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Ensuring fault tolerance of phase-locked clocks

Processors within a real-time multiprocessor system must be synchronized with as little overhead as possible. Although synchronization can be achieved via both software (e.g., interactive convergence and interactive consistency algorithms) and hardware (e.g., multistage synchronizers and phase-locked clocks), phase-locked clocks are most attractive due to their small overheads. Despite the fact that synchronization of the multiprocessor system with phase-locked clocks is totally different in nature from the interactive consistency algorithm, it is presently proven that it must satisfy the same condition, N equal to or greater than 3m + 1, where N is the total number of clocks in the multiprocessor system and m is the maximum number of faults tolerable. Also presented are results showing how to design phase-locked clocks so as to be impervious up to a given arbitrary number of malicious failures.

Krishna, C. M.↗

Interface Finite Elements for the Analysis of Fracture Initiation and Progression

Progressive failure analyses (PFA) are important for the prediction of residual strength and damage tolerance of vehicle structures, and to predict the energy absorbing capability of vehicle structures under crash-type loads. Typically continuum damage mechanics (CDM) and fracture mechanics (FM) are the methods used for PFA. The method of interfacial damage mechanics (IDM) is used for PFA in this research. IDM has capabilities intermediate between CDM and FM, and is used to numerically model the initiation, growth, and arrest of cracks. IDM smooths the stress singularity at the crack tip, and is easily adaptable with other nonlinearties such as plasticity and material damage. IDM is implemented by user-defined interface elements in the ABAQUS/ Standard structural analysis software package. The structural components selected to demonstrate the effectiveness PFA using interface elements are, for the most part, those with published test data. These structural components were subjected to quasi-static loading in the tests. Thus, the ABAQUS analyses are used to predict geometrically and materially nonlinear equilibrium states. Impact loading, dynamic fracture, reflected stress waves, inertia, and time dependent material behavior are not considered.

Ambur, Damodar R.↗

Long term trending of engineering data for the Hubble Space Telescope

A major goal in spacecraft engineering analysis is the detection of component failures before the fact. Trending is the process of monitoring subsystem states to discern unusual behaviors. This involves reducing vast amounts of data about a component or subsystem into a form that helps humans discern underlying patterns and correlations. A long term trending system has been developed for the Hubble Space Telescope. Besides processing the data for 988 distinct telemetry measurements each day, it produces plots of 477 important parameters for the entire 24 hours. Daily updates to the trend files also produce 339 thirty day trend plots each month. The total system combines command procedures to control the execution of the C-based data processing program, user-written FORTRAN routines, and commercial off-the-shelf plotting software. This paper includes a discussion the performance of the trending system and of its limitations.

Cox, Ross M.↗

Restoring Redundancy to the MAP Propulsion System

The Microwave Anisotropy Probe is a follow-on to the Differential Microwave Radiometer instrument on the Cosmic Background Explorer. Sixteen months before launch, it was discovered that from the time of the critical design review, configuration changes had resulted in a significant migration of the spacecraft's center of mass. As a result, the spacecraft no longer had a viable backup control mode in the event of a failure of the negative pitch axis thruster. Potential solutions to this problem were identified, such as adding thruster plume shields to redirect thruster torque, adding mass to, or removing it from, the spacecraft, adding an additional thruster, moving thrusters, bending thrusters (either nozzles or propellant tubing), or accepting the loss of redundancy for the thruster. The impacts of each solution, including effects on the mass, cost, and fuel budgets, as well as schedule, were considered, and it was decided to bend the thruster propellant tubing of the two roll control thrusters, allowing that pair to be used for back-up control in the negative pitch axis. This paper discusses the problem and the potential solutions, and documents the hardware and software changes that needed to be made to implement the chosen solution. Flight data is presented to show the propulsion system on-orbit performance.

ODonnell, James R., Jr.↗

In-Situ Nondestructive Evaluation of Kevlar(Registered Trademark)and Carbon Fiber Reinforced Composite Micromechanics for Improved Composite Overwrapped Pressure Vessel Health Monitoring

NASA has been faced with recertification and life extension issues for epoxy-impregnated Kevlar 49 (K/Ep) and carbon (C/Ep) composite overwrapped pressure vessels (COPVs) used in various systems on the Space Shuttle and International Space Station, respectively. Each COPV has varying criticality, damage and repair histories, time at pressure, and pressure cycles. COPVs are of particular concern due to the insidious and catastrophic burst-before-leak failure mode caused by stress rupture (SR) of the composite overwrap. SR life has been defined [1] as the minimum time during which the composite maintains structural integrity considering the combined effects of stress level(s), time at stress level(s), and associated environment. SR has none of the features of predictability associated with metal pressure vessels, such as crack geometry, growth rate and size, or other features that lend themselves to nondestructive evaluation (NDE). In essence, the variability or surprise factor associated with SR cannot be eliminated. C/Ep COPVs are also susceptible to impact damage that can lead to reduced burst pressure even when the amount of damage to the COPV is below the visual detection threshold [2], thus necessitating implementation of a mechanical damage control plan [1]. Last, COPVs can also fail prematurely due to material or design noncompliance. In each case (SR, impact or noncompliance), out-of-family behavior is expected leading to a higher probability of failure at a given stress, hence, greater uncertainty in performance. For these reasons, NASA has been actively engaged in research to develop NDE methods that can be used during post-manufacture qualification, in-service inspection, and in-situ structural health monitoring. Acoustic emission (AE) is one of the more promising NDE techniques for detecting and monitoring, in real-time, the strain energy release and corresponding stress-wave propagation produced by actively growing flaws and defects in composite materials [3,4,5,6,7,8]. To gain further insight into the mechanisms responsible for composite rupture, broadband modal acoustic emission analysis was used. Also, since AE data reduction proved to be very time consuming, specialized data reduction software was written to automate the process.

Waller, Jess↗

Dynamic Probabilistic Safety Assessment Studies for Advanced Reactor Using RAVEN

Probabilistic Safety Assessment (PSA) is used extensively to evaluate the risks associated with complex engineering systems like Nuclear Power Plants (NPPs). Current PSA models are based on the Event-Tree/Fault-Tree (ET/FT) methodology. ET and FT models are static and are based on Boolean logic approaches. In the past, concerns have been raised in the literature regarding the capability of the traditional static modelling approaches to adequately account for the impact of process, hardware, software, firmware and human interactions on the stochastic system behaviour. To overcome the limitations of the traditional approach to PSA, several dynamic PSA methodologies have been proposed. One of the dynamic PSA methodologies used for dynamic evaluations is Dynamic Event Tree (DET) framework which can be used to assess the impact of the parameter variability and scenario dynamics on the PSA model for the initiating event. The DET framework couples the stochastic model (number of component/trains that start on demand, operator action timing, etc.) with a Thermal-Hydraulic (TH) model of the plant. This paper explores the use of DET along with a case study on advanced reactor. The initiating event selected for the study was Class IV power supply failure event. The TH analysis considering uncertainty in various parameters was performed using RELAP5 and Reactor Analysis and Virtual control ENvironment (RAVEN) tool. Based on the uncertainty analysis, it is concluded that the peak clad temperatures (PCT) are within the limits in all the code runs implying a high-degree of safety margin. However, variation in time to reach the PCT was observed among the code runs and the mean time to reach the PCT was found to be around 8590sec (approximately 2.4 hours). Hence, sufficient time margin is available for human intervention and the operator might have a relatively stress-free state during such an accident scenario. Due to the static nature of the traditional PSA models, the safety margin available was lesser, whereas, with the help of dynamic PSA models, one can demonstrate that the actual available safety margin is more in the present case study and is valuable input from the design point of view.

99 GENERAL AND MISCELLANEOUS↗

Comprehensive Environmental Informatics System (CEIS) Integrating Crew and Vehicle Environmental Health

Integrated Vehicle Health Management (IVHM) systems have been pursued as highly integrated systems that include smart sensors, diagnostic and prognostics software for assessments of real-time and life-cycle vehicle health information. Inclusive to such a system is the requirement to monitor the environmental health within the vehicle and the occupants of the vehicle. In this regard an enterprise approach to informatics is used to develop a methodology entitled, Comprehensive Environmental Informatics System (CEIS). The hardware and software technologies integrated into this system will be embedded in the vehicle subsystems, and maintenance operations, to provide both real-time and life-cycle health information of the environment within the vehicle cabin and of its occupants. This comprehensive information database will enable informed decision making and logistics management. One key element of the CEIS is interoperability for data acquisition and archive between environment and human system monitoring. With comprehensive components the data acquired in this system will use model based reasoning systems for subsystem and system level managers, advanced on-board and ground-based mission and maintenance planners to assess system functionality. Knowledge databases of the vehicle health state will be continuously updated and reported for critical failure modes, and routinely updated and reported for life cycle condition trending. Sufficient intelligence, including evidence-based engineering practices which are analogous to evidencebased medicine practices, will be included in the CEIS to result in more rapid recognition of off-nominal operation to enable quicker corrective actions. This will result from better information (rather than just data) for improved crew/operator situational awareness, which will produce significant vehicle and crew safety improvements, as well as increasing the chance for mission success, future mission planning as well as training. Other benefits include improved reliability, increase safety in operations and cost of operations. The cost benefits stem from significantly reduced processing and operations manpower, predictive maintenance for systems and subjects. The improvements in vehicle functionality and cost will result from increased prognostic and diagnostic capability due to the detailed total human exploration system health knowledge from CEIS. A collateral benefit is that there will be closer observations of the vehicle occupants as wrist watch sized devices are worn for continuous health monitoring. Additional database acquisition will stem from activities in countermeasure practices to ensure peak performance capability by occupants of the vehicle. The CEIS will provide data from advanced sensing technologies and informatics modeling which will be useful in problem troubleshooting, and improving NASA s awareness of systems during operation.

Nall, Mark E.↗

Thermal-striping analysis methodology for sodium-cooled reactor design

Computational fluid dynamics simulations have been performed to study the applicability of engineering CFD methods for thermals striping analysis. Thermal striping is the fluctuating temperature profile in a solid caused by fluctuating fluid temperature, and the resulting fluctuating thermal stresses cause high cycle fatigue and eventual material failure. Here this study presents the methodology for thermal striping analysis that including a transient conjugate heat transfer RANS model and benchmark the results against a sodium triple jet experiment. The multiphysics calculations are implemented to analyze the thermal stresses in the solid domain caused by the coupled heat transfer between the fluid and solid domains. Validation data from a liquid sodium triple jet experiment include time-averaged temperature measurements and power spectra of the temperature signal. The numerical results agree well with these experimental measures, demonstrating key features such as the dominant frequency of temperature fluctuations. The applicability of a low-cost wall treatment method is demonstrated, enabling key computational savings. Finally, the performance of two finite element stress analysis software packages is compared, and the validity of the lower-cost method is confirmed. These results demonstrate the applicability of engineering methods for computational thermal striping calculations, enabling thermal striping estimations in large fluid systems such as the core of a Sodium-cooled nuclear reactor.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Code Sharing and Collaboration: Experiences from the Scientist's Expert Assistant Project and their Relevance to the Virtual Observatory

In the Virtual Observatory (VO), software tools will perform the functions that have traditionally been performed by physical observatories and their instruments. These tools will not be adjuncts to VO functionality but will make up the very core of the VO. Consequently, the tradition of observatory and system independent tools serving a small user base is not valid for the VO. For the VO to succeed, we must improve software collaboration and code sharing between projects and groups. A significant goal of the Scientist's Expert Assistant (SEA) project has been promoting effective collaboration and code sharing between groups. During the past three years, the SEA project has been developing prototypes for new observation planning software tools and strategies. Initially funded by the Next Generation Space Telescope, parts of the SEA code have since been adopted by the Space Telescope Science Institute. SEA has also supplied code for SOFIA, the SIRTF planning tools, and the JSky Open Source Java library. The potential benefits of sharing code are clear. The recipient gains functionality for considerably less cost. The provider gains additional developers working with their code. If enough users groups adopt a set of common code and tools, defacto standards can emerge (as demonstrated by the success of the FITS standard). Code sharing also raises a number of challenges related to the management of the code. In this talk, we will review our experiences with SEA - both successes and failures - and offer some lessons learned that may promote further successes in collaboration and re-use.

Jones, Jeremy↗

Human Systems Integration: Managing Risk in Anesthesia

The practice of anesthesia relies on clinicians’ ability to safely manage increasingly complex equipment. Devices such as ventilators, drug infusion pumps, and physiologic monitors use sophisticated algorithms to deliver care, but most clinicians are only trained to manage automated systems during normal operation. Few if any receive training on how to manage system failures. Although manufacturers are required to consult with human factors engineers as part of the equipment design process, most pieces of equipment are ultimately brought to market without extensive input from clinicians. Systems in the operating room can be as simple as an oxygen tank, or as complex as a multi-institutional healthcare organization. Humans are also a complex system, and play a critical role in the domains of operations, design, fabrication, maintenance, repair, and ultimately, dismantling and closeout. HSI seeks to provide a means for advocating the human side of the system. Human Systems Integration (HSI) is the cross disciplinary process used as part of the Systems Engineering process to reduce risk in systems. HSI professionals consider the human, hardware, and software elements of system design to optimize system performance and improve safety. HSI professionals work in domains of study that include training, management, human factors engineering, safety, and occupational health, among others. This article discusses the role of systems in the practice of anesthesia, and how consideration of the human during all phases of the system life cycle helps manage risks and promote a better patient outcome.

Human Factors↗

Micrometeoroid and Orbital Debris (MMOD) Testing, Ballistic Limit Definition and Risk Assessment of the Exploration Extravehicular Mobility Unit (xEMU)

A well-known hazard associated with exposure to the space environment is the risk of failure due to an impact from a micrometeoroid and orbital debris (MMOD) particle. As NASA prepares to return astronauts to the moon with the Artemis program, the next generation of spacesuit is in development to support future extravehicular activities (EVAs.) An MMOD impact to the spacesuit is of great concern as a large leak could prevent an astronaut from safely reaching an airlock in time resulting in a loss of life. The exploration extravehicular mobility unit (xEMU) must meet MMOD requirements for multiple environments including those in low earth orbit (LEO) as well as the meteoroid and secondary lunar regolith ejecta environments found on the lunar surface. The subject of this paper is an internal xEMU configuration design developed by NASA Johnson Space Center (JSC) personnel. The xEMU shares similarities with the legacy Extravehicular Mobility Unit (EMU) spacesuit that is currently used for ISS EVAs, however differences in the layup (e.g., materials, thicknesses, and layers) of the fabric environmental protection garment (EPG), portable life support system (xPLSS) and helmet required an extensive test program to determine ballistic performance. Over 100 hypervelocity impact (HVI) tests were performed by the NASA/JSC HVIT and White Sands Test Facility (WSTF) teams on the xEMU EPG, xPLSS and helmet to generate ballistic limit equations (BLEs) for MMOD impacts. Additionally, over 50 low speed tests (< 1km/s) were performed by the NASA/JSC HVIT and Southwest Research Institute (SwRI) teams on the xEMU EPG, xPLSS and helmet to generate BLEs for lunar ejecta impacts. Post testing, ballistic limit equations (BLEs) used to define the performance of the various regions on the xEMU spacesuit were developed from a generic set of BLEs. The HVI and low speed testing was performed to establish a physical basis for the equations with the coefficients and exponents of the generic BLEs adjusted to fit the test data. The xEMU BLEs were added to the NASA/JSC software application used for spacecraft MMOD risk assessments (BUMPER-3). A finite element model (FEM) of the xEMU spacesuit, which defines the size and shape of the spacesuit as well as the locations of the various shielding configurations, was created based on a solid model provided by the xEMU program office. Using the FEM file and added xEMU BLEs, BUMPER-3 assessments of the xEMU spacesuit for probability of no penetration (PNP) were performed. For the LEO assessment of a typical ISS EVA, the orbital debris and meteoroids environments were defined using the latest engineering models, ORDEM 3.2 and MEM-3 respectively. The lunar surface assessment again used the MEM-3 engineering model to define the meteoroid environment along with the current released lunar surface ejecta model, NASA SP-8013 (developed during the Apollo Program). The Space Team in the Natural Environments Branch at Marshall Space Flight Center (MSFC) will soon release the new Lunar Meteoroid Ejecta Engineering Model (LMEEM), at which time the xEMU lunar surface EVA will be reassessed. Assessment of the MMOD risk for an 8-hour, 2-person EVA in both LEO and on the lunar surface showed that the xEMU spacesuit meets the program technical requirement of 1 in 2500 failure odds. Similar to the legacy EMU spacesuit, the majority of the MMOD risk (96% of the LEO EVA risk and 99% of the lunar surface EVA risk) is concentrated in regions of xEMU that are comprised primarily of softgoods (arms, legs, and gloves) rather than the hardgoods (xPLSS, hard upper torso and helmet).

Micrometeoroid↗

An Optimization Approach to Support Science Decision Making for Lunar Surface Exploration

Introduction: Scientific exploration is one of the three pillars of NASA’s Moon2Mars architecture, with crew surface extra vehicular activities (EVA) serving a critical enabling function. Development of surface EVA operational planning and execution, specifically integrating science and flight control teams (FCT), is currently being explored through analog scenarios. This integration, exercised, for example, through the Joint EVA and Hu-man Surface Mobility Test Team (JETT), allows for science input on EVA activities in near real-time through a Science Evaluation Room (SER), or Arte-mis science backroom, which integrates with the broader FCT through the Science Officer. The SER works within the FCT to support dynamic EVA planning in response to changes in operational constraints as well as science opportunities and re-prioritization, increasing the mission science return and accelerating the accomplishment of the Moon2Mars science objectives. The SER works within the FCT to provide recommendations to traverse execution in near real-time. One challenge is the requirement to deliver SER inputs to the FCT on operationally relevant timelines. Failure to do so may result in suboptimal execution of science exploration EVAs or even loss of key science objectives. To close this gap, we present a network optimization tool to allow the SER to provide rapid input to the FCT in response to changes in operational constraints or science opportunities. Inputs are predicated on approved science objectives, and clear rationale must be provided to the FCT for any requested change. Accordingly, this tool incorporates the Science Traceability Matrix (STM), SER prioritization scheme, and station characterization and action planning with operational constraints such as duration, traverse speed, and distance to maximize science objectives based on SER priorities, consistent with FCT operational requirements. Method: As a proof of concept, we used an existing linear programing software package used to simulate optimal routes through cellular metabolism. We built a Demonstrative Model with three STM objectives and four stations on a region of the Moon. The objectives were given an arbitrary prioritization and mapped to the stations through four possible crew actions. (Figs. 1 and 2). This station to STM mapping is consistent with the method used by the JETT5 Science Team to develop analog surface EVA science planning. We used a grid system with the landing site at the origin and the four stations placed across the positive x,y quadrant. Actions were assigned to each station and the accomplishment of those actions resulted in a numerical “reward” based on the ability of that action to achieve science objectives. The aggregate reward from each individual STM objective contributes to a global score (Science Yield), weighted by its priority. Operational constraints included a requirement to start and end at the landing site, 5 minutes each for initial station characterization and “clean up,” and variable total EVA time, traverse rate (fixed to 0.5 meters per second in our example), and time to perform each action (10, 5, 7, and 15 min for actions 1, 2, 3, and 4, respectively). Additional constraints and variables will be added in the future (e.g., sample mass, number of stations, traverse route constraints, illumination). Optimization. We converted the connections (arcs) between these stations (nodes) into a mixed integer linear programming optimization problem (arcs = constraints, nodes = variables) with the objective to maximize Science Yield. For any action, the Science Yield is equal to the relevance of that action to an STM objective [3, 2, and 1 point(s) for High, Med., and Low relevance, respectively], multiplied by the STM Objective Priority [3, 2, and 1 point(s) for High, Med., and Low priority, respectively]. This resulted in a model that computes the optimal station and action combination to maximize the Science Yield. These weightings can be adjusted by the SER as desired. Results: We explored three test cases for the Demonstrative Model. First, we set the maximum EVA duration to 120 minutes and computed the optimal route (Fig. 3A). The model suggested per-forming Actions 1 and 2 at Station P01, followed by Actions 1 and 2 at Station P02, and finally Actions 1 and 3 at Station P04 before returning to the Landing Site. Second, we adjusted the STM Objective Priori-ty order and computed the new optimal route (Fig. 3B). Under this situation, the model suggested per-forming all Actions at Station P02 followed by all Actions at Station P03. The previous test cases were relevant to SER planning activities. Next, we explored providing mid-EVA replanning input to the FCT. Scenario: While executing the Route in Fig. 3A the crew finishes at Station P01 and FCT decides that the EVA needs to finish in 45 minutes back at the Landing Site. FCT asks SER to recommend changes to the plan to accommodate this operation-al change. Using the model and incorporating these new constraints (start at Station P01, max. time of 45 min), the model suggested performing Actions 2 and 4 at Station P03 (Fig. 4), requiring 41 minutes to complete and return to the Landing Site. Interestingly, Station 3 was not part of the original route. Using the model, we determined the EVA would need 66 minutes, instead of 45, in order for the original Station P04 to yield a larger Science Yield than Station P03. The parametrization and simulation was per-formed in less than a minute, demonstrating the operational relevance of the approach. Future Efforts: The results from the Demonstrative Model suggest this tool can accelerate SER decision making on operationally relevant timelines. Use in analog activities, such as JETT5 or follow-ons, which have over a dozen stations for a crew to explore and over a dozen actions per station, will provide needed validation of the utility of this tool for planning EVAs, replanning mid-EVA, or planning follow-on EVAs based on previous results. Further integration with FCT execution monitoring tools may provide additional efficiency gains, al-lowing rapid and iterative exploration of operation-al and science decision space by the FCT and SER.

Science Operations↗

Enabling Reliable, Fault-Tolerant Autonomous Lunar Habitats with High-Performance Spaceflight Computing

The lunar surface presents unfavorable constraints and harsh living conditions. To address these challenges, autonomous habitats will require complex integrated systems that combine advanced software, high-performance hardware, and cutting-edge sensors to ensure sustainability, safety, and operational efficiency. Consequently, maintaining a sustainable presence on the Moon requires reliable infrastructure and efficient development, precise monitoring, and utilization of resources within a lunar installation. These elements are essential not only to ensure that lunar settlement can be long-term, self-sustaining, and resource-efficient, but also to serve as a foundation for future missions and eventual human habitation on Mars. Humans are not native to the Moon; therefore, our survival and ability to thrive will depend on autonomous systems that can foster safety and resilience through high-availability architectures, graceful degradation, and highly fault-tolerant spaceflight hardware capable of continuing operation during failures. This requires advanced human-rated distributed systems architectures with specialized electronics, scalable capabilities, and an integrated design approach. Unlike current practices focused on short-term missions and regularly maintained components, permanent lunar compute systems must be designed for extended operations beyond mission durations. This paper explores the necessity of transitioning toward fault- tolerant, highly autonomous hardware systems designed for multi-year missions. It also identifies critical subsystems that require high levels of autonomy, supported by radiation-hardened processors and extreme thermal loads, which are essential to mitigate long-term degradation and ensure sustainable lunar habitation. Finally, the paper aligns with NASA’s identified Civil Space Shortfalls, particularly in high-performance onboard computing, advanced data acquisition, extreme-environment avionics, radiation monitoring and countermeasures, and autonomous health management. It proposes NASA’s new High-Performance Spaceflight Computing (HPSC) processor as a turnkey solution, delivering 100 times the performance-per-watt of legacy rad-hard CPUs and enabling onboard AI, edge computing, and fault-tolerant features essential for sustained lunar autonomy and beyond.

Sarkis S Mikaelian↗

Geomechanical and Fluid Transport Properties

Complex changes to fluid and mechanical properties of a pyrolyzing formation could lead to significant subsidence. Capturing subsidence requires accounting for changes in porosity due to generation and drainage of fluid. Pores, permeability and pore pressure are generated during pyrolysis of kerogen into oil and gas. In a series reaction scheme, oil is an intermediate product of pyrolysis. A large portion of oil-range fluids may be lost in an in-situ operation if the oil produced cannot be drained quickly enough. Petroleum fluid quality and production are highly dependent on the relative rates of creation, destruction, and transport of oil and gas in a given volume. All of these are dependent on the heating rate of oil shale. If oil shale is heated quickly, fluid flow may increase, but at a cost to the amount of oil that is finally extracted. To account for the effect of pore fluid on mechanical deformation, an elastic model was combined with a Mohr-Coulomb failure criterion and Biot’s linear consolidation model. The overall model is poroelastic, because it accounts for rock deforming by considering the response of the bulk system and the pore fluids it contains. Biot’s linear model includes all ways that pore fluid volume can change in a system, including stress-strain interactions between pores and the bulk material. Additionally, the model captures the distinction between fluid and solid matrix compression and describes how bulk deformation is affected by fluid drainage. The fluid response to changing stress is affected by changes in pore pressure, while the bulk material responds to effective stress changes. To capture all of these effects, a number of theoretical and empirical models were employed in FLAC3D™, a rock-mechanics software package produced by Itasca Consulting Group. The basic capabilities of FLAC3D™ have been supplemented by customized algorithms for the simulation package. The most important contribution has been to develop a methodology for describing poro-thermo-mechanical properties of oil shale across the complete chronology of in situ pyrolysis. This report highlights those methods and results for inferring realistic oil shale properties.

04 OIL SHALES AND TAR SANDS↗

Automation of the CFD Process on Distributed Computing Systems

A script system was developed to automate and streamline portions of the CFD process. The system was designed to facilitate the use of CFD flow solvers on supercomputer and workstation platforms within a parametric design event. Integrating solver pre- and postprocessing phases, the fully automated ADTT script system marshalled the required input data, submitted the jobs to available computational resources, and processed the resulting output data. A number of codes were incorporated into the script system, which itself was part of a larger integrated design environment software package. The IDE and scripts were used in a design event involving a wind tunnel test. This experience highlighted the need for efficient data and resource management in all parts of the CFD process. To facilitate the use of CFD methods to perform parametric design studies, the script system was developed using UNIX shell and Perl languages. The goal of the work was to minimize the user interaction required to generate the data necessary to fill a parametric design space. The scripts wrote out the required input files for the user-specified flow solver, transferred all necessary input files to the computational resource, submitted and tracked the jobs using the resource queuing structure, and retrieved and post-processed the resulting dataset. For computational resources that did not run queueing software, the script system established its own simple first-in-first-out queueing structure to manage the workload. A variety of flow solvers were incorporated in the script system, including INS2D, PMARC, TIGER and GASP. Adapting the script system to a new flow solver was made easier through the use of object-oriented programming methods. The script system was incorporated into an ADTT integrated design environment and evaluated as part of a wind tunnel experiment. The system successfully generated the data required to fill the desired parametric design space. This stressed the computational resources required to compute and store the information. The scripts were continually modified to improve the utilization of the computational resources and reduce the likelihood of data loss due to failures. An ad-hoc file server was created to manage the large amount of data being generated as part of the design event. Files were stored and retrieved as needed to create new jobs and analyze the results. Additional information is contained in the original.

Tejnil, Ed↗

Emergency Flight Control of a Twin-Jet Commercial Aircraft using Manual Throttle Manipulation

The Department of Homeland Security (DHS) created the PCAR (Propulsion-Controlled Aircraft Recovery) project in 2005 to mitigate the ManPADS (man-portable air defense systems) threat to the commercial aircraft fleet with near-term, low-cost proven technology. Such an attack could potentially cause a major FCS (flight control system) malfunction or other critical system failure onboard the aircraft, despite the extreme reliability of current systems. For the situations in which nominal flight controls are lost or degraded, engine thrust may be the only remaining means for emergency flight control [ref 1]. A computer-controlled thrust system, known as propulsion-controlled aircraft (PCA), was developed in the mid 1990s with NASA, McDonnell Douglas and Honeywell. PCA's major accomplishment was a demonstration of an automatic landing capability using only engine thrust [ref 11. Despite these promising results, no production aircraft have been equipped with a PCA system, due primarily to the modifications required for implementation. A minimally invasive option is TOC (throttles-only control), which uses the same control principles as PCA, but requires absolutely no hardware, software or other aircraft modifications. TOC is pure piloting technique, and has historically been utilized several times by flight crews, both military and civilian, in emergency situations stemming from a loss of conventional control. Since the 1990s, engineers at NASA Dryden Flight Research Center (DFRC) have studied TOC, in both simulation and flight, for emergency flight control with test pilots in numerous configurations. In general, it was shown that TOC was effective on certain aircraft for making a survivable landing. DHS sponsored both NASA Dryden Flight Research Center (Edwards, CA) and United Airlines (Denver, Colorado) to conduct a flight and simulation study of the TOC characteristics of a twin-jet commercial transport, and assess the ability of a crew to control an aircraft down to a survivable runway landing using TOC. The PCAR project objective was a set of pilot procedures for operation of a specific aircraft without hydraulics that (a) have been validated in both simulation and flight by relevant personnel, and (b) mesh well with existing commercial operations, maintenance, and training at a minimum cost. As a result of this study, a procedure has been developed to assist a crew in making a survivable landing using TOC. In a simulation environment, line pilots with little or no previous TOC experience performed survivable runway landings after a few practice TOC approaches. In-flight evaluations put line pilots in a simulated emergency situation where TOC was used to recover the aircraft, maneuver to a landing site, and perform an approach down to 200 feet AGL. The results of this research, including pilot observations, procedure comments, recommendations, future work and lessons learned, will he discussed. Flight data and video footage of TOC approaches may also be shown.

Cole, Jennifer H.↗

mystic : software for autonomous discovery and design under uncertainty

Throughout the diverse range of science and engineering applications, there is a growing desire to develop computational methods that can reliably predict the behavior of complex systems. Specifically, there is a strategic need for tools that can robustly forecast the behavior of complex physical systems, where data may be high-dimensional, noisy, or sparse, and models of the system may be time-dependent or include uncertainty. We use mystic to build tools that leverage statistical learning, physics-informed learning, and active learning in the efficient generation of reliably predictive surrogates for complex physical systems. mystic is a robust, proven, open-source optimization and uncertainty quantification toolkit with over a decade of use in the design and optimization of neutron instrumentation, solar-powered drones, and gasguns, and in iterative tuning of models for Raman spectroscopy and elastoplastic materials strength. Recent developments have focused on automated learning of statistically robust surrogates under uncertainty, with applications in materials in extreme environments, nanostructures, materials simulations and strength models, and the failure of shielding under particle radiation. In 2020, McKerns demonstrated active learning of optimally robust surrogates with respect to new simulated data for molecular dynamics simulations of materials mixing in warm dense matter, and is currently applying active learning to the automated steering of particle accelerator beams and the optimal design and control of quantum optical sensor instrumentation.

42 ENGINEERING↗

A Multi-Scale Computational Platform for Predictive Modeling of Corrosion in Al-Steel Joints (Final Report)

The research team proposed to develop innovative multi-scale models to predict corrosion and the resulting mechanical performances in aluminum-steel joints. The methods of joining considered are resistance spot welding, self-piercing riveting, and rivet-welding, all suitable for mass production applications. The multi-scale models integrate high throughput first-principle calculations based on density functional theory (DFT), high throughput calculation of phase diagrams (CALPHAD) modeling, and finite element method (FEM) simulations. These models are to be validated through laboratory experiments. Furthermore, the models are available as open source so as to enable scientists and engineers in the community to adapt and contribute to the development and application. The approaches rely on the research team’s extensive experience on the prediction of properties of individual phases at finite temperatures and variable compositions through DFT calculations, and our broad expertise on dissimilar material joining and their corrosion. The proposed computational framework enables high throughput computations for improved predictions of corrosion and the associated mechanical performance in dissimilar material joints, resulting in significant reduction in computational time needed by the current state-of-the-art methods. With the participation of researchers from three universities, an auto manufacturer, two manufacturing technology/equipment suppliers, and a software developer/vendor, the interdisciplinary research team applies the technical development on both phase-based modeling and laboratory experiments into the automobile body joining processes for validation and technology demonstration. The global cost of corrosion was estimated at about 3.4% of the global GDP in 2013. By using available corrosion control practices, it is estimated a saving between 15-35% of the cost of corrosion. In the U.S., more than $276 billion is spent repairing corrosion damage. Prediction of the corrosion and its impact on performance of the dissimilar material joints is critical for reducing the massive number of the current corrosion-based recalls for automobiles. Thus, the project goal is to develop models to enable predictive maintenance and end-of-life planning of multi-metal joints with risk of corrosion under different conditions such as exposure to high temperatures in summer and salt solutions in winter, quantified through its pH. An academia-industry consortium led by the University of Michigan and including Pennsylvania State University, University of Illinois Urbana-Champaign, University of Georgia, General Motors Company, Livermore Software Technology Corporation, and Optimal Process Technologies, LLC. created multi-scale models for prediction of corrosion in aluminum-steel joint structures such of them used in vehicle subassemblies – chassis and transmission systems. Starting from the first principle calculations, the team developed mathematical and data-driven models to predict the metallic components, which are formed during joining of two metals, for example aluminum and steel - a lightweight multilateral system which is currently used in more than 60% car bodies. These models were used for simulating chemical reactions that are happening when the joining metallic components are exposed to high temperatures and different pH values. The team was able to predict how the corrosion installs on the metallic components and how they lead to a sudden failure of components in cars. Newly developed machine learning algorithms combining Science, Technology, Engineering and Math disciplines, advanced finite element simulation and experimental validations have been integrated in a platform for prediction of the corrosion evolution and prediction the failure of joints under mechanical loadings and fatigue. Moreover, based on machine learning and inverse analysis, the team proposed solutions for designing new metallic alloys less susceptible to corrosion when joining multi-material assembles. An average of 4% error compared with experiments was achieved for the most common joints that are used in vehicle subassemblies.

36 MATERIALS SCIENCE↗