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DOE OSTI2013

Efficient simulation of press hardening process through integrated structural and CFD analyses

Press hardened steel parts are being increasingly used in automotive structures for their higher strength to meet safety standards while reducing vehicle weight to improve fuel consumption. However, manufacturing of sheet metal parts by press hardening process to achieve desired properties is extremely challenging as it involves complex interaction of plastic deformation, metallurgical change, thermal distribution, and fluid flow. Numerical simulation is critical for successful design of the process and to understand the interaction among the numerous process parameters to control the press hardening process in order to consistently achieve desired part properties. Until now there has been no integrated commercial software solution that can efficiently model the complete process from forming of the blank, heat transfer between the blank and tool, microstructure evolution in the blank, heat loss from tool to the fluid that flows through water channels in the tools. In this study, a numerical solution based on Altair HyperWorks® product suite involving RADIOSS®, a non-linear finite element based structural analysis solver and AcuSolve®, an incompressible fluid flow solver based on Galerkin Least Square Finite Element Method have been utilized to develop an efficient solution for complete press hardening process design and analysis. RADIOSS is used to handle the plastic deformation, heat transfer between the blank and tool, and microstructure evolution in the blank during cooling. While AcuSolve is used to efficiently model heat loss from tool to the fluid that flows through water channels in the tools. The approach is demonstrated through some case studies.

36 MATERIALS SCIENCE↗

NASA NTRS2001

Space Shuttle Navigation in the GPS Era

The Space Shuttle navigation architecture was originally designed in the 1970s. A variety of on-board and ground based navigation sensors and computers are used during the ascent, orbit coast, rendezvous, (including proximity operations and docking) and entry flight phases. With the advent of GPS navigation and tightly coupled GPS/INS Units employing strapdown sensors, opportunities to improve and streamline the Shuttle navigation process are being pursued. These improvements can potentially result in increased safety, reliability, and cost savings in maintenance through the replacement of older technologies and elimination of ground support systems (such as Tactical Air Control and Navigation (TACAN), Microwave Landing System (MLS) and ground radar). Selection and missionization of "off the shelf" GPS and GPS/INS units pose a unique challenge since the units in question were not originally designed for the Space Shuttle application. Various options for integrating GPS and GPS/INS units with the existing orbiter avionics system were considered in light of budget constraints, software quality concerns, and schedule limitations. An overview of Shuttle navigation methodology from 1981 to the present is given, along with how GPS and GPS/INS technology will change, or not change, the way Space Shuttle navigation is performed in the 21 5 century.

Goodman, John L.↗

DOE OSTI2021

HyRAM+ (Hydrogen Plus Other Alternative Fuels Risk Assessment Models) v.4.0

HyRAM+ is a software toolkit for conducting quantitative risk assessment (QRA) and consequence modeling for hydrogen and other alternative fuels infrastructure and transportation systems. HyRAM+ contains validated, simplified release behavior models, a standardized QRA approach, and engineering models and generic data relevant to hydrogen installations. HyRAM (hydrogen-only) versions 1.0 to 3.1 were developed by Sandia for the U.S. Department of Energy (DOE) Hydrogen and Fuel Cell Technologies Office (HFTO). The U.S. DOE Vehicle Technologies Office (VTO) and U.S. Department of Transportation (DOT) Pipeline and Hazardous Material Safety Administration (PHMSA) contributed to the development of HyRAM+ version 4.0 regarding the addition of methane (natural gas) and propane models. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525. SAND2021-10862 O

Groth, Katrina↗

DOE OSTI2022

HyRAM+ (Hydrogen Plus Other Alternative Fuels Risk Assessment Models) v.4.1.1

Groth, Katrina↗

DOE OSTI2024

HyRAM+ (Hydrogen Plus Other Alternative Fuels Risk Assessment Models) v.5.1.1

Groth, Katrina↗

NASA NTRS2003

An Evaluation of Electronic Nose for Space Program Applications

The ability to monitor air contaminants in the Shuttle and the International Space Station is important to ensure the health and safety of astronauts. Three specific space applications have been identified that would benefit from a chemical monitor: organic contaminants in crew cabins, propellant contaminants in the airlock, and pre-combustion fire detection. NASA has assessed several commercial and developing electronic noses (e-noses) for these applications. A preliminary series of tests identified those e-noses that exhibited sufficient sensitivity to the vapors of interest. These e-noses were further tested to assess their ability to identify vapors, and in-house software has been developed to enhance identification. This paper describes the tests, the classification ability of selected e-noses, and the software improvements made to meet the requirements for these space program applications.

Young, Rebecca C.↗

NASA NTRS2005

Experimental Validation: Subscale Aircraft Ground Facilities and Integrated Test Capability

Experimental testing is an important aspect of validating complex integrated safety critical aircraft technologies. The Airborne Subscale Transport Aircraft Research (AirSTAR) Testbed is being developed at NASA Langley to validate technologies under conditions that cannot be flight validated with full-scale vehicles. The AirSTAR capability comprises a series of flying sub-scale models, associated ground-support equipment, and a base research station at NASA Langley. The subscale model capability utilizes a generic 5.5% scaled transport class vehicle known as the Generic Transport Model (GTM). The AirSTAR Ground Facilities encompass the hardware and software infrastructure necessary to provide comprehensive support services for the GTM testbed. The ground facilities support remote piloting of the GTM aircraft, and include all subsystems required for data/video telemetry, experimental flight control algorithm implementation and evaluation, GTM simulation, data recording/archiving, and audio communications. The ground facilities include a self-contained, motorized vehicle serving as a mobile research command/operations center, capable of deployment to remote sites when conducting GTM flight experiments. The ground facilities also include a laboratory based at NASA LaRC providing near identical capabilities as the mobile command/operations center, as well as the capability to receive data/video/audio from, and send data/audio to the mobile command/operations center during GTM flight experiments.

Bailey, Roger M.↗

NASA NTRS2004

Innovative Technology Transfer Partnerships

The National Aeronautics and Space Administration (NASA) seeks to license its Advanced Tire and Strut Pressure Monitor (TSPM) technology. The TSPM is a handheld system to accurately measure tire and strut pressure and temperature over a wide temperature range (20 to 120 OF), as well as improve personnel safety. Sensor accuracy, electronics design, and a simple user interface allow operators quick, easy access to required measurements. The handheld electronics, powered by 12-VAC or by 9-VDC batteries, provide the user with an easy-to-read visual display of pressure/temperature or the streaming of pressure/temperature data via an RS-232 interface. When connected to a laptop computer, this new measurement system can provide users with automated data recording and trending, eliminating the chance for data hand-recording errors. In addition, calibration software allows for calibration data to be automatically utilized for the generation of new data conversion equations, simplifying the calibration processes that are so critical to reliable measurements. The design places a high-accuracy pressure sensor (also used as a temperature sensor) as close to the tire or strut measurement location as possible, allowing the user to make accurate measurements rapidly, minimizing the amount of high-pressure volumes, and allowing reasonable distance between the tire or strut and the operator. The pressure sensor attaches directly to the pressure supply/relief valve on the tire and/or strut, with necessary electronics contained in the handheld enclosure. A software algorithm ensures high accuracy of the device over the wide temperature range. Using the pressure sensor as a temperature sensor permits measurement of the actual temperature of the pressurized gas. This device can be adapted to create a portable calibration standard that does not require thermal conditioning. This allows accurate pressure measurements without disturbing the gas temperature. In-place calibration can save considerable time and money and is suitable in many process applications throughout industry.

Kohler, Jeff↗

NASA NTRS2013

Shuttle Repair Tools Automate Vehicle Maintenance

Successfully building, flying, and maintaining the space shuttles was an immensely complex job that required a high level of detailed, precise engineering. After each shuttle landed, it entered a maintenance, repair, and overhaul (MRO) phase. Each system was thoroughly checked and tested, and worn or damaged parts replaced, before the shuttle was rolled out for its next mission. During the MRO period, workers needed to record exactly what needed replacing and why, as well as follow precise guidelines and procedures in making their repairs. That meant traceability, and with it lots of paperwork. In 2007, the number of reports generated during electrical system repairs was getting out of hand-placing among the top three systems in terms of paperwork volume. Repair specialists at Kennedy Space Center were unhappy spending so much time at a desk and so little time actually working on the shuttle. "Engineers weren't spending their time doing technical work," says Joseph Schuh, an electrical engineer at Kennedy. "Instead, they were busy with repetitive, time-consuming processes that, while important in their own right, provided a low return on time invested." The strain of such inefficiency was bad enough that slow electrical repairs jeopardized rollout on several occasions. Knowing there had to be a way to streamline operations, Kennedy asked Martin Belson, a project manager with 30 years experience as an aerospace contractor, to co-lead a team in developing software that would reduce the effort required to document shuttle repairs. The result was System Maintenance Automated Repair Tasks (SMART) software. SMART is a tool for aggregating and applying information on every aspect of repairs, from procedures and instructions to a vehicle s troubleshooting history. Drawing on that data, SMART largely automates the processes of generating repair instructions and post-repair paperwork. In the case of the space shuttle, this meant that SMART had 30 years worth of operations that it could apply to ongoing maintenance work. According to Schuh, "SMART standardized and streamlined many shuttle repair processes, saving time and money while increasing safety and the quality of repairs." Maintenance technicians and engineers now had a tool that kept them in the field, and because SMART is capable of continually evolving, each time an engineer put it to use, it would enrich the Agency-wide knowledge base. "If an engineer sees something in the work environment that they could improve, a repair process or a procedure, SMART can incorporate that data for use in future operations," says Belson.

Source record↗

NASA NTRS2018

Monitoring Astronaut Health with DNA Sequencing

In recent years microbe a plethora of microbe populations have been identified onboard the ISS (International Space Station). Approaches for real-time tracking of microbes for routine housekeeping and food/water safety monitoring will be critical for mission safety and crew health on future longer duration missions to the Moon or Mars. This work is a proof-of-concept study demonstrating an end-to-end phylogenetic identification and full genome sequencing effort of multiple microbial populations. Our methodology utilized the ISS flight-certified WetLab-2 molecular toolbox and the Biomolecule Sequencer projects for real-time end-to-end on-orbit microbial biological samples processing and molecular analysis with real time results generated utilizing only field "offline" analytic software. For this experiment we colony-cultured several ISS isolated microorganisms before generation of the pre-sequencing library via the automated VolTRAX device which enabled high library turnover with little wet-bench activity or potential future costly astronaut time. The pre-sequencing library is diluted in loading buffer and injected into the MinION sample port, drawn into the nanopore window by capillary action, and sequenced using the MinKnown. 16S and full genome alignment, nucleotide matching, gene identification, and phylogenetic sorting was accomplished utilizing the Epi2me software and the offline NCBI Blast viral, microbiome, and human somatic databases. In short, the methodologies developed herein replace the myriad of specific, often highly targeted microbiological tests used in the clinical laboratory, which would be difficult if not impossible to currently implement aboard the ISS or in deep space, with a single metagenomics test.

genomics↗

DOE OSTI2022

Domain-Specific Type-Safe APIs for Hierarchical Scientific Data with Modern C++

General-purpose library application programming interfaces (APIs) for self-describing hierarchical scientific data storage, such as the HDF5 and NetCDF libraries, are traditionally of runtime nature. Runtime errors for entry existence and data types are typically caught later in the development process of higher-level application-specific APIs. In this paper, we propose exploiting modern C++ metaprogramming features to add compile-time type-safety to improve the interaction with a well-defined metadata-rich scientific schema in domain-specific hierarchical datasets. We tackle two aspects of common use: (i) direct data access, (ii) flexible “in-memory” index models for efficient search and data processing. The proposed APIs use C++17’s template type auto deduction features, C++11’s enum class for type-safety and C-style preprocessor macros for generative templated code. We showcase the pros and cons of our initial work on the standard NeXus schema used for annotating and storing experimental neutron scattering data at several facilities around the world on top of HDF5. Extendable compile-time type-safe APIs are a desirable feature that could be indexed by any modern integrated development environment (IDE). Hence, such APIs can help ease the learning curve for domain scientists using a less error-prone software interaction to enhance the findability of their data without resorting to a domain-specific language (DSL).

Godoy, William↗

DOE OSTI2013

Hygrothermal Simulations of Foundations: Part 1 - Soil Material Properties

Hygrothermal performance of soils coupled to buildings is a complicated process. The computational approach for heat transfer via the ground is well defined (EN-ISO-13370:, 2007) together with simplified methods (Staszczuk, Radon, & Holm). Though the soil moisture transfer is generally ignored, it is proven not negligible (Janssen, Carmeliet, & Hens, 2004). Even though reliable material properties of soils are required to perform realistic hygrothermal calculations of soils coupled to buildings, such material properties have not been well defined in hygrothermal calculations tools. Typical building constructions which are greatly influenced by soils are basements, crawl spaces and slab on grade and reliable hygrothermal performance of such construction are highly requested; as it is ranked within the top 10 Building America Enclosure Research Ideas according to Enclosures STC - Residential Energy Efficiency Stakeholder Meeting, February 29, 2012 Austin, TX. There exists an extensive amount of measurements on soil properties in Soil Science though this information must be gathered as well as adapted to be applicable in Building Science and for hygrothermal simulation purposes. Soil properties are important when analyzing and designing both new building constructions and retrofitting measures, where the outer boundary of the buildings enclosure consists of soil materials. Concerning basement energy retrofits, interior solutions of improving the energy demand has to cooperate with the existing soil properties and must therefore be designed thereafter. In concerns of exterior retrofits, the soil material can be replaced, if needed, with a more suitable filling material, though this approach applies only for basement walls. The soil material beneath the basement floor can naturally not be replaced hence the soil properties of this part of the buildings enclosure still must be taken into consideration. This study is divided into several parts. The intention of the first part is to gather, comprehend and adapt soil properties from soil science. The obtained information must be applicable for Building Science related tasks and validated in hygrothermal calculation tools hence the second part of this study will focus on validation of the implemented soil properties. Basic changes in the software code may be requested as well. Different basement constructions will be created with a hygrothermal calculation tool, WUFI, from which simulations will be compared with existing or on-going measurements. The final outcome of the study is to enable an evaluation of several soil types in several climate zones combined with a number of basement assemblies. The study will define which type of soil together with a certain building construction which is considered most and least reliable in concerns of energy consumption and moisture safety. Further, what influences different soils will have on the total energy loss via the ground and if the performance of a different soils can be measured by a comparison of soil properties solely.

Pallin, Simon B↗

NASA NTRS1991

Data acquisition and analysis on a Macintosh

The introduction of inexpensive analog-to-digital boards for the Macintosh opens the way for its use in areas that have previously been filled by either specialized, dedicated or more expensive mainframe based systems. Two such Macintosh-based systems are the Acoustic Laboratory Data Acquisition System (ALDAS) and the Jet Calibration and Hover Test Facility (JCAHT) data acquisition system. ALDAS provides an inexpensive, transportable means to digitize four channels at up to 50,000 samples per second and analyze this data. The ALDAS software package was written for use with rotorcraft acoustics and performs automatic acoustic calibration of channels, data display, and various types of data analysis. The program can use data obtained either from internal analog-to-digital conversion or discrete external data imported in ASCII format. All aspects of ALDAS can be improved as new hardware becomes available and new features are introduced into the code. The JCAHT data acquisition system was built as not only an analysis program but also to act as the online safety monitoring system. This paper will provide an overview of these systems.

Watts, Michael E.↗

NASA NTRS2017

Safeguard: Progress and Test Results for a Reliable Independent On-Board Safety Net for UAS

As demands increase to use unmanned aircraft systems (UAS) for a broad spectrum of commercial applications, regulatory authorities are examining how to safely integrate them without compromising safety or disrupting traditional airspace operations. For small UAS, several operational rules have been established; e.g., do not operate beyond visual line-of-sight, do not fly within five miles of a commercial airport, do not fly above 400 feet above ground level. Enforcing these rules is challenging for UAS, as evidenced by the number of incident reports received by the Federal Aviation Administration (FAA). This paper reviews the development of an onboard system - Safeguard - designed to monitor and enforce conformance to a set of operational rules defined prior to flight (e.g., geospatial stay-out or stay-in regions, speed limits, and altitude constraints). Unlike typical geofencing or geo-limitation functions, Safeguard operates independently of the off-the-shelf UAS autopilot and is designed in a way that can be realized by a small set of verifiable functions to simplify compliance with existing standards for safety-critical systems (e.g. for spacecraft and manned commercial transportation aircraft systems). A framework is described that decouples the system from any other devices on the UAS as well as introduces complementary positioning source(s) for applications that require integrity and availability beyond what can be provided by the Global Positioning System (GPS). This paper summarizes the progress and test results for Safeguard research and development since presentation of the design concept at the 35th Digital Avionics Systems Conference (DASC '16). Significant accomplishments include completion of software verification and validation in accordance with NASA standards for spacecraft systems (to Class B), development of improved hardware prototypes, development of a simulation platform that allows for hardware-in-the-loop testing and fast-time Monte Carlo evaluations, and flight testing on multiple air vehicles. Integration testing with NASA's UAS Traffic Management (UTM) service-oriented architecture was also demonstrated.

Young, Steven D.↗

DOE OSTI2017

Spanning the Core Design Space with Binary Perturbations - A Mathematical Investigation

A reactor core design engineer, even one with many years of experience or one using advanced fuel pattern optimization software, will likely fine tune the pattern before finalizing the design. Fine tuning can further minimize local enthalpy peaks, optimize reactivity to extend burnup, and add additional margin to limits on reactivity coefficients or heat flux. For reactors that have reached an equilibrium fuel cycle, the number of feeds each cycle is typically the similar to previous cycles as is their placement in the core. It is then the engineer's responsibly to efficiently select the placement of burned assemblies to ensure optimal fuel utilization, satisfy safety limits, and meet cycle energy requirements. One of the engineer's most commonly used tools in this fine tuning investigation is to swap the positions of two assemblies, most likely two previously irradiated ('burned') assemblies since their reactivity is lower than fresh fuel. Such an operation is referred to in this work as a binary perturbation or a 'swap'. If quarter core symmetry is maintained, the perturbation translates to the other three quadrants. Likewise if eighth core symmetry is maintained, the perturbation translates to other seven octants. The question is then, how much of the core design space can binary perturbations possibly span? This work seeks to quantitatively define the space spanned by m number of binary perturbations as a function of variable size through combinatorial principles and computer simulation. The results of this study are useful in understanding the in-core fuel management problem faced by both professionals who employ hand manipulations and those who attempt stochastic solutions of the problem.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2014

SU-E-T-277: Raystation Electron Monte Carlo Commissioning and Clinical Implementation

Purpose: To evaluate the Raystation v4.0 Electron Monte Carlo algorithm for an Elekta Infinity linear accelerator and commission for clinical use. Methods: A total of 199 tests were performed (75 Export and Documentation, 20 PDD, 30 Profiles, 4 Obliquity, 10 Inhomogeneity, 55 MU Accuracy, and 5 Grid and Particle History). Export and documentation tests were performed with respect to MOSAIQ (Elekta AB) and RadCalc (Lifeline Software Inc). Mechanical jaw parameters and cutout magnifications were verified. PDD and profiles for open cones and cutouts were extracted and compared with water tank measurements. Obliquity and inhomogeneity for bone and air calculations were compared to film dosimetry. MU calculations for open cones and cutouts were performed and compared to both RadCalc and simple hand calculations. Grid size and particle histories were evaluated per energy for statistical uncertainty performance. Acceptability was categorized as follows: performs as expected, negligible impact on workflow, marginal impact, critical impact or safety concern, and catastrophic impact of safety concern. Results: Overall results are: 88.8% perform as expected, 10.2% negligible, 2.0% marginal, 0% critical and 0% catastrophic. Results per test category are as follows: Export and Documentation: 100% perform as expected, PDD: 100% perform as expected, Profiles: 66.7% perform as expected, 33.3% negligible, Obliquity: 100% marginal, Inhomogeneity 50% perform as expected, 50% negligible, MU Accuracy: 100% perform as expected, Grid and particle histories: 100% negligible. To achieve distributions with satisfactory smoothness level, 5,000,000 particle histories were used. Calculation time was approximately 1 hour. Conclusion: Raystation electron Monte Carlo is acceptable for clinical use. All of the issues encountered have acceptable workarounds. Known issues were reported to Raysearch and will be resolved in upcoming releases.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

STAT7 v1.2 User Guide: The STAT7 Code for Statistical Propagation of Uncertainties in Steady-State Thermal Hydraulics Analysis of Plate-Fueled Reactors

The STAT7 software was developed to perform steady-state, single-phase thermal hydraulics analysis of plate-fueled reactors based on statistical propagation of uncertainties. Application of the software is for non-power research and test reactors, including conversion to low-enriched uranium fuel of U.S. High-Performance Research Reactors such as Massachusetts Institute of Technology Research Reactor. Since it can be necessary to repeat analysis during fuel reloading, STAT7 accommodates flexibility in analyzing many realistic aspects of reactor fuel management. STAT7 uses a Monte Carlo approach to model uncertainty in common fuel fabrication parameters and other key reactor operating parameters required for thermal hydraulics analyses of research and test reactors. These safety calculations are ultimately intended to protect against high fuel plate temperatures due to critical heat flux, or onset of flow instability. STAT7 supports water properties based on the IAPWS-IF97 functions (The International Association for the Properties of Water and Steam Industrial Formulation 1997 for the Thermodynamic Properties of Water and Steam) in addition to the fit functions. STAT7 predicts axial profiles of fuel, cladding, and coolant temperature along a lateral stripe that runs the full length of the fuel plate from the bottom to the top. STAT7 can simultaneously analyze all of the axial nodes of all of the fuel plates and all of the coolant channels for one latera stripe of a fuel element. Power splits are calculated for each axial node of each plate to determine how much of the power goes out each face of the plate. By running STAT7 multiple times, full core analysis can be performed by analyzing the margin to onset of nucleate boiling and onset of flow instability for each axial node of each stripe of each plate of each fuel element in the core.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1990

Jet Propulsion Laboratory/Kennedy Space Center telerobotic inspection and manipulation demonstration

The goal of this effort is to demonstrate telerobotic inspection and mainpulation of space shuttle payloads in the presence of substantial communications time delays between the operator station and the robotic work space. The processing of space shuttle payloads provides a variety of tasks which are typical of both space shuttle ground operations and Space Station in-flight operations, and communications time delays are inevitable in space operations where the operator station will be light-seconds away from the telerobot. With this demonstration we hope to show the efficacy and safety of robotic technology for ground and space operations. Our approach is to develop an experimental telerobotic system with the remote sensing, actuation and reflex portions located at KSC in Florida, while the operator control station will be located at Jet Propulsion Laboratory (JPL) in California. The JPL portion of the system includes a high-level operator interface, intelligent spatial planning and machine vision, while the KSC portion includes the robot arm, end effectors, cameras and proximity sensors, and the necessary control and communications computers and software. The communications between JPL and KSC are over a limited-bandwidth network channel (19200 baud) with unpredictable and unrepeatable time delays. In FY89 we integrated a basic version of the robotic, communications, and computer hardware, and we developed the software to perform an operator-supervised inspection of a PAM-D satellite upper stage rocket motor and its shuttle support cradle. The demonstration, though severely limited by the bulk of the available computer arm, showed the potential of telerobotics for inspection tasks. In the future, we plan to develop additional capabilities which will allow manipulation tasks to be performed, including removal of dust covers and lens caps, insertion of connectors and batteries, and installation of payload objects.

Wilcox, Brian↗