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At least 1,279 records · Page 71

Lightweight Thrust Chamber Composite Overwrap Lessons Learned

The manufacturing, design, and analysis of filament wound carbon fiber/polymer composite overwraps for additively manufactured, copper combustion chambers are a critical part of NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project. Ideally, the composite overwrap acts as a light-weight structural jacket and allows significant weight reduction of the high pressure thrust chamber assembly, reduction of overall cost, and reduced fabrication schedules. Chamber assemblies for 2000 lb. (2k) and 7000 lb. (7k) of thrust have been successfully tested at NASA’s Marshall Space Flight Center. Multiple lessons were learned throughout the overwrap process development and manufacturing trials. The lessons learned on small scale hardware, such as the 2k and 7k chambers, will guide further composite manufacturing technologies and enable a progression to larger scale assemblies with greater structural loads. Material performance requirements, manufacturing process development, and surface preparation were evaluated during the small chamber trials, with the broad thermal requirements of the resin being the primary driver for material selection and processing. Both epoxy and bismaleimide (BMI) materials were evaluated with respect to both performance in the hot-fire test and ease of fabrication. Separately, surface preparation procedures were studied with the goal of providing a smooth chamber surface to promote a non-bonded overwrap. Recent testing of the 7k trust chamber has provided data in Non-Destructive Evaluation (NDE) and processing in order to continue to evaluate the performance requirements stated.

Allison Clark↗

An In-depth Review On the Scientific and Policy Issues Associated with Additive Manufacturing

Historically, manufacturing processes have been predominantly subtractive, i.e. three-dimensional objects were created by successively cutting material away from a solid block, by scraping, machining, turning or dissolving. Additive manufacturing (AM) or three-dimensional (3D) printing, in contrast, is controlled material addition, implemented by successively depositing layers of material until a predesigned shape is formed. AM represents an innovative manufacturing technology, and is set to transform production processes from design to manufacture, and to eventual distribution to end users, ultimately leading to an increase in energy efficiency and a reduction in gas emissions for future generation of industries. The unique capability of this technology to produce intricate geometries with customizable material properties has made it a widely interesting and welcome development among scientists, industry and the general public. Its wide acceptance has continued to make 3D printing technology more openly accessible, and low-cost desktop printing, with the capability to reproduce 3D objects from medical prostheses to weapons, is rapidly increasing in availability to the public. However, most research and media attention has been focused on the ingenuity of this ground-breaking technology and its wide range of possibilities. Very little consideration is being given to the adverse effects of the seemingly unstoppable advancement of AM technology and unrestricted access to 3D printing techniques. Also, proponents of AM technology rarely take into account the overall life-cycle cost and risks of failure of the manufactured part. Despite the promising prospects of this novel development, there are still concerns about how printed products will perform over time, the consistency of their quality, and the types and safety of materials used with this technology, especially with very large scale additive-manufactured products. This paper brings to light some scientific and policy risks and challenges concerning the material science and engineering aspects of these issues. Matters discussed include life-cycle cost analysis, end-product safety and quality assurance/control, regulation gaps, digital piracy, and resulting loopholes in safety and national security. The paper also presents potential options for curbing these risks, and otherwise adapting to the eventualities which, with certain inevitable factors in play, may lie beyond control.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

A critical review on additive manufacturing of refractory alloys from a data analytics perspective- beyond nickel-based superalloys

Refractory alloys (RAs) are promising materials due to their exceptional physicochemical properties, but most research remains at the laboratory scale. For broader adoption, advancements in manufacturing are essential. Because their high stability makes conventional methods like machining and casting difficult, additive manufacturing (AM) is emerging as an effective approach for fabricating refractory alloy components. However, AM's repeated non-equilibrium thermal cycles introduce undesired features (e.g. defects, anisotropic microstructures, and residual stresses), which are magnified due to RAs’ unique properties. This paper comprehensively reviews the state-of-the-art methods of AM for refractory alloys. It explores data analytics techniques to establish design rules based on multi-fidelity experimental and computational methods. Furthermore, it investigates integrated, collaborative efforts to harmonise standalone databases, information, knowledge, and predictive models at multi-physics, multi-stage, and multi-scale. Unlike the existing literature that focuses primarily on material systems or process fundamentals, this work provides an integrated perspective on AM of refractory alloys from a data analytics standpoint, highlighting the roles of integrated computational materials engineering (ICME), verification, validation, and uncertainty quantification (VV&UQ), and digital twin-driven qualification in overcoming data scarcity and accelerating rapid qualification.

Additive manufacturing↗

Laser Additive Manufacturing of F/M Steels for Radiation Tolerant Nuclear Components

According to the Nuclear Energy R&D Roadmap Report submitted to Congress in 2010, one the key challenges facing the nuclear energy industry involves development of new reactor designs with reduced capital costs. Two related R&D objectives outlined in the report include: 1) Making improvements in the affordability of new reactors; and 2) Development of structural materials to withstand irradiation for longer periods. Laser additive manufacturing (LAM) is particularly well suited for more rapid and economical fabrication of reactor components relative to current fabrication methods. The proposed work involving LAM directly addresses the two R&D objectives outlined above relevant to the pertinent mission problems. The classical Materials Science approach involving development of Process/Structure/Property/Performance (P/S/P/P) relations was employed in this project. Processing included LAM and heat-treating. Thermal cycling during LAM is discussed here, and phase diagrams and continuous cooling transformation (CCT) diagrams are used to rationalize microstructural evolution. Structures were characterized including grain size & morphology, volume fraction, morphology, composition and location of carbides in as-deposited and heat-treated conditions. In the simplest sense, the goal was to control microstructures through process manipulation with a view toward optimizing properties and performance in service.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

airborne data analysis/monitor system

An Airborne Data Analysis/Monitor System (ADAMS), a ROLM 1666 computer based system installed onboard test airplanes used during experimental testing is evaluated. In addition to the 1666 computer, the ADAMS hardware includes a DDC System 90 fixed head disk and a Miltape DD400 floppy disk. Boeing designed a DMA interface to the data acquisition system and an intelligent terminal to reduce system overhead and simplify operator commands. The ADAMS software includes RMX/RTOS and both ROLM FORTRAN and assembly language are used. The ADAMS provides real time displays that enable onboard test engineers to make rapid decisions about test conduct thus reducing the cost and time required to certify new model airplanes, and improved the quality of data derived from the test, leading to more rapid development of improvements resulting in quieter, safer, and more efficient airplanes. The availability of airborne data processing removes most of the weather and geographical restrictions imposed by telemetered flight test data systems. A data base is maintained to describe the airplane, the data acquisition system, the type of testing, and the conditions under which the test is performed.

Stephison, D. B.↗

The Design of PC/MISI, a PC-Based Common User Interface to Remote Information Storage and Retrieval Systems

The amount of information contained in the data bases of large-scale information storage and retrieval systems is very large and growing at a rapid rate. The methods available for assessing this information have not been successful in making the information easily available to the people who have the greatest need for it. This thesis describes the design of a personal computer based system which will provide a means for these individuals to retrieve this data through one standardized interface. The thesis identifies each of the major problems associated with providing access to casual users of IS and R systems and describes the manner in which these problems are to be solved by the utilization of the local processing power of a PC. Additional capabilities, not available with standard access methods, are also provided to improve the user's ability to make use of this information. The design of PC/MISI is intended to facilitate its use as a research vehicle. Evaluation mechanisms and possible areas of future research are described. The PC/MISI development effort is part of a larger research effort directed at improving access to remote IS and R systems. This research effort, supported in part by NASA, is also reviewed.

Dominick, Wayne D.↗

A Real-Time Microwave Camera at K-Band (24 GHz)

Nondestructive testing (NDT) community has been moving towards effective and robust inspection systems that can provide real-time information about materials, geometrical, structural and mechanical characteristics of composite materials/structures. Moreover, in many applications it is desired to have an image of the structure, after which the information contained in the image is correlated to the above characteristics. Microwave signals penetrate inside of dielectric composite structures and their interaction with the interior of the structure renders critical information for NDT purposes. Subsequently, this information (i.e., magnitude and phase or reflected signal) may be used to produce an image of the interior of the structure revealing potential flaws or anomalies. Image processing and reconstruction techniques may also be incorporated to produce high-resolution images (i.e., synthetic-aperture, back-propagation, etc.). There are several different approaches for designing areal-time microwave camera system. One approach is based on modulated scatterer technique (MST), which is used to tag scattered electric field in a discrete two-dimensional (2D) spatial domain (e.g. a retina) resulting in the 2D magnitude and phase distribution of the scattered electric field which is required for producing an image of a material or structure under inspection. The ability to rapidly modulate resonant slot antennas in such a retina along with using receivers with fast responses provide for real-time image production capability. Design issue and criteria become more challenging at higher frequencies and for a relatively large retina size. This paper presents the basic design and challenges for a microwave camera with a retina size of 6" by 6" operating at a frequency of 24 GHz.

Ghasr, M. T.↗

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogeneities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogeneities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogeneities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogenities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogenities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Efficient Clustering of Software Vulnerabilities using Self Organizing Map (SOM)

The common vulnerabilities and exposures (CVE) database was created with a mission to ``identify, define, and catalog publicly disclosed cybersecurity vulnerabilities''. This rich body of information can be used to enable rapid and efficient response to secure and defend cyber operations and protect critical cyber infrastructure. The main goal of this paper is to develop a visual analytics tool to enable deep analysis of CVEs using unsupervised clustering techniques. We enhance our analysis by first mapping CVEs to hierarchical-classes in Common Weakness Enumeration (CWE) using information in the National Vulnerability Database (NVD). Both the mapping and the numerical representation of CVEs are enabled by V2W-BERT, which uses natural language processing of the extensive information in NVD to generate a large tabular database of 137,226 CVE entries from 1999 to 2020, where each CVE is represented by a vector of 768 numerical features. The vectorized data is processed by Self-Organizing Maps (SOM), which is an unsupervised machine learning technique for dimensionality reduction, visual representation and clustering. Using a Torus map of 6417 units, we achieve ~10-fold data compression of ~140k CVEs using SOM. The trained map is further clustered using standard K-means clustering into 138 clusters of CVEs. We conducted a brief investigation of the rich mapping of CVEs to best-matching-units to K-means clusters, as well as CVEs to CWEs. For example, this novel mapping provided insight into the role of CWE-59 and CWE-264 in several CVEs that is otherwise hard to explore in the original data. We conclude that our this novel approach will not only enable deep analysis of the complex relationships between CVEs and CWEs, but also a mechanism to quickly respond to and design mitigation actions for rapidly evolving vulnerabilities that have not been mapped to existing CWEs.

Panchal, Khyati↗

Bridging the gap between atomistic phenomena and continuum behavior in electrochemical energy storage processes

One of the most significant impediments to advances in electrochemical energy storage lies in the gap between fundamental understanding of atomistic phenomena and our understanding of the impact of these phenomena on system performance at device scales. Atomistic models (DFT, MD, MC) provide insight into such phenomena along with a means of quantification, but such models are too computationally intensive to address device-scale behavior. Similarly, device-scale insight for design and optimization can be obtained through continuum models that are sufficiently fast, but these models account for only the simplest atomistic phenomena. There is thus a large gap between our ability to develop fundamental understanding and our ability to use this understanding to make rapid advances in energy storage technologies. The goal of this work is to help bridge this gap through an innovative synthesis of atomistic and continuum approaches in which atomistic phenomena are captured through fast reduced-order integral methods that can be imbedded into continuum-like models describing device-scale behavior.

Davidson, Scott M.↗

Modular Subsurface Sensors and Integrated Software for Advanced Subsurface Characterization and Monitoring using Unoccupied Vehicles

The advent and subsequent proliferation of autonomous airborne, waterborne, and groundbased vehicles (i.e., “drones”) promises to broadly transform the geosciences and associated industries, including fossil energy exploration and development, mineral resource exploration and development, water-resource management, and environmental remediation. For geophysical characterization and monitoring, the prospect of programming highly repeatable and low-cost drone missions for subsurface imaging will allow for deployments in hazardous and previously inaccessible areas. Coupled with autonomous workflows for data processing, management, and visualization, drone-based geophysical characterization and monitoring will enable unprecedented, real-time insight into diverse subsurface properties and processes of scientific and engineering importance. Toward this end, the objectives of this Lab Directed Research and Development (LDRD) project were to develop new (1) instrumentation for dronebased electromagnetic induction (EMI) geophysical imaging, including separated transmitter and receivers and associated electronics, (2) software for real-time data telemetry, processing, management, and visualization. Although EMI has been previously deployed using unoccupied aerial systems (UASs), these applications failed to capitalize on the game-changing capabilities of drone platforms. Whereas drone-based data acquisition allows for collection of rich, three-dimensional (3D) multi-offset/multi-angle configurations between transmitters and receivers, past efforts have relied on conventional instrumentation that was designed for ground-based data collection with the transmitter and a single receiver housed in the same unit; nor did these previous applications demonstrate real-time delivery of results to support rapid management decisions in the field. In this 1-year project, we (1) designed and constructed new lightweight independent transmitter and receiver antenna platforms that communicate with a laptop computer; (2) developed software to control data acquisition, manage/transfer data, and visualize data as its collected; and (3) demonstrated the operation of the new hardware and software systems in a ground-based field test. Our work entails major technological advances for EMI and established a foundation on which to build a new drone-based, real-time geophysical EMI imaging capability to support diverse challenges facing the nation.

47 OTHER INSTRUMENTATION↗

Techniques for control of long-term reliability of complex integrated circuits. I - Reliability assurance by test vehicle qualification.

Development of an alternate approach to the conventional methods of reliability assurance for large-scale integrated circuits. The product treated is a large-scale T squared L array designed for space applications. The concept used is that of qualification of product by evaluation of the basic processing used in fabricating the product, providing an insight into its potential reliability. Test vehicles are described which enable evaluation of device characteristics, surface condition, and various parameters of the two-level metallization system used. Evaluation of these test vehicles is performed on a lot qualification basis, with the lot consisting of one wafer. Assembled test vehicles are evaluated by high temperature stress at 300 C for short time durations. Stressing at these temperatures provides a rapid method of evaluation and permits a go/no go decision to be made on the wafer lot in a timely fashion.

Van Vonno, N. W.↗

Requirements for effective use of CFD in aerospace design

This paper presents a perspective on the requirements that Computational Fluid Dynamics (CFD) technology must meet for its effective use in aerospace design. General observations are made on current aerospace design practices and deficiencies are noted that must be rectified for the U.S. aerospace industry to maintain its leadership position in the global marketplace. In order to rectify deficiencies, industry is transitioning to an integrated product and process development (IPPD) environment and design processes are undergoing radical changes. The role of CFD in producing data that design teams need to support flight vehicle development is briefly discussed. An overview of the current state of the art in CFD is given to provide an assessment of strengths and weaknesses of the variety of methods currently available, or under development, to produce aerodynamic data. Effectiveness requirements are examined from a customer/supplier view point with design team as customer and CFD practitioner as supplier. Partnership between the design team and CFD team is identified as an essential requirement for effective use of CFD. Rapid turnaround, reliable accuracy, and affordability are offered as three key requirements that CFD community must address if CFD is to play its rightful role in supporting the IPPD design environment needed to produce high quality yet affordable designs.

Raj, Pradeep↗

Microwave Extraction of Lunar Water for Rocket Fuel

Nearly 50% of the lunar surface is oxygen, present as oxides in silicate rocks and soil. Methods for reduction of these oxides could liberate the oxygen. Remote sensing has provided evidence of significant quantities of hydrogen possibly indicating hundreds of millions of metric tons, MT, of water at the lunar poles. If the presence of lunar water is verified, water is likely to be the first in situ resource exploited for human exploration and for LOX-H2 rocket fuel. In-Situ lunar resources offer unique advantages for space operations. Each unit of product produced on the lunar surface represents 6 units that need not to be launched into LEO. Previous studies have indicated the economic advantage of LOX for space tugs from LEO to GEO. Use of lunar derived LOX in a reusable lunar lander would greatly reduce the LEO mass required for a given payload to the moon. And Lunar LOX transported to L2 has unique advantages for a Mars mission. Several methods exist for extraction of oxygen from the soil. But, extraction of lunar water has several significant advantages. Microwave heating of lunar permafrost has additional important advantages for water extraction. Microwaves penetrate and heat from within not just at the surface and excavation is not required. Proof of concept experiments using a moon in a bottle concept have demonstrated that microwave processing of cryogenic lunar permafrost simulant in a vacuum rapidly and efficiently extracts water by sublimation. A prototype lunar water extraction rover was built and tested for heating of simulant. Microwave power was very efficiently delivered into a simulated lunar soil. Microwave dielectric properties (complex electric permittivity and magnetic permeability) of lunar regolith simulant, JSC-1A, were measured down to cryogenic temperatures and above room temperature. The microwave penetration has been correlated with the measured dielectric properties. Since the microwave penetration depth is a function of temperature and frequency, an extraction system can be designed for water removal from different depths.

Ethridge, Edwin C.↗