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NASA NTRSDate not supplied

Application of Norton-Thevenin Receptance Coupling (NTRC) to Space Launch System (SLS) Payload Coupled Loads Analysis (CLA)

Norton-Thevenin Receptance Coupling (NTRC), as described in several NASA Engineering and Safety Center (NESC) papers shows promise in enabling loads development for payloads with less computational cost and analyst time as compared to a full integrated vehicle coupled loads analysis (CLA). NTRC allows the free vehicle responses and impedance (accelerance) at the payload to vehicle interface (derived from integrated vehicle CLA) to be used with a payload model in a payload CLA. Due to the NTRC damping differing from the full integrated vehicle damping, results are slightly different, so coverage factors were developed to ensure NTRC results enveloped results from a traditional CLA. NTRC results with coverage factors were very close to full CLA results. The Space Launch System (SLS) coupled loads team has developed an implementation of the NTRC method to enable support of co-manifested payloads with analysis needs that do not fit the primary SLS load cycle schedule. The NTRC method was successfully used to support the European System Providing Refueling, Infrastructure, and Communications (ESPRIT) module for Gateway planned to fly on Artemis V and has been adopted as the SLS approach for supporting payload CLA requests that do not align with vehicle load cycles.

SLS↗

DOE OSTI2021

High-Luminance LED Platform for Improved Efficacy in Directional Applications (Final Technical Report)

In this project, Lumileds developed a platform of high-luminance LEDs and LED light engines to increase efficacy and reduce energy consumption of directional lighting applications. The platform was developed through innovations in three key areas: (1) epi and device architectures optimized for high drive current density, breaking through the tradeoff in efficacy (lm/W) vs. emittance (lm/mm 2 ) exhibited by state-of-the-art products; (2) a compact chip-scale package allowing high packing density and thus high overall luminance in multi-emitter arrays; and (3) phosphor technology to enable correlated color temperature (CCT) tuning in multi-emitter arrays with optimized LED utilization, efficacy, color uniformity and color quality. Directional indoor and outdoor lighting applications make up a major portion of the total lighting energy consumption in the U.S, accounting for >40% of the energy savings potential of solid-state lighting. Success of this project helps accelerate the realization of these energy savings both through higher system efficacy and adoption due to new functionality, and thus contributes significantly to realizing the DOE Lighting program goals.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

A Printed Microscopic Universal Gradient Interface for Super Stretchable Strain‐Insensitive Bioelectronics

Abstract Stretchable electronics capable of conforming to nonplanar and dynamic human body surfaces are central for creating implantable and on‐skin devices for high‐fidelity monitoring of diverse physiological signals. While various strategies have been developed to produce stretchable devices, the signals collected from such devices are often highly sensitive to local strain, resulting in inevitable convolution with surface strain‐induced motion artifacts that are difficult to distinguish from intrinsic physiological signals. Here all‐printed super stretchable strain‐insensitive bioelectronics using a unique universal gradient interface (UGI) are reported to bridge the gap between soft biomaterials and stiff electronic materials. Leveraging a versatile aerosol‐based multi‐materials printing technique that allows precise spatial control over the local stiffnesses with submicron resolution, the UGI enables strain‐insensitive electronic devices with negligible resistivity changes under a 180% uniaxial stretch ratio. Various stretchable devices are directly printed on the UGI for on‐skin health monitoring with high signal quality and near‐perfect immunity to motion artifacts, including semiconductor‐based photodetectors for sensing blood oxygen saturation levels and metal‐based temperature sensors. The concept in this work will significantly simplify the fabrication and accelerate the development of a broad range of wearable and implantable bioelectronics for real‐time health monitoring and personalized therapeutics.

Song, Kaidong [Department of Aerospace and Mechani↗

DOE OSTI2020

Elucidating the effect of preheating temperature on melt pool morphology variation in Inconel 718 laser powder bed fusion via simulation and experiment

In laser powder bed fusion (L-PBF) additive manufacturing, the mechanical performance, microstructure and defects of fabricated parts are closely associated with the melt pool morphology, e.g., its dimension and shape through the building process. Past studies have largely focused on how the process parameters such as laser power and scan speed affect melt pool characteristics. In this study, the melt pool morphology variation as a function of preheating temperature in the conduction, transition, and keyhole regimes and the underlying mechanisms in each regime are investigated through ex-situ sample characterization and computation thermal fluid dynamics (CtFD) simulation. Single tracks with different combinations of laser power and scan speed are deposited on an Inconel 718 bare plate preheated to a temperature range of 100–500 °C in the experiment. Significant changes are observed in melt pool morphology as a function of preheating temperature from optical measurements of melt track cross sections. The depth of melt pool in the three regimes increases monotonically with preheating temperature, e.g., at 500 °C, the experimental melt pool depth is increased by 49% in conduction regime, 34% in transition regime and 33% in keyhole regime, respectively, while the variation of melt pool width in each regime does not all follow an increasing trend but depends on the melt pool regimes. Melt pool width variation in the conduction and transition regimes is found to depend on the enhanced heat conduction directly related to temperature dependent thermal properties. Through validated CtFD simulations, it is found that in the keyhole regime the evaporation mass, recoil pressure, and laser drilling effect is enhanced with higher preheating temperature, which gives rise to a deeper melt pool. The simulations also reveal that preheating temperature significantly elongates the melt track length due to the increased flow rate and strong recoil pressure that accelerates the backward flow.

36 MATERIALS SCIENCE↗

DOE OSTI2024

A novel transient infrared imaging method for non-intrusive, low-cost, fast, and accurate air leakage detection in building envelopes

Air leakage through the building envelope in the U.S. accounts for about four quads of energy annually, costing approximately $40 billion per year. However, a high-fidelity and non-intrusive method to detect air leakage has not been demonstrated to date. Here, in this paper, we propose a novel non-intrusive and low-cost method called Transient Infrared (IR) Imaging (TIRI) that can rapidly and accurately identify air leakage locations and relative rates on building envelopes. When the interior and exterior temperatures are different, and a small internal pressure pulse is created by HVAC, the temperature at locations with air leakages will change rapidly, while the areas without a leakage do not change. Based on a heat transfer model, we have derived the temperature change as a function of time after the HVAC is turned on. By tracking the temperature change, which depends on leakage rate and size, we have obtained the air leakage map in the case studies. Using an exterior door as an example, we took transient IR images in different seasons and different times of the day, and successfully obtained the leakage map in all the scenarios. Successfully obtained the air leakage map even when the indoor-outdoor air temperature difference is as small as 2 °C. We have also realized a detection speed of 10s and demonstrated that this method also worked for windows, which have mirror-like IR reflections. Our TIRI method will accelerate the improvement of airtightness in buildings, save building energy, and help reduce greenhouse gas emissions.

42 ENGINEERING↗

DOE OSTI2021

Fast switching magnet for heavy ion beam separation

This paper presents the design for a switching magnet capable of deflecting 6.5 MeV/u heavy-ion beams with mass-to-charge ratio of 7 by 10 degrees. This magnet can produce variable flat-top pulses from 1 to 30 ms with rise and fall times of less than 0.5 ms at a variable duty cycle of 3–91% into a heavily inductive load. The magnet has a laminated, iron dominated, H-shaped core. Directly-cooled copper pancake coils energize the magnet. We present the magnet design considerations, including the results of extensive computer modeling. Finally, we also present the conceptual engineering design and the studies of magnet yoke fabrication.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Construction of Cryogen-Free 4.3T Superconducting Wiggler for NSLS-II Ring

With the 3 GeV electron beam energy for the National Synchrotron Light Source II (NSLS-II) ring, only superconducting wigglers (SCW) producing greater than 4T peak field can cover the photon energy range of 20 keV and 200 keV with sufficient number of photons. The High energy Engineering X-ray (HEX) Diffraction beamline, which is primarily funded by the New York State Energy Research and Development Authority (NYSERDA) and NSLS-II, will be equipped with a 1.2m-long SCW with 70 mm period length and 4.3 T on-axis field. This SCW is free from the use of liquid Helium and is cooled only with cryo-coolers. The Electron Beam Chamber (EBC) with vertical aperture of 8 mm is made from 316LN stainless steel and copper plating is applied both surface and +-12.5mm wide from the center in the inner surface. The expected heat load from the electron beam of the NSLS-II ring is estimated to be 10 W/m. Here, we describe the design principles and engineering challenges for the device.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Data Challenges for Structural Health Monitoring of Electrical Machines [Slides]

Induction motors (ID) consist of a stator and a rotor. Induction motor slip decreases with decreasing load. Induction motor slip decreases with decreasing load. This talk will focus on removing closely coupled power grid frequencies in an effort to observe the true dynamic response signature of induction motors. Using the time difference between the zeros, we found the frequency as it changes over time for each of the 3 phases. The frequencies of the 3 phases were averaged to reduce the effects of sidebands on the instantaneous frequency. The frequencies of the 3 phases were averaged to reduce the effects of sidebands on the instantaneous frequency. The Kalman filter rapidly synchronizes with the expected output. The sidebands were recreated using spectral subtraction. The frequency domain shows the reduction in magnitude of the power grid frequency the Kalman output was subtracted out. Kalman filtering also reveals important data about the sidebands in healthy motors. The Continuous Wavelet Transform is an alternative to a Bandpass IIR filter used in the analysis of the acceleration data. Analysis of the acceleration data reveals 4 sidebands around the slip frequency.

42 ENGINEERING↗

DOE OSTI2022

FAIR principles for AI models with a practical application for accelerated high energy diffraction microscopy

Abstract A concise and measurable set of FAIR (Findable, Accessible, Interoperable and Reusable) principles for scientific data is transforming the state-of-practice for data management and stewardship, supporting and enabling discovery and innovation. Learning from this initiative, and acknowledging the impact of artificial intelligence (AI) in the practice of science and engineering, we introduce a set of practical, concise, and measurable FAIR principles for AI models. We showcase how to create and share FAIR data and AI models within a unified computational framework combining the following elements: the Advanced Photon Source at Argonne National Laboratory, the Materials Data Facility, the Data and Learning Hub for Science, and funcX, and the Argonne Leadership Computing Facility (ALCF), in particular the ThetaGPU supercomputer and the SambaNova DataScale ® system at the ALCF AI Testbed. We describe how this domain-agnostic computational framework may be harnessed to enable autonomous AI-driven discovery.

47 OTHER INSTRUMENTATION↗

NASA NTRS2002

Extending Ion Engine Technology to NEXT and Beyond

Extending ion engine technology beyond the current state-of-the art primary interplanetary electric propulsion system, the 2.3-kW NASA Solar Electric Propulsion Technology and Applications Readiness (NSTAR) system, will require thrusters with improved propellant throughput and total impulse capability. Many of the design choices that culminated in the NSTAR thrusters must be revisited, and their application to next generation ion engine technology must be evaluated. The concept of derating, which was successfully employed in NSTAR, has been applied to the 40 cm NASA Evolutionary Xenon Thruster (NEXT) currently under development at NASA Glenn Research Center (GRC). At 5-kW, NEXT operates with the same average beam current density as NSTAR, and at 10-kW, the peak beam current density is only ten percent greater than NSTAR. The result is that similar Ion optics technology is expected to yield comparable lifetime. Thick-accelerator- grid ion optics are also being tested to realize additional lifetime benefits. A 40-A discharge cathode is being developed for NEXT based on scaling the NSTAR design. Nevertheless, the experiences of the NSTAR ground tests and the thruster on the Deep Space One spacecraft indicate that the discharge cathode wear must be studied experimentally and theoretically to ensure that it meets the lifetime requirements. Although NEXT is in its infancy, investigations have already begun to examine possible modifications to engine design for even higher-power and higher-specific impulse engines. Ion optics using alternate materials such as titanium, graphite, or carbon-carbon composite are currently being investigated due to their low sputter yields at high voltage. To avoid the difficulties encountered using electrodes at high-currents, the use of a microwave-based ion thruster is under investigation for potential high-power ion thruster systems requiring long lifetimes. Additionally, alternative propellants are being considered for applications requiring high-specific impulse (>> 5000 s) and extremely long-life (>> 15,000 hr). Testing requirements make condensable propellants attractive for high-power engines. Although the NSTAR ion engine demonstrated the flight maturity of ion thruster technology, many challenges remain for the development of thrusters with improved propellant throughput and power handling capabilities.

Domonkos, Matthew T.↗

DOE OSTI2021

Seismic isolation: A pathway to standardized advanced nuclear reactors

Standardizing advanced nuclear reactors is a pathway to substantially reducing their overnight capital cost and achieving parity with other power sources, including renewables and fossil fuels. The seismic load case has thwarted standardization of nuclear power plants because site-specific seismic hazard and local near-surface geology has triggered soil-structure-interaction analysis, design, equipment qualification, regulatory review, and licensing, ensuring that each build is different. To achieve standardized or site-independent certified advanced reactor designs, the impact of the seismic load case on the engineering and construction cost and time must be substantially mitigated. Seismic isolation is a mature technology that has been used for more than 30 years in non-nuclear sectors to substantially reduce earthquake demands in buildings and other infrastructure. In this paper, seismic isolation is used to enable standardization of advanced reactor designs, aimed at the complete re-use of a site-independent, certified design and repeated procurement of safety-class equipment. A pathway to standardized designs using seismic isolation is demonstrated for two fundamentally different advanced reactors: a molten salt reactor and a high temperature gas reactor. Each reactor building is equipped with three specialized pieces of safety-class equipment, namely, a reactor vessel, a steam generator, and a control rod drive mechanism housing that is attached to the reactor head. Analysis is performed per ASCE and ASME standards to design the buildings and the equipment for two base conditions: conventional (fixed base) and base isolated. The impact of the seismic load case is characterized for the reinforced concrete walls in the buildings and for the equipment, measured using vessel wall thickness and horizontal accelerations. Here the analysis results show that the fixed-base buildings, designed for a site of low seismic hazard (peak ground acceleration, PGA = 0.15 g) could be constructed at a site of much greater seismic hazard (PGA = 0.7 g) if seismic base isolation is employed. Importantly, the scope of the site-specific analysis, design, and qualification would be limited to the seismic isolators and the isolated substructure, drastically reducing plant-specific engineering, review, and licensing, and time to construction start. Regulatory challenges and opportunities with standardized reactor designs are identified.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Using Demanded Power and RDE Aggressiveness Metrics to Analyze the Impact of CACC Aggressiveness on Heavy Duty Platooning Power Consumption

Presently, a main mobility sector objective is to reduce its impact on the global greenhouse gas emissions. While there are many techniques being explored, a promising approach to improve fuel economy is to reduce the required energy by using slipstream effects. This study analyzes the demanded engine power and mechanical energy used by heavy-duty trucks during platooning and non-platooning operation to determine the aerodynamic benefits of the slipstream. A series of platooning tests utilizing class 8 semi-trucks platooning via Cooperative Adaptive Cruise Control (CACC) are performed. Comparing the demanded engine power and mechanical energy used reveals the benefits of platooning on the aerodynamic drag while disregarding any potential negative side effects on the engine. However, energy savings were lower than expected in some cases. It was hypothesized that the CACC may have amplified transient platooning events relative to the individual truck baseline results, hampering the potential energy savings. Therefore, the impact of the controller on the observed driving style was analyzed in detail. In order to quantify the transient operational characteristics of the experimental trials, metrics from the European Real Driving Emissions (RDE) legislation were modified to serve as metrics of aggressiveness during platooning. The metrics (v · apos)95 and Relative Positive Acceleration (RPA) were calculated for platooning and non-platooning runs. These results indicate that the CACC induces small acceleration events during platooning to retain the commanded longitudinal separation between vehicles. These small acceleration events increase following vehicle aggressiveness during platooning and prevent the following vehicles from obtaining maximum energy savings. Moreover, a correlation between the RDE metric (v · apos)95 and energy savings is developed. Hence, this work establishes the ability of RDE metrics to assess CACC impacts on platoon energy savings.

European Real Driving Emissions, RDE, greenhouse g↗

NASA NTRS2022

Application Table: A Bridge Connecting the Designing “With-The-Material” and “The-Material” Paradigms

Over the last few decades, advances in high-performance computing, new material characterization methods, and, more recently, an emphasis on integrated computational materials engineering (ICME) have been a catalyst for multiscale modeling and simulation-based design of materials and structures in the aerospace industry. In 2016 NASA sponsored a 2040 Vision study (which appeared in 2018) to define the potential 25-year future state required for integrated multiscale modeling of materials and systems (e.g., load-bearing structures) to accelerate the pace and reduce the expense of innovation in future aerospace and aeronautical systems. The study envisions a cyber-physical-social ecosystem comprised of experimentally verified and validated (V & V) computational models, tools, and techniques, along with the associated digital tapestry, that impacts the entire supply chain to enable cost-effective, rapid, and revolutionary design of “fit-for-purpose” materials, components, and systems. Consequently, the development of a robust information management system that incorporates (across the full life cycle) both experimental (real data) and virtual data resulting from the application of various simulation tools (at single or multiple length scales), therefore enabling the virtual design and optimization of materials throughout their processing – internal structure – property – performance envelope, has become critical. This need is also fueled by the demands for higher efficiency in material testing; consistency, quality, and traceability of data; product design; engineering analysis; as well as control of access to proprietary or sensitive information. This is particularly true when attempting to merge ICME practices with recent additive manufacturing technology which will enable production of the resulting 2040 Vision material and structural designs. At NASA Glenn Research Center we are exploring the future of material science through the use of novel characterization methodologies, high performance computing, and recently an emphasis on integrated computational materials engineering (ICME). Herein, recent efforts to incorporate an Application Table within NASA Glenn Research Center’s ICME Granta MI database is presented. The goal is to provide a place where material and structural application information/requirements can be linked so as to marry the “design the-material” and the “design-with-material” paradigms and thereby enable application-driven design and optimization of materials and structures by providing a central location that links material processing at various length scales to the application’s performance requirements. This paper discusses the specifics of this Application Table as well as best practices and key principles for the development of a robust materials information management system to enable the 2040 Vision integrated materials and structures ecosystem. Furthermore, it presents the intended role of the Application Table in the future of ICME design of “fit-for-purpose” materials, showing the need for a well-established framework that can successfully bridge the gap between the design “the material” and design “with-the-material” paradigms.

Materials↗

NASA NTRSDate not supplied

Application Table: A Bridge Connecting the Designing “With-the-Material” and “the-Material”

Materials↗

DOE OSTI2023

Genomic materials design: CALculation of PHAse Dynamics

The CALPHAD system of fundamental phase-level databases, now known as the Materials Genome, has enabled a mature technology of computational materials design and qualification that has already met the acceleration goals of the national Materials Genome Initiative. Here, as first commercialized by QuesTek Innovations, the methodology combines efficient genomic-level parametric design of new material composition and process specifications with multidisciplinary simulation-based forecasting of manufacturing variation, integrating efficient uncertainty management. Recent projects demonstrated under the multi-institutional CHiMaD Design Center notably include novel alloys designed specifically for additive manufacturing. With the proven success of the CALPHAD-based Materials Genome technology, current university research emphasizes new methodologies for affordable accelerated expansion of more accurate CALPHAD databases. Rapid adoption of these new capabilities by US apex corporations has compressed the materials design and development cycle to under 2 years, enabling a new “materials concurrency” integrated into a new level of concurrent engineering supporting an unprecedented level of manufacturing innovation.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Nanochannel electrodes facilitating interfacial transport for PEM water electrolysis

Proton-exchange membrane water electrolyzers (PEMWEs) are a promising technology for green hydrogen production; however, interfacial transport behaviors are poorly understood, hindering device performance and longevity. Here, we first utilized finite-gap electrolyzer to demonstrate the possibility of proton transfer through water in PEMWEs. The measured high-frequency resistances (HFRs) exhibit a linear trend with increasing gap distance, where extrapolation shows a lower value compared with HFRs in regular zero-gap electrolyzers, indicating that ohmic resistance could be further reduced. We introduce nanochannels to facilitate mass transport, as evidenced by both liquid-fed and vapor-fed electrolysis. Nanochannel electrodes achieve a voltage reduction of 190 mV at 9 A·cm –2 compared with the Ir-PTEs without nanochannels. Furthermore, nanochannel electrodes show negligible degradation through 100,000 accelerated-stress tests and over 2,000 h of operation at 1.8 A·cm –2 with a decay rate of 11.66 μV·h –1 . These results provide new insights into localized transport dynamics for PEMWEs and highlight the significance of interfacial engineering for electrochemical devices.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Time domain probabilistic seismic risk analysis using ground motion prediction equations of Fourier amplitude spectra

Modeling of Fourier amplitude spectra (FAS) of seismic motions has gained much attention in engineering seismology. In the past few years, several ground motion prediction equations (GMPEs) and inter-frequency correlation structure of FAS have been established. Due to many preferable characteristics of FAS, probabilistic seismic hazard/risk analysis is rapidly changing from ergodic, spectrum acceleration Sa(T 0 )-based approach to non-ergodic, site-specific, FAS-based approach. This paper presents time domain intrusive framework for probabilistic seismic risk analysis using GMPE of FAS. Herein, methodology for time domain stochastic ground motion modeling based on GMPEs of FAS is presented in some detail. The simulated uncertain motions are modeled as a random process and represented by polynomial chaos Karhunen-Loève expansion. The random process excitations are further propagated into the uncertain structural system using Galerkin stochastic finite element method (SFEM). Probabilistic evolution of structural response is solved, and such solution is used to develop seismic risk for any damage state. The presented framework is illustrated through seismic risk analysis of a four-story building subjected to possible earthquakes from two strike slip faults. The influences of the epistemic uncertainties in source stress drop Δσ and site attenuation κ0 on seismic risk are investigated. The need for non-ergodic seismic risk analysis with source-specific and site specific characterizations is emphasized.

58 GEOSCIENCES↗

DOE OSTI2026

Q-IRIS: The Evolution of the IRIS Task-Based Runtime to Enable Classical-Quantum Workflows

Extreme heterogeneity in emerging HPC systems are starting to include quantum accelerators, motivating runtimes that can coordinate between classical and quantum workloads. We present a proof-of-concept hybrid execution framework integrating the IRIS asynchronous task-based runtime with the XACC quantum programming framework via the Quantum Intermediate Representation Execution Engine (QIR-EE). IRIS orchestrates multiple programs written in the quantum intermediate representation (QIR) across heterogeneous backends (including multiple quantum simulators), enabling concurrent execution of classical and quantum tasks. Although not a performance study, we report measurable outcomes through the successful asynchronous scheduling and execution of multiple quantum workloads. To illustrate practical runtime implications, we decompose a four-qubit circuit into smaller subcircuits through a process known as quantum circuit cutting, reducing per-task quantum simulation load and demonstrating how task granularity can improve simulator throughput and reduce queueing behavior -- effects directly relevant to early quantum hardware environments. We conclude by outlining key challenges for scaling hybrid runtimes, including coordinated scheduling, classical-quantum interaction management, and support for diverse backend resources in heterogeneous systems.

Miniskar, Narasinga Rao [ORNL] (ORCID:000000018259↗