurations to enable optimization of the settle/decant process to concentrate solids. Hanford waste processing behavior specific to liquid feed availability following a slurry transfer in a DST is summarized, including process stream characteristics and process equipment configurations. The performance of DST process equipment configurations is evaluated for possible improvements using computational fluid dynamics (CFD) and simple analytical models. Potential new vessel design(s) specific to enabling effective settle/decant processes, and cursory summary of other separate and inline solids separations processes, are also provided. The CFD results indicated that improvement in outflow solids concentration was promoted by a reduction in the slurry flow rate, angling the distributor nozzles downward, and lifting the transfer pump. The solid-liquid analysis evaluating particle trajectory confirmed that the potential for particle ingestion (in the transfer pump) was decreased with increased radial separation between the inlet and outlet (transfer pump inlet), decreased inlet flow, and decreased liquid density and viscosity for a neutrally buoyant inlet flow. An assessment was also made of the potential for inflow configuration changes to result in the discrete mounding or piling of solids within the tank. Based on the characterization of the settled waste to date, HLW sediments will be unlikely to sustain a substantial angle of repose to facilitate significant variations in the elevation of the settled solids.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRSDate not supplied

Development and Testing of Pulse Guns for Combustion Instability Testing

To test liquid rocket engines (LREs) for combustion instabilities, devices such as bombs are often used to create pressure wave disturbances. Bombs, while effective, are inherently dangerous, expensive, and difficult to procure. Over the years, pulse guns have been used as a safer and more cost-effective way to generate controlled pressure disturbances in engine chambers. In anticipation of the need for stability testing of prototype LREs at NASA Marshall Space Flight Center (MSFC), a set of pulse guns have been designed, fabricated, tested, and characterized. The pulse gun program is funded by the RS-25 Engine Program managed out of MSFC and funded by NASA’s Space Launch System (SLS) through the MSFC Liquid Engines Office (LEO). A pulse gun is a simple device – like a traditional gun, it has a breech and barrel section. However, unlike a traditional gun, there is no bullet, as the purpose of the pulse gun is strictly to fire a high pressure pulse. Instead of a firing pin and primer that would normally be used in a traditional gun, an initiator is used to activate the gun powder. The initiator is a highly reliable pyrotechnic initiator. For this study, clone versions of the NASA Standard Initiator (NSI) were used. The initiator is used to ignite a pre-measured amount of gun powder loaded into the breech. When the pressure of the burnt gun powder exceeds the set point of a downstream burst disk, the disk ruptures, allowing the high pressure pulse to travel downstream through the barrel section. A ballistic pressure transducer located in the breech section is used to measure the short duration, high pressure pulse. Some configurations of the pulse gun have barrel sections that include one or more additional ballistic pressure transducers. These additional pressure measurements help track the degradation and damping of the pulse as it travels out of the barrel section. The measurements may also be used to determine the velocity of pulse. The objective of this paper is to present the different variants of this newly-developed pulse gun and characterize performance over a range of parameters. The parameters include breech diameter, barrel length, amount of gun powder used, the way the gun powder is packed, and the pressure setting of the burst disk. There are a total of six pulse guns: three with the 0.25 inch breech and three different length barrels, and three with the 0.40 inch breech and three different length barrels. For both breech sizes, the associated barrels are referred to as standard, one-port, and two-port barrels. The standard barrel has no instrumentation and is likely the barrel that will be used for engine stability testing. The one- and two-port barrels were designed specifically for pulse gun component testing to allow measurements of the magnitude and timing of the high pressure pulse as it makes its way through the pulse gun. The burst disks tested were commercially-available burst disks designed to rupture at 8,000, 16,000, and 24,000 psid. Testing was accomplished by firing the pulse gun into a test chamber pressurized with nitrogen at about 2300 psig. A total of four Model 113B23 High frequency ICP® pressure sensors (10k psi) were mounted in the test chamber, in the same plane as the pulse gun. Two of the sensors had “trimmed” adapters, and two did not. Given the symmetrical configuration of the sensors within the test chamber, different amplitudes of pressure measurements are attributed to the use of trimmed versus untrimmed adapters. The untrimmed adapters, with their narrower passages, tended to amplify the pressure amplitudes by as much as 50%. In total, 41 pulse gun tests have been conducted.Data are still being analyzed, but some trends are apparent. For example, measurements taken within the pulse gun are shown in Figures 3 and 4 for Hot-fires (HFs) # 11 and 39, respectively. Both tests were identical in that the 0.40 inch ID breech, two-port barrel, 8,000 psid burst disk, and same amount of gunpowder (6.639 grains for HF# 11, and 6.576 grains for HF# 39) were used, and the back pressure in the nitrogen test chamber was ~2300 psig. Despite keeping all these variables constant, the results from these two tests look quite different. For both tests, the first pressure peak shown in the P2111 trace within the breech is the firing of the initiator. The second peak and any subsequent peaks are from the combustion of the gunpowder. It should be noted that because the sensors are dynamic, the ~2300 psig baseline static pressure is not shown in the figures. For HF# 11, the burst disk clearly ruptured in a little over 0.1 ms from the time the initiator was fired. This is evident from the abrupt rise in pressure for P2112 followed by another abrupt rise in pressure for P2113. The sensors track the movement of the high pressure pulse through the pulse gun. For HF# 39, however, there was nearly 1 ms delay between the initiator firing and the burst disk rupturing. The only difference between these two tests was the way in which the gunpowder was packed within the breech. For HF# 11, the gunpowder was poured directly into the breech, atop the initiator, and held in place with a vegetable fiber wad appropriately sized for the barrel diameter. Once in place, the wad firmly held the gunpowder in place. For HF# 39, the gunpowder was rolled within cigarette paper with the ends of the paper twisted. The rolled gunpowder was gently pushed down into the breech, toward the initiator, and no wad was used. This method of loading the gunpowder consistently produced longer delays in the rupture of the burst disk, presumably because there was a steady, fuller burning of the gunpowder. The burst disk was rated for 8,000 psid, which means that the burst disk should not have opened until the pressure in the breech reached ~10,300 since there was ~2300 psig back pressure in the test chamber. In the case of HF# 11, the breech pressure only reached roughly 4200 psi before there was leakage either through or past the burst disk, but for HF#39, the breech pressure reached 10,600 psi prior to the burst disk opening. The temperature of the burst disk is certainly a factor in determining when the burst disk will rupture. A sharp rise in the burst disk temperature could weaken it and cause it to stray from the designed set point burst pressure. The burst disks are manufactured of Inconel to try to reduce their sensitivity to temperature, but how the burst disks perform above 900°F is not documented. All burst disks were engineered and tested by the manufacturer for ambient temperature conditions. One theory for why rolling the gunpowder in cigarette paper may produce better results is related to a more controlled temperature environment. The cigarette paper may act as a sheath that protects the burst disk from excessive temperatures during the rapid buildup of pressure in the breech. The ultimate benefit of not breeching the burst disk prematurely is shown in Figures 5 and 6, which graphs the resultant pressure pulse produced in the test chamber. For HF #11, the peak pressure on the P2123 trimmed adapter is about 270 psi, while for HF# 39 it is 343 psi, which is about 1.27 times greater in magnitude. In either case, the pressure pulse is ~20 μs in width once it reaches the test chamber. Another pressure rise about 100 μs later can be seen on the sensors located across from the pulse gun port, P2124 and P2121. These pressures are lower due to attenuation of the pressure wave as it moves across the test chamber. After the wave encounters the wall, it reflects back and forth within the chamber until it completely dissipates.

Pulse Gun↗