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DOE OSTI2023

GRAPHITE–MOLTEN SALT CONSIDERATIONS FOR COMPONENTS IN NUCLEAR APPLICATIONS

The new High Temperature Reactor (HTR) designs being considered for future Gen IV nuclear reactor deployment include designs utilizing molten salt as the primary coolant. These molten-salt cooled, graphite core designs pose new material compatibility challenges that are not considered within the gas-cooled HTR designs that have been previously built and operated. While the Molten Salt Reactor Experiment (MSRE) demonstrated that the molten salt can be considered chemically inert to graphite the novel physical and thermal interactions that the molten salt poses may be just as impactful as the chemical reactivity. Specifically, molten salt intrusion into the open pore structure of nuclear graphite grades can provide additional internal stresses within the microstructure exacerbating the stress buildup from irradiation induced dimensional change. Additionally, designs using a molten salt containing liquid fuel could provide “hot spots” within graphite structural components causing local thermal stresses. Abrasion and erosion concerns are magnified with molten salt due to the extremely high density of the salts (some have higher densities than the structural graphite components). Finally, the graphite-graphite and fuel pebble-graphite tribological behavior are distinctly difference within the molten salt from the inert gas environments and must be investigated. These topics and others are currently under investigation within the DOE Advanced Reactor Technologies (ART) graphite program and will be discussed in depth.

Gallego, Nidia↗

NASA NTRS2000

Variable Emissivity Through MEMS Technology

This paper discusses a new technology for variable emissivity (vari-e) radiator surfaces, which has significant advantages over traditional radiators and promises an alternative design technique for future spacecraft thermal control systems. All spacecraft rely on radiative surfaces to dissipate waste heat. These radiators have special coatings, typically with a low solar absorptivity and a high infrared-red emissivity, that are intended to optimize performance under the expected heat load and thermal sink environment. The dynamics of the heat loads and thermal environment make it a challenge to properly size the radiator and often require some means of regulating the heat rejection rate of the radiators in order to achieve proper thermal balance. Specialized thermal control coatings, which can passively or actively adjust their emissivity offer an attractive solution to these design challenges. Such systems would allow intelligent control of the rate of heat loss from a radiator in response to heat load and thermal environmental variations. Intelligent thermal control through variable emissivity systems is well suited for nano and pico spacecraft applications where large thermal fluctuations are expected due to the small thermal mass and limited electric resources. Presently there are three different types of vari-e technologies under development: Micro ElectroMechanical Systems (MEMS) louvers, Electrochromic devices, and Electrophoretic devices. This paper will describe several prototypes of micromachined (MEMS) louvers and experimental results for the emissivity variations measured on theses prototypes. It will further discuss possible actuation mechanisms and space reliability aspects for different designs. Finally, for comparison parametric evaluations of the thermal performances of the new vari-e technology and standard thermal control systems are presented in this paper.

Darrin, Ann Garrison↗

DOE OSTI2025

Scenario Generation for Built Environment Decision Support under Uncertainty: Case Studies of Airflow Modeling and Climate-Resilient Infrastructure System Design

When confronted with unforeseen challenges, practicing informed decision making is crucial for enhancing resilience in the built environment. While scan-to-building information modeling (BIM) is a well-established approach for creating detailed digital representations of physical assets, its application in assessing and improving infrastructure resilience remains underexplored. This study addresses this gap by proposing a novel application of scan-to-BIM, namely, scan-to-BIM-to-digital twin (S-BIM-DT) workflow. By integrating reality capture and digital twin technologies, this workflow creates continuously updated and accurate digital representations of physical assets, enabling the generation of various scenarios. Unlike traditional methods, the S BIM-DT workflow facilitates continuous model refinement, supporting informed resilience strategies. By combining these technologies into a cohesive process, the workflow facilitates decision making under uncertainty, enabling stakeholders to evaluate and respond to various scenarios effectively. We demonstrate the implementation of the S-BIM-DT workflow through two use cases that highlight its capability to enhance resilience at different scales. The first use case involves the Combined Transportation, Emergency, and Communications Center (CTECC) in Austin, Texas. BIM-enriched computational fluid dynamics (CFD) modeling simulates airflow and develops alternative scenarios for optimizing the heating, ventilation, and air conditioning (HVAC) systems. This approach enhances resilience against airborne health threats in a postCOVID context. The second use case focuses on designated areas within Beaumont, Texas, as part of the Southeast Texas Urban Integrated Field Laboratory (SETx-UIFL) research. By developing inundation maps to assess extreme weather events, this modeling aids in preparedness efforts and informs the development of climate-resilient infrastructure in vulnerable neighborhoods. Results indicate that the S-BIM-DT workflow effectively generates scenarios that enhance resilience in the built environment by facilitating informed decision making. Furthermore, this study serves as a bridge between advanced scan-to-BIM methodologies and the practical strategies needed to improve built infrastructure resilience.

Built environment↗

NASA NTRS2011

Autonomous rover traverse and precise arm placement on remotely designated targets

Exploring planetary surfaces typically involves traversing challenging and unknown terrain and acquiring insitu measurements at designated locations using arm-mounted instruments. We present field results for a new implementation of an autonomous capability that enables a rover to traverse and precisely place an arm-mounted instrument on remote targets. Using point-and-click mouse commands, a scientist designates targets in the initial imagery acquired from the rover’s mast cameras. The rover then autonomously traverses the rocky terrain for a distance of 10 – 15 m, tracks the target(s) of interest during the traverse, positions itself for approaching the target, and then precisely places an arm-mounted instrument within 2-3 cm from the originally designated target. The rover proceeds to acquire science measurements with the instrument. This work advances what has been previously developed and integrated on the Mars Exploration Rovers by using algorithms that are capable of traversing more rock-dense terrains, enabling tight thread-the-needle maneuvers. We integrated these algorithms on the newly refurbished Athena Mars research rover and fielded them in the JPL Mars Yard. We conducted 43 runs with targets at distances ranging from 5 m to 15 m and achieved a success rate of 93% for placement of the instrument within 2-3 cm.

Volpe, Richard↗

DOE OSTI2022

Initial Design and Experimental Results of a Novel Near-Isothermal Compressor for Heat Pump Applications

In efforts to increase the efficiency of residential and commercial air conditioners and heat pumps, it is found that the compressor has the highest electrical energy usage of the system. Therefore, it is appropriate to try to increase the efficiency of this component to reduce its energy usage. Another challenge with heat pump design is that some compressor types have drawbacks that make modulation difficult. To answer these challenges, we are developing an isothermal liquid compressor. The compressor uses propylene glycol to compress carbon dioxide. In the compression chamber the propylene glycol can enter either from the bottom to create a liquid piston for compression or it can enter through a spray nozzle at the top of the chamber. In the latter case, heat transfer from the gas to be compressed to the liquid droplets is high. This allows near isothermal operation of the compressor, which increases the efficiency by 17% to 30%, compared to adiabatic compression. In addition, the isothermal liquid compressor enables very efficient and simple part load modulation.Experimental results demonstrating the operation of the liquid compressor are presented. Initial data demonstrated a temperature rise of 7 K at pressure ratios of almost 4. For comparison at the same initial pressure, temperature, and pressure ratio, adiabatic compression would result in a temperature increase of approximately 70 K. Plotting data on a P-h diagram demonstrates that the compression started at superheated state and ended in supercritical state. Testing was later performed with repeated compressions in the superheated region of the P-h diagram at liquid flow rates of 2 x 10-3 m3/min and 2 x 10-3 m3/min to understand the limitations of the prototype for use with an actual heat pump system. This work demonstrated a novel cycle on a T-s diagram. Results from this work will be used to develop a second-generation prototype where more rapid cycling is possible.

Kowalski, Steve↗

NASA NTRS2012

The Design of Large-Scale Complex Engineered Systems: Present Challenges and Future Promise

Model-Based Systems Engineering techniques are used in the SE community to address the need for managing the development of complex systems. A key feature of the MBSE approach is the use of a model to capture the requirements, architecture, behavior, operating environment and other key aspects of the system. The focus on the model differentiates MBSE from traditional SE techniques that may have a document centric approach. In an effort to assess the benefit of utilizing MBSE on its flight projects, NASA Langley has implemented a pilot program to apply MBSE techniques during the early phase of the Materials International Space Station Experiment-X (MISSE-X). MISSE-X is a Technology Demonstration Mission being developed by the NASA Office of the Chief Technologist i . Designed to be installed on the exterior of the International Space Station (ISS), MISSE-X will host experiments that advance the technology readiness of materials and devices needed for future space exploration. As a follow-on to the highly successful series of previous MISSE experiments on ISS, MISSE-X benefits from a significant interest by the

Bloebaum, Christina L.↗

DOE OSTI2023

An AI-driven microstructure optimization framework for elastic properties of titanium beyond cubic crystal systems

Materials design aims to identify the material features that provide optimal properties for various engineering applications, such as aerospace, automotive, and naval. One of the important but challenging problems for materials design is to discover multiple polycrystalline microstructures with optimal properties. This paper proposes an end-to-end artificial intelligence (AI)-driven microstructure optimization framework for elastic properties of materials. In this work, the microstructure is represented by the Orientation Distribution Function (ODF) that determines the volume densities of crystallographic orientations. The framework was evaluated on two crystal systems, cubic and hexagonal, for Titanium (Ti) in Joint Automated Repository for Various Integrated Simulations (JARVIS) database and is expected to be widely applicable for materials with multiple crystal systems. The proposed framework can discover multiple polycrystalline microstructures without compromising the optimal property values and saving significant computational time.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Three-dimensional structure-guided evolution of a ribosome with tethered subunits

We report RNA-based macromolecular machines, such as the ribosome, have functional parts reliant on structural interactions spanning sequence-distant regions. These features limit evolutionary exploration of mutant libraries and confound three-dimensional structure-guided design. To address these challenges, we describe Evolink (evolution and linkage), a method that enables high-throughput evolution of sequence-distant regions in large macromolecular machines, and library design guided by computational RNA modeling to enable exploration of structurally stable designs. Using Evolink, we evolved a tethered ribosome with a 58% increased activity in orthogonal protein translation and a 97% improvement in doubling times in SQ171 cells compared to a previously developed tethered ribosome, and reveal new permissible sequences in a pair of ribosomal helices with previously explored biological function. The Evolink approach may enable enhanced engineering of macromolecular machines for new and improved functions for synthetic biology.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

On-the-fly data set combinations with RNTuple

With the expected data volume increase for HL-LHC and the even more complex computing challenges set by future colliders, the need for efficient data storage and processing becomes more pressing. ROOT’s next-generation data format and I/O subsystem, RNTTuple, is designed to address these challenges. RNTTuple already demonstrates a clear improvement in storage and I/O efficiency, as well as overall stability and robustness with respect to its predecessor, TTTree. These improvements provide a solid baseline to introduce novel extensions to common high-energy and nuclear physics (HENP) workflows. Notably, many workflows could benefit from the ability to arbitrarily join and chain data set samples at runtime, which could reduce overall storage requirements and improve application runtime and ergonomics. In this paper, we present the RNTupleProcessor, which enables HENP data set combinations with RNTuple. We will discuss the main design considerations, present the interfaces to support data set combinations and show how they integrate in typical workflows.

de Geus, Florine Willemijn [CERN; Twente U., Ensch↗

NASA NTRS1999

Viscoplastic Constitutive Theory Demonstrated for Monolithic Ceramic Materials

Development of accurate three-dimensional (multiaxial) inelastic stress-strain models is critical in utilizing advanced ceramics for challenging 21st century high-temperature structural applications. The current state of the art uses elastic stress fields as a basis for both subcritical crack growth and creep life prediction efforts aimed at predicting the time dependent reliability response of ceramic components subjected to elevated service temperatures. However, to successfully design components that will meet tomorrow's challenging requirements, design engineers must recognize that elastic predictions are inaccurate for these materials when subjected to high-temperature service conditions such as those encountered in advanced heat engine components. Analytical life prediction methodologies developed for advanced ceramics and other brittle materials must employ accurate constitutive models that capture the inelastic response exhibited by these materials at elevated service temperatures. A constitutive model recently developed at the NASA Lewis Research Center helps address this issue by accounting for the time-dependent (inelastic) material deformation phenomena (e.g., creep, rate sensitivity, and stress relaxation) exhibited by monolithic ceramics exposed to high-temperature service conditions. In addition, the proposed formulation is based on a threshold function that is sensitive to hydrostatic stress and allows different behavior in tension and compression, reflecting experimental observations obtained for these material systems.

Janosik, Lesley A.↗

NASA NTRS2016

Design Lessons Learned from Temperature Management of Galileo's Retro-Propulsion Module

Launched in 1989, the Galileo mission added dramatically to our understanding of the Jovian system and our entire solar system1. To make best use of limited resources, the Galileo Orbiter used excess power from its Radioisotope Thermoelectric Generators (RTGs) for temperature management of its Retro-Propulsion Module (RPM). This paper describes operational challenges introduced by this design and how, despite major mission changes through development and flight, they were overcome through a challenging six-year interplanetary cruise to Jupiter. This case study offers lessons for missions planning to couple critical spacecraft subsystems in unconventional ways.

Gounley, Robert↗

DOE OSTI2020

Tucker-1 Boolean Tensor Factorization with Quantum Annealers

Quantum annealers are an emerging computational architecture that have the potential to address some challenging computational issues that will be left unresolved as we approach the end of the Moore's Law era of computing. D-Wave quantum annealers are designed to solve a challenging set of problems - quadratic unconstrained binary optimization problems. This makes them a natural fit for solving problems with binary or Boolean variables. Here, we explore the use of a quantum annealer to solve Boolean tensor factorization. The goal of Boolean tensor factorization is to represent a high-dimensional tensor filled with Boolean values as a product of Boolean matrices and a Boolean core tensor. We show that a particular Boolean tensor factorization problem (called Tucker-1 factorization) can be decomposed into a sequence of quadratic unconstrained binary optimization problems that can be solved with a D-Wave 2000Q quantum annealer. While quantum annealers specifically and quantum computers in general are at a fairly early stage in their development, they are currently capable of solving these Boolean tensor factorization problems. Importantly, our results show that for fairly small tensors, we are frequently able to obtain an accurate (sometimes exact) factorization using quantum annealing.

97 MATHEMATICS AND COMPUTING↗

NASA NTRSDate not supplied

A Distributed Simulation-to-Flight Framework to Support Investigating Trust/Trustworthiness in Multi-Agent Systems

As autonomous systems continue to grow both in use and complexity, the necessity for robust and extensible simulation-to-flight frameworks is paramount for establishing an effective architecture for autonomous systems. Hardware test flights are time-consuming and cost prohibitive during early system design and development. Simulation environments can be useful tools to accelerate algorithm development and testing. However, transitions from simulation to flight (sim-to-flight) can be challenging, unless systems are designed with this transition in mind and with the necessary capabilities built into the architecture and framework. One of the objectives of Autonomy Teaming and TRAjectories for Complex Trusted Operational Reliability (ATTRACTOR) was to design and develop a distributed mixed-reality simulation environment to begin establishing a basis for certification of autonomous systems via research into trust and trustworthiness. ATTRACTOR’s objective was to construct computational concepts of trustworthiness and justifiable trust in multi-agent autonomous teams, to inform future certification of safety-critical and time-critical autonomous systems in aviation. In this paper, we present an autonomous systems architecture and development framework paired with a persistent distributed modeling and simulation (ModSim) environment for test and evaluation of autonomous systems. They were designed under ATTRACTOR in order to measure and establish trustworthiness and trust in single-and multi-agent human-machine systems whether these machines are fixed-wing general aviation, rotary-wing Unmanned Aerial Vehicles (UAVs), ground rovers, or even spacecraft. The Autonomous Entity Operational Network (AEON) framework enables autonomous system development with an easily extensible collection of libraries and plug-n-play nodes facilitated by the Data Distribution Service (DDS) communication protocol standard. The Baseline Environment for Autonomous Modeling (BEAM) simulation environment is a distributed mixed-reality Unity™-based environment built around the same DDS communication paradigm allowing for easy integration with AEON-based autonomous applications, enabling sim-to-flight with minimal configuration changes. Using AEON and BEAM, source code that runs in simulation ports directly to hardware and has successfully flown in the National Airspace System (NAS) at NASA LaRC many times over the lifetime of ATTRACTOR.

Benjamin N Kelley↗

NASA NTRSDate not supplied

The Influence of Material Characterization on Thermal Loads Development and Flight Vehicle Design

The thermal management team faces a significant challenge to meet the aggressive thermal loading associated with hypersonic flight. Design strategies require the involvement of many engineering disciplines, as each must design their respective subsystem and then interface with all remaining subsystems to successfully close the vehicle design space. High fidelity thermal solid models will capture the variation in material properties and the effects of chemical reactions associated with hypersonic flight. Selection of the best materials for the mission will be based upon computational fluid dynamics and thermal modeling results. To enhance the probability for success, it is recommended that frequent communication occur between the thermal modeler and the materials scientist regarding design strategies and modeling assumptions. Early in the design process, lower fidelity modeling will be used to narrow the trade space. As promising designs are found, greater fidelity in the modeling process will be required to address more of the flowfield challenges and the material performance under the prescribed flight profile. The end goal is to select the most technically sound and physically advantageous material for the mission while avoiding overdesigning the vehicle due to modeling or material uncertainties. This presentation seeks to give an overview of the key thermal parameters that are affected through materials engineering, the interactions between a thermal engineer and other disciplines, and an example of the thermal design process, the X-43.

hypersonic↗

NASA NTRS1991

Lessons learned for composite structures

Lessons learned for composite structures are presented in three technology areas: materials, manufacturing, and design. In addition, future challenges for composite structures are presented. Composite materials have long gestation periods from the developmental stage to fully matured production status. Many examples exist of unsuccessful attempts to accelerate this gestation period. Experience has shown that technology transition of a new material system to fully matured production status is time consuming, involves risk, is expensive and should not be undertaken lightly. The future challenges for composite materials require an intensification of the science based approach to material development, extension of the vendor/customer interaction process to include all engineering disciplines of the end user, reduced material costs because they are a significant factor in overall part cost, and improved batch-to-batch pre-preg physical property control. Historical manufacturing lessons learned are presented using current in-service production structure as examples. Most producibility problems for these structures can be traced to their sequential engineering design. This caused an excessive emphasis on design-to-weight and schedule at the expense of design-to-cost. This resulted in expensive performance originated designs, which required costly tooling and led to non-producible parts. Historically these problems have been allowed to persist throughout the production run. The current/future approach for the production of affordable composite structures mandates concurrent engineering design where equal emphasis is placed on product and process design. Design for simplified assembly is also emphasized, since assembly costs account for a major portion of total airframe costs. The future challenge for composite manufacturing is, therefore, to utilize concurrent engineering in conjunction with automated manufacturing techniques to build affordable composite structures. Composite design experience has shown that significant weight savings have been achieved, outstanding fatigue and corrosion resistance have been demonstrated, and in-service performance has been very successful. Currently no structural design show stoppers exist for composite structures. A major lesson learned is that the full scale static test is the key test for composites, since it is the primary structural 'hot spot' indicator. The major durability issue is supportability of thin skinned structure. Impact damage has been identified as the most significant issue for the damage tolerance control of composite structures. However, delaminations induced during assembly operations have demonstrated a significant nuisance value. The future challenges for composite structures are threefold. Firstly, composite airframe weight fraction should increase to 60 percent. At the same time, the cost of composite structures must be reduced by 50 percent to attain the goal of affordability. To support these challenges it is essential to develop lower cost materials and processes.

Whitehead, R. S.↗

NASA NTRS1999

National Aeronautics and Space Administration (NASA)/American Society for Engineering Education (ASEE) Summer Faculty Fellowship Program, 1998

The continuous increase in complexity of electronic systems is making the design and manufacturing of such systems more challenging than ever before. As a result, designers are finding it impossible to design efficient systems without the use of sophisticated Electronic Design Automation (EDA) tools. These tools offer integrated simulation of the electrical, mechanical, and manufacturing functions and lead to a correct by design methodology. This report identifies the EDA tools that would be needed to design, analyze, simulate, and evaluate electronic systems for spacecraft vehicles. In addition, the report presents recommendations to enhance the current JSC electronic design capabilities. This includes cost information and a discussion as to the impact, both positive and negative, of implementing the recommendations.

Richard B Bannero↗

NASA NTRS1999

Electronic Systems for Spacecraft Vehicles: Required EDA Tools

Bachnak, Rafic↗

NASA NTRS2005

Learning from Failures: Archiving and Designing with Failure and Risk

Identifying and mitigating risks during conceptual design remains an ongoing challenge. This work presents the results of collaborative efforts between The University of Missouri-Rolla and NASA Ames Research Center to examine how an early stage mission design team at NASA addresses risk, and, how a computational support tool can assist these designers in their tasks. Results of our observations are given in addition to a brief example of our implementation of a repository based computational tool that allows users to browse and search through archived failure and risk data as related to either physical artifacts or functionality.

VanWie, Michael↗