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DOE OSTI2025

Sequential Infiltration Synthesis of Multinary Metal Oxides: The Role of Precursor Diffusion and Reactivity

Understanding volatile metal–organic precursor transport in polymer matrices during sequential infiltration synthesis (SIS) is critical to the design of hybrid materials of tailored composition and uniform structure. Here, we investigate the diffusion and reaction behavior of diethylzinc (DEZ) in poly(methyl methacrylate) (PMMA) matrices with variable indium and zinc incorporation. Unlike conventional SIS where precursors adduct or react directly with the polymer backbone, DEZ shows minimal interaction with PMMA. However, DEZ may interact strongly with In–OH or Zn–OH moieties that are previously incorporated into a PMMA thick film. Using spectroscopic ellipsometry, X-ray photoelectron spectroscopy depth profiling, and EDX line scans, we quantify Zn incorporation as a function of exposure time, polymer thickness, and previous infiltration steps. The Zn distribution evolves from surface-localized to deep within the ∼1 μm thick film with increasing DEZ exposures up to 30 min. A reaction-diffusion model incorporating a hindering factor to capture diffusivity decay due to product accumulation reproduces the Zn depth profile and yields physically meaningful parameters to guide future growth. Furthermore, this study provides a framework for interpreting metal–organic precursor infiltration behavior and highlights the utility of model-guided SIS process design.

diethylzinc↗

DOE OSTI2020

Adjoint-optimized nanoscale light extractor for nitrogen-vacancy centers in diamond

Abstract We designed a nanoscale light extractor (NLE) for the efficient outcoupling and beaming of broadband light emitted by shallow, negatively charged nitrogen-vacancy (NV) centers in bulk diamond. The NLE consists of a patterned silicon layer on diamond and requires no etching of the diamond surface. Our design process is based on adjoint optimization using broadband time-domain simulations and yields structures that are inherently robust to positioning and fabrication errors. Our NLE functions like a transmission antenna for the NV center, enhancing the optical power extracted from an NV center positioned 10 nm below the diamond surface by a factor of more than 35, and beaming the light into a ±30° cone in the far field. This approach to light extraction can be readily adapted to other solid-state color centers.

42 ENGINEERING↗

DOE OSTI2025

Coupling Waste Feedstocks to Microbial Protein Production in a Circular Food System

Global food production is a major contributor to greenhouse gas emissions, water consumption, and land use. As an alternative to conventional agriculture, the production of waste-derived microbial protein (MP) holds promise for reducing environmental impacts. MP can be mass-produced in volumetrically scalable fermentation processes on short time scales, enabling facile scale-up with lower greenhouse gas emissions, land use, and water impacts than animal and, in some cases, plant protein. MP can also be produced from waste feedstocks, diverting waste from landfills or the natural environment. This Perspective explores the availability and suitability of waste feedstocks for MP production, suggesting that MP generated from waste feedstocks in the United States could fulfill twice the current national protein demand. Here, we also discuss the biotechnological and separations processes required to produce food-grade MP for human consumption from waste. Key challenges include MP consistency, consumer and regulatory acceptance, and the process utilities (electricity, heat, and nutrients) that account for up to 85% of MP costs and most environmental impacts, all of which present opportunities for innovation in the microbiology and process design spaces. Overall, this work highlights the potential of MP to contribute to a more circular, resilient, and sustainable food system.

09 BIOMASS FUELS↗

DOE OSTI2025

Overcoming sparse datasets with multi-task learning as applied to high entropy alloys

Abstract The design of novel High Entropy Alloys for use in high-temperature applications is an area of active interest due to their potential to provide exceptional properties compared to conventional alloys. Since the increased popularity of machine learning, an important cog in the design process has been training surrogate models on alloy properties. However, these Single-Task models are trained on individual mechanical properties and do not take advantage of the relatedness between properties. Multi-Task models can capture the interdependencies between tasks, leading to potentially more accurate predictions for all tasks. In this paper, we investigate if Multi-Task models can show improvement over Single-Task models when used for predicting the mechanical properties of these alloys. To ensure fair evaluation between the models, we apply L 0 regularization and skip connections to the models, which allows them to adjust the number of model parameters and depth for optimal performance. We find that the Multi-Task models can leverage task relationships to perform better than Single-Task models, especially for high amounts of missing data in the tasks. Furthermore, adding simple auxiliary targets can boost Multi-Task performance even further despite not being effective as input descriptors to single-task models themselves. We anticipate that the proposed strategies can achieve more accurate predictions and consequently enable better design capabilities for such data-constrained domains without incurring much additional computational cost.

Debnath, Arindam (ORCID:0000000194274499)↗

DOE OSTI2024

Electrochemical CO 2 Conversion Commercialization Pathways: A Concise Review on Experimental Frontiers and Technoeconomic Analysis

Technoeconomic analysis (TEA) studies are vital for formulating guidelines that drive the commercialization of electrochemical CO 2 reduction (eCO 2 R) technologies. In this review, we first discuss the progress in the field of eCO 2 R processes by providing current state-of-the-art metrices (e.g., faradic efficiency, current density) based on the recent heterogeneous catalysts’ discovery, electrolytes, electrolyzers configuration, and electrolysis process designs. Next, we assessed the TEA studies for a wide range of eCO 2 R final products, different modes of eCO 2 R systems/processes, and discussed their relative competitiveness with relevant commercial products. Finally, we discuss challenges and future directions essential for eCO 2 R commercialization by linking suggestions from TEA studies. We believe that this review will catalyze innovation in formulating advanced eCO 2 R strategies to meet the TEA benchmarks for the conversion of CO 2 into valuable chemicals at the industrial scale.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Ion-Exchange Modeling of Crystalline Silicotitanate for Cesium Removal - 20283

The Tank Closure Cesium Removal (TCCR) system is a Savannah River Site (SRS) demonstration 'at-tank' process designed to remove {sup 137}Cs from the high-level aqueous tank waste so that the decontaminated solution can be disposed as low-level waste. Cesium is removed by ion exchange (IX) columns using engineered IONSIV{sup TM} R9120-B form of the Crystalline Silicotitanate (CST) media. The TCCR system is deployed at Tanks 10 and Tank 11 in the SRS H Tank Farm. Water is added to the salt-cake in Tank 10 H to dissolve it. The dissolved salt solution waste is pumped out of Tank 10H (feed tank), through filters and IX columns. The decontaminated salt solution is transferred to Tank 11 (receipt tank), and on to Tank 50H for final disposal in the Saltstone Production Facility. The current TCCR can accommodate lead-lag (two-column) or lead-lag-guard (three-column) configurations to optimize media utilization and achieve the target decontamination. To assist the TCCR operations, a parametric study was conducted to evaluate the impact of different parameters (e.g., column configurations (single column, two columns or three columns in series), waste characteristics, operating temperature, process flow rate, CST average particle size) on the IX column performance including CST bed utilization. The initial results indicate that the IX column performance is improved at slower process flow rate, at lower operating temperature, and with smaller CST average particle size. Multi-column configurations are recommended, because the single-column configuration does not utilize CST bed effectively. This paper demonstrates the versatility of the ion exchange modeling to evaluate the effects of CST characteristics and operational parameters on IX column performances. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Analysis of Postulated Accident Scenarios for the Transformational Challenge Reactor

The Transformational Challenge Reactor (TCR) is a helium-cooled, yttrium-hydride-moderated reactor that was designed for the U.S. Department of Energy Office of Nuclear Energy. A key objective of the TCR was to employ advanced manufacturing techniques in a nuclear system and demonstrate their potential for revolutionizing the nuclear reactor design process. One purpose of the present work is to demonstrate the safety of the TCR under postulated accidents. Based on RELAP5-3D and COMSOL analyses, the TCR remained below all current safety limits and far below the expected failure limits for the core materials. Another purpose of this work is to provide useful insights and recommendations regarding the application of RELAP5-3D to gas-cooled or other advanced reactors. A novel approach was implemented for simultaneously modeling conduction and radiation in RELAP5-3D, which was found to provide reasonable predictions of radial core, vessel, and ex-vessel heat transfer during postulated events. A multicode approach was also applied, in which high-fidelity COMSOL calculations were used to tune the radial heat transfer parameters in RELAP5-3D. The tuned RELAP5-3D model demonstrated comparable peak temperature predictions as COMSOL, despite a coarse treatment of the core in RELAP5-3D consisting of only two lumped heat structures. This high-fidelity tuning approach enabled enhanced accuracy as well as minimal complexity within the RELAP5-3D model, even for complex fuel geometric designs as in the TCR. Finally, investigations were made into the potential for flow reversal during a pressurized loss-of-forced-flow event in the TCR. The TCR is designed with downward helium flow through the core during normal operation. The RELAP5-3D model predicted that this downward flow would persist, without flow reversal, up to several days after the circulator trip. This was attributed to natural circulation hysteresis effects as have been noted in similar thermofluidic systems. Although flow stagnation and eventual reversal did not lead to unsafe TCR conditions, interesting spatial effects were observed which may have safety relevance for other reactor system designs and coolant types that are designed for downward core flow during normal operation, warranting closer investigation of the flow reversal phenomenon.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2011

Developing a Prototype ALHAT Human System Interface for Landing

The goal of the Autonomous Landing and Hazard Avoidance Technology (ALHAT) project is to safely execute a precision landing anytime/anywhere on the moon. This means the system must operate in any lighting conditions, operate in the presence of any thruster generated regolith clouds, and operate without the help of redeployed navigational aids or prepared landing site at the landing site. In order to reach this ambitious goal, computer aided technologies such as ALHAT will be needed in order to permit these landings to be done safely. Although there will be advanced autonomous capabilities onboard future landers, humans will still be involved (either onboard as astronauts or remotely from mission control) in any mission to the moon or other planetary body. Because many time critical decisions must be made quickly and effectively during the landing sequence, the Descent and Landing displays need to be designed to be as effective as possible at presenting the pertinent information to the operator, and allow the operators decisions to be implemented as quickly as possible. The ALHAT project has established the Human System Interface (HSI) team to lead in the development of these displays and to study the best way to provide operators enhanced situational awareness during landing activities. These displays are prototypes that were developed based on multiple design and feedback sessions with the astronaut office at NASA/ Johnson Space Center. By working with the astronauts in a series of plan/build/evaluate cycles, the HSI team has obtained astronaut feedback from the very beginning of the design process. In addition to developing prototype displays, the HSI team has also worked to provide realistic lunar terrain (and shading) to simulate a "out the window" view that can be adjusted to various lighting conditions (based on a desired date/time) to allow the same terrain to be viewed under varying lighting terrain. This capability will be critical to determining the effect of terrain/lighting on the human pilot, and how they use windows and displays during landing activities. The Apollo missions were limited to about 28 possible launch days a year due to lighting and orbital constraints. In order to take advantage of more landing opportunities and venture to more challenging landing locations, future landers will need to utilize sensors besides human eyes for scanning the surface. The ALHAT HSI system must effectively convey ALHAT produced information to the operator, so that landings can occur during less "optimal" conditions (lighting, surface terrain, slopes, etc) than was possible during Apollo missions. By proving this capability, ALHAT will simultaneously provide more flexible access to the moon, and greater safety margins for future landers. This paper will specifically focus on the development of prototype displays (the Trajectory Profile Display (TPD), Landing Point Designation (LPD), and Crew Camera View (CCV) ), implementation of realistic planetary terrain, human modeling, and future HSI plans.

Hirsh, Robert L.↗

NASA NTRSDate not supplied

The Effect of Fiber-Angle Fidelity on the Linear Response of Tow-steered Composite Plates

Composite laminate tailoring is traditionally performed by uniformly changing the in-plane ply orientation to obtain the desired mechanical performance. The emergence of tow-steered plies, where the fibers follow a prescribed curvilinear path, have increased the tailorability of composite laminates. However, characterizing the behavior of tow-steered laminates using finite element analysis is challenging because additional, and often numerous, orientation definitions may be required. The additional orientation definitions detrimentally increase the computational cost and hinder the use of advanced analysis techniques, such as Monte Carlo or uncertainty quantification, in the design process. To reduce computational cost without adversely affecting mechanics-based performance, the results of a parametric study that was used to investigate the effects of fiber-angle fidelity, element size, and tow-steered radius-of-curvature on various loading scenarios for tow-steered composite plates are presented. The three loading scenarios that were analyzed using finite element analysis included an axial tension load, an applied constant through-thickness-direction pressure load, and an axial compression load. Results for mechanics-based metrics of interest are presented and discussed for each loading scenario. Little sensitivity (less than one percent difference) to the effect of fiber-angle fidelity is observed in the mechanics-based metrics until the coarse-end of the considered range. Sensitivity to element size generally dominates the observed results for the mechanics-based metrics. Notable reductions in the preprocessing time are observed for increasingly coarse element size and fiber-rounding parameters. The preprocessing times decreased up to three orders of magnitude from a few thousand seconds to a few seconds without loss of accuracy in the mechanics-based metrics. Such increased computational performance is of particular interest to the structural design and analysis communities that may be conducting large counts of finite-element analyses, such as in other parametric studies, Monte-Carlo analyses, uncertainty quantification, or tow-steered optimization.

tow-steered composites↗

DOE OSTI2020

Predicting Device Parameters for Dye-Sensitized Solar Cells from Electronic Structure Calculations to Reproduce Experiment.

Given that improvements to the power-conversion efficiency (PCE) of dye-sensitized solar cells (DSSCs) have slowed in recent years, a means to accurately predict the device parameters yielded by trial dyes in silico, without having to synthesize them, would be extremely valuable to speed up the design process. Currently, the best-performing methods of calculating device parameters rely on a set of experimentally determined kinetic coefficients. In practice, it is very difficult to measure these kinetic parameters accurately, limiting the overall accuracy of such predictive methods. This work proposes a model to obtain key parameters such as J(SC), V-OC, and PCE using only the results from density functional theory (DFT) and time-dependent DFT calculations, noting that rates of electron-transfer steps are ultimately linked to the electronic structure of the dye center dot center dot center dot TiO2 working electrode. Six organic DSSC dyes from dissimilar chemical classes (L0, L1, L2, WS-2, WS-92, and C281) were chosen to demonstrate the power of this approach. Their a priori known experimentally determined device performance metrics served to validate our predictions. The greatest absolute error in our predicted PCE values was 0.36% relative to the experiment, while the greatest fractional error was 0.042. This indicates that the proposed model offers a dramatic improvement on previous predictive methods for DSSC device parameters, both in accuracy and in consistency. Moreover, such a predictive model has great potential to be applied to other photovoltaic applications, further enabling the design of novel, highly efficient photoactive materials.

density functional theory↗

NASA NTRSDate not supplied

Lunar Mega Project: Processes, Work Flow and Terminology of the Terrestrial Construction Industry versus the Space Industry

Recent developments around the world show an increased interest and international activity toward developing a lunar surface human and robotic presence with a long term, sustainable vision. In Europe, the construction of a "Moon Village" has been proposed, and China has stated its intention to build a research station with a crew at the lunar South Pole. Russia stated it will land cosmonauts on the Moon in the 2030's. India has sent an orbiter, a robotic lander, and rover to the Moon. The USA intends to land the first woman and a man on the Moon by 2024 to initiate a sustained human lunar presence.A lunar research station with associated commercial activities will require infrastructure to become a permanent capability. Landing and launch pads, propellant storage and distribution farms, spacecraft access and handling structures, cranes, blast protection berms or walls, roads, graded areas, dust stabilized areas, foundations, parking lots, radiation shelters, micro-meteorite protection hangars, habitats and other human shelters, greenhouse farms, utility trenches, power plants, industrial water and oxygen extraction plants, communications antenna towers, thermal protection, mining zones, crater access and sub-surface access will be required to create a safe and sustainable lunar operations capability. This infrastructure will require significant construction activities in an extreme environment, with risky and expensive operations. On Earth, there are similar large and expensive projects (>$1 Billion) in difficult locations that attract a lot of public attention. These are known as "Mega Projects" and examples include bridges, tunnels, highways, railways, airports, seaports, power plants, dams, wastewater projects, Special Economic Zones (SEZ), oil and natural gas extraction projects, public buildings, information technology systems, aerospace projects, and weapons systems. Large consortiums consisting of public and private entities typically implement these infrastructure Mega-Projects.This paper will compare the typical design process, project management process, and work flow in the terrestrial construction industry to the space industry in order to create a better understanding between the terrestrial construction industry and the space industry, to further enable collaboration on a lunar Mega Project to build infrastructure on the Moon. In addition, a glossary of respective industry terminology with annotated linkages and definitions has been compiled. This information will enable contracts and business practices to be formulated for generating requests for proposals (RFP) by governments to consortiums consisting of construction and space industry companies that will bid on Lunar Infrastructure Projects that could lead to contracts to build the permanent capabilities.

Robert P Mueller↗

NASA NTRS1989

Generation of precedence relations for mechanical assemblies

Planning of assembly sequences is essential to the manufacturing system design process. Several methodologies have been proposed to represent all the feasible assembly sequences. In this thesis, three algorithms are presented to generate three sets of precedence relations based on all the infeasible assembly tasks, all the infeasible assembly states, and all the feasible assembly sequences, respectively. The equivalence of the resulting sets of precedence relations to the AND/OR graph is established. A new property, the real time property, of a representation of assembly sequences is defined and discussed. A representation of assembly sequences is said to have the real time property, if it is possible to generate the next assembly task by testing locally in the representation, and it will guarantee that the generated assembly task will not lead the assembly sequence to a dead end situation, in which no feasible assembly task can be performed any more. It is shown that the correctness and completeness of one representation can not guarantee the real time property of the representation. It is proven that the directed graph representation and the set of precedence relations based on all the infeasible assembly states have the real time property, while the AND/OR graph representation and the set of precedence relations based on all the infeasible assembly tasks do not have the real time property. Finally in the thesis, the PLEIDEAS system, a PLanning Environment for Integrated DEsign of Assembly Systems, is described and illustrated by an example.

Zhang, Hui↗

DOE OSTI2023

A Comprehensive Assessment Tool for Low-TRL Current Energy Converters

Along with a market-competitive levelized cost of energy, a current energy converter technology strongly benefits from an extensive consideration of socioeconomic, environmental, and regulatory factors early in the design process. As part of a technology performance level assessment, a series of assessment questions and guidance are developed and presented to evaluate an early-stage current energy technology on holistic criteria considering the entire device lifecycle. The assessment represents an accumulation of industry and research experience to date and relies on regular updates to ensure alignment with industry best-practices, regulatory requirements, and up-to-date technical understanding. A cradle-to-grave (materials, manufacturing, installation and deployment, operations and maintenance, and end-of-life) assessment of capabilities and functional requirements (i.e., high, medium, and low) performance criteria for current energy converters deployed in tidal, ocean current, and/or river applications. Key considerations related to manufacturing and installation include supply chain robustness, manufacturability and related job creation in the end-user and/or adjacent communities, and the time-to-repayment of the embodied energy debt. During deployment and maintenance operations, the safety of the device and subsystems during disconnect or grid failure, the difficulty and frequency of offshore heavy-lift activities, the avoidance or mitigation of area-use conflicts, the sea-states and weather conditions that permit maintenance access, and the availability of contingency plans (should conditions change unexpectedly) are a portion of the considered assessment criteria. Results include the potential impact of early-stage design decisions on the socioeconomic, environmental, and regulatory performance of a technology that allows developers to increase the product value and probability of success, and minimize costly late-stage design iterations through early and broad consideration of factors affecting overall performance and acceptability.

life cycle analysis↗

DOE OSTI2025

Flow Reactor Study of the Soot Precursors of Novel Cycloalkanes as Synthetic Jet Fuel Compounds: Octahydroindene, p -Menthane, and 1,4-Dimethylcyclooctane

Sustainable aviation fuels (SAFs) or Synthetic aviation turbine fuels (SATFs) derived from nonpetroleum sources are essential for energy security and a strong rural and agricultural economy. Airplanes operating on SAF can have lower particle emissions compared to those of conventional jet fuel, reducing air quality impacts near airports. Processing biobased isoprene or wood and agricultural waste can produce cycloalkane-rich fuels with properties meeting ASTM International’s SATF requirements. The unique structures of these cycloalkanes yield lower soot emissions because of their lack of aromatic rings. We measured the soot formation tendency as yield sooting index (YSI) and used laminar flow reactor experiments to evaluate soot precursors formed for isoprene-derived compounds p-menthane and 1,4-dimethylcyclooctane (DMCO), and octahydroindene (OHI)─ produced from woody biomass via catalytic fast pyrolysis. The combustion chemistry of the OHI and DMCO has not been previously studied. Experiments were conducted at 10 bar from 800 to 1200 K, equivalence ratios of 1.0 and 3.0, and residence times of 1.0 and 0.6 s, respectively. Experimentally detected species were used to elucidate the mechanisms of soot precursor formation. OHI exhibited the highest YSI (94.5) and formed a high concentration of benzene primarily by direct dehydrogenation of the six-membered ring. p-Menthane (YSI 92.0) and DMCO (YSI 85.0) oxidation products included fewer aromatic components but higher benzene precursors, including 1,3-butadiene, propyne, and allene. This suggests that the ring-opening pathway is dominant over the dehydrogenation pathway in the benzene formation for these compounds. This experimental speciation provides insight into the influence of the cycloalkane structure on the sooting tendencies of potential SAF blend components, thereby aiding in fuel design processes.

09 BIOMASS FUELS↗

DOE OSTI2023

A Comprehensive Assessment Tool for Low-TRL Current Energy Converters: Preprint

Along with a market-competitive levelized cost of energy, a current energy converter technology strongly benefits from an extensive consideration of socioeconomic, environmental, and regulatory factors early in the design process. As part of a technology performance level assessment, a series of assessment questions and guidance are developed and presented to evaluate an early-stage current energy technology on holistic criteria considering the entire device lifecycle. The assessment represents an accumulation of industry and research experience to date and relies on regular updates to ensure alignment with industry best-practices, regulatory requirements, and up-to-date technical understanding. A cradle-to-grave (materials, manufacturing, installation and deployment, operations and maintenance, and end-of-life) assessment of capabilities and functional requirements for tidal, river, and ocean current technologies has been completed. This work presents the evaluation questions and qualitative performance criteria for current energy converters deployed in tidal, ocean current, and/or river applications. Key considerations related to manufacturing and installation include supply chain robustness, manufacturability and related job creation in the end-user and/or adjacent communities, and the time-to-repayment of the embodied energy debt. During deployment and maintenance operations, the safety of the device and subsystems during disconnect or grid failure, the difficulty and frequency of offshore heavy-lift activities, the avoidance or mitigation of area use conflicts, the sea-states and weather conditions that permit maintenance access, and the availability of contingency plans (should conditions change unexpectedly) are a portion of the considered assessment criteria. Results include the potential impact of early-stage design decisions on the socioeconomic, environmental, and regulatory performance of a technology that allows developers to increase the product value and probability of success, and minimize costly late-stage design iterations through early and broad consideration of factors affecting overall performance and acceptability.

industry support↗

DOE OSTI2023

A Comprehensive Assessment Tool for Low-TRL Current Energy Converters

Along with a market-competitive levelized cost of energy, a current energy converter technology strongly benefits from an extensive consideration of socioeconomic, environmental, and regulatory factors early in the design process. As part of a technology performance level assessment, a series of assessment questions and guidance are developed and presented to evaluate an early-stage current energy technology on holistic criteria considering the entire device lifecycle. The assessment represents an accumulation of industry and research experience to date and relies on regular updates to ensure alignment with industry best-practices, regulatory requirements, and up-to-date technical understanding. A cradle-to-grave (materials, manufacturing, installation and deployment, operations and maintenance, and end-of-life) assessment of capabilities and functional requirements for tidal, river, and ocean current technologies has been completed. This work presents the evaluation questions and qualitative performance criteria for current energy converters deployed in tidal, ocean current, and/or river applications. Key considerations related to manufacturing and installation include supply chain robustness, manufacturability and related job creation in the end-user and/or adjacent communities, and the time-to-repayment of the embodied energy debt. During deployment and maintenance operations, the safety of the device and subsystems during disconnect or grid failure, the difficulty and frequency of offshore heavy-lift activities, the avoidance or mitigation of area use conflicts, the sea-states and weather conditions that permit maintenance access, and the availability of contingency plans (should conditions change unexpectedly) are a portion of the considered assessment criteria. Results include the potential impact of early-stage design decisions on the socioeconomic, environmental, and regulatory performance of a technology that allows developers to increase the product value and probability of success, and minimize costly late-stage design iterations through early and broad consideration of factors affecting overall performance and acceptability.

converter↗

NASA NTRS2002

Prediction of Aerodynamic Coefficient using Genetic Algorithm Optimized Neural Network for Sparse Data

Wind tunnels use scale models to characterize aerodynamic coefficients, Wind tunnel testing can be slow and costly due to high personnel overhead and intensive power utilization. Although manual curve fitting can be done, it is highly efficient to use a neural network to define the complex relationship between variables. Numerical simulation of complex vehicles on the wide range of conditions required for flight simulation requires static and dynamic data. Static data at low Mach numbers and angles of attack may be obtained with simpler Euler codes. Static data of stalled vehicles where zones of flow separation are usually present at higher angles of attack require Navier-Stokes simulations which are costly due to the large processing time required to attain convergence. Preliminary dynamic data may be obtained with simpler methods based on correlations and vortex methods; however, accurate prediction of the dynamic coefficients requires complex and costly numerical simulations. A reliable and fast method of predicting complex aerodynamic coefficients for flight simulation I'S presented using a neural network. The training data for the neural network are derived from numerical simulations and wind-tunnel experiments. The aerodynamic coefficients are modeled as functions of the flow characteristics and the control surfaces of the vehicle. The basic coefficients of lift, drag and pitching moment are expressed as functions of angles of attack and Mach number. The modeled and training aerodynamic coefficients show good agreement. This method shows excellent potential for rapid development of aerodynamic models for flight simulation. Genetic Algorithms (GA) are used to optimize a previously built Artificial Neural Network (ANN) that reliably predicts aerodynamic coefficients. Results indicate that the GA provided an efficient method of optimizing the ANN model to predict aerodynamic coefficients. The reliability of the ANN using the GA includes prediction of aerodynamic coefficients to an accuracy of 110% . In our problem, we would like to get an optimized neural network architecture and minimum data set. This has been accomplished within 500 training cycles of a neural network. After removing training pairs (outliers), the GA has produced much better results. The neural network constructed is a feed forward neural network with a back propagation learning mechanism. The main goal has been to free the network design process from constraints of human biases, and to discover better forms of neural network architectures. The automation of the network architecture search by genetic algorithms seems to have been the best way to achieve this goal.

Rajkumar, T.↗

NASA NTRS2005

High-Temperature Structures, Adhesives, and Advanced Thermal Protection Materials for Next-Generation Aeroshell Design

The next generation of planetary exploration vehicles will rely heavily on robust aero-assist technologies, especially those that include aerocapture. This paper provides an overview of an ongoing development program, led by NASA Langley Research Center (LaRC) and aimed at introducing high-temperature structures, adhesives, and advanced thermal protection system (TPS) materials into the aeroshell design process. The purpose of this work is to demonstrate TPS materials that can withstand the higher heating rates of NASA's next generation planetary missions, and to validate high-temperature structures and adhesives that can reduce required TPS thickness and total aeroshell mass, thus allowing for larger science payloads. The effort described consists of parallel work in several advanced aeroshell technology areas. The areas of work include high-temperature adhesives, high-temperature composite materials, advanced ablator (TPS) materials, sub-scale demonstration test articles, and aeroshell modeling and analysis. The status of screening test results for a broad selection of available higher-temperature adhesives is presented. It appears that at least one (and perhaps a few) adhesives have working temperatures ranging from 315-400 C (600-750 F), and are suitable for TPS-to-structure bondline temperatures that are significantly above the traditional allowable of 250 C (482 F). The status of mechanical testing of advanced high-temperature composite materials is also summarized. To date, these tests indicate the potential for good material performance at temperatures of at least 600 F. Application of these materials and adhesives to aeroshell systems that incorporate advanced TPS materials may reduce aeroshell TPS mass by 15% - 30%. A brief outline is given of work scheduled for completion in 2006 that will include fabrication and testing of large panels and subscale aeroshell test articles at the Solar-Tower Test Facility located at Kirtland AFB and operated by Sandia National Laboratories. These tests are designed to validate aeroshell manufacturability using advanced material systems, and to demonstrate the maintenance of bondline integrity at realistically high temperatures and heating rates. Finally, a status is given of ongoing aeroshell modeling and analysis efforts which will be used to correlate with experimental testing, and to provide a reliable means of extrapolating to performance under actual flight conditions. The modeling and analysis effort includes a parallel series of experimental tests to determine TSP thermal expansion and other mechanical properties which are required for input to the analysis models.

Collins, Timothy J.↗