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NASA NTRSDate not supplied

In-Situ Consolidation Automated Fiber Placement of Thermoplastic Composites for High-Rate Aircraft Manufacturing

The National Aeronautics and Space Administration (NASA) initiated the Hi-Rate Composites Aircraft Manufacturing (HiCAM) project in 2021 with the goal of significantly increasing composite structures manufacturing rate in the commercial aircraft industry. The technologies currently under investigation include resin infusion and automated fiber placement (AFP) of novel thermoset materials and thermoplastic composites. Thermoplastic composites offer attractive solutions to rapid manufacturing due to their ability to be formed and consolidated quickly. NASA is particularly focused on assessing composite structure manufacturing utilizing an in-situ consolidation AFP of thermoplastics (ICAT) process employing a recently developed laser heating system. Two semi-crystalline polyaryletherketone thermoplastic tape materials were characterized to ascertain the ICAT process parameters at AFP placement speeds approaching 423 mm/s. The required laser power settings were determined at Electroimpact, measuring material temperatures utilizing a forward looking infrared (FLIR) thermal imaging camera and thermocouples. The material temperature, tool temperature, and placement speed were varied for resulting consolidation quality assessment. The resulting temperature data were also utilized to calibrate thermal analysis models under development at NASA. The experimental temperature data confirmed analytical results. An overview of the HiCAM project as well as initial data from ICAT process characterizations are described.

thermoplastic composites↗

NASA NTRS2022

In-Situ Consolidation Automated Fiber Placement of Thermoplastic Composites for High-Rate Aircraft Manufacturing

laser heating↗

NASA NTRS2016

Station Program Note Pull Automation

Upon commencement of my internship, I was in charge of maintaining the CoFR (Certificate of Flight Readiness) Tool. The tool acquires data from existing Excel workbooks on NASA's and Boeing's databases to create a new spreadsheet listing out all the potential safety concerns for upcoming flights and software transitions. Since the application was written in Visual Basic, I had to learn a new programming language and prepare to handle any malfunctions within the program. Shortly afterwards, I was given the assignment to automate the Station Program Note (SPN) Pull process. I developed an application, in Python, that generated a GUI (Graphical User Interface) that will be used by the International Space Station Safety & Mission Assurance team here at Johnson Space Center. The application will allow its users to download online files with the click of a button, import SPN's based on three different pulls, instantly manipulate and filter spreadsheets, and compare the three sources to determine which active SPN's (Station Program Notes) must be reviewed for any upcoming flights, missions, and/or software transitions. Initially, to perform the NASA SPN pull (one of three), I had created the program to allow the user to login to a secure webpage that stores data, input specific parameters, and retrieve the desired SPN's based on their inputs. However, to avoid any conflicts with sustainment, I altered it so that the user may login and download the NASA file independently. After the user has downloaded the file with the click of a button, I defined the program to check for any outdated or pre-existing files, for successful downloads, to acquire the spreadsheet, convert it from a text file to a comma separated file and finally into an Excel spreadsheet to be filtered and later scrutinized for specific SPN numbers. Once this file has been automatically manipulated to provide only the SPN numbers that are desired, they are stored in a global variable, shown on the GUI, and transferred over to a new Excel worksheet for comparison. I managed to get my application to acquire the CSWG (Computer Safety Working Group) and the SPNWG (Space Station Working Group) SPN's with just two mouse clicks for each pull, as opposed to several from the original process. When all three pulls are performed, an Excel sheet containing all three different results will be generated for the user to compare and determine which SPN's will be presented or reviewed the following month. The experience from this internship has been spectacular. As a high school senior who will begin attending college in the fall, this internship has been both educationally and occupationally beneficial. The internship has allowed me the opportunities to learn new programming languages, effectively network with NASA personnel from a variety of departments at JSC, and allowed me to learn new professional skills and etiquette. My internship at NASA's Johnson Space Center has further motivated me to pursue a Master's degree in Software Engineering and strive for a prosperous career with NASA as a civil servant.

Delgado, Ivan↗

NASA NTRS2018

Automated Impact Assessment: A New Approach to ISS Payload Operations Anomaly Response

The International Space Station (ISS) Payload Operations and Integration Center (POIC) is undergoing rapid growth as the space station program focuses on science and commercial activities. The ISS is expanding its onboard capabilities to support additional science activities. In parallel, the POIC is expanding the capabilities of our operations tools to support the higher pace of payload activities being executed each week. An effect of these changes is that anomaly resolution has become more challenging. In the event of a real-time system fault, operators are responsible for analyzing telemetry displays, anomaly monitoring tools, documentation, and system models in order to produce failure impacts and recovery strategies. This approach to operations relies on the operator to ingest, process, and analyze information from an array of deterministic sources to provide actionable data on impacted systems and activities. Changing the existing approach of anomaly response is necessary if the ISS community is to succeed in the age of science and commercialization of space. The creation of a tool that captures deterministic technical systems knowledge and integrates existing telemetry, documentation, and planning information will allow the burden of impact assessment to be automated, thereby allowing the operator to focus on non-deterministic tasks, such as recovering failed systems and restoring critical payload operations.

Hall, R. Mason↗

DOE OSTI2025

Findings on subtask 3.3 – applicability of automated brine chemistry determinations for treatment and recovery processes through facility automation/modularization: engineering design study

Under the Energy & Environmental Research Center’s (EERC’s) ~$\$$22 million Phase II Brine Extraction and Storage Test (BEST) Program, a multimillion-dollar brine treatment technology test bed facility was established in western North Dakota to provide a platform for evaluating developing technologies and approaches for brine treatment and volume reduction. The initial facility, and associated research effort, was funded by the U.S. Department of Energy (DOE), with in-kind contributions provided by several industry participants and the state of North Dakota. Since its opening, the Brine Technology Test Facility (BTTF) has supported performance evaluations of desalination technologies capable of treating high-salinity produced water (PW) and enabled data collection for multiple approaches of PW management and critical material recovery. As part of the decommissioning process for the original project, facility ownership and liability were transferred to Select Water, which is providing the EERC with a continuing site access option for state or federal research and/or commercial technology development. This report documents the findings from a design study conducted by the EERC and the engineering firm that was originally contracted to design and construct the facility (Advanced Engineering and Environmental Services, LLC [AE2S]) that evaluated the current status of BTTF and its systems and developed a retrofit design to increase the facility’s capabilities through automation and modularization of its PW treatment infrastructure. The proposed retrofit will provide DOE and industry with an expanded range of conditioned PW that can be produced at the facility for evaluating fit-for-purpose water treatment technologies, online instrumentation for brine chemistry determination, and systems that recover critical materials like lithium and magnesium. The current facility consists of an 9600-square-foot facility that includes a 40-foot by 65-foot Class 1, Division 2-rated demonstration area and associated control rooms and lab-ready space capable of sourcing oil and gas PW and wastewater from industrial sources or tailoring brine compositions up to 300,000 mg/L total dissolved solids (TDS) and supplying them at rates up to 25 gpm for extended-duration technology demonstrations. The colocation of the facility with Select Water’s water management facilities allows for access and unloading of more than 10,000 bbl/day of trucked water delivered to site and associated access to on-site Class I and Class II brine disposal wells and nearby hazardous waste landfills operated and/or contracted by Select Water to dispose of concentrate and/or effluents associated with the testing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Machine learning enabling high-throughput and remote operations at large-scale user facilities

Imaging, scattering, and spectroscopy are fundamental in understanding and discovering new functional materials. Contemporary innovations in automation and experimental techniques have led to these measurements being performed much faster and with higher resolution, thus producing vast amounts of data for analysis. These innovations are particularly pronounced at user facilities and synchrotron light sources. Machine learning (ML) methods are regularly developed to process and interpret large datasets in real-time with measurements. However, there remain conceptual barriers to entry for the facility general user community, whom often lack expertise in ML, and technical barriers for deploying ML models. Herein, we demonstrate a variety of archetypal ML models for on-the-fly analysis at multiple beamlines at the National Synchrotron Light Source II (NSLS-II). We describe these examples instructively, with a focus on integrating the models into existing experimental workflows, such that the reader can easily include their own ML techniques into experiments at NSLS-II or facilities with a common infrastructure. The framework presented here shows how with little effort, diverse ML models operate in conjunction with feedback loops via integration into the existing Bluesky Suite for experimental orchestration and data management.

36 MATERIALS SCIENCE↗

DOE OSTI2020

New Architecture to Support Integration and Processing of Seismic Data from Heterogeneous Sources

The Geophysical Monitoring Program (GMP) at Lawrence Livermore National Lab (LLNL) maintains a database and supporting infrastructure for geophysical data used in support of the Nuclear Detonation Detection mission. This database includes data from multiple sources, many of which do not distribute data to the public or for which there is no automated means of access. For example, Figure 1 shows (left) the distribution of waveform data in our database by source. The Incorporated Research Institutions for Seismology Data Management Center (IRISDMC) is our major source of waveform data and those data may be retrieved at will using the Federated Digital Seismograph Networks FDSN web Application Programming Interface (API). However, the next 6 most important sources of waveform data have no or only limited automated access to waveforms. As Figure 1 (right) shows, it is very common for waveform records associate with an event in our database to come from two or more sources, and in some cases data come from 10 sources. This diversity of data sources drives our need for efficient and correct integration of metadata, parametric data, and waveform data.

58 GEOSCIENCES↗

NASA NTRS1973

Feasibility study of an Integrated Program for Aerospace vehicle Design (IPAD). Volume 1A: Summary

IPAD was defined as a total system oriented to the product design process. This total system was designed to recognize the product design process, individuals and their design process tasks, and the computer-based IPAD System to aid product design. Principal elements of the IPAD System include the host computer and its interactive system software, new executive and data management software, and an open-ended IPAD library of technical programs to match the intended product design process. The basic goal of the IPAD total system is to increase the productivity of the product design organization. Increases in individual productivity were feasible through automation and computer support of routine information handling. Such proven automation can directly decrease cost and flowtime in the product design process.

Miller, R. E., Jr.↗

NASA NTRS1981

Basic research planning in mathematical pattern recognition and image analysis

Fundamental problems encountered while attempting to develop automated techniques for applications of remote sensing are discussed under the following categories: (1) geometric and radiometric preprocessing; (2) spatial, spectral, temporal, syntactic, and ancillary digital image representation; (3) image partitioning, proportion estimation, and error models in object scene interference; (4) parallel processing and image data structures; and (5) continuing studies in polarization; computer architectures and parallel processing; and the applicability of "expert systems" to interactive analysis.

Bryant, J.↗

NASA NTRS1994

Automated documentation generator for advanced protein crystal growth

To achieve an environment less dependent on the flow of paper, automated techniques of data storage and retrieval must be utilized. This software system, 'Automated Payload Experiment Tool,' seeks to provide a knowledge-based, hypertext environment for the development of NASA documentation. Once developed, the final system should be able to guide a Principal Investigator through the documentation process in a more timely and efficient manner, while supplying more accurate information to the NASA payload developer. The current system is designed for the development of the Science Requirements Document (SRD), the Experiment Requirements Document (ERD), the Project Plan, and the Safety Requirements Document.

Maddux, Gary A.↗

NASA NTRS1993

Mission operations and command assurance - Automating an operations TQM task

A long-term program is in progress at JPL to reduce cost and risk of mission operations through defect prevention and error management. A major element of this program, Mission Operations and Command Assurance (MO&CA), provides a system level function on flight projects to instill quality in mission operations. MO&CA embodies the total quality management TQM principle of continuous process improvement (CPI) and uses CPI in applying automation to mission operations to reduce risk and costs. MO&CA has led efforts to apply and has implemented automation in areas that impact the daily flight project work environment including Incident Surprise Anomaly tracking and reporting; command data verification, tracking and reporting; and command support data usage. MO&CA's future work in automation will take into account that future mission operations systems must be designed to avoid increasing error through the introduction of automation, while adapting to the demands of smaller flight teams.

Welz, Linda↗

NASA NTRS1994

The Pacor 2 expert system: A case-based reasoning approach to troubleshooting

The Packet Processor 2 (Pacor 2) Data Capture Facility (DCF) acquires, captures, and performs level-zero processing of packet telemetry for spaceflight missions that adhere to communication services recommendations established by the Consultative Committee for Space Data Systems (CCSDS). A major goal of this project is to reduce life-cycle costs. One way to achieve this goal is to increase automation. Through automation, using expert systems, and other technologies, staffing requirements will remain static, which will enable the same number of analysts to support more missions. Analysts provide packet telemetry data evaluation and analysis services for all data received. Data that passes this evaluation is forwarded to the Data Distribution Facility (DDF) and released to scientists. Through troubleshooting, data that fails this evaluation is dumped and analyzed to determine if its quality can be improved before it is released. This paper describes a proof-of-concept prototype that troubleshoots data quality problems. The Pacor 2 expert system prototype uses the case-based reasoning (CBR) approach to development, an alternative to a rule-based approach. Because Pacor 2 is not operational, the prototype has been developed using cases that describe existing troubleshooting experience from currently operating missions. Through CBR, this experience will be available to analysts when Pacor 2 becomes operational. As Pacor 2 unique experience is gained, analysts will update the case base. In essence, analysts are training the system as they learn. Once the system has learned the cases most likely to recur, it can serve as an aide to inexperienced analysts, a refresher to experienced analysts for infrequently occurring problems, or a training tool for new analysts. The Expert System Development Methodology (ESDM) is being used to guide development.

Sary, Charisse↗

NASA NTRS2002

Automation of NDE on RSRM Metal Components

An automated eddy current system has been designed and built, and is being implemented to inspect RSRM (Space Shuttle) metal components. The system provides a significant increase in inspection reliability, as well as other benefits such as data storage, chemical waste reduction and reduction in overall process time. This paper is in viewgraph form.

Hartman, John↗

NASA NTRS2015

Methodology to Define Delivery Accuracy Under Current Day ATC Operations

In order to enable arrival management concepts and solutions in a NextGen environment, ground- based sequencing and scheduling functions have been developed to support metering operations in the National Airspace System. These sequencing and scheduling algorithms as well as tools are designed to aid air traffic controllers in developing an overall arrival strategy. The ground systems being developed will support the management of aircraft to their Scheduled Times of Arrival (STAs) at flow-constrained meter points. This paper presents a methodology for determining the undelayed delivery accuracy for current day air traffic control operations. This new method analyzes the undelayed delivery accuracy at meter points in order to understand changes of desired flow rates as well as enabling definition of metrics that will allow near-future ground automation tools to successfully achieve desired separation at the meter points. This enables aircraft to meet their STAs while performing high precision arrivals. The research presents a possible implementation that would allow delivery performance of current tools to be estimated and delivery accuracy requirements for future tools to be defined, which allows analysis of Estimated Time of Arrival (ETA) accuracy for Time-Based Flow Management (TBFM) and the FAA's Traffic Management Advisor (TMA). TMA is a deployed system that generates scheduled time-of-arrival constraints for en- route air traffic controllers in the US. This new method of automated analysis provides a repeatable evaluation of the delay metrics for current day traffic, new releases of TMA, implementation of different tools, and across different airspace environments. This method utilizes a wide set of data from the Operational TMA-TBFM Repository (OTTR) system, which processes raw data collected by the FAA from operational TMA systems at all ARTCCs in the nation. The OTTR system generates daily reports concerning ATC status, intent and actions. Due to its availability, ease of use, and vast collection of data across several airspaces it was determined that the OTTR data set would be the best method to utilize moving forward with this analysis. The particular variables needed for further analysis were determined along with the necessary OTTR reports, by working closely with the repository team additional analysis reports were developed that provided key ETA and STA information at the freeze horizon. One major benefit of the OTTR data is that using the correct reports the data across several airports could be analyzed over large periods of time. The OTTR data processes the TBFM data daily and is stored in various formats across several airspaces. This allowed us to develop our own parsing methods and raw data processing that would not rely on other computationally expensive tools that perform more in depth analysis of similar sets of data. The majority of this work consisted of the development of the ability to filter flights to create a subset of flights that could be considered undelayed, which is defined as a flight at the freeze horizon with an ETA and STA difference that was minimal or close to zero. This was a broad method that allowed the consideration of a large data set which consisted of all the traffic across a two month period in 2013, the hottest and coldest months, arriving into four airports: George Bush Intercontinental, Denver International, Los Angeles International, and Phoenix Sky Harbor.

delivery accuracy↗

NASA NTRS2026

Benchmarking Bayesian Optimization Frameworks and Acquisition Strategies for Materials Discovery and Autonomous Laboratories

Bayesian optimization (BO) can accelerate materials discovery by guiding expensive experiments toward the most promising processing conditions. We systematically compare five BO surrogate and framework combinations (Gaussian processes in Ax, Gaussian processes and Monte-Carlo neural networks in BayBE, random forests in Lolopy, and tree-structured Parzen (TPE) estimators in Hyperopt) on three benchmarks that mimic common materials design tasks (a discrete solid-electrolyte composition space, a hybrid discrete/continuous laminate-composite design problem solved with micromechanics modeling, and the continuous Ishigami analytic function which is a standard optimization benchmark). Each BO surrogate is paired with posterior mean, probability of improvement, and expected improvement acquisition functions and run for 100 trials from randomized initial samples with uniform random search providing a control. Across five random seeds per setting, BayBE’s Gaussian-process surrogate with expected improvement consistently reached ≥95 % of the known optimum in the fewest evaluations, while Lolopy’s random forest matched or exceeded GP performance on purely categorical or mixed spaces at a higher computational cost. Posterior mean alone often stagnated at local optima, underscoring the need for exploration, whereas probability and expected improvement balanced exploration and exploitation leading to better optimization in fewer trials. Execution times ranged from milliseconds for TPE to minutes for neural-network and random-forest surrogates. These results establish baseline expectations for BO in automated materials laboratories and highlight expected improvement with Gaussian processes as a reliable first choice, with random forests offering a strong alternative when categorical variables dominate. The benchmark suite and code are released to facilitate future surrogate, acquisition, and constraint-handling research in data-driven materials optimization.

Bayesian optimization↗

NASA NTRS2003

Enhanced Weather Radar (EWxR) System

An airborne weather radar system, the Enhanced Weather Radar (EWxR), with enhanced on-board weather radar data processing was developed and tested. The system features additional weather data that is uplinked from ground-based sources, specialized data processing, and limited automatic radar control to search for hazardous weather. National Weather Service (NWS) ground-based Next Generation Radar (NEXRAD) information is used by the EWxR system to augment the on-board weather radar information. The system will simultaneously display NEXRAD and on-board weather radar information in a split-view format. The on-board weather radar includes an automated or hands-free storm-finding feature that optimizes the radar returns by automatically adjusting the tilt and range settings for the current altitude above the terrain and searches for storm cells near the atmospheric 0-degree isotherm. A rule-based decision aid was developed to automatically characterize cells as hazardous, possibly-hazardous, or non-hazardous based upon attributes of that cell. Cell attributes are determined based on data from the on-board radar and from ground-based radars. A flight path impact prediction algorithm was developed to help pilots to avoid hazardous weather along their flight plan and their mission. During development the system was tested on the NASA B757 aircraft and final tests were conducted on the Rockwell Collins Sabreliner.

Kronfeld, Kevin M.↗

DOE OSTI2024

Identifying Sample Provenance From SEM/EDS Automated Particle Analysis via Few-Shot Learning Coupled With Similarity Graph Clustering

Automated particle analysis (APA) provides a vast amount of compositional data via energy-dispersive X-ray spectroscopy along with size and shape data via scanning electron microscopy for individual particles in a sample. In many instances, APA data are leveraged to support identification of the source of a sample based on the detection of particles of a specific composition. Often, the particles that provide context make up a minuscule portion of the sample. Additionally, the interpretation of complex samples can be difficult due to the diversity of compositions both in the mixture and within a particle. In this work, we demonstrate a method to compute and cluster similarity graphs that describe inter-particle relationships within a sample using a multi-modal few-shot learning neural network. Here, as a proof-of-concept, we show that samples known to have been exposed to gunshot residue can be distinguished from samples occasionally mistaken for gunshot residue. Our workflow builds upon standard APA techniques and data processing methods to unveil additional information in a readily interpretable and quantitatively comparable format.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS2007

Stepwise Regression Analysis of MDOE Balance Calibration Data Acquired at DNW

This paper reports a comparison of two experiment design methods applied in the calibration of a strain-gage balance. One features a 734-point test matrix in which loads are varied systematically according to a method commonly applied in aerospace research and known in the literature of experiment design as One Factor At a Time (OFAT) testing. Two variations of an alternative experiment design were also executed on the same balance, each with different features of an MDOE experiment design. The Modern Design of Experiments (MDOE) is an integrated process of experiment design, execution, and analysis applied at NASA's Langley Research Center to achieve significant reductions in cycle time, direct operating cost, and experimental uncertainty in aerospace research generally and in balance calibration experiments specifically. Personnel in the Instrumentation and Controls Department of the German Dutch Wind Tunnels (DNW) have applied MDOE methods to evaluate them in the calibration of a balance using an automated calibration machine. The data have been sent to Langley Research Center for analysis and comparison. This paper reports key findings from this analysis. The chief result is that a 100-point calibration exploiting MDOE principles delivered quality comparable to a 700+ point OFAT calibration with significantly reduced cycle time and attendant savings in direct and indirect costs. While the DNW test matrices implemented key MDOE principles and produced excellent results, additional MDOE concepts implemented in balance calibrations at Langley Research Center are also identified and described.

DeLoach, RIchard↗