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DOE OSTI2014

LCCP Desktop Application v1.0 Engineering Reference

This Life Cycle Climate Performance (LCCP) Desktop Application Engineering Reference is divided into three parts. The first part of the guide, consisting of the LCCP objective, literature review, and mathematical background, is presented in Sections 2-4. The second part of the guide (given in Sections 5-10) provides a description of the input data required by the LCCP desktop application, including each of the input pages (Application Information, Load Information, and Simulation Information) and details for interfacing the LCCP Desktop Application with the VapCyc and EnergyPlus simulation programs. The third part of the guide (given in Section 11) describes the various interfaces of the LCCP code.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2014

New-Generation Thermal Neutron Detectors and Electronics for High-Count-Rate Applications

Neutron measurements are important in many nonproliferation and treaty verification applications. Helium-3 proportional counters and analog electronics are the backbone of neutron detection systems. Helium-3 tubes with a 1-in. diameter have been used with classical electronics for over three decades because of the almost ideal behavior of the 3 He tube as a neutron detector. However, some demanding applications of 3 He tubes (high gamma dose rate, high count rate) and the use of non-ideal detectors (such as 10 B-lined proportional counters) mean that the limitations of these conventional systems are being reached. For example, neutron multiplicity deadtime corrections can be large, and some applications have had trouble with multiple pulsing. Also, instrumentation designs for spent fuel applications often rely on large amounts of lead shielding to reduce the gamma dose at the detector location, making them heavy and expensive. This major challenge for a short dead time and operation in high gamma fields is difficult to address by simply changing the gas admixture and tweaking the shaper time constants. Those small gains are adequate for measurements of some lower-burn-up, low-enrichment-uranium spent fuel assemblies, but not for mixed oxide (MOX) fuel or advanced fast reactor fuel, where the neutron source term is greater.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2014

An Investigation of the Applicability and Limitations of the ORNL Expanded Plug Test

The expanded plug test technique for measuring the circumferential tensile properties of irradiated nuclear fuel cladding was developed at Oak Ridge National Laboratory (ORNL) and has been used successfully in several applications. The primary advantage of this technique over other procedures is its simplicity for application in the complex hot cell environment. During the development stage, efforts were made to both qualify the technique as much as possible regarding its experimental application and to develop and validate the data reduction procedures. However, since this is a new technique, the technical community is cautious in adopting a procedure that has not been fully vetted. The purpose of this effort was to address several baseline issues regarding the applicability of the technique and the precision of the use of experimental expanded ring load-deformation data to calculate material circumferential stress-strain properties. The tests performed, in conjunction with the developed data reduction procedures, demonstrate good reliability in the prediction of ring material stress-strain behavior for several materials of widely different strengths.

tensile, nuclear fuel cladding↗

DOE OSTI2014

Using architecture information and real-time resource state to reduce power consumption and communication costs in parallel applications.

As computer systems grow in both size and complexity, the need for applications and run-time systems to adjust to their dynamic environment also grows. The goal of the RAAMP LDRD was to combine static architecture information and real-time system state with algorithms to conserve power, reduce communication costs, and avoid network contention. We devel- oped new data collection and aggregation tools to extract static hardware information (e.g., node/core hierarchy, network routing) as well as real-time performance data (e.g., CPU uti- lization, power consumption, memory bandwidth saturation, percentage of used bandwidth, number of network stalls). We created application interfaces that allowed this data to be used easily by algorithms. Finally, we demonstrated the benefit of integrating system and application information for two use cases. The first used real-time power consumption and memory bandwidth saturation data to throttle concurrency to save power without increasing application execution time. The second used static or real-time network traffic information to reduce or avoid network congestion by remapping MPI tasks to allocated processors. Results from our work are summarized in this report; more details are available in our publications [2, 6, 14, 16, 22, 29, 38, 44, 51, 54].

Brandt, James M.↗

DOE OSTI2014

Recovery Act: Oxy-Combustion Technology Development for Industrial-Scale Boiler Applications. Task 4 - Testing in Alstom's 15 MW th Boiler Simulation Facility

Alstom Power Inc. (Alstom), under U.S. DOE/NETL Cooperative Agreement No. DE-NT0005290, is conducting a development program to generate detailed technical information needed for application of oxy-combustion technology. The program is designed to provide the necessary information and understanding for the next step of large-scale commercial demonstration of oxy combustion in tangentially fired boilers and to accelerate the commercialization of this technology. The main project objectives include: Design and develop an innovative oxyfuel system for existing tangentially-fired boiler units that minimizes overall capital investment and operating costs; Evaluate performance of oxyfuel tangentially fired boiler systems in pilot scale tests at Alstom’s 15 MWth tangentially fired Boiler Simulation Facility (BSF); Address technical gaps for the design of oxyfuel commercial utility boilers by focused testing and improvement of engineering and simulation tools; Develop the design, performance and costs for a demonstration scale oxyfuel boiler and auxiliary systems; Develop the design and costs for both industrial and utility commercial scale reference oxyfuel boilers and auxiliary systems that are optimized for overall plant performance and cost; and, Define key design considerations and develop general guidelines for application of results to utility and different industrial applications. The project was initiated in October 2008 and the scope extended in 2010 under an ARRA award. The project is scheduled for completion by April 30, 2014. Central to the project is 15 MWth testing in the BSF, which provided in-depth understanding of oxy-combustion under boiler conditions, detailed data for improvement of design tools, and key information for application to commercial scale oxy-fired boiler design. Eight comprehensive 15 MWth oxy-fired test campaigns were performed with different coals, providing detailed data on combustion, emissions, and thermal behavior over a matrix of fuels, oxy-process variables and boiler design parameters. Significant improvement of CFD modeling tools and validation against 15 MWth experimental data has been completed. Oxy-boiler demonstration and large reference designs have been developed, supported with the information and knowledge gained from the 15 MWth testing. This report addresses the results from the 15 MWth testing in the BSF.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2014

Recovery Act: Oxy-Combustion Technology Development for Industrial-Scale Boiler Applications

Alstom Power Inc. (Alstom), under U.S. DOE/NETL Cooperative Agreement No. DE-NT0005290, is conducting a development program to generate detailed technical information needed for application of oxy-combustion technology. The program is designed to provide the necessary information and understanding for the next step of large-scale commercial demonstration of oxy combustion in tangentially fired boilers and to accelerate the commercialization of this technology. The main project objectives include: • Design and develop an innovative oxyfuel system for existing tangentially-fired boiler units that minimizes overall capital investment and operating costs. • Evaluate performance of oxyfuel tangentially fired boiler systems in pilot scale tests at Alstom’s 15 MWth tangentially fired Boiler Simulation Facility (BSF). • Address technical gaps for the design of oxyfuel commercial utility boilers by focused testing and improvement of engineering and simulation tools. • Develop the design, performance and costs for a demonstration scale oxyfuel boiler and auxiliary systems. • Develop the design and costs for both industrial and utility commercial scale reference oxyfuel boilers and auxiliary systems that are optimized for overall plant performance and cost. • Define key design considerations and develop general guidelines for application of results to utility and different industrial applications. The project was initiated in October 2008 and the scope extended in 2010 under an ARRA award. The project completion date was April 30, 2014. Central to the project is 15 MWth testing in the BSF, which provided in-depth understanding of oxy-combustion under boiler conditions, detailed data for improvement of design tools, and key information for application to commercial scale oxy-fired boiler design. Eight comprehensive 15 MWth oxy-fired test campaigns were performed with different coals, providing detailed data on combustion, emissions, and thermal behavior over a matrix of fuels, oxyprocess variables and boiler design parameters. Significant improvement of CFD modeling tools and validation against 15 MWth experimental data has been completed. Oxy-boiler demonstration and large reference designs have been developed, supported with the information and knowledge gained from the 15 MWth testing. The results from the 15 MWth testing in the BSF and complimentary bench-scale testing are addressed in this volume (Volume II) of the final report. The results of the modeling efforts (Volume III) and the oxy boiler design efforts (Volume IV) are reported in separate volumes.

42 ENGINEERING↗

DOE OSTI2013

Large-Scale Uncertainty and Error Analysis for Time-dependent Fluid/Structure Interactions in Wind Turbine Applications

The following is the final report covering the entire period of this aforementioned grant, June 1, 2011 - May 31, 2013 for the portion of the effort corresponding to Stanford University (SU). SU has partnered with Sandia National Laboratories (PI: Mike S. Eldred) and Purdue University (PI: Dongbin Xiu) to complete this research project and this final report includes those contributions made by the members of the team at Stanford. Dr. Eldred is continuing his contributions to this project under a no-cost extension and his contributions to the overall effort will be detailed at a later time (once his effort has concluded) on a separate project submitted by Sandia National Laboratories. At Stanford, the team is made up of Profs. Alonso, Iaccarino, and Duraisamy, post-doctoral researcher Vinod Lakshminarayan, and graduate student Santiago Padron. At Sandia National Laboratories, the team includes Michael Eldred, Matt Barone, John Jakeman, and Stefan Domino, and at Purdue University, we have Prof. Dongbin Xiu as our main collaborator. The overall objective of this project was to develop a novel, comprehensive methodology for uncertainty quantification by combining stochastic expansions (nonintrusive polynomial chaos and stochastic collocation), the adjoint approach, and fusion with experimental data to account for aleatory and epistemic uncertainties from random variable, random field, and model form sources. The expected outcomes of this activity were detailed in the proposal and are repeated here to set the stage for the results that we have generated during the time period of execution of this project: 1. The rigorous determination of an error budget comprising numerical errors in physical space and statistical errors in stochastic space and its use for optimal allocation of resources; 2. A considerable increase in efficiency when performing uncertainty quantification with a large number of uncertain variables in complex non-linear multi-physics problems; 3. A solution to the long-time integration problem of spectral chaos approaches; 4. A rigorous methodology to account for aleatory and epistemic uncertainties, to emphasize the most important variables via dimension reduction and dimension-adaptive refinement, and to support fusion with experimental data using Bayesian inference; 5. The application of novel methodologies to time-dependent reliability studies in wind turbine applications including a number of efforts relating to the uncertainty quantification in vertical-axis wind turbine applications. In this report, we summarize all accomplishments in the project (during the time period specified) focusing on advances in UQ algorithms and deployment efforts to the wind turbine application area. Detailed publications in each of these areas have also been completed and are available from the respective conference proceedings and journals as detailed in a later section.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2014

Sight Application Analysis Tool

The scale and complexity of scientific applications makes it very difficult to optimize, debug and extend them to support new capabilities. We have developed a tool that supports developers’ efforts to understand the logical flow of their applications and interactions between application components and hardware in a way that scales with application complexity and parallelism.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2015

GaN Initiative for Grid Applications (GIGA)

For nearly 4 ½ years, MIT Lincoln Laboratory (MIT/LL) led a very successful, DoE-funded team effort to develop GaN-on-Si materials and devices, targeting high-voltage (>1 kV), high-power, cost-effective electronics for grid applications. This effort, called the GaN Initiative for Grid Applications (GIGA) program, was initially made up of MIT/LL, the MIT campus group of Prof. Tomas Palacios (MIT), and the industrial partner M/A Com Technology Solutions (MTS). Later in the program a 4th team member was added (IQE MA) to provide commercial-scale GaN-on-Si epitaxial materials. A basic premise of the GIGA program was that power electronics, for ubiquitous utilization -even for grid applications - should be closer in cost structure to more conventional Si-based power electronics. For a number of reasons, more established GaN-on-SiC or even SiC-based power electronics are not likely to reach theses cost structures, even in higher manufacturing volumes. An additional premise of the GIGA program was that the technical focus would be on materials and devices suitable for operating at voltages > 1 kV, even though there is also significant commercial interest in developing lower voltage (< 1 kV), cost effective GaN-on-Si devices for higher volume applications, like consumer products. Remarkable technical progress was made during the course of this program. Advances in materials included the growth of high-quality, crack-free epitaxial GaN layers on large-diameter Si substrates with thicknesses up to ~5 μm, overcoming significant challenges in lattice mismatch and thermal expansion differences between Si and GaN in the actual epitaxial growth process. Such thick epilayers are crucial for high voltage operation of lateral geometry devices such as Schottky barrier (SB) diodes and high electron mobility transistors (HEMTs). New “Normally-Off” device architectures were demonstrated – for safe operation of power electronics circuits. The trade-offs between lateral and vertical devices were explored, with the conclusion that lateral devices are superior for fundamental thermal reasons, as well as for the demonstration of future generations of monolithic power circuits. As part of the materials and device investigations breakdown mechanisms in GaN-on-Si structures were fully characterized and effective electric field engineering was recognized as critical for achieving even higher voltage operation. Improved device contact technology was demonstrated, including the first gold-free metallizations (to enable processing in CMOS foundries) while maintaining low specific contact resistance needed for high-power operation and 5-order-of magnitude improvement in device leakage currents (essential for high power operation). In addition, initial GaN-on-Si epitaxial growth was performed on 8”/200 mm Si starting substrates.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2015

Development of an Efficient Meso- scale Multi-phase Flow Solver in Nuclear Applications

The proposed research aims at formulating a predictive high-order Lattice Boltzmann Equation for multi-phase flows relevant to nuclear energy related application - namely, saturated and sub-cooled boiling in reactors, and liquid- liquid mixing and extraction for fuel cycle separation. An efficient flow solver will be developed based on the Finite Element based Lattice Boltzmann Method (FE- LBM), accounting for phase-change heat transfer and capable of treating multiple phases over length scales from the submicron to the meter. A thermal LBM will be developed in order to handle adjustable Prandtl number, arbitrary specific heat ratio, a wide range of temperature variations, better numerical stability during liquid-vapor phase change, and full thermo-hydrodynamic consistency. Two-phase FE-LBM will be extended to liquid–liquid–gas multi-phase flows for application to high-fidelity simulations building up from the meso-scale up to the equipment sub-component scale. While several relevant applications exist, the initial applications for demonstration of the efficient methods to be developed as part of this project include numerical investigations of Critical Heat Flux (CHF) phenomena in nuclear reactor fuel bundles, and liquid-liquid mixing and interfacial area generation for liquid-liquid separations. In addition, targeted experiments will be conducted for validation of this advanced multi-phase model.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

Delayed Gamma-ray Spectroscopy for Safeguards Applications

The delayed gamma-ray assay technique utilizes an external neutron source (D-D, D-T, or electron accelerator-driven), and high-resolution gamma-ray spectrometers to perform characterization of SNM materials behind shielding and in complex configurations such as a nuclear fuel assembly. High-energy delayed gamma-rays (2.5 MeV and above) observed following the active interrogation, provide a signature for identification of specific fissionable isotopes in a mixed sample, and determine their relative content. Potential safeguards applications of this method are: 1) characterization of fresh and spent nuclear fuel assemblies in wet or dry storage; 2) analysis of uranium enrichment in shielded or non-characterized containers or in the presence of a strong radioactive background and plutonium contamination; 3) characterization of bulk and waste and product streams at SNM processing plants. Extended applications can include warhead confirmation and warhead dismantlement confirmation in the arms control area, as well as SNM diagnostics for the emergency response needs. In FY16 and prior years, the project has demonstrated the delayed gamma-ray measurement technique as a robust SNM assay concept. A series of empirical and modeling studies were conducted to characterize its response sensitivity, develop analysis methodologies, and analyze applications. Extensive experimental tests involving weapons-grade Pu, HEU and depleted uranium samples were completed at the Idaho Accelerator Center and LLNL Dome facilities for various interrogation time regimes and effects of the neutron source parameters. A dedicated delayed gamma-ray response modeling technique was developed and its elements were benchmarked in representative experimental studies, including highresolution gamma-ray measurements of spent fuel at the CLAB facility in Sweden. The objective of the R&D effort in FY17 is to experimentally demonstrate the feasibility of the delayed gamma-ray interrogation of shielded SNM samples with portable neutron sources suitable for field applications.

61 RADIATION PROTECTION AND DOSIMETRY↗

DOE OSTI2016

STREAM2016: Streaming Requirements, Experience, Applications and Middleware Workshop

The Department of Energy (DOE) Office of Science (SC) facilities including accelerators, light sources and neutron sources and sensors that study, the environment, and the atmosphere, are producing streaming data that needs to be analyzed for next-generation scientific discoveries. There has been an explosion of new research and technologies for stream analytics arising from the academic and private sectors. However, there has been no corresponding effort in either documenting the critical research opportunities or building a community that can create and foster productive collaborations. The two-part workshop series, STREAM: Streaming Requirements, Experience, Applications and Middleware Workshop (STREAM2015 and STREAM2016), were conducted to bring the community together and identify gaps and future efforts needed by both NSF and DOE. This report describes the discussions, outcomes and conclusions from STREAM2016: Streaming Requirements, Experience, Applications and Middleware Workshop, the second of these workshops held on March 22-23, 2016 in Tysons, VA. STREAM2016 focused on the Department of Energy (DOE) applications, computational and experimental facilities, as well software systems. Thus, the role of “streaming and steering” as a critical mode of connecting the experimental and computing facilities was pervasive through the workshop. Given the overlap in interests and challenges with industry, the workshop had significant presence from several innovative companies and major contributors. The requirements that drive the proposed research directions, identified in this report, show an important opportunity for building competitive research and development program around streaming data. These findings and recommendations are consistent with vision outlined in NRC Frontiers of Data and National Strategic Computing Initiative (NCSI) [1, 2]. The discussions from the workshop are captured as topic areas covered in this report's sections. The report discusses four research directions driven by current and future application requirements reflecting the areas identified as important by STREAM2016. These include (i) Algorithms, (ii) Programming Models, Languages and Runtime Systems (iii) Human-in-the-loop and Steering in Scientific Workflow and (iv) Facilities.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗

DOE OSTI2017

Carbon Fiber Composite Materials for Automotive Applications

Volkswagen (VW) is internationally recognized for quantity and quality of world-wide vehicle production and the Oak Ridge National Laboratory (ORNL) is internationally recognized in materials research and development. With automotive production ramping up in the recently constructed VW Group of America facility in Chattanooga, Tennessee, ORNL and VW initiated discussions in 2012 concerning opportunities for collaboration around ORNL’s carbon fiber and composites programs. ORNL is conducting an internationally recognized program to develop and implement lower cost carbon fibers and composites for automotive and other “energy missions” for the US Department of Energy. Significant effort is ongoing in selecting, developing, and evaluating alternative precursors, developing and demonstrating advanced conversion techniques, and developing and tailoring surface treatment, sizings, and formatting fiber for specific composite matrices and end-use applications. ORNL already had North America’s most comprehensive suite of tools for carbon fiber research and development and established a semiproduction demonstration line referred to as the Carbon Fiber Technology Facility (CFTF) to facilitate implementation of low cost carbon fiber (LCCF) approaches in early 2013. ORNL and VW agreed to collaborate in a formal Cooperative Research and Development Agreement (NFE-12-03992) specifically focused on evaluating applicability of low cost carbon fiber products for potential vehicle components. The goal of the work outlined in this report was to develop and qualify uses for carbon fiber-reinforced structures in connection with civilian ground transportation. Significant progress was achieved in evaluating and understanding lignin-based precursor materials; however, availability of carbon fiber converted from lignin precursor combined with logistical issues associated with the Visa limitations for the VW participant resulted in significantly shortening of the collaboration period and development of the targeted application(s). Alternatively, objectives of this work have been refined and are now largely being pursued through the involvement of ORNL and VW participation in the more recently established Innovation for Advanced Composites Manufacturing Innovation (IACMI) where composite materials applications are being demonstrated in a much larger scope.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Proxy App Prospectus for ECP Application Development Projects

The Exascale Computing Project (ECP) includes 25 application development (AD) projects1 and five co-design centers funded by the Office of Science, NNSA, and National Cancer Institute. Their full code bases are large and complex, and can be difficult for co-design partners to assimilate for use in collaboration for Exascale challenges. To alleviate this challenge, proxy applications (“apps”) are being developed: these are small, self-contained, simplified codes that are intended to model the performance-critical computations within applications. Proxy apps also capture programming methods and styles that drive requirements for compilers and other elements of the tool chain. Within ECP, application teams, co-design centers, software technology (ST) projects and vendors all plan to use proxies as a major mechanism to drive collaborations and co-design solutions for exascale challenges.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2018

Survey on cladded component design procedures for nuclear and non-nuclear applications

Corrosion resistant weld overlay and integral claddings are used to provide corrosion resistance to components made of structural materials that are susceptible to corrosion. Generally, cladding is used in industry to offset the cost of expensive corrosion resistance alloys. In the application to nuclear, cladding provides a mechanism to allow use of limited code approved base materials in corrosive environments. Applicable design rules will need to be developed to support the design and construction of these cladded components for MSR applications. This document provides a survey of the state-of-the-art in design practice of cladded components for both the nuclear and non-nuclear industry. Design practice and service experience in the nuclear and non-nuclear is investigated. A gap analysis on applying these design practice to nuclear applications is included.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2019

Low Cost High Efficiency Magnetrons for Accelerator Applications

High efficiency, low cost RF sources are required for proton, ion, and muon accelerators. These sources must be compact and provide precise control of the output power and phase. Currently only large, expensive klystrons can provide this performance. Calabazas Creek Research Inc. proposes to develop a phase locked magnetron-based system that has phase and amplitude control via a low power amplifier. The system uses phase modulation to control the RF power. The efficiency can exceed 80% and the cost is expected to be less than $3/Watt, significantly lower than other high power amplifiers. CCR originally proposed to develop a magnetron with a grid for control of phase and amplitude. Detailed simulations showed that this was not a promising approach. The grid was found to be viable only in magnetrons with low duty cycle, and amplitude control was demonstrated; but the grid was found to be not effective for phase locking. Attention was turned to a concept from Fermilab, which is very promising for both amplitude and phase control and does not require a grid. CCR will develop an RF system providing phase and amplitude control of a 100 kW peak, 10 kW average 1.3 GHz magnetron. Procedures and techniques will be applicable to design of systems at other frequencies and power levels. The program will include development of the magnetron and locking electronics. The system will be tested at Fermilab. Commercial Applications and Other Benefits Magnetrons can provide high levels of RF power at very high efficiency at low cost. As oscillators, however, their applications are limited. Magnetrons with more precise control of the output power and control of the phase could find wide application in accelerators and colliders. They would also provide improved performance for high resolution radar.

43 PARTICLE ACCELERATORS↗

DOE OSTI2020

Compact, Achromatic Non-scaling FFAG Accelerator for HEP, Commercial and Medical Applications (CRADA FRA-2008-0005 Final Report)

Proton and light-ion accelerators have many research and medical applications, but the current state of technology in accelerators severely limits their widespread use: (1) synchrotrons have an intrinsic low duty cycle and become quite large for light ions; and (2) cyclotrons do not have energy variability and require complex superconducting magnets for high energy. A new concept in non-scaling Fixed-Field Alternating-Gradient (FFAGs) has been invented that incorporates both the energy variability of the synchrotron and the high duty cycle of the cyclotron. The concept uses normal-conducting, combined-function magnets that apply only constant (dipole) and linear-gradient (quadrupole) fields to stabilize the accelerator. This project will develop an optimized design for a new non-scaling and cost-effective innovation in FFAG accelerators. The accelerator design will have optics that can stably accelerate protons to 250 MeV (or higher) and carbon ions to =200 MeV, an energy considered ideal for radiation therapy. Phase I will optimize, fully simulate, and demonstrate the feasibility of this accelerator. Commercial Applications and other Benefits as described by the awardee: The fixed-field acceleration concept should eliminate some of the most pronounced technical difficulties, expense, maintenance, and required expertise faced in conventional proton and light-ion accelerators. In addition to the application for high energy physics, these accelerators should have application in cancer treatment, radiopharmaceuticals, and medical isotope production, and materials science.

43 PARTICLE ACCELERATORS↗

DOE OSTI2020

Application and Certification of Comparative Vacuum Monitoring Sensors for Structural Health Monitoring of 737 Wing Box Fittings

Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today's extensive fleet of aging aircraft and space vehicles. The use of in-situ sensors for real-time health monitoring of aircraft structures are a viable option to overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. Prevention of unexpected flaw growth and structural failure can be improved if on-board health monitoring systems are used to continuously assess structural integrity. Such systems are able to detect incipient damage before catastrophic failures occurs. Condition-based maintenance practices could be substituted for the current time-based maintenance approach. Other advantages of on-board distributed sensor systems are that they can eliminate costly, and potentially damaging, disassembly, improve sensitivity by producing optimum placement of sensors and decrease maintenance costs by eliminating more time- consuming manual inspections. This report presents a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Boeing, Delta Air Lines, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp. and the Federal Aviation Administration (FAA) carried out a certification program to formally introduce Comparative Vacuum Monitoring (CVM) as a structural health monitoring solution to a specific aircraft wing box application. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM into an airline maintenance program and the document revisions necessary to allow for routine use of CVM as an alternate means of performing periodic structural inspects. To carry out the validation process, knowledge of aircraft maintenance practices was coupled with an unbiased, independent evaluation. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically-relevant experimental effort to quantify the reliability of the CVM system applied to the Boeing 737 Wing Box fitting application. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for CVM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and also is acceptable to both the aviation industry and regulatory bodies. This report presents the use of several different statistical methods, some of them adapted from NDI performance assessments and some proposed to address the unique nature of damage detection via SHM systems, and discusses how they can converge to produce a confident quantification of SHM performance An important element in developing SHM validation processes is a clear understanding of the regulatory measures needed to adopt SHM solutions along with the knowledge of the structural and maintenance characteristics that may impact the operational performance of an SHM system. This report describes the major elements of an SHM validation approach and differentiates the SHM elements from those found in NDI validation. The activities conducted in this program demonstrated the feasibility of routine SHM usage in general and CVM in particular for the application selected. They also helped establish an optimum OEM-airline-regulator process and determined how to safely adopt SHM solutions. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM technology. It will also streamline the regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗