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Materials Science Laboratory

The NASA Materials Science Laboratory (MSL) provides science and engineering services to NASA and Contractor customers at KSC, including those working for the Space Shuttle. International Space Station. and Launch Services Programs. These services include: (1) Independent/unbiased failure analysis (2) Support to Accident/Mishap Investigation Boards (3) Materials testing and evaluation (4) Materials and Processes (M&P) engineering consultation (5) Metrology (6) Chemical analysis (including ID of unknown materials) (7) Mechanical design and fabrication We provide unique solutions to unusual and urgent problems associated with aerospace flight hardware, ground support equipment and related facilities.

Jackson, Dionne↗

High-Altitude MMIC Sounding Radiometer for the Global Hawk Unmanned Aerial Vehicle

Microwave imaging radiometers operating in the 50-183 GHz range for retrieving atmospheric temperature and water vapor profiles from airborne platforms have been limited in the spatial scales of atmospheric structures that are resolved not because of antenna aperture size, but because of high receiver noise masking the small variations that occur on small spatial scales. Atmospheric variability on short spatial and temporal scales (second/ km scale) is completely unresolved by existing microwave profilers. The solution was to integrate JPL-designed, high-frequency, low-noise-amplifier (LNA) technology into the High-Altitude MMIC Sounding Radiometer (HAMSR), which is an airborne microwave sounding radiometer, to lower the system noise by an order of magnitude to enable the instrument to resolve atmospheric variability on small spatial and temporal scales. HAMSR has eight sounding channels near the 60-GHz oxygen line complex, ten channels near the 118.75-GHz oxygen line, and seven channels near the 183.31-GHz water vapor line. The HAMSR receiver system consists of three heterodyne spectrometers covering the three bands. The antenna system consists of two back-to-back reflectors that rotate together at a programmable scan rate via a stepper motor. A single full rotation includes the swath below the aircraft followed by observations of ambient (roughly 0 C in flight) and heated (70 C) blackbody calibration targets located at the top of the rotation. A field-programmable gate array (FPGA) is used to read the digitized radiometer counts and receive the reflector position from the scan motor encoder, which are then sent to a microprocessor and packed into data files. The microprocessor additionally reads telemetry data from 40 onboard housekeeping channels (containing instrument temperatures), and receives packets from an onboard navigation unit, which provides GPS time and position as well as independent attitude information (e.g., heading, roll, pitch, and yaw). The raw data files are accessed through an Ethernet port. The HAMSR data rate is relatively low at 75 kbps, allowing for real-time access over the Global Hawk high-data-rate downlink. Once on the ground, the raw data are unpacked and processed through two levels of processing. The Level 1 product contains geo-located, time-stamped, calibrated brightness temperatures for the Earth scan. These data are then input to a lD variational retrieval algorithm to produce temperature, water vapor, and cloud liquid water profiles, as well as several derived products such as potential temperature and relative humidity.

Brown, Shannon T.↗

Report on the 2011 and 2012 NASA Ames Research Center (ARC) / Alaska State Cargo Airship Workshops

This presentation will summarize the Cargo Airships for Northern Operations workshop that was held August 24-25, 2011. This workshop co-sponsored by NASA ARC and the Alaska State Department of Transportation was initiated by interest from Alaska Lt. Governor Mead Treadwell for assistance in investigating the potential benefits of proposed cargo airships for the Alaskan economy and societal needs. The workshop provided a brief background on the technology and operational aspects of conventional airships and hybrids followed by presentations on issues affecting cargo airship operations such as weather management, insurance, regulations, crew duty/rest rules, and available support infrastructures. Speakers representing potential cargo airship users from Alaskan State and commercial organizations presented the needs they felt could be met by cargo airship services. Presenters from Canadian private and military interests also detailed applications and missions that cargo airships could provide to remote regions of Canada. Cost drivers of cargo airship operations were also addressed and tools for modeling and analyzing operational factors and costs affecting cargo airship operations were discussed. Four breakout sessions were held which allowed workshop participants to contribute inputs to four topic areas: Business Approaches and Strategies (financing incentives public/private partnerships etc) for Airship Development and Operation, Design, Development, Production Challenges, and Possible Solutions, Regulatory, Certification, Legal, and Insurance Issues, and Operational Issues, Customer Requirements, and Airship Requirements. A follow on to the 2011 cargo airship workshop is being planned for July 31 August 2, 2012. A status update on this second workshop will also be presented.

Hochstettler, Ronald↗

Modeling of an Adjustable Beam Solid State Light Project

This proposal is for the development of a computational model of a prototype variable beam light source using optical modeling software, Zemax Optics Studio. The variable beam light source would be designed to generate flood, spot, and directional beam patterns, while maintaining the same average power usage. The optical model would demonstrate the possibility of such a light source and its ability to address several issues: commonality of design, human task variability, and light source design process improvements. An adaptive lighting solution that utilizes the same electronics footprint and power constraints while addressing variability of lighting needed for the range of exploration tasks can save costs and allow for the development of common avionics for lighting controls.

Clark, Toni↗

Global Optimization of Low-Thrust Interplanetary Trajectories Subject to Operational Constraints

Low-thrust interplanetary space missions are highly complex and there can be many locally optimal solutions. While several techniques exist to search for globally optimal solutions to low-thrust trajectory design problems, they are typically limited to unconstrained trajectories. The operational design community in turn has largely avoided using such techniques and has primarily focused on accurate constrained local optimization combined with grid searches and intuitive design processes at the expense of efficient exploration of the global design space. This work is an attempt to bridge the gap between the global optimization and operational design communities by presenting a mathematical framework for global optimization of low-thrust trajectories subject to complex constraints including the targeting of planetary landing sites, a solar range constraint to simplify the thermal design of the spacecraft, and a real-world multi-thruster electric propulsion system that must switch thrusters on and off as available power changes over the course of a mission.

Design↗

Systems Engineering and Management Applications of ISO 9001:2015 for Government

The manufacturing segment of the business world is busy assessing the impact of ISO 9001:2015, and updating their management systems to meet the required compliance date. What does the new revision mean for government agencies that deliver large engineering projects rather than mass production? In fact, the standard, especially the new revision, can be used quite readily for government agencies, or applied to specific projects, once it is understood in terms of the similarities with systems engineering and project management. From there it can be extrapolated to "mission realization" systems, and a Quality Management System (QMS) is a logical result that can bring order to processes and systems that likely already exist in some fashion. ISO 9001:2015 is less product-oriented than previous versions. It can be more broadly applied to public organizations as well as private; and to services (missions) as well as products. The emphasis on risk management in the revised standard provides the needed balance for weighing decisions with respect to cost, schedule, technical, safety, and regulatory compliance; so if this is not part of agency governance already, this is a good place to start, especially for large engineering projects. The Systems Engineering standard used for this analysis is from NASA's NPR 7123.1 NASA Systems Engineering Processes and Requirements; however, those who are more familiar with ISO/IEC 26702 Systems Engineering-application and management of the systems engineering process, or SAE/EIA 632 Processes for Engineering a System will also recognize the similarities. In reality, the QMS outlined by ISO 9001 reinforces the systems engineering processes, and serves to ensure that they are adequately implemented, although most of the ISO 9001 literature emphasizes the production and process aspects of the standard. Rather than beginning with ISO 9001and getting lost in the vocabulary, it is useful to begin with the systems engineering lifecycle. Identification of stakeholder expectations, identifying solutions, creating specific product or service designs, production of the product or service, delivery to the public, and the associated management, planning, and control processes, are a familiar place to begin thinking of the overall system of identifying, designing, and competing a project or mission. Lining up this lifecycle with the ISO requirements (see Figure 1) illustrates how a quality management system is concerned with the same processes, and provides a governance and assurance function. If implemented properly, there are cost savings resulting from less rework, repair, reprocessing, failures, misplaced documents, and similar types of deficiencies1. Starting with an organization's systems engineering processes allows the organization to use their own terminology for a QMS plan, and tailor the plan to their own project or organization, so that it is more easily developed, understood, and implemented.

Shepherd, Christena C.↗

Magnetic Shield Design Modeling and Validation on SWOT Spacecraft Applied to Mars Flux Pinning Orbiting Sample Design

A modeling methodology was developed for use on the Surface Water and Ocean Topography (SWOT) mission for the computational modeling and design of a magnetic shield for a 63 A-sq m source. Shield options were modeled and tested across various design parameters and validated with measurement. Measurement results fell within 10% of simulation in most cases of concern with sources of error well understood. These methods results informed a subsequent modeling activity for a future Mars Sample Return (MSR) mission concept with stringent magnetic cleanliness requirements to retain geologic integrity of the samples. One option for capturing the sample from orbit requires rare earth magnets in close proximity to the Martian samples. Magnetic modeling with a finite-element method solver estimated the magnetic environment and established the need for shielding. Further modeling then determined the shielding necessary to meet magnetic requirements, followed by the design of a mass-optimized solution.

Gonzales, Edward↗

From the Field to the Lab and Back Again

University-based research is often driven by questions of theory and is carried out in artificial manner. Applied research is aimed at solving practical problems in ways that are informed by the theories and in a manner that is ecologically valid. The talk discusses the two approaches and describes two studies in which the practical problem drove laboratory studies resulting in practical solutions.

experimental design↗

Lunar Browser trajectory tool

The Lunar Browser is a tool developed at NASA Ames Research Center for building, processing, and analyzing a database of lunar transfer trajectory solutions. Examples of intended uses include design trades for lunar missions and preliminary assessments of key parameters such as launch opportunities, delta-v and propulsion budgets, communication windows, eclipse durations, and lunar landing windows. The Lunar Browser tool is in the development phase and it is already producing results in its current form to address various NASA program requirements, proposals, and mission trajectories. The tool has also been used for research analysis in trajectory design, including a first publication regarding its application to the CLPS and Artemis programs. In particular, the results included transfers to lunar frozen orbits. Future work include the generation of more trajectories to expand the existing database and the optimization of the results.

Lunar Browser trajectory tool↗

Integration of Uncertainty Quantification in a Model-Based Systems Analysis and Engineering Framework

This paper presents a technical approach to improve the confidence in the systems analysis process by integrating Uncertainty Quantification (UQ) techniques within a Model-Based Systems Analysis and Engineering (MBSA&E) framework. The MBSA&E architecture uses system models and multidisciplinary analytical solutions as central artifacts for system design and analysis. The integration of UQ enables engineers to assess and mitigate uncertainties associated with a system model, design parameters, and constraint inputs, leading to more complete design studies and further informed decision-making processes. The proposed approach leverages the strengths of MBSA&E and extends it with a UQ methodology to quantify uncertainties in the input parameters and to trace the uncertainties as they propagate throughout the system model. To demonstrate the effectiveness of an integrated MBSA&E-UQ approach, a case study involving a simplified analysis of a Transonic Truss-Braced Wing (TTBW) concept vehicle is performed. This integration enables a more comprehensive evaluation of system performance and behavior under uncertainty and a more robust approach for system design and analysis. Lastly, the paper addresses the challenges and considerations associated with integrating UQ into an MBSA&E framework.

systems analysis↗

Integration of Uncertainty Quantification in a Model-Based Systems Analysis and Engineering Framework

This paper presents a technical approach to improve the confidence in the systems analysis process by integrating Uncertainty Quantification (UQ) techniques within a Model-Based Systems Analysis and Engineering (MBSA&E) framework. The MBSA&E architecture uses system models and multidisciplinary analytical solutions as central artifacts for system design and analysis. The integration of UQ enables engineers to assess and mitigate uncertainties associated with a system model, design parameters, and constraint inputs, leading to more complete design studies and further informed decision-making processes. The proposed approach leverages the strengths of MBSA&E and extends it with a UQ methodology to quantify uncertainties in the input parameters and to trace the uncertainties as they propagate throughout the system model. To demonstrate the effectiveness of an integrated MBSA&E-UQ approach, a case study involving a simplified analysis of a Transonic Truss-Braced Wing (TTBW) concept vehicle is performed. This integration enables a more comprehensive evaluation of system performance and behavior under uncertainty and a more robust approach for system design and analysis. Lastly, the paper addresses the challenges and considerations associated with integrating UQ into an MBSA&E framework.

systems analysis↗

Building Enhanced Resilience into Aviation

The aviation sector is a very complex but generally successful enterprise within the United States. Unfortunately, over multiple decades a series of demonstrable major aviation disruptions have occurred, for a wide-ranging set of reasons. Thus, it is more than timely to consider how to enhance the resilience of the aviation sector. This will entail developing research projects that promote system-of-systems engineering solutions that focus on both vehicle design advances and novel airspace system architectures. Several such potential research initiatives are outlined in this paper.

Aviation↗

Design and Contruction of a Longitudinally Polarized Solid Nuclear Target for CLAS12

A new polarized nuclear target has been developed, constructed, and deployed at Jefferson Laboratory in Newport News, VA for use with the upgraded 12 GeV CEBAF (Continuous Electron Beam Accelerator Facility) accelerator and the Hall B CLAS12 (12 GeV CEBAF Large Acceptance Spectrometer) detector array. This ?APOLLO? (Ammonia PO-Larized LOngitudinally) target is a longitudinally polarized, solid ammonia, nuclear target which employs DNP (Dynamic Nuclear Polarization) to induce a net polarization in samples of protons (NH3) and deuterons (ND3) cooled to 1 K via helium evaporation, held in a 5 T polarizing field supplied by the CLAS12 spectrometer, and irradiated with 140 GHz microwave radiation. It was utilized in the RGC (Run Group C) experiment suite through a collaboration of the JLab Target Group, Old Dominion University, Christopher Newport University, the University of Virginia, and the CLAS Collaboration. RGC comprised six experiments which measured multiple spin-dependent observables across a wide kinematic phase space for use in nucleon spin studies. The dimensional constraints necessary for the incorporation of APOLLO into CLAS12, as well as the considerations necessary to utilize the CLAS12 solenoid, introduced unique challenges to the target design. This document presents the innovative solutions developed for these challenges including a novel material transport system, superconducting magnetic correction coils, and an all new bespoke NMR (Nuclear Magnetic Resonance) system. In addition to a detailed description of the complete target system and an initial report of the RGC experimental run, it will also present a study of Quark-Hadron Duality in the g1 spin structure function based on Hall B EG1b data and pQCD fits from the JAM (Jefferson Lab Angular Momentum) Collaboration.

Lagerquist, Victoria Lagerquist↗

Rural Hybrid Generation & Microgrids: National Labs are Here to Help

Hear about the tools and technical assistance National Labs can offer to co-ops and other rural utilities seeking to build or enhance hybrid generation projects combining multiple technologies including wind, solar, battery storage, and others resources. These hybrids can deliver additional value by combining complimentary resources and by increasing reliability and resilience, including as part of a microgrid to serve a local load or community. Experienced cooperative and lab experts will share their perspectives on the opportunities there are to make use of their advanced modeling capabilities and expertise to scope, design, and implement these emerging hybrid solutions. Key takeaways for participants will include better understanding of the resilience benefits distributed hybrid systems provide, awareness of National Laboratory assistance programs and resources, tips for successful federal funding applications for these types of projects, and peer-to-peer learning through shared experiences and discussion.

14 SOLAR ENERGY↗

Development of creep resistant ferritic-martensitic steels for operation at 650°C

Creep resistant ferritic-martensitic steels capable of operating at 650°C have long been under development for electricity generation. This presentation will showcase the design and development of alloys CPJ-7 and JMP with approximately 420,000 h of in-house creep testing, the equivalent of ~50 years of cumulative creep tests. Approximately fifty different alloy compositions were manufactured as part of an ICME approach. CPJ-7 present superior creep properties compared to COST alloys for steam turbine and P91/92 for boiler applications. The prolonged creep life was attributed to slowing down the destabilization of fine precipitates at 650°C. The JMP steels were designed with higher Co for solid solution strengthening and increased W for matrix strength and stability. The creep life compared to CPJ-7 increased between 118 and 150% at 650°C depending on the stress. On a Larson-Miller plot, the performance of the JMP steels surpasses that of MARBN steel. Composition-microstructure-properties relationships will be discussed.

Detrois, Martin↗

Smart Inverters, Dumb Risk: Taking Control of IBR Security in the Digital Age

This presentation addresses the security challenges posed by Inverter-Based Resources (IBRs) in the modern energy landscape. The presentation highlights the vulnerabilities and risks associated with IBRs, including the potential for cyber-attacks, the impact of insecure defaults, and the systemic risks posed by supply chain dependencies. Key topics covered include: 1) The increasing digital transformation in energy systems and the associated security risks. 2) Specific vulnerabilities in IBRs, including weak passwords, hardcoded credentials, and insecure web application interfaces. 3) The implications of persistent connectivity and the strategic risks posed by foreign-manufactured components. 4) The role of regulatory frameworks, such as NERC CIP, in addressing these challenges and the limitations of current oversight. 5) Practical solutions for mitigating risks, including secure design practices, vendor risk assessments, and the importance of strong passwords and role-based access control. The presentation underscores the necessity of a comprehensive, system-of-systems approach to securing IBRs, emphasizing the need for collaboration across various stakeholders, including operators, developers, and regulators, to ensure the resilience and security of the energy grid.

24 - POWER TRANSMISSION AND DISTRIBUTION↗

Effect of Nuclear Data Covariances on Integral Experiment Design with Sensitivity and Uncertainty Analysis

Washington River Protection Solutions (WRPS) uses MCNP6.2 and the Whisper code for criticality safety analyses of the Hanford Tank Farm. Together the codes derive baseline upper subcritical limits (USLs) for the waste models using experimental benchmarks. Whisper returns higher USLs, i.e. , has less of a conservative penalty, when the neutronic similarity of the experimental benchmarks to the application is high. Unfortunately, few critical benchmarks have high similarity to the Hanford tanks. The waste in the tanks is highly dilute in plutonium and contains large masses of weakly neutron-absorbing elements like iron and manganese. Experimental benchmarks typically have low sensitivity to these absorbers because they are present as structural materials. Lacking similar benchmarks, new Thermal Epithermal eXperiment (TEX) configurations with high Pu content and interstitial iron absorbers have been designed for the criticality safety validation. The features of the design have been iterated upon to maximize the similarity between the experiment and different Hanford waste models. The similarity is quantified with sensitivity analysis and uncertainty quantification using the representativity coefficient, or c k . The representativity calculation requires nuclear data covariances, which may differ between nuclear data libraries and between library versions. Because of these variations, the optimal design may depend on the nuclear data covariances library. A scenario can be envisioned where an experiment is designed, and c k is maximized, with one set of covariance data. However, when the covariance data is changed, say from ENDF/B-VII.1 to ENDF/B-VIII.0, and the benchmark is used in a criticality safety evaluation, the experiment becomes suboptimal with respect to c k . In this paper, we present how the optimal design of the new TEX experiments varied depending on the nuclear data covariances used to calculate c k . We compare ENDF/B-VII.1 and ENDF/B-VIII.0, as if the library had been updated since the design of the experiment. Additionally, we use JEFF3.3 to simulate if the covariance data of a different library had been used. The results show that the covariances do have an important effect on the designs, less so for thermal systems (where the data are more consistent between evaluations) and more so for epithermal systems where more differences exist.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Current research on shear buckling and thermal loads with PASCO: Panel Analysis and Sizing Code

The PASCO computer program to obtain the detailed dimensions of optimum stiffened composite structural panels is described. Design requirements in terms of inequality constraints can be placed on buckling loads or vibration frequencies, lamina stresses and strains, and overall panel stiffness for each of many load conditions. General panel cross sections can be treated. An analysis procedure involving a smeared orthotropic solution was investigated. The conservatism in the VIPASA solution and the danger in a smeared orthotropic solution is explored. PASCO's capability to design for thermal loadings is also described. It is emphasized that design studies illustrate the importance of the multiple load condition capability when thermal loads are present.

Stroud, W. J.↗