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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Developing Geology Sampling Tools for the Artemis Program

Humans are set to return to the Moon for the first time since 1972 with the National Aeronautics and Space Administration’s (NASA) Artemis Program. One of the primary objectives will be the collection and return of lunar samples. To support this objective, the Extravehicular Activity (EVA) Tools Team at the Johnson Space Center (JSC) has started developing the next generation of lunar geology sampling tools. The EVA Tools Team are experts in the hardware certification process for space hardware and have been working on planetary surface tools for nearly a decade. Funded by the EVA Office at JSC, the Artemis tools project began on October 1, 2019 with an initial set of eight tools. That initial set of tools was brought to a Preliminary Design Review (PDR) on October 30, 2020. An additional 17tools have been proposed to support geology sampling operations, with the development of a subset of that list beginning on October 1, 2020.Additional tools may also be considered in the future should the science requirements drive this need. This abstract describes how this project is defining requirements, what tools are being developed, and the schedule for this work.

Artemis↗
NASA NTRSDate not supplied

Towards A Flexible Data Fusion Tool Incorporating Model, Satellite, Regulatory Monitor and Low-Cost Sensor Data for Air Quality Estimation and Forecasting

Air quality managers, researchers, and concerned community scientists around the world have a variety of sources for air quality information, ranging from traditional regulatory monitoring networks and atmospheric chemistry models to remote sensing data products and low-cost sensor networks. However, the ability to incorporate data from these disparate sources and synthesize a comprehensive overview of the local air quality situation remains a considerable barrier for many end-users. This presentation will outline a tool, currently in development, which will address this need using a flexible data fusion approach. The tool will make use of air quality forecast model outputs (primarily from the NASA GEOS-CF composition forecast modeling system), satellite remote sensing data (from instruments including MODIS, VIIRS, TROPOMI, plus TEMPO for the US when available), and in-situ data from official regulatory and/or low-cost networks where these are available. The ability to incorporate data from low-cost sensor networks will be a key feature of the tool; it will make use of other available data sources to calibrate the low-cost sensor data on a regional scale, then use these calibrated low-cost sensor data for localized updating to resolve finer-scale air quality patterns. Development of this tool is taking place with the help of national and international partners and end-user groups, coordinated through the US EPA and the United Nations Environment Programme (UNEP). The tool is being developed on the Google Earth Engine cloud computing platform to facilitate integration of diverse data sources and free access by a broad community of end-users. Stewardship of the tool will be passed to US EPA and UNEP to support future activities with end-users in the US and around the world, and the tool itself will remain freely accessible. We hope that this tool will lower the barrier to entry for various user groups worldwide, including community scientists, who struggle to integrate disparate data sources to gain insight into their local air quality situations. This presentation will cover the early stages of the development of the tool, including the underlying methods and some pilot case studies in integrating low-cost sensor data.

global models↗
DOE OSTI2022

Spray coating for washout tooling by binder jet additive manufacturing

We report washout tooling is a process in which a removable mold or fixture is disintegrated using a solvent. Binder Jet (BJ) additive manufacturing holds promise for creating customized washout molds from common materials. BJ-based washout tooling provides an advanced strategy in manufacturing fiber-reinforced composites (FRCs), especially for customized hollow FRCs. However, washout tools formed by BJ require an impermeable barrier between the porous tooling surface and the parts laid up on the surface to prevent the resin from infiltrating the tooling surface and bonding the tool to the FRC. The conventional method for preventing resin migration into the washout mold from the FRC is winding Teflon® tape over the entire surface, which is labor-intensive and very difficult to deploy for specific geometries. Here, we report the development of a polymer spray coating method to seal the tooling surface and prevent resin infiltration without affecting the washout properties needed for sacrificial tooling. Two water-soluble polymers, poly(sodium 4-styrenesulfonate) (PSS–Na) and poly(vinylsulfonic acid, sodium salt) (PVS–Na), were investigated for spray coating. PVS-Na maintained tighter geometric tolerances and provided excellent thermal stability with the onset of decomposition at 320 °C and glass transition temperature of 280 °C. Spray coating with PVS-Na streamlines the process of forming a protective layer for the washout molds by BJ, reduces migration of the resins from the FRC, and significantly improves the production efficiency of complex washout tools.

42 ENGINEERING↗
DOE OSTI2026

Servomotor-driven leveling elements for machine tool frame-to-floor alignment

This paper presents the results of aligning the frame to concrete floor of a large 5-axis machine tool by leveling element adjustments using servomotors instead of manual operation. The machine tool leveling elements used in this study are mechanical devices that attach the machine tool frame to the concrete foundation. These leveling elements are also adjustable so that each location along the machine tool can be uniquely adjusted such that the geometric errors of the frame are minimized, and the accuracy of the machine tool is improved. Off-the-shelf servomotors and connection equipment were installed at each of 12 leveling element locations for a precision 5-axis machine tool at Oak Ridge National Laboratory. The servomotors allow a technician to align the machine tool frame remotely, instead of crawling under the machine tool to iteratively manually adjust each of the 12 leveling elements. The open-loop servomotor-leveling element system design is presented in this paper as well as machine tool frame alignment results. The servomotor system significantly reduces leveling element adjustment time, eliminates the need for under-machine access, reduces technician physical strain, and significantly improves the adjustment repeatability.

Honeycutt, Andrew [ORNL]↗
DOE OSTI2020

Urban building energy modeling (UBEM) tools: A state-of-the-art review of bottom-up physics-based approaches

Regulations corroborate the importance of retrofitting existing building stocks or constructing new energy-efficient districts. There is, thus, a need for modeling tools to evaluate energy scenarios to better manage and design cities, and numerous methodologies and tools have been developed. Among them, Urban Building Energy Modelling (UBEM) tools allow the energy simulation of buildings at large scales. Choosing an appropriate UBEM tool, balancing the level of complexity, accuracy, usability, and computing needs, remains a challenge for users. The review focuses on the main bottom-up physics-based UBEM tools, comparing them from a user-oriented perspective. Five categories are used: (i) the required inputs, (ii) the reported outputs, (iii) the exploited workflow, (iv) the applicability of each tool, and (v) the potential users. Moreover, a critical discussion is proposed, focusing on interests and trends in research and development. The results highlighted major differences between UBEM tools that must be considered to choose the proper one for an application. Finally, barriers of adoption of UBEM tools include the needs of a standardized ontology, a common three-dimensional city model, a standard procedure to collect data, and a standard set of test cases. This feeds into future development of UBEM tools to support cities’ sustainability goals.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Subsurface mechanical damage of fused silica glass during grinding by various sub-aperture tools with and without ultrasonics

The subsurface mechanical damage (SSD) depth after grinding fused silica glass with a comprehensive set of sub-aperture fixed abrasive grinding tools [cup, wheel, belt, pad, and rotary face mill (with and without ultrasonics)] and process parameters has been statistically measured using the taper wedge technique and evaluated. Consistent with a previously reported grinding model [J. Non-Cryst. Solids 352, 5601–5617 (2006) Crossref , Materials Science and Technology of Optical Fabrication (Wiley & Sons, 2018)], based on the sliding indentation fracture by sliding particles or asperities where the normal load per particle determines the depth of the fracture (and ultimately the overall SSD depth), the dominant factor controlling SSD depth was found to be the abrasive size regardless of the tool type and process conditions. Compared to full aperture grinding methods, the overall SSD depth was higher using the sub-aperture tools, likely due to the higher effective pressure and higher load per particle distribution. Here, in addition to abrasive size, a significant reduction in SSD depth was achieved by: (1) reducing the load distribution on the abrasive particles via increase in contact area and/or decrease in mechanical loading; (2) using a more compliant host tool medium; and (3) in what we believe is a more novel way, using ultrasonics. Combining low abrasive size, larger contact area, and a compliant host, the 6 µm diamond in a resin matrix (Trizact) on a foam pad led to very low SSD depth (~ 4.6 µm), relatively fast grinding rate (186 mm 3 /h), and little or no figure degradation. This grinding tool/process is an attractive choice for final grind, resulting in significantly reduced polish out (i.e., “grey out”) times. With the rotary face mill tool, the use of ultrasonics consistently led to a SSD depth reduction (ranging from 17%–34%). A new fracture mechanics-based model, to the best of our knowledge, where the relevant normal load is parallel to the feed direction, has been developed to explain how ultrasonics leads to lower SSD depth. The key factors, supported by finite element stress analysis and load measurements, are (1) the initiation of fractures at higher z heights during the tool’s ultrasonic vertical oscillations, thus propagating less deep into workpiece; (2) reduction in load (and therefore reduction in fracture propagation distance) due to smaller tool-workpiece feed direction contact area (again caused by higher heights relative to depth of cut); (3) upward movement of the tool during oscillation leads to fracturing toward the surface instead into the depth; and finally (4) at tool’s lowest point of oscillation cycle, there may not be enough time for the fracture to propagate to its full length.

Optics and optical instruments↗
DOE OSTI2024

Carbon Transport and Storage Planning and Viability Support Tools

The EDX disCO2ver Carbon Transport and Storage Planning and Viability Support Tools are made up of the Carbon Storage Planning Inquiry Tool (CS PlanIT, Justman et al. 2024) and the Carbon Storage Technical Viability Approach Support Tool (CS TVA). Together, these tools support data access to support understanding data availability to support planning efforts for carbon transport and storage. The Carbon Storage Planning Inquiry Tool (CS PlanIT) is an online web mapping application designed to help users explore, query, and evaluate multiple data layers to support and accelerate carbon storage resource and feasibility assessments and planning efforts. CS PlanIT currently contains a range of datasets associated with geologic, technical, and infrastructure factors. The data sets can be filtered geographically for an area of interest to update statistics and charts within the dashboard. The dashboard is divided into different sections called widgets, relating to different steps in the carbon storage planning process. The resources in this submission include a link to PlanIT, as well as a data catalog and link to user documentation. The original citation for the CS PlanIT tool, which has now been integrated into the toolset here, was: - Devin Justman, Scott Pantaleone, Maneesh Sharma, Lucy Romeo, Paige Morkner, CS PlanIT (Carbon Storage Planning Inquiry Tool) , 6/28/2024, https://edx.netl.doe.gov/dataset/cs-planit-carbon-storage-planning-inquiry-tool, DOI: 10.18141/2377953 The Carbon Storage Technical Viability Approach Support (CS TVA) Tool displays spatial data availability for the many components of Geologic Carbon Storage (GCS) technical viability assessment (Creason al 2025). Identifying sites suitable for GCS requires evaluating the intersection of myriad factors, including reservoir conditions, subsurface and surface hazards, infrastructure requirements, and energy community metrics. The technical viability of a site can only be confirmed for instances where all these factors have data available, and where those data support viability. Additional Resources related to the Technical Viability Assessment Tool: - Julia Mulhern, Casey White, Araceli Lara, Neyda Cordero Rodriguez, Zachary Jackson, Jacob Shay, Gabriel Creason, MacKenzie Mark-Moser, Paige Morkner, Kelly Rose, Carbon Storage Technical Viability Approach (CS TVA) Database, 3/26/2025, https://edx.netl.doe.gov/dataset/edx4ccs-carbon-storage-technical-viability-approach-database , DOI:10.18141/1984655 - Julia Mulhern, MacKenzie Mark-Moser, Gabriel Creason, Casey White, Araceli Lara, Neyda Cordero Rodriguez, Zach Jackson, Paige Morkner, Kelly Rose, Carbon Storage Technical Viability Approach (CS TVA) Matrix, 3/27/2025, https://edx.netl.doe.gov/dataset/carbon-storage-technical-viability-approach-cs-tva-matrix , DOI: 10.18141/2539979 - Gabriel Creason, Zach Jackson, Neyda Cordero Rodriguez, Julia Mulhern, Casey White, Araceli Lara, MacKenzie Mark-Moser, Paige Morkner, Kelly Rose, Carbon Storage Technical Viability Approach (CS TVA) Data Availability Results Database, 3/27/2025, https://edx.netl.doe.gov/dataset/carbon-storage-technical-viability-approach-cs-tva-data-availability-results-database, DOI:10.18141/2538557

Carbon storage↗
DOE OSTI2021

Reclaimed Carbon Fiber Reinforced Automotive Part Using 3-DEP® Preforming Technology on Additive Manufacturing Tool Made with Reclaimed Carbon Fibers

The project focused on how well tools designed and built using reclaimed carbon fiber on the Big Area Additive Manufacturing (BAAM) can be used to manufacture preforms made with reclaimed carbon fibers. The project supported multiple Institute for Advanced Composite Manufacturing Innovation (IACMI) goals: • Enables the use of recycled carbon fibers in two areas: o Tooling material compounded with reclaimed carbon fiber. o Preforms made with recycled carbon fiber (rCF). • Lowers manufacturing costs by producing low cost 3-DEP® preform tooling. • Reduces manufacturing cycle time with quick additive manufacturing techniques. • Produces lightweight automotive components that will increase fuel economy which will in turn reduce greenhouse gas emissions. The project demonstrated a tool made from reclaimed carbon fibers, gathered technical data that will guide optimization of tooling materials, evaluated preforms made with the BAAM printed tool, and developed cost evaluations. This project has been a total success. First the project demonstrated that reclaimed carbon fiber can be compounded and successfully printed in the BAAM equipment. Second preforms were successfully made from reclaimed carbon fiber using a reclaimed fiber printed tool. Third the team successfully printed a molding tool out of reclaimed carbon fiber. Fourth the project went beyond the scope of this phase I project in 3 areas: (1)- Techmer PM compounded rCF in 2 resin systems instead of just one system (2)- Local Motors evaluated and collected data that will support their IACMI 3.6 project (Robert Bedsole, 2017) . (3)- University of Tennessee Knoxville (UTK) molded a part using the reclaimed preform on a molding tool made from printed reclaim fiber.

36 MATERIALS SCIENCE↗
DOE OSTI2023

The disCO2ver Platform: Curating Data and Tools for Geologic Carbon Sequestration and Deep Subsurface Research Systems

The U.S. DOE National Energy Technology Laboratory has invested 12+ years of development into the data repository and digital laboratory, the Energy Data eXchange (EDX, edx.netl.doe.gov). Supporting a variety of research areas across the DOE Office of Fossil Energy and Carbon Management, the platform has successfully curated and preserved thousands of data products from DOE research. The Carbon Storage Program has successfully supported data curation, upload, and publishing of data products on EDX for many years, demonstrating a success story of how resources like EDX can effectively help with long term preservation and publishing of DOE data products. EDX continues to shift towards cloud-supported infrastructure, taking a hybrid approach combining on-premises compute and storage integrated with cloud-hosted services. The integration of cloud compute and hybrid architecture enables the development of EDX-hosted platforms that tailor the data and tools hosted on them to a specific community, enables implementation of machine learning tools for data discovery and filtering, and enables the hosting of virtual (online user interface) tools. Geologic carbon sequestration (GCS) research continues to scale up in response to the current administration goals to reduce greenhouse gas emissions and transition the energy economy. Over the last year, EDX’s disCO2ver platform has been developed in response to the need for access to data products and tools to support the scaling up of GCS research. disCO2ver provides access to data resources and tools, produced by DOE and outside authoritative external resources. The platform also provides a user-access control component for the virtualization and cloud hosting of tools. Tools that need to be virtualized, to eliminate the need for users to download the tool and use local compute resources, is essential to supporting big-data analysis and machine learning that is becoming common place in carbon storage modeling, risk analysis, and data publishing practices. This talk will review the EDX’s disCO2ver platform and the current work ongoing to curate data and tools to support GCS and deep subsurface systems research.

Morkner, Paige↗
DOE OSTI2025

A Computational Tool Compatible with NEAMS Code Packages for Optimizing the Shape of Nuclear Reactor Components and of Whole Core Performance

We designed and implemented a shape optimization tool that functions with NEAMS codes, and that nuclear scientists and engineers can employ to optimize the shape of individual components and the whole core under the applicable single- or multi-physics model comprising the employed code(s). The shape-optimization tool enables varying the geometric shape itself as well as its dimensions to yield, potentially, new component designs that are not limited by the designer’s intuition and previous experience. In cases where the optimal-shape object is an individual component, we provide the capability for additional verification that the whole-core performance using the optimized component performs better, under the prescribed optimization criteria, than the initial design. Our shape-optimization tool couples to NEAMS codes via a flexible input- composer interface and enables the user to constrain the shape’s evolution to ensure the component’s manufacturability. Finally, we demonstrate our shape-optimization tool with single- and multi-physics NEAMS codes. This objective is motivated by the recent advances in manufacturing technology that, combined with rising interest in novel reactor concepts, are creating new opportunities for innovation in the design of individual components that affect the performance of the full reactor system. In particular, Additive Manufacturing (AM) enables mass production of highly precise, intricate and complex component shapes that are not feasible with traditional manufacturing techniques. To accomplish this goal we developed and implemented in MOOSE: (1) discrete shape optimization capability based on a state-space search that uses Artificial Intelligence strategies to find the optimal state/shape; (2) smooth shape optimization tool that employs PETSc’s toolkit for advanced optimization (TAO) to optimize node-displacement of the components’ model sidesets; (3) hierarchical core optimization workflow that recognizes the repeating patterns typical in a nuclear reactor and performs the optimization one level at a time with increasing length scale. Each of these tools is equipped with user-specified constraints to avoid optimal shapes that are not manufacturable. The developed shape optimization tool is verified and demonstrated on various nuclear reactor core components and models. The optimization process accounts for tightly coupled physics that govern the behavior of these target reactors, and exercises several NEAMS codes in a coupled multiphysics fashion. The impact of the delivered shape optimization tool will materialize in the optimal design, from the outset, of advanced reactors currently contemplated to regain the US’s leadership in nuclear energy R&D. Novel reactor concepts, e.g. Molten Salt Reactors, and sizes/capacities, e.g. micro- reactors, provide a unique opportunity to optimize performance from the early stages of development, before the investment in components’ production lines, validation experiments, and licensing regimes make future improvements in performance prohibitively expensive and force sub-optimal performance on the affected reactor concept in perpetuity. This benefit will be realized by the delivered shape optimization tool regardless of the applicable manufacturing process whether traditional or AM, thereby broadening the impact of this project on current and future reactor concepts and technologies

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1993

Retractable tool bit having latch type catch mechanism

A retractable tool bit assembly for a tool such as an allen key is presented. The assembly includes one or more spring loaded nestable or telescoping tubular sections together with a catch mechanism for capturing and holding the tool in its retracted position. The catch mechanism consists of a latch mechanism located in a base section and which engages a conically shaped tool head located at the inner end of the tool. The tool head adjoins an eccentric oval type neck portion which extends to a rear lip of the tool head. The latch mechanism releases when the ovular neck portion rotates about the catch members upon actuation of a rotary tool drive motor. When released, all the telescoping sections and the tool extends fully outward to a use position.

Voellmer, George↗
NASA NTRS1995

Integrating Reliability Analysis with a Performance Tool

A large number of commercial simulation tools support performance oriented studies of complex computer and communication systems. Reliability of these systems, when desired, must be obtained by remodeling the system in a different tool. This has obvious drawbacks: (1) substantial extra effort is required to create the reliability model; (2) through modeling error the reliability model may not reflect precisely the same system as the performance model; (3) as the performance model evolves one must continuously reevaluate the validity of assumptions made in that model. In this paper we describe an approach, and a tool that implements this approach, for integrating a reliability analysis engine into a production quality simulation based performance modeling tool, and for modeling within such an integrated tool. The integrated tool allows one to use the same modeling formalisms to conduct both performance and reliability studies. We describe how the reliability analysis engine is integrated into the performance tool, describe the extensions made to the performance tool to support the reliability analysis, and consider the tool's performance.

Nicol, David M.↗
NASA NTRS2008

Adjustable-Viewing-Angle Endoscopic Tool for Skull Base and Brain Surgery

The term Multi-Angle and Rear Viewing Endoscopic tooL (MARVEL) denotes an auxiliary endoscope, now undergoing development, that a surgeon would use in conjunction with a conventional endoscope to obtain additional perspective. The role of the MARVEL in endoscopic brain surgery would be similar to the role of a mouth mirror in dentistry. Such a tool is potentially useful for in-situ planetary geology applications for the close-up imaging of unexposed rock surfaces in cracks or those not in the direct line of sight. A conventional endoscope provides mostly a frontal view that is, a view along its longitudinal axis and, hence, along a straight line extending from an opening through which it is inserted. The MARVEL could be inserted through the same opening as that of the conventional endoscope, but could be adjusted to provide a view from almost any desired angle. The MARVEL camera image would be displayed, on the same monitor as that of the conventional endoscopic image, as an inset within the conventional endoscopic image. For example, while viewing a tumor from the front in the conventional endoscopic image, the surgeon could simultaneously view the tumor from the side or the rear in the MARVEL image, and could thereby gain additional visual cues that would aid in precise three-dimensional positioning of surgical tools to excise the tumor. Indeed, a side or rear view through the MARVEL could be essential in a case in which the object of surgical interest was not visible from the front. The conceptual design of the MARVEL exploits the surgeon s familiarity with endoscopic surgical tools. The MARVEL would include a miniature electronic camera and miniature radio transmitter mounted on the tip of a surgical tool derived from an endo-scissor (see figure). The inclusion of the radio transmitter would eliminate the need for wires, which could interfere with manipulation of this and other surgical tools. The handgrip of the tool would be connected to a linkage similar to that of an endo-scissor, but the linkage would be configured to enable adjustment of the camera angle instead of actuation of a scissor blade. It is envisioned that thicknesses of the tool shaft and the camera would be less than 4 mm, so that the camera-tipped tool could be swiftly inserted and withdrawn through a dime-size opening. Electronic cameras having dimensions of the order of millimeters are already commercially available, but their designs are not optimized for use in endoscopic brain surgery. The variety of potential endoscopic, thoracoscopic, and laparoscopic applications can be expected to increase as further development of electronic cameras yields further miniaturization and improvements in imaging performance.

Bae, Youngsam↗
NASA NTRS2009

Innovative Tools Advance Revolutionary Weld Technique

The iconic, orange external tank of the space shuttle launch system not only contains the fuel used by the shuttle s main engines during liftoff but also comprises the shuttle s backbone, supporting the space shuttle orbiter and solid rocket boosters. Given the tank s structural importance and the extreme forces (7.8 million pounds of thrust load) and temperatures it encounters during launch, the welds used to construct the tank must be highly reliable. Variable polarity plasma arc welding, developed for manufacturing the external tank and later employed for building the International Space Station, was until 1994 the best process for joining the aluminum alloys used during construction. That year, Marshall Space Flight Center engineers began experimenting with a relatively new welding technique called friction stir welding (FSW), developed in 1991 by The Welding Institute, of Cambridge, England. FSW differs from traditional fusion welding in that it is a solid-state welding technique, using frictional heat and motion to join structural components without actually melting any of the material. The weld is created by a shouldered pin tool that is plunged into the seam of the materials to be joined. The tool traverses the line while rotating at high speeds, generating friction that heats and softens but does not melt the metal. (The heat produced approaches about 80 percent of the metal s melting temperature.) The pin tool s rotation crushes and stirs the plasticized metal, extruding it along the seam as the tool moves forward. The material cools and consolidates, resulting in a weld with superior mechanical properties as compared to those weld properties of fusion welds. The innovative FSW technology promises a number of attractive benefits. Because the welded materials are not melted, many of the undesirables associated with fusion welding porosity, cracking, shrinkage, and distortion of the weld are minimized or avoided. The process is more energy efficient, safe (no toxic smoke or shielding gas, liquid metal splatter, arcing, dangerous voltage, or radiation), and environmentally sound (no consumables, fumes, or noise) than fusion welding. Under computer control, an automated FSW machine can create welds with high reproducibility, improving efficiency and overall quality of manufactured materials. The process also allows for welding dissimilar metals as well as those metals considered to be "unweldable" such as the 7xxx series aluminum alloys. Its effectiveness and versatility makes FSW useful for aerospace, rail, automotive, marine, and military applications. A downside to FSW, however, is the keyhole opening left in the weld when the FSW pin tool exits the weld joint. This is a significant problem when using the FSW process to join circumferential structures such as pipes and storage containers. Furthermore, weld joints that taper in material thickness also present problems when using the conventional FSW pin tool, because the threaded pin rotating within the weld joint material is a fixed length. There must be capability for the rotating pin to both increase and decrease in length in real time while welding the tapered material. (Both circumferential and tapered thickness weldments are found in the space shuttle external tank.) Marshall engineers addressed both the keyhole and tapered material thickness problems by developing the auto-adjustable pin tool. This unique piece of equipment automatically withdraws the pin into the tool s shoulder for keyhole closeout. In addition, the auto-adjustable pin tool retracts, or shortens, the rotating pin while welding a weld joint that tapers from one thickness to a thinner thickness. This year, the impact of the Marshall innovation was recognized with an "Excellence in Technology Transfer Award" from the Federal Laboratory Consortium.

Source record↗
NASA NTRS2010

Tool for Forecasting Cool-Season Peak Winds Across Kennedy Space Center and Cape Canaveral Air Force Station

The expected peak wind speed for the day is an important element in the daily morning forecast for ground and space launch operations at Kennedy Space Center (KSC) and Cape Canaveral Air Force Station (CCAFS). The 45th Weather Squadron (45 WS) must issue forecast advisories for KSC/CCAFS when they expect peak gusts for >= 25, >= 35, and >= 50 kt thresholds at any level from the surface to 300 ft. In Phase I of this task, the 45 WS tasked the Applied Meteorology Unit (AMU) to develop a cool-season (October - April) tool to help forecast the non-convective peak wind from the surface to 300 ft at KSC/CCAFS. During the warm season, these wind speeds are rarely exceeded except during convective winds or under the influence of tropical cyclones, for which other techniques are already in use. The tool used single and multiple linear regression equations to predict the peak wind from the morning sounding. The forecaster manually entered several observed sounding parameters into a Microsoft Excel graphical user interface (GUI), and then the tool displayed the forecast peak wind speed, average wind speed at the time of the peak wind, the timing of the peak wind and the probability the peak wind will meet or exceed 35, 50 and 60 kt. The 45 WS customers later dropped the requirement for >= 60 kt wind warnings. During Phase II of this task, the AMU expanded the period of record (POR) by six years to increase the number of observations used to create the forecast equations. A large number of possible predictors were evaluated from archived soundings, including inversion depth and strength, low-level wind shear, mixing height, temperature lapse rate and winds from the surface to 3000 ft. Each day in the POR was stratified in a number of ways, such as by low-level wind direction, synoptic weather pattern, precipitation and Bulk Richardson number. The most accurate Phase II equations were then selected for an independent verification. The Phase I and II forecast methods were compared using an independent verification data set. The two methods were compared to climatology, wind warnings and advisories issued by the 45 WS, and North American Mesoscale (NAM) model (MesoNAM) forecast winds. The performance of the Phase I and II methods were similar with respect to mean absolute error. Since the Phase I data were not stratified by precipitation, this method's peak wind forecasts had a large negative bias on days with precipitation and a small positive bias on days with no precipitation. Overall, the climatology methods performed the worst while the MesoNAM performed the best. Since the MesoNAM winds were the most accurate in the comparison, the final version of the tool was based on the MesoNAM winds. The probability the peak wind will meet or exceed the warning thresholds were based on the one standard deviation error bars from the linear regression. For example, the linear regression might forecast the most likely peak speed to be 35 kt and the error bars used to calculate that the probability of >= 25 kt = 76%, the probability of >= 35 kt = 50%, and the probability of >= 50 kt = 19%. The authors have not seen this application of linear regression error bars in any other meteorological applications. Although probability forecast tools should usually be developed with logistic regression, this technique could be easily generalized to any linear regression forecast tool to estimate the probability of exceeding any desired threshold . This could be useful for previously developed linear regression forecast tools or new forecast applications where statistical analysis software to perform logistic regression is not available. The tool was delivered in two formats - a Microsoft Excel GUI and a Tool Command Language/Tool Kit (Tcl/Tk) GUI in the Meteorological Interactive Data Display System (MIDDS). The Microsoft Excel GUI reads a MesoNAM text file containing hourly forecasts from 0 to 84 hours, from one model run (00 or 12 UTC). The GUI then displays e peak wind speed, average wind speed, and the probability the peak wind will meet or exceed the 25-, 35- and 50-kt thresholds. The user can display the Day-1 through Day-3 peak wind forecasts, and separate forecasts are made for precipitation and non-precipitation days. The MIDDS GUI uses data from the NAM and Global Forecast System (GFS), instead of the MesoNAM. It can display Day-1 and Day-2 forecasts using NAM data, and Day-1 through Day-5 forecasts using GFS data. The timing of the peak wind is not displayed, since the independent verification showed that none of the forecast methods performed significantly better than climatology. The forecaster should use the climatological timing of the peak wind (2248 UTC) as a first guess and then adjust it based on the movement of weather features.

Barrett, Joe H., III↗
NASA NTRS2005

Chimera Grid Tools

Chimera Grid Tools (CGT) is a software package for performing computational fluid dynamics (CFD) analysis utilizing the Chimera-overset-grid method. For modeling flows with viscosity about geometrically complex bodies in relative motion, the Chimera-overset-grid method is among the most computationally cost-effective methods for obtaining accurate aerodynamic results. CGT contains a large collection of tools for generating overset grids, preparing inputs for computer programs that solve equations of flow on the grids, and post-processing of flow-solution data. The tools in CGT include grid editing tools, surface-grid-generation tools, volume-grid-generation tools, utility scripts, configuration scripts, and tools for post-processing (including generation of animated images of flows and calculating forces and moments exerted on affected bodies). One of the tools, denoted OVERGRID, is a graphical user interface (GUI) that serves to visualize the grids and flow solutions and provides central access to many other tools. The GUI facilitates the generation of grids for a new flow-field configuration. Scripts that follow the grid generation process can then be constructed to mostly automate grid generation for similar configurations. CGT is designed for use in conjunction with a computer-aided-design program that provides the geometry description of the bodies, and a flow-solver program.

Chan, William M.↗
NASA NTRS2011

AN Fitting Reconditioning Tool

A tool was developed to repair or replace AN fittings on the shuttle external tank (ET). (The AN thread is a type of fitting used to connect flexible hoses and rigid metal tubing that carry fluid. It is a U.S. military-derived specification agreed upon by the Army and Navy, hence AN.) The tool is used on a drill and is guided by a pilot shaft that follows the inside bore. The cutting edge of the tool is a standard-size replaceable insert. In the typical Post Launch Maintenance/Repair process for the AN fittings, the six fittings are removed from the ET's GUCP (ground umbilical carrier plate) for reconditioning. The fittings are inspected for damage to the sealing surface per standard operations maintenance instructions. When damage is found on the sealing surface, the condition is documented. A new AN reconditioning tool is set up to cut and remove the surface damage. It is then inspected to verify the fitting still meets drawing requirements. The tool features a cone-shaped interior at 36.5 , and may be adjusted at a precise angle with go-no-go gauges to insure that the cutting edge could be adjusted as it wore down. One tool, one setting block, and one go-no-go gauge were fabricated. At the time of this reporting, the tool has reconditioned/returned to spec 36 AN fittings with 100-percent success of no leakage. This tool provides a quick solution to repair a leaky AN fitting. The tool could easily be modified with different-sized pilot shafts to different-sized fittings.

Lopez, Jason↗
NASA NTRS2012

Plug-in Plan Tool v3.0.3.1

The role of PLUTO (Plug-in Port UTilization Officer) and the growth of the International Space Station (ISS) have exceeded the capabilities of the current tool PiP (Plug-in Plan). Its users (crew and flight controllers) have expressed an interest in a new, easy-to-use tool with a higher level of interactivity and functionality that is not bound by the limitations of Excel. The PiP Tool assists crewmembers and ground controllers in making real-time decisions concerning the safety and compatibility of hardware plugged into the UOPs (Utility Outlet Panels) onboard the ISS. The PiP Tool also provides a reference to the current configuration of the hardware plugged in to the UOPs, and enables the PLUTO and crew to test Plug-in locations for constraint violations (such as cable connector mismatches or amp limit violations), to see the amps and volts for an end item, to see whether or not the end item uses 1553 data, and the cable length between the outlet and the end item. As new equipment is flown or returned, the database can be updated appropriately as needed. The current tool is a macroheavy Excel spreadsheet with its own database and reporting functionality. The new tool captures the capabilities of the original tool, ports them to new software, defines a new dataset, and compensates for ever-growing unique constraints associated with the Plug-in Plan. New constraints were designed into the tool, and updates to existing constraints were added to provide more flexibility and customizability. In addition, there is an option to associate a "Flag" with each device that will let the user know there is a unique constraint associated with it when they use it. This helps improve the safety and efficiency of real-time calls by limiting the amount of "corporate knowledge" overhead that has to be trained and learned through use. The tool helps save time by automating previous manual processes, such as calculating connector types and deciding which cables are required and in what order.

Andrea-Liner, Kathleen E.↗