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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,405 records · Page 78

Hardware Fuzzing with An Emulator

Bugs in digital logic have led to some significant security vulnerabilities. Hardware bugs are particularly troublesome since they cannot be easily patched. Additionally, if the bug is in the root of trust, all trust built upon it can be vulnerable. Traditional testing either require a deep knowledge of the system, creative attack vectors and lots of human interaction. This is not scalable as there are very few engineers that can wear the hat of a designer, a verification engineer, and a cybersecurity expert. Hardware fuzzing is a relatively new research area in dynamic hardware testing. It has proven to be an effective method for discovering bugs, unexpected behaviors, and security vulnerabilities in software. While hardware fuzzing is new to the hardware domain, it has a strong track record in software testing. Fuzzing is a testing technique that randomly mutates the input data to uncover bugs or vulnerabilities in the design. It is especially good at finding corner cases that test engineers can not envision. Another advantage over other dynamic testing techniques is that, if done well, deep knowledge of the design is not required. Additionally, fuzzing scales well. If the system is set up correctly, it can run unsupervised for weeks if necessary. In this work, we propose using hardware fuzzing to improve the input vector generation for an information flow tracking tool. To get reasonable throughput of test vectors, an emulator is targeted as the execution platform. Efficient emulator execution has some specific requirements.

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Accelerating Learning with Set-Based Concurrent Engineering

The traditional design approach for product development is to develop a design based on customer requirements and technical knowledge, build the product according to the detail requirements provided, and then test the product to validate that it works as intended. The team typically starts by identifying a single design approach and spends their time validating a single design during testing. Design teams often encounter issues in the course of development with performance, manufacturability, interfaces and more. To compensate for test failures, teams often build in time into the schedule for additional design loopbacks. Further, when the loopbacks lead to change, the late changes are costly and risky, causing the team to focuses on "fixing the bare minimum" to meet cost and schedule expectations.

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Design Considerations Which Can Simplify Manufacturing (U) [Slides]

The purpose of this paper is to recommend design considerations which can significantly reduce the time required to manufacture parts, reducing cost to manufacture parts while increasing the quality of manufactured parts and minimize the likelihood of nonconformance conditions. The product design is ultimately the responsibility of the project engineers and their design teams. This paper is not intended to supersede design requirements.

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Diagnostics for Burning Plasmas

Here, recent progress in the design and manufacturing development of in-vessel diagnostic components by the U.S. ITER team is reported. Design and manufacturing choices are driven by engineering challenges stemming from ITER’s burning plasma mission, which entails levels of plasma neutron emission, pulse lengths, and size scales well beyond the existing database. Challenges include port access limitations, neutron irradiation and activation risks, nuclear heating of components, complex interfaces, remote handling compatibility, and constraints on component and processing materials. Responses to these challenges are presented using examples from the low field side reflectometer, toroidal interferometer polarimeter, and electron cyclotron emission diagnostics. Relevance of the experience from ITER diagnostics engineering to the design of future integrated fusion facilities based on burning plasmas is addressed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Integrated two-cylinder liquid piston Stirling engine

Heat engines utilizing the Stirling cycle may run on low temperature differentials with the capacity to function at high efficiency due to their near-reversible operation. However, current approaches to building Stirling engines are laborious and costly. Typically the components are assembled by hand and additional components require a corresponding increase in manufacturing complexity, akin to electronics before the integrated circuit. We present a simple and integrated approach to fabricating Stirling engines with precisely designed cylinders. We utilize computer aided design and one-step, planar machining to form all components of the engine. The engine utilizes liquid pistons and displacers to harness useful work from heat absorption and rejection. As a proof of principle of the integrated design, a two-cylinder engine is produced and characterized and liquid pumping is demonstrated.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

MST-7 Engineered Materials

Materials design, fabrication, assembly, and characterization for national security needs

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DE-FE0026098 Final Report - Advanced Materials and Manufacturing Processes for SOFC Power Systems Revision 1

The aim of the project is to qualify an integrated material set and processing solution for selected metallic components of an advanced integrated stack block. As the integrated stack block is the “engine” of the solid oxide fuel cell power system, the project will also support significant cost reductions, increased reliability, and improved performance of the LG Fuel Cell Systems Inc. (“LGFCS”) cell and stack technology to be included in the initial commercial product offering. In the proposed work an integrated material set, and processing solution will be developed using powder metals processing which has been proven to be an enabling technology capable of delivering net or near net shape components, as well as for creating compositions, microstructures, and properties that are otherwise unattainable. Several advanced manufacturing processes will be screened to select one or more that are most advantageous for the selected metallic components when produced at commercial volumes. This work will be accomplished through the integration of metallurgists and processing engineers from Carpenter Technology, with the product design and cost engineers from LGFCS. The expected outcome of the proposed work is an optimized material set and processing solution that will reduce the current cost.

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Containment at the Source during Waste Volume Reduction of Large Radioactive Components Using Oxylance High-Temperature Cutting Equipment - 13595

As a waste-volume reduction and management technique, highly contaminated Control Element Drive Mechanism (CEDM) housings were severed from the Reactor Pressure Vessel Head (RPVH) inside the San Onofre Unit 2 primary containment utilizing Oxylance high-temperature cutting equipment and techniques. Presented are relevant data concerning: - Radiological profiles of the RPVH and individual CEDMs; - Design overviews of the engineering controls and the specialized confinement housings; - Utilization of specialized shielding; - Observations of apparent metallurgical-contamination coalescence phenomena at high temperatures resulting in positive control over loose-surface contamination conditions; - General results of radiological and industrial hygiene air sampling and monitoring; - Collective dose and personnel contamination event statistics; - Lessons learned. (author)

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Development of a Low NOx Medium sized Industrial Gas Turbine Operating on Hydrogen-Rich Renewable and Opportunity Fuels (Final Technical Report)

This report presents the accomplishments at the completion of the DOE sponsored project (Contract # DE-FC26-09NT05873) undertaken by Solar Turbines Incorporated. The objective of this 54-month project was to develop a low NOx combustion system for a medium sized industrial gas turbine engine operating on Hydrogen-rich renewable and opportunity Fuels. The work in this project was focused on development of a combustion system sized for 15MW Titan 130 gas turbine engine based on design analysis and rig test results. Although detailed engine evaluation of the complete system is required prior to commercial application, those tasks were beyond the scope of this DOE sponsored project. The project tasks were organized in three stages, Stages 2 through 4. In Stage 2 of this project, Solar Turbines Incorporated characterized the low emission capability of current Titan 130 SoLoNOx fuel injector while operating on a matrix of fuel blends with varying Hydrogen concentration. The mapping in this phase was performed on a fuel injector designed for natural gas operation. Favorable test results were obtained in this phase on emissions and operability. However, the resulting fuel supply pressure needed to operate the engine with the lower Wobbe Index opportunity fuels would require additional gas compression, resulting in parasitic load and reduced thermal efficiency. In Stage 3, Solar characterized the pressure loss in the fuel injector and developed modifications to the fuel injection system through detailed network analysis. In this modification, only the fuel delivery flowpath was modified and the air-side of the injector and the premixing passages were not altered. The modified injector was fabricated and tested and verified to produce similar operability and emissions as the Stage 2 results. In parallel, Solar also fabricated a dual fuel capable injector with the same air-side flowpath to improve commercialization potential. This injector was also test verified to produce 15-ppm NOx capability on high Hydrogen fuels. In Stage 4, Solar fabricated a complete set of injectors and a combustor liner to test the system capability in a full-scale atmospheric rig. Extensive high-pressure single injector rig test results show that 15-ppm NOx guarantee is achievable from 50% to 100% Load with fuel blends containing up to 65% Hydrogen. Because of safety limitations in Solar Test Facility, the atmospheric rig tests were limited to methane-based fuel blends. Further work to validate the durability and installed engine capability would require long-term engine field test.

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Reducing Methane Emissions with an Engine Fuel Reformer

Southwest Research Institute (SwRI) designed and demonstrated a compact, plasma-based fuel reformer designed to reduce methane leaks from natural-gas engines used in pipeline compression and industrial power applications. The system uses pulsed electrical discharges to convert a small portion of methane (CH4) into hydrogen (H2) and light hydrocarbons, promoting more complete combustion and reducing unburned methane in the exhaust. The reformer was evaluated through bench-scale testing, high-flow facility testing, and engine-integration testing on representative low-speed and high-speed natural-gas engines. Measured methane-leak reductions ranged from 1 to 27 percent, depending on engine type and operating condition, while reformer energy consumption remained below one percent of total engine output. Design refinements addressed thermal and electrical challenges, resulting in reliable operation with minimal impact on engine control systems. The project achieved all performance objectives within budget and schedule, produced a patentable pulsed-power system design, and established a scalable, energy-efficient pathway for mitigating methane leaks from existing natural-gas engine infrastructure.

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Deep Borehole Disposal Safety Analysis.

This report presents a preliminary safety analysis for the deep borehole disposal (DBD) concept, using a safety case framework. A safety case is an integrated collection of qualitative and quantitative arguments, evidence, and analyses that substantiate the safety, and the level of confidence in the safety, of a geologic repository. This safety case framework for DBD follows the outline of the elements of a safety case, and identifies the types of information that will be required to satisfy these elements. At this very preliminary phase of development, the DBD safety case focuses on the generic feasibility of the DBD concept. It is based on potential system designs, waste forms, engineering, and geologic conditions; however, no specific site or regulatory framework exists. It will progress to a site-specific safety case as the DBD concept advances into a site-specific phase, progressing through consent-based site selection and site investigation and characterization.

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Retaining Systems Engineering Model Meaning Through Transformation: Demo 2

Digital engineering strategies typically assume that digital engineering models interoperate seamlessly across the multiple different engineering modeling software applications involved, such as model- based systems engineering (MBSE), mechanical computer-aided design (MCAD), electrical computer-aided design (ECAD), and other engineering modeling applications. The presumption is that the data schema in these modeling software applications are structured in the familiar flat- tabular schema like any other software application. Engineering domain-specific applications (e.g., systems, mechanical, electrical, simulation) are typically designed to solve domain-specific problems, necessarily excluding explicit representations of non-domain information to help the engineer focus on the domain problems (system definition, design, simulation). Such exclusions become problematic in inter-domain information exchange. The obvious assumptions of one domain might not be so obvious to experts in another domain. Ambiguity in domain-specific language can erode the ability to enable different domain modeling applications to interoperate, unless the underlying language is understood and used as the basis for translation from one application to another. The engineering modeling software application industry has struggled for decades to enable these applications to interoperate. Industry standards have been developed, but they have not unified the industry. Why is this? The authors assert that the industry has relied on traditional database integration methods. The basic issue prohibiting successful application integration then is that traditional database-driven integration does not consider the distinct languages of each domain. An engineering models meaning is expressed through the underlying language of that engineering domain. In essence, traditional integration methods do not retain the semantic context (meaning) of the model. The basis of this research stems from the widely held assumption that systems engineering models are (or can be) structured according to the underlying semantic ontology of the model. This assumption can be imagined from two thoughts. 1) Digital systems engineering models are often represented using graph theory (the graph of a complex systems model can contain millions of nodes and edges). When examining the nodes one at a time and following the outbound edges of each node one by one, one can end up with rudimentary statements about the model (i.e., node A relates to node B), as in a semantic graph. 2) Likewise, from the study of natural languages, a sentence can be structured into unambiguous triples of subject-predicate-object within formal and highly expressive semantic ontologies. The rudimentary statements about a systems model discerned with graph theory closely mimic the triples used in the ontologies that try to structure natural languages. In other words, a systems models semantic graph can be (or is) structured into an ontology. Additionally, it is well established in industry that through natural language processing (NLP), which provides the means to create language structures, that computers can interpret ontological graphs. Therefore, the authors hypothesized that if the integrity of the underlying semantic structure of a systems model is retained, the contextual meaning of the model is retained. By structuring system models into the triples of the underlying ontology during the transformation from one MBSE application to another, the authors have provided a proof of the concept that the meaning of a system model can be retained during transformation. The authors assert that this is the missing ingredient in effective systems model-to-model interoperability. ACKNOWLEDGEMENTS The authors would like to thank the FY19 Model Interoperability team members who provided a solid foundation for the FY20 team to leverage: John McCloud, for the work he did to guide us toward the right use of technology that will appropriately discover and manipulate ontologies. Carlos Tafoya, for the work he did to develop an application programming interface (API)/Adapter that would export ontology-based data from GENESYS. Peter Chandler, for the work he did to architect our overall integration solution, with an eye toward the future that would influence a large-scale federated production-level systems engineering digital model ecosystem.

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SLUDGE TREATMENT PROJECT ENGINEERED CONTAINER RETRIEVAL AND TRANSFER SYSTEM PRELIMINARY DESIGN HAZARD ANALYSIS SUPPLEMENT 1

This 'What/If' Hazards Analysis addresses hazards affecting the Sludge Treatment Project Engineered Container Retrieval and Transfer System (ECRTS) NPH and external events at the preliminary design stage. In addition, the hazards of the operation sequence steps for the mechanical handling operations in preparation of Sludge Transport and Storage Container (STSC), disconnect STSC and prepare STSC and Sludge Transport System (STS) for shipping are addressed.

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Developing Ultra-small Scale Mechanical Testing Methods and Microstructural Investigation Procedures for Irradiated Materials

Nuclear materials are an essential aspect of nuclear engineering. While great effort is spent on designing more advanced reactors or enhancing a reactor’s safety, materials have been the bottleneck of most new developments. The designs of new reactor concepts are driven by neutronic and thermodynamic aspects, leading to unusual coolants (liquid metal, liquid salt, gases), higher temperatures, and higher radiation doses than conventional light water reactors have. However, any (nuclear) engineering design must consider the materials used in the anticipated application in order to ever be realized. Designs which may look easy, simple and efficient considering thermodynamics or neutronic aspects can show their true difficulty in the materials area, which then prevents them from being deployed. In turn, the materials available are influencing the neutronic and thermodynamic designs and therefore must be considered from the beginning, requiring close collaborations between different aspects of nuclear engineering. If a particular design requires new materials, the licensing of the reactor must be considered, but licensing can be a costly and time consuming process that results in long lead times to realize true materials innovation.

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Reuse of low specific activity material as part of LLWR design optimisation

A final cap will be emplaced over the disposed waste as part of the closure engineering for the UK's Low Level Waste Repository (LLWR). Additional profiling material will be required above the waste to obtain the required land-form. Consideration has been given to the potential opportunity to reuse Low Specific Activity Material (LSAM, defined as up to 200 Bq g{sup -1}) imported from other sites as a component of the necessary profiling material for the final repository cap. Justification of such a strategy would ultimately require a demonstration that the solution is optimal with respect to other options for the long-term management of such materials. The proposal is currently at the initial evaluation stage and seeks to establish how LSAM reuse within the cap could be achieved within the framework of an optimised safety case for the LLWR, should such a management approach be pursued. The key considerations include the following: The LSAM must provide the same engineering function as the remainder of the profiling material. The cap design must ensure efficient leachate collection, drainage and control for Low Level Waste (LLW) (and, by extension, LSAM) during the Period of Authorisation. In the longer term the engineering design must passively direct any accumulating waters preferentially away from surface water systems. An initial design has been developed that would allow the placement of around 220,000 m{sup 3} of LSAM. The potential impact of the proposal has been assessed against the current Environmental Safety Case. (authors)

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Small Reactor Designs Suitable for Direct Nuclear Thermal Propulsion (Interim Report)

Advancement of U.S. scientific, security, and economic interests requires high performance propulsion systems to support missions beyond low Earth orbit. A robust space exploration program will include robotic outer planet and crewed missions to a variety of destinations including the moon, near Earth objects, and eventually Mars. Past studies, in particular those in support of both the Strategic Defense Initiative (SDI) and the Space Exploration Initiative (SEI), have shown nuclear thermal propulsion systems provide superior performance for high mass high propulsive delta-V missions. In NASA's recent Mars Design Reference Architecture (DRA) 5.0 study, nuclear thermal propulsion (NTP) was again selected over chemical propulsion as the preferred in-space transportation system option for the human exploration of Mars because of its high thrust and high specific impulse (~900 s) capability, increased tolerance to payload mass growth and architecture changes, and lower total initial mass in low Earth orbit. The recently announced national space policy supports the development and use of space nuclear power systems where such systems safely enable or significantly enhance space exploration or operational capabilities. An extensive nuclear thermal rocket technology development effort was conducted under the Rover/NERVA, GE-710 and ANL nuclear rocket programs (1955-1973). Both graphite and refractory metal alloy fuel types were pursued. The primary and significantly larger Rover/NERVA program focused on graphite type fuels. Research, development, and testing of high temperature graphite fuels was conducted. Reactors and engines employing these fuels were designed, built, and ground tested. The GE-710 and ANL programs focused on an alternative ceramic-metallic 'cermet' fuel type consisting of UO 2 (or UN) fuel embedded in a refractory metal matrix such as tungsten. The General Electric program examined closed loop concepts for space or terrestrial applications as well as open loop systems for direct nuclear thermal propulsion. Although a number of fast spectrum reactor and engine designs suitable for direct nuclear thermal propulsion were proposed and designed, none were built. This report summarizes status results of evaluations of small nuclear reactor designs suitable for direct nuclear thermal propulsion.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗