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Safety, reliability and quality assurance design analysis results are presented as well as design requirements recommended for implementation in the PEP design.
Although design analyses of a G-90 graphite integral throat entrance for the Antares 3 solid rocket motor nozzle indicated acceptable margins of safety, the nozzle throat insert suffered a thermostructural failure during the first development firing. Subsequent re-analysis using properties measured on material from the same billet as the nozzle throat insert showed negative margins. Carbon-carbon was investigated and found to result in large positive margins of safety. The G-90 graphite was replaced by SAI fast processed 4-D material which uses Hercules HM 10000 fiber as the reinforcement. Its construction allows powder filling of the interstices after preform fabrication which accelerates the densification process. Allied 15V coal tar pitch is then used to complete densification. The properties were extensively characterized on this material and six nozzles were subjected to demonstration, development and qualification firings.
An overview of the library's design will be presented, along with mission adaptation experiences and lessons learned, and the kinds of additional functionality that have been added while still retaining its multimission character. The application programs using the library will also be briefly described.
The Multimission Ground Data System was designed as a generic data system to meet the needs of multiple missions and avoid re-inventing capabilities for each new mission and thus reduce costs.
The interdependence of technology development, conceptual design, and system analysis is examined in the context of an overall systems engineering set of processes. In particular, the role of technology portfolio management - from initial investment decision-making all the way through technology maturation and transfer to industry - is emphasized. Additionally, the role of state of the art assessments is considered in terms of planning and tracking progress towards the development of enhanced predictive capabilities.
NASA designed a test rig, High-Pressure Oxygen Generation Assembly (HPOGA) to test a novel method of electrolysis as an alternative technology to the state-of-the-art Oxygen Generation Assembly (OGA) currently on the International Space Station (ISS). This approach involves utilizing a specialized electrolysis cell stack designed to both generate and compress high-pressure oxygen up to 3600 PSIG. The design eliminates the need for an external compressor and hydrogen separator, streamlining the oxygen generation process. HPOGA tests the viability of an electrolysis cell stack for extended life usage. Within the system, there are several key subsystems: nitrogen, high/low pressure oxygen, hydrogen, water recirculation, and water injection. The water injection subsystem supplies deionized (DI) water to a centralized reservoir for consumption. Subsequently, a water recirculation loop transfers the DI water across the cathode side of the electrolysis cell stack with constant flow rate. The result is a supply of hydrogen in the water loop and oxygen accumulation on the anode side of the cell stack. Hydrogen is evaporated out as part of the hydrogen sub-system which also measures hydrogen/oxygen concentration for safety. The oxygen subsystem is responsible for managing high pressure oxygen, O2 exhaust, and conducting hydrogen/oxygen concentration measurements. The nitrogen subsystem serves dual functions, purging the hydrogen/oxygen subsystems, and regulating pressure in both high/low-pressure O2 sections via pneumatic back pressure regulators. Various sensors monitor pressure, temperature, humidity, gas concentration and flow rate in each subsystem. This paper presents the design and testing of a comprehensive test stand, which serves to operate and functionally verify the performance of the electrolysis cell while offering valuable lessons learned.
With the resurgence of interest in molten salt reactors, there is a need for new experiments and modeling capabilities to characterize the unique phenomena present in this fluid fuel system. A Versatile Experimental Salt Irradiation Loop (VESIL) is currently under investigation at Idaho National Laboratory to be placed in the Advanced Test Reactor (ATR). One of the key phenomena this proposed experiment plans to elucidate is fission product speciation in the fuel-salt and the subsequent effects this has on the fuel-salt properties, source term generation, and corrosion control. Specifically, noble gases (Xe & Kr) will bubble out to a plenum or off-gas system, and noble metals (Mo, Tc, Te, etc.) will precipitate and deposit in specific zones in the loop. This work extends the mass transfer and species interaction models in CTF (Coolant-Boiling in Rod Arrays—Two Fluids) and applies these models to give a preliminary estimation of fission product behavior in the proposed VESIL design. A noble metal–helium bubble mass transfer model is coupled with the thermal-hydraulic results from CTF to determine the effectiveness of this insoluble fission product (IFP) extraction method for VESIL. Amounts of IFP species extracted to the off-gas system and species distributions in VESIL after a 60-day ATR cycle are reported.
This document establishes the design guideline of the Modular Instrumentation Data Acquisition (MI‐DAQ) system in utilization of several designs available in EV. The MI‐ DAQ provides the options to the customers depending on their system requirements i.e. a 28V interface power supply, a low power battery operated system, a low power microcontroller, a higher performance microcontroller, a USB interface, a Ethernet interface, a wireless communication, various sensor interfaces, etc. Depending on customer's requirements, the each functional board can be stacked up from a bottom level of power supply to a higher level of stack to provide user interfaces. The stack up of boards are accomplished by a predefined and standardized power bus and data bus connections which are included in this document along with other physical and electrical guidelines. This guideline also provides information for a new design options. This specification is the product of a collaboration between NASA/JSC/EV and Texas A&M University. The goal of the collaboration is to open source the specification and allow outside entities to design, build, and market modules that are compatible with the specification. NASA has designed and is using numerous modules that are compatible to this specification. A limited number of these modules will also be released as open source designs to support the collaboration. The released designs are listed in the Applicable Documents.
With the increase of interests in the design and deployment of advanced reactor systems, a desire for simulation tools supporting system analysis of reactor operation and safety is rising. Molten salt reactors (MSRs), one of the advanced reactor systems, utilize liquid fused salt fuel as both coolant and fuel. During operation, MSR generates insoluble fission products, including noble metals and gases. The buildup of these species in fuel salt presents safety concerns as they may deposit on surfaces of critical components and produce excessive decay heat, causing the failure of system components. Timely removal of these noble metals and gases would ensure the safe operation of the reactor system. The dynamic nature of salt fuel system, involving the generation, decay, deposition, and extraction of noble metals and gases, calls for robust species transport models to facilitate system analysis and monitoring, and design of efficient species removal components. This paper concentrates on the development of a computational framework for species transport, consisting of multiphase transport model formulation, mass transfer between phases, numerical implementation in MOOSE environment, verification through Method of Manufacture Solutions (MMS) and validation against experimental data from the Molten Salt Reactor Experiment (MSRE). Integrating this framework into the System Analysis Module (SAM) code further enhances SAM’s capabilities for advanced reactor analysis in the future.
In 2017, the Chinese government announced an ambitious, broad strategy to become the global leader in artificial intelligence (AI) theories, technologies, and applications by 2030 and indicated that China’s ability to indigenously produce cutting-edge AI chips would be integral to its success. China’s goal to become a dominant producer of AI hardware within a decade is a bold undertaking because China faces domestic chip production challenges and fierce competition from US chip producers. Our review of Chinese AI chip product lines shows various levels where Chinese companies compete with global firms in the production chain. China lacks a robust indigenous AI chip production infrastructure, and the United States and its allies are tightening controls on the supply of advanced semiconductor manufacturing equipment (SME) and electronic design automation (EDA) software to China. In contrast to their Chinese counterparts, US companies operate in all areas of AI chip production and have consistently driven the development of new chip designs. AI chip production is a costly endeavor, and China’s chip producers currently lack the customer base to lead global AI chip development by the 2030 goal. An expanded customer base may help China attract the necessary expertise to bolster its AI chip production chain. This would also help Chinese producers make their investments in the requisite technology economically sustainable. Chinese researchers continue to pursue promising next-generation AI chip designs, such as neuromorphic computing-based architectures, which in the next five to ten years could position Chinese companies to make or contribute to key innovations in the field.
This is a report documenting the details of my work as a NASA KSC intern for the Summer Session from June 2nd to August 8th, 2014. This work was conducted within the Design Visualization Group, a Contractor staffed organization within the C1 division of the IT Directorate. The principle responsibilities of the KSC Design Visualization Group are the production of 3D simulations of NASA equipment and facilities for the purpose of planning complex operations such as hardware transportation and vehicle assembly. My role as an intern focused on aiding engineers in using 3D scanning equipment to obtain as-built measurements of NASA facilities, as well as using CATIA and DELMIA to process this data. My primary goals for this internship focused on expanding my CAD knowledge and capabilities, while also learning more about technologies I was previously unfamiliar with, such as 3D scanning. An additional goal of mine was to learn more about how NASA operates, and how the U.S. Space Program operates on a day-to-day basis. This opportunity provided me with a front-row seat to the daily maneuvers and operations of KSC and NASA as a whole. Each work day, I was able to witness, and even take part of, a small building block of the future systems that will take astronauts to other worlds. After my experiences this summer, not only can I say that my goals have been met, but also that this experience has been the highlight of my experience in higher education.
The feasibility of reducing data volume and data rate is evaluated for the Earth Observing System (EOS) Synthetic Aperture Radar (SAR). All elements of data stream from the sensor downlink data stream to electronic delivery of browse data products are explored. The factors influencing design of a data compression system are analyzed, including the signal data characteristics, the image quality requirements, and the throughput requirements. The conclusion is that little or no reduction can be achieved in the raw signal data using traditional data compression techniques (e.g., vector quantization, adaptive discrete cosine transform) due to the induced phase errors in the output image. However, after image formation, a number of techniques are effective for data compression.
Recent studies have focused on optimising wave energy converter (WEC) designs, maximising their power performance and techno-economic feasibility. Reliability has yet to be fully considered in these formulations, despite its impact on cost and performance. In this study, this gap is addressed by developing a reliability-based design optimisation framework for WEC hull geometries to explore the trade-off between power performance and power take-off (PTO) system damage equivalent loading (DEL). Optimised hull geometries for two sites are considered (from the centre of the North Sea and off the west coast of Norway), and two directions of motions (heave and surge). Results indicate that site characteristics affect the potential power production and DEL for an optimal WEC design. These are also affected by the direction of motion for power extraction, which also significantly changes optimal hull shape characteristics. Optimal surging WEC designs have edges facing oncoming wave directions, while heaving WECs have pointed bottoms, both to streamline movement. Larger, more convex WECs result in greater power production and DEL, while smaller, more concave WECs result in lesser power production and DEL. These findings underline the importance of considering WEC hull geometry in early design processes to optimise cost, power production, and reliability.
As the global trauma fixation devices market expands rapidly, it is imperative to improve the production of fixation devices through enhanced design accuracy and fit for best performance and maximum patient comfort. Selective laser melting (SLM) is one of the mature additive manufacturing methods, which provides a viable route for the rapid production of such devices. In this work, the ability of SLM to produce near-net-shape parts, as desired for medical implants, was utilized for the fabrication of bone plates from Ti-6Al-4V alloy powder. Martensitic microstructure obtained after the printing of alloy resulted in poor ductility, limiting its application in the field of orthopedics. A specially designed repeated cyclic heating and cooling close to but below the β-transus was used to transform from acicular to a bimodal microstructure without the need for plastic deformation prior to heat treatment for improving the ductility. Bone plates subjected to this heat treatment were mechanically tested by means of tensile and 3-point bend tests and demonstrated large improvement in ductility, and the values were comparable to those similar plates prepared from wrought alloy. Other important properties required for implants were assessed, such as corrosion resistance in simulated body fluid and cytocompatibility in vitro using MC3T3-E1 cells. These results for the bone plate after heat treatment were excellent and similar to those of the additively manufactured and wrought plates. Taken together, the performance of the additively manufactured bone plates after subjecting to heat treatment was similar to those of bone plate manufactured using wrought alloy. These results have important implications for the fabrication of patient-specific metallic orthopedic devices using SLM without compromising their biomechanical performance by subjecting them to a tailored heat treatment.
NASA’s Mars Architecture Team (MAT) has recently developed a collection of concepts to assess the capabilities and constraints presented by architectures incorporating large-scale Mars In-Situ Resource Utilization (ISRU) propellant production. The focus of this manuscript is on the concept design of chemical propellant-based transportation systems including a dual role lander/ascent vehicle and an in-space transporter. Mission performance analyses performed during a recent design analysis cycle derived the 300,000 kg propellant production capacity utilized for preliminary concept designs of enabling surface ISRU systems, power systems, fluid handling systems, and their concept of operation, detailed in companion papers.
NASA’s Mars Architecture Team (MAT) has recently developed a collection of concepts to assess the capabilities and constraints presented by architectures incorporating large-scale Mars In-Situ Resource Utilization (ISRU) propellant production. The focus of this manuscript is on the concept design of chemical propellant-based transportation systems including a dual role lander/ascent vehicle and an in-space transporter. Mission performance analyses performed during a recent design analysis cycle derived the 300,000 kg propellant production capacity utilized for preliminary concept designs of enabling surface ISRU systems, power systems, fluid handling systems, and their concept of operation, detailed in companion papers.
Directed self-assembly (DSA) of block copolymers (BCPs) is one of the most promising developments in the cost-effective production of nanoscale devices. The process makes use of the natural tendency for BCP melts to form nanoscale structures upon phase separation. The phase separation can be directed through the use of chemically patterned substrates to promote the formation of morphologies that are essential to the production of semiconductor devices. Moreover, the design of substrate pattern can be formulated as an optimization problem for which we seek optimal substrate designs that effectively produce given target morphologies. In this paper, we adopt a phase field model given by a nonlocal Cahn–Hilliard partial differential equation (PDE) based on the minimization of the Ohta–Kawasaki free energy, and present an efficient PDE-constrained optimization framework for the optimal design problem. The design variables are the locations of circular- or strip-shaped guiding posts that are used to model the substrate chemical pattern. To solve the ensuing optimization problem, we propose a variant of an inexact Newton conjugate gradient algorithm tailored to this problem. Additionally, we demonstrate the effectiveness of our computational strategy on numerical examples that span a range of target morphologies. Owing to our second-order optimizer and fast state solver, the numerical results demonstrate five orders of magnitude reduction in computational cost over previous work. The efficiency of our framework and the fast convergence of our optimization algorithm enable us to rapidly solve the optimal design problem in not only two, but also three spatial dimensions.
The Flight Production Process (FPP) Re-engineering project has established a Model-Based Systems Engineering (MBSE) methodology and the technological infrastructure for the design and development of a reference, product-line architecture as well as an integrated workflow model for the Mission Operations System (MOS) for human space exploration missions at NASA Johnson Space Center. The design and architectural artifacts have been developed based on the expertise and knowledge of numerous Subject Matter Experts (SMEs). The technological infrastructure developed by the FPP Re-engineering project has enabled the structured collection and integration of this knowledge and further provides simulation and analysis capabilities for optimization purposes. A key strength of this strategy has been the judicious combination of COTS products with custom coding. The lean management approach that has led to the success of this project is based on having a strong vision for the whole lifecycle of the project and its progress over time, a goal-based design and development approach, a small team of highly specialized people in areas that are critical to the project, and an interactive approach for infusing new technologies into existing processes. This project, which has had a relatively small amount of funding, is on the cutting edge with respect to the utilization of model-based design and systems engineering. An overarching challenge that was overcome by this project was to convince upper management of the needs and merits of giving up more conventional design methodologies (such as paper-based documents and unwieldy and unstructured flow diagrams and schedules) in favor of advanced model-based systems engineering approaches.