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All sources NASA NTRS DOE OSTI

DOE OSTI2025

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials using MALAMUTE

The Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy aims to develop and qualify additively manufactured materials for nuclear applications. One key challenge to this is the microstructural variability observed in the additively manufactured products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-throughput experimental and modeling techniques to accelerate qualification. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the additive manufacturing process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture microstructural variability is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning models to develop a digital twin for additive manufacturing that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation. The melting and subsequent solidification that occurs during the additive process is a complex phenomenon that requires multiscale multiphysics analysis. This work package focuses on understanding the role of process variabilities on the unique microstructural characteristics of additively manufactured materials. Microstructural features at the subgrain level, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. Idaho National Laboratory’s Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for additively manufactured materials in an efficient, reliable, and cost-effective way. This work focuses on capturing the microstructural variabilities at the subgrain level that are often missing in the part-scale models. In fiscal year 2025, we significantly advanced upon our work in the last fiscal year, in terms of the predictive capabilities of the physics-based and ML models, by adding the capabilities to capture subgrain-level micro-segregation during solidification using phase-field model and to predict the time-dependent dynamics of the AM process through the MOGPAR model. The alloy solidification model in MOOSE incorporates the thermodynamic properties and free energy relevant to 316 stainless steel. The model demonstrates the Cr and Ni segregation that occurs during solidification, including that the rate of solidification. The microstructural evolution model is connected to the process conditions via the surrogate model developed in this work. This enables predictions of the final microstructure in conjunctions with the manufacturing process. This work supports AMMT's rapid qualification goals by laying the foundation for an efficient and cost-effective model establishing the PSPP correlation for AM. The generated microstructures and predicted micro-segregation can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work helps to identify the key microstructural features at the subgrain level that are significant in property and performance predictions of additively manufactured components. This work will also provide inputs to the large-scale process variability models to reevaluate and validate assumptions and simplifications made in the part-scale models. Furthermore, through active learning this work can help identify the data need from both modeling and experimental sides for development of a robust digital twin for additive manufacturing and accelerate the AMMT's qualification efforts.

36 - MATERIALS SCIENCE↗

NASA NTRS1977

A distributed microprocessor system for spacecraft control and data handling

The specific requirements for spacecraft computing systems are considered. These requirements are partly related to the constraints of limited resources of power, weight, and volume. Another important factor is the requirement of extremely high reliability. These reliability requirements have led to introduction of automated redundancy techniques on board the spacecraft. The various redundant computers check each other and provide recovery procedures when a computer is found to have failed. Past and future capabilities are considered along with distributed processing requirements. System considerations are discussed, taking into account suboptimum computer throughput, sensitivity to software modifications, hierarchic timing, I/O granularity, restricted communications, synchronous functions, hierarchic control, and concurrent error detection. A description is presented of the Unified Data System (UDS), which consists of a set of standard microcomputers connected by several buses. Attention is also given to synchronization and timing, the executive control structure, the programming language, and the executive program.

Rennels, D. A.↗

NASA NTRS2020

Development of a Supervisory Tool for Fault Detection and Diagnosis of DC Electric Power Systems with the Application of Deep Space Vehicles

This dissertation formulates the problem of fault detection and diagnosis of DC electric power systems for the application of autonomous spacecraft. The ability to accurately identify and isolate failures in the electrical power system is critical to ensure the reliability of a spacecraft. This problem becomes more pronounced during deep space missions that lack the ability to monitor from ground control. The current state of electrical power system fault supervision is insufficient to guarantee highly reliable and robust operation. To solve this issue, a combination of model-based and rules-based techniques are used in a hierarchical framework to improve the diagnostic performance of the spacecraft electrical power system. Noise, disturbances, and modeling errors are considered in the design of the method. Practical considerations related to the hardware and software are discussed for the flight application. A wide array of failure types are simulated in a series of experiments to assess the functionality of the design. The experiments showed that the methods used improved the diagnostic capability of the autonomous system while taking into account the limitations attributed to flight software requirements. The significance of this study is to provide a framework capable of advanced diagnostics of an electrical power system with little to no interaction from a human operator.

Fault Detection and Diagnosis↗

DOE OSTI2015

Extreme_SeaState_Contour_v1

This software generates environmental contours of extreme sea states using buoy observations of significant wave height and energy period or peak period. The code transforms these observations using principal component analysis (PCA) to create an uncorrelated representation of the data. The subsequent components are modeled using probability distributions and parameter fitting functions. The inverse first-order reliability method (I-FORM) is then applied to these models in order to generate an extreme event contour based on a given return period (i.e., 100 years).The subsequent contour is then transformed back into the original input space defined by the variables of interest in order to create an environmental contour of extreme sea states.

Source record↗

DOE OSTI2015

First test results from the Front-End Board with Cyclone V as a test high-resolution platform for the Auger-Beyond-2015 Front End Electronics

The paper presents the first results from the Front- End Board (FEB) with the biggest Cyclone{sup R} V E FPGA 5CEFA9F31I7N, supporting 8 channels sampled up to 250 MSps at 14-bit resolution. Considered sampling for the SD is 120 MSps, however, the FEB has been developed with external anti-aliasing filters to keep a maximal flexibility. Six channels are targeted to the SD, two the rest for other experiments like: Auger Engineering Radio Array and additional muon counters. More channels and higher sampling generate larger size of registered events. We used the standard radio channel for a radio transmission from the detectors to the Central Data Acquisition Station (CDAS) to avoid at present a significant modification of a software in both sides: the detector and the CDAS (planned in a future for a final design). Seven FEBs have been deployed in the test detectors on a dedicated Engineering Array in a hexagon. Several variants of the FPGA code were tested for 120, 160, 200 and even 240 MSps DAQ. Tests confirmed a stability and reliability of the FEB design in real pampas conditions with more than 40 deg. C daily temperature variation and a strong sun exposition with a limited power budget only from a single solar panel. (authors)

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2017

NRC technical basis for evaluation of its position on protection against common cause failure in digital systems used in nuclear power plants - 378

Digital technology has advantages over analog systems, including automated monitoring and alerts for standby safety functions, and predictive algorithms to maintain critical safety systems. Additionally, digital technology generally has higher reliability and can be designed to reduce single point vulnerabilities. For these reasons many nuclear plants have applied digital technology to safety and non-safety related applications, including reactor protection system, feedwater and turbine controls, etc. with a corresponding significant improvement in trip reduction. Nonetheless, digital instrumentation and control (I and C) systems also present potential new vulnerabilities that need to be assessed, including potential failures due to increased complexity of digital systems, the introduction of unique failure modes due to software (including software common cause failure (CCF)), and limited operating history of digital systems in nuclear safety related applications compared to analog systems. The fact that software is intangible means that common methods, such as analysis or testing, used for detecting CCF may not be effective when applied to software. Consequently, digital technology is perceived to pose a potential risk from the introduction of undetected systematic faults that could result in CCF. Despite the I and C system upgrades and modifications performed to date, the U.S. Nuclear Regulatory Commission (NRC) and industry stakeholders have identified the need to modernize the regulatory infrastructure to efficiently address risks associated with the use of digital technology for nuclear safety applications and address regulatory uncertainties. The NRC's current position on CCF is guided by the staff requirements memorandum (SRM) on SECY 93-087. The SRM provides specific acceptance criteria for the evaluation of CCF, which the staff implemented in the Branch Technical Position (BTP) 7-19. However, industry stakeholders have proposed using methods to characterize the likelihood of software CCF and eliminate it from further consideration in a defense-in-depth and diversity analysis. The NRC's current position does not consider these alternatives, and thus corresponding acceptance criteria is not currently available. The work discussed in this paper assesses the underlying technical basis associated with CCF, provides technical support for updating the NRC position and considers proposed methods for addressing potential CCF in digital systems while enhancing efficiency, clarity, and confidence. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2002

The Use of Probabilistic Methods to Evaluate the Systems Impact of Component Design Improvements on Large Turbofan Engines

Probabilistic Structural Analysis (PSA) is now commonly used for predicting the distribution of time/cycles to failure of turbine blades and other engine components. These distributions are typically based on fatigue/fracture and creep failure modes of these components. Additionally, reliability analysis is used for taking test data related to particular failure modes and calculating failure rate distributions of electronic and electromechanical components. How can these individual failure time distributions of structural, electronic and electromechanical component failure modes be effectively combined into a top level model for overall system evaluation of component upgrades, changes in maintenance intervals, or line replaceable unit (LRU) redesign? This paper shows an example of how various probabilistic failure predictions for turbine engine components can be evaluated and combined to show their effect on overall engine performance. A generic model of a turbofan engine was modeled using various Probabilistic Risk Assessment (PRA) tools (Quantitative Risk Assessment Software (QRAS) etc.). Hypothetical PSA results for a number of structural components along with mitigation factors that would restrict the failure mode from propagating to a Loss of Mission (LOM) failure were used in the models. The output of this program includes an overall failure distribution for LOM of the system. The rank and contribution to the overall Mission Success (MS) is also given for each failure mode and each subsystem. This application methodology demonstrates the effectiveness of PRA for assessing the performance of large turbine engines. Additionally, the effects of system changes and upgrades, the application of different maintenance intervals, inclusion of new sensor detection of faults and other upgrades were evaluated in determining overall turbine engine reliability.

Packard, Michael H.↗

DOE OSTI2026

Absorption Correction for Reliable Pair Distribution Functions from Low Energy X-ray Sources

This paper explores the development and testing of a simple absorption correction model for processing powder X-ray diffraction data from Debye−Scherrer geometry laboratory X-ray experiments. This may be used as a preprocessing step before using PDFGETX3 to obtain reliable pair distribution functions (PDFs). Various experimental and theoretical methods for estimating μR were explored, and the most appropriate μR values for correction were identified for different capillary diameters and X-ray beam sizes. We identify operational ranges of μR where a reasonable signal-to-noise ratio is possible after correction. A user-friendly software package, DIFFPY.LABPDFPROC, is presented that can help estimate μR and perform absorption corrections with a rapid calculation for efficient processing.

Absorption↗

DOE OSTI2015

Final Report to the National Energy Technology Laboratory on FY09-FY13 Cooperative Research with the Consortium for Electric Reliability Technology Solutions

The Consortium for Electric Reliability Technology Solutions (CERTS) was formed in 1999 in response to a call from U.S. Congress to restart a federal transmission reliability R&D program to address concerns about the reliability of the U.S. electric power grid. CERTS is a partnership between industry, universities, national laboratories, and government agencies. It researches, develops, and disseminates new methods, tools, and technologies to protect and enhance the reliability of the U.S. electric power system and the efficiency of competitive electricity markets. It is funded by the U.S. Department of Energy’s Office of Electricity Delivery and Energy Reliability (OE). This report provides an overview of PSERC and CERTS, of the overall objectives and scope of the research, a summary of the major research accomplishments, highlights of the work done under the various elements of the NETL cooperative agreement, and brief reports written by the PSERC researchers on their accomplishments, including research results, publications, and software tools.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2002

Virtually Out of This World!

Ames Research Center granted Reality Capture Technologies (RCT), Inc., a license to further develop NASA's Mars Map software platform. The company incorporated NASA#s innovation into software that uses the Virtual Plant Model (VPM)(TM) to structure, modify, and implement the construction sites of industrial facilities, as well as develop, validate, and train operators on procedures. The VPM orchestrates the exchange of information between engineering, production, and business transaction systems. This enables users to simulate, control, and optimize work processes while increasing the reliability of critical business decisions. Engineers can complete the construction process and test various aspects of it in virtual reality before building the actual structure. With virtual access to and simulation of the construction site, project personnel can manage, access control, and respond to changes on complex constructions more effectively. Engineers can also create operating procedures, training, and documentation. Virtual Plant Model(TM) is a trademark of Reality Capture Technologies, Inc.

Source record↗

NASA NTRS2000

SAVANT: Solar Array Verification and Analysis Tool Demonstrated

The photovoltaics (PV) industry is now being held to strict specifications, such as end-oflife power requirements, that force them to overengineer their products to avoid contractual penalties. Such overengineering has been the only reliable way to meet such specifications. Unfortunately, it also results in a more costly process than is probably necessary. In our conversations with the PV industry, the issue of cost has been raised again and again. Consequently, the Photovoltaics and Space Environment Effects branch at the NASA Glenn Research Center at Lewis Field has been developing a software tool to address this problem. SAVANT, Glenn's tool for solar array verification and analysis is in the technology demonstration phase. Ongoing work has proven that more efficient and less costly PV designs should be possible by using SAVANT to predict the on-orbit life-cycle performance. The ultimate goal of the SAVANT project is to provide a user-friendly computer tool to predict PV on-orbit life-cycle performance. This should greatly simplify the tasks of scaling and designing the PV power component of any given flight or mission. By being able to predict how a particular PV article will perform, designers will be able to balance mission power requirements (both beginning-of-life and end-of-life) with survivability concerns such as power degradation due to radiation and/or contamination. Recent comparisons with actual flight data from the Photovoltaic Array Space Power Plus Diagnostics (PASP Plus) mission validate this approach.

Chock, Ricaurte↗

NASA NTRS2012

A Perspective on NASA Ames Air Traffic Management Research

This paper describes past and present air-traffic-management research at NASA Ames Research Center. The descriptions emerge from the perspective of a technical manager who supervised the majority of this research for the last four years. Past research contributions built a foundation for calculating accurate flight trajectories to enable efficient airspace management in time. That foundation led to two predominant research activities that continue to this day - one in automatically separating aircraft and the other in optimizing traffic flows. Today s national airspace uses many of the applications resulting from research at Ames. These applications include the nationwide deployment of the Traffic Management Advisor, new procedures enabling continuous descent arrivals, cooperation with industry to permit more direct flights to downstream way-points, a surface management system in use by two cargo carriers, and software to evaluate how well flights conform to national traffic management initiatives. The paper concludes with suggestions for prioritized research in the upcoming years. These priorities include: enabling more first-look operational evaluations, improving conflict detection and resolution for climbing or descending aircraft, and focusing additional attention on the underpinning safety critical items such as a reliable datalink.

Schroeder, Jeffery A.↗

NASA NTRS2012

Holodeck: Telepresence Dome Visualization System Simulations

This paper explores the simulation and consideration of different image-projection strategies for the Holodeck, a dome that will be used for highly immersive telepresence operations in future endeavors of the National Aeronautics and Space Administration (NASA). Its visualization system will include a full 360 degree projection onto the dome's interior walls in order to display video streams from both simulations and recorded video. Because humans innately trust their vision to precisely report their surroundings, the Holodeck's visualization system is crucial to its realism. This system will be rigged with an integrated hardware and software infrastructure-namely, a system of projectors that will relay with a Graphics Processing Unit (GPU) and computer to both project images onto the dome and correct warping in those projections in real-time. Using both Computer-Aided Design (CAD) and ray-tracing software, virtual models of various dome/projector geometries were created and simulated via tracking and analysis of virtual light sources, leading to the selection of two possible configurations for installation. Research into image warping and the generation of dome-ready video content was also conducted, including generation of fisheye images, distortion correction, and the generation of a reliable content-generation pipeline.

Hite, Nicolas↗

NASA NTRS2016

Trajectory Specification for Automation of Terminal Air Traffic Control

"Trajectory specification" is the explicit bounding and control of aircraft tra- jectories such that the position at each point in time is constrained to a precisely defined volume of space. The bounding space is defined by cross-track, along-track, and vertical tolerances relative to a reference trajectory that specifies position as a function of time. The tolerances are dynamic and will be based on the aircraft nav- igation capabilities and the current traffic situation. A standard language will be developed to represent these specifications and to communicate them by datalink. Assuming conformance, trajectory specification can guarantee safe separation for an arbitrary period of time even in the event of an air traffic control (ATC) sys- tem or datalink failure, hence it can help to achieve the high level of safety and reliability needed for ATC automation. As a more proactive form of ATC, it can also maximize airspace capacity and reduce the reliance on tactical backup systems during normal operation. It applies to both enroute airspace and the terminal area around airports, but this paper focuses on arrival spacing in the terminal area and presents ATC algorithms and software for achieving a specified delay of runway arrival time.

air traffic control↗

NASA NTRSDate not supplied

Assessing Engine Hot Fire Data for Human Spaceflight Applications

Development and certification of liquid engine systems for human spaceflight missions requires exhaustive analysis to meet the NASA’s requirements for engine health, reliability, and performance. The techniques used to assess requirement conformance and test-to-test engine health pose many unique challenges including the unusually large scale of data, complex component and system analysis, and rigorous engineering judgement standards. To address these challenges, NASA Marshall Space Flight Center’s Engine Systems branch has developed and maintained a robust software suite and operational processes that satisfy programmatic requirements levied on engines and the 7 Elements of Flight Rationale. Analysis at a systems level includes subsystem assessment of components such as turbomachinery and combustion devices as well as structural and fluid dynamics and transient and steady-state assessment at a systems level. Some of the most important tools to accomplish this analysis are automated script databases, creation of historical and statistical comparisons, and parameters calculated at the full data rate. These tools greatly simplify the crucial processes of anomaly investigation, limit monitoring, health assessment, and timely communication of key conclusions drawn from hot fire testing and flight data analysis.

Data Assessment↗

NASA NTRSDate not supplied

Assessing Engine Hot Fire Data for Human Spaceflight Applications

Data Assessment↗

DOE OSTI2017

Analysis of the VERA Core Physics Benchmark Problems using cosRMC Code

In reactor physics, two kinds of numerical methods are generally employed to solve the neutron transport equations, one of which is the deterministic method and the other one is the Monte Carlo method. Monte Carlo is widely used to provide reference solution because of its ability to deal with continuous energy cross sections and complex geometry. Just like any statistical process, the Monte Carlo method requires repetition to achieve a small relative uncertainty, and therefore may inevitably have larger simulation times than deterministic method. Fortunately, the great advancements of computer technology make it possible to apply Monte Carlo method in reactor core analysis. To promote nuclear power plant system design and simulation software self-reliance development, a Monte Carlo neutron/photon transport code cosRMC has been developed jointly by State Nuclear Power Software Development Center (SNPSDC) and Tsinghua University. The cosRMC is aimed at achieving full core calculations and analysis with high fidelity and efficiency by means of advanced methodologies and algorithms as well as high performance computing techniques. The cosRMC has many functions as criticality calculation, fixed-source calculation, burnup calculation, etc. In order to ensure its reliability, several types of verification and validation (V and V) work have been and are being carried out for cosRMC. The simulation results of cosRMC based on Problem 1 to 3 of VERA Core Physics Benchmark showed its good capability of 2D lattice and 3D assembly modeling. In this paper, some progressive verification results of multi-assembly and full core problems are presented.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2015

Physics-based multiscale coupling for full core nuclear reactor simulation

Numerical simulation of nuclear reactors is a key technology in the quest for improvements in efficiency, safety, and reliability of both existing and future reactor designs. Historically, simulation of an entire reactor was accomplished by linking together multiple existing codes that each simulated a subset of the relevant multiphysics phenomena. Recent advances in the MOOSE (Multiphysics Object Oriented Simulation Environment) framework have enabled a new approach: multiple domain-specific applications, all built on the same software framework, are efficiently linked to create a cohesive application. This is accomplished with a flexible coupling capability that allows for a variety of different data exchanges to occur simultaneously on high performance parallel computational hardware. Examples based on the KAIST-3A benchmark core, as well as a simplified Westinghouse AP-1000 configuration, demonstrate the power of this new framework for tackling—in a coupled, multiscale manner—crucial reactor phenomena such as CRUD-induced power shift and fuel shuffle. 2014 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-SA license

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗