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DOE OSTI2024

ThunderBoltz API

The ThunderBoltz application programming interface (API) code is written in Python and is comprised of a set of tools to facilitate compilation of the ThunderBoltz code, as well as fast assembly and formatting of input files for the ThunderBoltz code, post-processing tools of ThunderBoltz results, plotting tools, and runs/schedules the ThunderBoltz code executable for calculations. The ThunderBoltz API code is utilized for importing and manipulating input cross section sets, input conditions, and any other simulation settings made available within the ThunderBoltz input deck via user-defined settings or via automatic generation. The API comes with a set of plotting capabilities of input cross sections, results from ThunderBoltz, and post-processed results carried out with the API.

Park, Ryan↗

DOE OSTI2021

Cross Section Generation Capability in Griffin

The Griffin code is a Multiphysics Object-Oriented Simulation Environment (MOOSE) based reactor multiphysics analysis application jointly developed by Idaho National Laboratory and Argonne National Laboratory. The code includes a variety of steady-state solvers for fixed-source, k-eigenvalue, adjoint, and subcritical multiplication, as well as transient solvers for point-kinetics, improved quasi-static, and spatial dynamics. The code reads multigroup cross sections in the ISOXML format generated from external deterministic or Monte Carlo cross section generation codes. The implementation of the cross section generation capability in Griffin was initiated last year by plugging in the cross section application programming interface (CSAPI) and reviewing the methodologies for treating particulate fuels. The focus this year was on improving the CSAPI integration and implementing advanced self-shielding methods for applications to advanced reactor problems with TRISO fuels. First, the process for cross section library generation was updated to accurately and rigorously produce isotopic cross section data. Second, the equivalent Dancoff factor cell method performing slowing down calculations on the fly for the resonance treatment was implemented in CSAPI to improve the accuracy of effective multigroup cross sections in the resonance energy range. Third, the iterative local spatial self-shielding method was implemented under the calculation framework of the equivalent Dancoff factor cell method to accurately deal with the double heterogeneity effect of particulate fuel. The updated CSAPI with the advanced self-shielding methods, together with the cross section libraries generated based on the improved process, were tested for pin-cell, unit-cell, and fuel assembly problems with various resonance self-shielding conditions based on very high temperature reactor, high temperature test reactor, and Empire benchmark cores, indicating that the updated CSAPI in Griffin is able to produce multigroup cross sections accurately and efficiently. We also showed that the methodology worked well for pebble bed fuel from HTR-10, but the capability still needs to be fully integrated into CSAPI. In the future, further benchmark tests will be performed for various thermal reactor core problems, including particulate fuel-based pebble bed reactors.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2022

Scorpius Injector Solenoid Magnet Alignment and Characterization

The Scorpius project consists of a linear induction accelerator (LIA) that will be built in the coming few years at the Nevada test site. Large radius solenoid magnets are used to focus and transport the electron beam through the injector of Scorpius. Typically, solenoid magnets are wrapped directly around the beam pipe. They have an inner radius of about 8 cm and weight approximately 170 lbs. The magnets for the Scorpius injector are much larger, the largest of which extends to an inner radius of 45 cm with a weight of 709 lbs. In addition, the magnet measurement effort is typically time-consuming, taking several months to complete. With 5 different designs of 52 solenoid magnets to measure in under a year, this is a challenging undertaking that requires a systems solution. Due to the size, variability, and quantity of solenoid magnets, as well as the compressed schedule, the process of measuring the solenoid magnets before integrating them into their respective assemblies and shipping them to Nevada is a challenging problem. There is a need for the injector magnets to be characterized and aligned in preparation for the commissioning of Scorpius. This will ensure that the injector magnet installation meets requirements.

42 ENGINEERING↗

DOE OSTI2024

Solid State Li Ion Batteries Using Si Composite Anodes

Solid Power has teamed with Argonne National Laboratory (ANL) to develop an all solid-state lithium-ion battery (ASSB), enabled by a high-capacity Si anode and a solid state electrolyte (SSE). Replacing liquid electrolytes with solid electrolytes addresses the calendar life challenges that currently limit the widespread adoption of Si anodes. In this project, Si-SSE composite materials have been developed with a specific capacity >1500 mAh/g (at electrode level). A Si anode was coated by using a roll-to-roll process. All-solid-state NMC-Si pouch cells have been assembled and tested. Cycle life of 1100 at 100% DOD has been demonstrated in the solid state Si pouch cell. Excellent calendar life is achieved in the cell via a high temperature storage test.

25 ENERGY STORAGE↗

DOE OSTI2025

Reducing Mass of Steel Auto Bodies using Thin Advanced High Strength Steel with Carbon-Fiber Reinforced Epoxy

Diversitak, a company based in Detroit, MI, has developed a proprietary, low specific gravity, carbon fiber-reinforced epoxy (CFRE) under U.S. patent number 9,963,58832. Preliminary testing on this new material conducted in collaboration with ArcelorMittal Steel Company proved out the CFRE concept. A thin layer of this CFRE was applied to a stamped sheet of steel with residual stamping oils from a mill, in a time corresponding to automotive processing (e.g., ~15 seconds), and processed following automotive e-coat procedures (phosphating + 175–200°C heating), to complete the curing. No problems with adherence or performance were noted. While the CFRE does add weight to a thin gauge steel panel, it weighs much less than what is displaced by using thicker conventional mild steel gauges. The application of the coating showed a significant increased dent resistance, oil canning resistance, and part stiffness.This current two-year project was designed to mature this new technology to near manufacturing readiness to reduce the weight of a vehicle and lower the cost of weight reduction. The process involves the use of thinner gauge steels than are currently used. The collaborative development team included two industrial manufacturers: Diversitak and ArcelorMittal Steel Company; LightMAT; and two National Laboratories: Oak Ridge National Laboratory (ORNL) and Idaho National Laboratory (INL). The team developed a new manufacturing process to reduce the weight of a vehicle and lower the cost of weight reduction, as well as a better understanding of how to apply the coating so that it will perform to a high standard in-service. The team also performed an in-depth study to determine the long-term durability of the materials manufactured using this technology and well-known automotive industry standard tests.The overall process involved stiffening the thinner gauge steel by applying the CFRE on only one side. To accomplish this goal, the optimal reinforcement fiber length and fiber concentration was first determined. This was followed by measuring the coefficient of thermal expansion (CTE) in all three directions, so it could be fed into manufacturing models and methods for rapidly and inexpensively applying the coating. This was followed by panel level evaluations of the coating and steel combination, and then by full part demonstration of the technology on door panels. The final step was corrosion testing of the parts.ArcelorMittal characterized the advanced high strength steel (AHSS) (e.g., metallurgy-heat treatment for required AHSS properties as a function of the sheet thickness, state of internal stress) and quantified CFRE adhesion to the steel as a function of sheet preparation (e.g., rolling and stamping).ORNL optimized the fiber length, fiber concentration, and coating thickness for best vehicle function and performance at the least cost. Along with the suppliers, ORNL developed a durable CFRE application process (e.g., gun material, design, robotic dispensing process) and identified the adhesion stability of the CFRE during process holding. An approach to ensure that application/curing timing conforms to conventional assembly line speed and plant cycle times was determined. ORNL also determined the CTE of the material in all three directions and performed material scanning electron microscopy (SEM) analyses.INL characterized the corrosion properties of the steel panels coated with CFRE. The panels were investigated for corrosion resistance and stability as replacement materials used in automotive body panels to reduce mass. The coupons tested at INL were supplied by Diversitak after an optimized CFRE formulation was achieved in the already coated form for corrosion testing.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2024

metabCombiner 2.0: Disparate Multi-Dataset Feature Alignment for LC-MS Metabolomics

Liquid chromatography–high-resolution mass spectrometry (LC-HRMS), as applied to untargeted metabolomics, enables the simultaneous detection of thousands of small molecules, generating complex datasets. Alignment is a crucial step in data processing pipelines, whereby LC-MS features derived from common ions are assembled into a unified matrix amenable to further analysis. Variability in the analytical factors that influence liquid chromatography separations complicates data alignment. This is prominent when aligning data acquired in different laboratories, generated using non-identical instruments, or between batches from large-scale studies. Previously, we developed metabCombiner for aligning disparately acquired LC-MS metabolomics datasets. Here, we report significant upgrades to metabCombiner that enable the stepwise alignment of multiple untargeted LC-MS metabolomics datasets, facilitating inter-laboratory reproducibility studies. To accomplish this, a “primary” feature list is used as a template for matching compounds in “target” feature lists. We demonstrate this workflow by aligning four lipidomics datasets from core laboratories generated using each institution’s in-house LC-MS instrumentation and methods. We also introduce batchCombine, an application of the metabCombiner framework for aligning experiments composed of multiple batches. metabCombiner is available as an R package on Github and Bioconductor, along with a new online version implemented as an R Shiny App.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Assessing impacts of selective logging on water, energy, and carbon budgets and ecosystem dynamics in Amazon forests using the Functionally Assembled Terrestrial Ecosystem Simulator

Abstract. Tropical forest degradation from logging, fire, and fragmentation not only alters carbon stocks and carbon fluxes, but also impacts physical land surface properties such as albedo and roughness length. Such impacts are poorly quantified to date due to difficulties in accessing and maintaining observational infrastructures, as well as the lack of proper modeling tools for capturing the interactions among biophysical properties, ecosystem demography, canopy structure, and biogeochemical cycling in tropical forests. As a first step to address these limitations, we implemented a selective logging module into the Functionally Assembled Terrestrial Ecosystem Simulator (FATES) by mimicking the ecological, biophysical, and biogeochemical processes following a logging event. The model can specify the timing and aerial extent of logging events, splitting the logged forest patch into disturbed and intact patches; determine the survivorship of cohorts in the disturbed patch; and modifying the biomass and necromass (total mass of coarse woody debris and litter) pools following logging. We parameterized the logging module to reproduce a selective logging experiment at the Tapajós National Forest in Brazil and benchmarked model outputs against available field measurements. Our results suggest that the model permits the coexistence of early and late successional functional types and realistically characterizes the seasonality of water and carbon fluxes and stocks, the forest structure and composition, and the ecosystem succession following disturbance. However, the current version of FATES overestimates water stress in the dry season and therefore fails to capture seasonal variation in latent and sensible heat fluxes. Moreover, we observed a bias towards low stem density and leaf area when compared to observations, suggesting that improvements are needed in both carbon allocation and establishment of trees. The effects of logging were assessed by different logging scenarios to represent reduced impact and conventional logging practices, both with high and low logging intensities. The model simulations suggest that in comparison to old-growth forests the logged forests rapidly recover water and energy fluxes in 1 to 3 years. In contrast, the recovery times for carbon stocks, forest structure, and composition are more than 30 years depending on logging practices and intensity. This study lays the foundation to simulate land use change and forest degradation in FATES, which will be an effective tool to directly represent forest management practices and regeneration in the context of Earth system models.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1980

Aerospace electrode line

A facility which produces electrodes for spacecraft power supplies is described. The electrode assembly procedures are discussed. A number of design features in the production process are reported including a batch operation mode and an independent equipment module design approach for transfering the electrode materials from process tank to process tank.

Miller, L.↗

NASA NTRS1980

Application of transmission loss concept in the evaluation of an acoustic filter for liquid-borne transverse resonance modes in a duct of circular cross section

The transmission loss concept is used in the evaluation of an acoustic filter for liquid-borne transverse modes. Tests are conducted to determine the nature of filter element designs required to suppress transverse modes, to verify the presence of transverse modes in the test assembly, to define the acoustic wave incident, and to establish data recording, processing and analysis techniques providing transmission wave filter data. The first, second, and third tangential modes, and the first radial mode are found at frequencies of 2150, 3330, 4420, and 4110 Hz, respectively, and peaks of the tangential modes recede while the radial mode peak remains, demonstrating agreement with theoretical nodal patterns. The present design is found applicable to a liquid-oxygen system, and allows the easy-to-fabricate filter to fit within the available space envelope.

Iwanicki, L. R.↗

NASA NTRS1983

Absorbable-Susceptor Welding of Ceramics

Susceptor becomes part of joint. Susceptor is heated to high temperature by RF energy, then melts adjacent ceramic material. Susceptor dissolves in molten ceramic. When cooled, ceramic parts form moloithic assembly. Suitable for joining complex subassemblies in heat exchangers or other ceramic process equipment for high temperatures.

Schroeder, J. E.↗

NASA NTRS1989

Isotropic graphite multistage depressed collectors - A progress report

A small isotropic-graphite-electrode multistage depressed collector (MDC) was designed, fabricated, and evaluated in conjunction with a 500-W CW 4.8-9.6-GHz TWT. The carbon electrode surfaces were used to improve the TWT overall efficiency by minimizing the secondary-electron emission losses in the MDC. The design and fabrication of the brazed graphite MDC assembly are described. The TWT and graphite-electrode MDC bakeout and processing (outgassing) characteristics were evaluated and found to be comparable to those for TWTs equipped with copper-electrode MDCs. The TWT and MDC performance was optimized for broadband CW operation at saturation. The average RF, overall, and MDC efficiencies were 14.9, 46.4, and 83.6 percent, respectively, across the octave operating band. A 1500-h CW test showed no gas buildup and excellent stability of the electrode surfaces.

Ramins, Peter↗

NASA NTRS1986

Independent Orbiter Assessment (IOA): Analysis of the manned maneuvering unit

Results of the Independent Orbiter Assessment (IOA) of the Failure Modes and Effects Analysis (FMEA) and Critical Items List (CIL) are presented. The IOA approach features a top-down analysis of the hardware to determine failure modes, criticality, and potential critical items (PCIs). To preserve indepedence, this analysis was accomplished without reliance upon the results contained within the NASA FMEA/CIL documentation. This report documents the independent analysis results corresponding to the Manned Maneuvering Unit (MMU) hardware. The MMU is a propulsive backpack, operated through separate hand controllers that input the pilot's translational and rotational maneuvering commands to the control electronics and then to the thrusters. The IOA analysis process utilized available MMU hardware drawings and schematics for defining hardware subsystems, assemblies, components, and hardware items. Final levels of detail were evaluated and analyzed for possible failure modes and effects. Criticality was assigned based upon the worst case severity of the effect for each identified failure mode. The IOA analysis of the MMU found that the majority of the PCIs identified are resultant from the loss of either the propulsion or control functions, or are resultant from inability to perform an immediate or future mission. The five most severe criticalities identified are all resultant from failures imposed on the MMU hand controllers which have no redundancy within the MMU.

Bailey, P. S.↗

NASA NTRS1987

Independent Orbiter Assessment (IOA): Analysis of the remote manipulator system

The results of the Independent Orbiter Assessment (IOA) of the Failure Modes and Effects Analysis (FMEA) and Critical Items List (CIL) are presented. The IOA approach features a top-down analysis of the hardware to determine failure modes, criticality, and potential critical items (PCIs). To preserve independence, this analysis was accomplished without reliance upon the results contained within the NASA FMEA/CIL documentation. The independent analysis results for the Orbiter Remote Manipulator System (RMS) are documented. The RMS hardware and software are primarily required for deploying and/or retrieving up to five payloads during a single mission, capture and retrieve free-flying payloads, and for performing Manipulator Foot Restraint operations. Specifically, the RMS hardware consists of the following components: end effector; displays and controls; manipulator controller interface unit; arm based electronics; and the arm. The IOA analysis process utilized available RMS hardware drawings, schematics and documents for defining hardware assemblies, components and hardware items. Each level of hardware was evaluated and analyzed for possible failure modes and effects. Criticality was assigned based upon the severity of the effect for each failure mode. Of the 574 failure modes analyzed, 413 were determined to be PCIs.

Tangorra, F.↗

NASA NTRS1986

Independent Orbiter Assessment (IOA): Analysis of the hydraulics/water spray boiler subsystem

The results of the Independent Orbiter Assessment (IOA) of the Failure Modes and Effects Analysis (FMEA) and Critical Items List (CIL) are presented. The IOA approach features a top-down analysis of the hardware to determine failure modes, criticality, and potential critical items (PCIs). To preserve independence, this analysis was accomplished without reliance upon the results contained within the NASA FMEA/CIL documentation. This report documents the independent analysis results for the Orbiter Hydraulics/Water Spray Boiler Subsystem. The hydraulic system provides hydraulic power to gimbal the main engines, actuate the main engine propellant control valves, move the aerodynamic flight control surfaces, lower the landing gear, apply wheel brakes, steer the nosewheel, and dampen the external tank (ET) separation. Each hydraulic system has an associated water spray boiler which is used to cool the hydraulic fluid and APU lubricating oil. The IOA analysis process utilized available HYD/WSB hardware drawings, schematics and documents for defining hardware assemblies, components, and hardware items. Each level of hardware was evaluated and analyzed for possible failure modes and effects. Criticality was assigned based upon the severity of the effect for each failure mode. Of the 430 failure modes analyzed, 166 were determined to be PCIs.

Duval, J. D.↗

NASA NTRS1987

Independent Orbiter Assessment (IOA): Analysis of the crew equipment subsystem

Sinclair, Susan↗

NASA NTRS1993

Robotic Variable Polarity Plasma Arc (VPPA) Welding

The need for automated plasma welding was identified in the early stages of the Space Station Freedom Program (SSFP) because it requires approximately 1.3 miles of welding for assembly. As a result of the Variable Polarity Plasma Arc Welding (VPPAW) process's ability to make virtually defect-free welds in aluminum, it was chosen to fulfill the welding needs. Space Station Freedom will be constructed of 2219 aluminum utilizing the computer controlled VPPAW process. The 'Node Radial Docking Port', with it's saddle shaped weld path, has a constantly changing surface angle over 360 deg of the 282 inch weld. The automated robotic VPPAW process requires eight-axes of motion (six-axes of robot and two-axes of positioner movement). The robot control system is programmed to maintain Torch Center Point (TCP) orientation perpendicular to the part while the part positioner is tilted and rotated to maintain the vertical up orientation as required by the VPPAW process. The combined speed of the robot and the positioner are integrated to maintain a constant speed between the part and the torch. A laser-based vision sensor system has also been integrated to track the seam and map the surface of the profile during welding.

Jaffery, Waris S.↗

NASA NTRS1993

Profile of NASA software engineering: Lessons learned from building the baseline

It is critically important in any improvement activity to first understand the organization's current status, strengths, and weaknesses and, only after that understanding is achieved, examine and implement promising improvements. This fundamental rule is certainly true for an organization seeking to further its software viability and effectiveness. This paper addresses the role of the organizational process baseline in a software improvement effort and the lessons we learned assembling such an understanding for NASA overall and for the NASA Goddard Space Flight Center in particular. We discuss important, core data that must be captured and contrast that with our experience in actually finding such information. Our baselining efforts have evolved into a set of data gathering, analysis, and crosschecking techniques and information presentation formats that may prove useful to others seeking to establish similar baselines for their organization.

Hall, Dana↗

NASA NTRS1999

The Role of Independent Assessment in the International Space Station Program

This paper presents the role of Independent Assessment in the International Space Station (ISS) Program. Independent Assessment is responsible for identifying and specifying technical and programmatic risks that may impact development, launch, and on-orbit assembly and operations of the ISS. The various phases of the assessment process are identified and explained. This paper also outlines current and future participation by Independent Assessment in Human Exploration and Development of Space projects including the X-38 Space Plane, Mars mission scenarios, and applications of Nanotechnology. This paper describes how Independent Assessment helps the shuttle, ISS, and other programs to safely achieve mission goals now and into the next century.

Strachan, Russell L.↗