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At least 1,729 records · Page 96

An artifical corrosion protocol for lap-splices in aircraft skin

This paper reviews the progress to date to formulate an artificial corrosion protocol for the Tinker AFB C/KC-135 Corrosion Fatigue Round Robin Test Program. The project has provided new test methods to faithfully reproduce the corrosion damage within a lap-splice by accelerated means, the rationale for a new laboratory test environment, and a means for corrosion damage quantification. The approach is pragmatic and the resulting artificial corrosion protocol lays the foundation for future research in the assessment of aerospace alloys. The general means for quantification of corrosion damage has been presented in a form which can be directly applied to structural integrity calculations.

Shaw, Bevil J.↗

Benefits of Force Limiting Vibration Testing

Force limited random vibration testing is used at NASA John Glenn Research Center (formerly NASA Lewis Research Center) for qualifying aerospace hardware for flight. The benefit of force limiting testing is that it limits overtesting of flight hardware, by controlling input force and acceleration from the shaker (dual control) to the test article. The purpose of force limiting is to replicate the test article resonant response for the actual flight mounting condition. The force limiting testing technology has been implemented at the Jet Propulsion Laboratory for the past 10 years on various spacecraft testing programs. The Cassini mission to Saturn, most notably, utilized force limiting vibration testing as part of the spacecraft system level vibration testing. NASA John Glenn Research Center is responsible for microgravity combustion and fluid science research on the Shuttle and the International Space Station. Qualification testing of delicate and vibration sensitive science instrumentation is particularly challenging to successfully qualify for flight. In order to facilitate the testing process, force limiting has been implemented to minimize overtesting of flight hardware. This paper will address recent flight camera testing (qualification random vibration and strength testing) for the Combustion Module-2 mission and the impact of Semi-empirical Method force limits.

McNelis, Mark E.↗

Sensitivity of Force Specifications to the Errors in Measuring the Interface Force

Force-Limited Random Vibration Testing has been applied in the last several years at NASA/GSFC for various programs at the instrument and system level. Different techniques have been developed over the last few decades to estimate the dynamic forces that the test article under consideration will encounter in the operational environment. Some of these techniques are described in the handbook, NASA-HDBK-7004, and the monograph, NASA-RP-1403. A key element in the ability to perform force-limited testing is multi-component force gauges. This paper will show how some measurement and calibration errors in force gauges are compensated for w en tie force specification is calculated. The resulting notches in the acceleration spectrum, when a random vibration test is performed, are the same as the notches produced during an uncompensated test that has no measurement errors. The paper will also present the results of tests that were used to validate this compensation. Knowing that the force specification can compensate for some measurement errors allows tests to continue after force gauge failures or allows dummy gauges to be used in places that are inaccessible.

Worth, Daniel↗

Dynamical System Scaling of a Thermocline Thermal Storage System in the Thermal Energy Distribution System (TEDS) Facility

The purpose of this study was to develop a process to convert input signals from one facility into another by reflecting geometric and environmental settings. The Dynamic Energy Transport and Integration Laboratory (DETAIL) is one facility in development that aims to emulate the daily interactions among power production industry systems and be capable of receiving real-time data from those systems as inputs. To convert signals and ensure that the temporal sequences and magnitudes reflect the laboratory settings, the ability to scale and project data is essential. To demonstrate this ability, Dynamical System Scaling (a methodology that enables systems to scale and project or extrapolate datasets to desired environments while conserving the observed transient behavior based on first principles) was applied to DETAIL’s thermocline thermal storage system in the Thermal Energy Distribution System. The thermocline system was successfully scaled and a test case was conducted to generate a doubly accelerated energy charge and discharge in reference to past experimental data from the facility. The accelerated data were determined as able to conserve the amount of energy stored and the associated test boundary conditions were charge line maximum temperature, charge line velocity, and thermocline maximum temperature at 354 °C, 0.458 m/s, and 418 °C, respectively. The research results represented a case that required signals to be accelerated without altering the stored energy.

Yoshiura, Ramon (ORCID:0000000319781313)↗

NASA ride quality program at the Flight Research Center

A flight test program to determine the effects of low frequency vibrations on passengers in short haul aircraft is discussed. The objective of the program is to accumulate flight test data on aircraft ride quality in terms of vehicle motion and acceleration and human responses. The subjects discussed are: (1) test procedures, (2) data processing, and (3) the program schedule.

Gee, S. W.↗

Neural Network Modeling of UH-60A Pilot Vibration

Full-scale flight-test pilot floor vibration is modeled using neural networks and full-scale wind tunnel test data for low speed level flight conditions. Neural network connections between the wind tunnel test data and the tlxee flight test pilot vibration components (vertical, lateral, and longitudinal) are studied. Two full-scale UH-60A Black Hawk databases are used. The first database is the NASMArmy UH-60A Airloads Program flight test database. The second database is the UH-60A rotor-only wind tunnel database that was acquired in the NASA Ames SO- by 120- Foot Wind Tunnel with the Large Rotor Test Apparatus (LRTA). Using neural networks, the flight-test pilot vibration is modeled using the wind tunnel rotating system hub accelerations, and separately, using the hub loads. The results show that the wind tunnel rotating system hub accelerations and the operating parameters can represent the flight test pilot vibration. The six components of the wind tunnel N/rev balance-system hub loads and the operating parameters can also represent the flight test pilot vibration. The present neural network connections can significandy increase the value of wind tunnel testing.

Kottapalli, Sesi↗

Residual acceleration data on IML-1: Development of a data reduction and dissemination plan

The main thrust of our work in the third year of contract NAG8-759 was the development and analysis of various data processing techniques that may be applicable to residual acceleration data. Our goal is the development of a data processing guide that low gravity principal investigators can use to assess their need for accelerometer data and then formulate an acceleration data analysis strategy. The work focused on the flight of the first International Microgravity Laboratory (IML-1) mission. We are also developing a data base management system to handle large quantities of residual acceleration data. This type of system should be an integral tool in the detailed analysis of accelerometer data. The system will manage a large graphics data base in the support of supervised and unsupervised pattern recognition. The goal of the pattern recognition phase is to identify specific classes of accelerations so that these classes can be easily recognized in any data base. The data base management system is being tested on the Spacelab 3 (SL3) residual acceleration data.

Rogers, Melissa J. B.↗

Initial conditions for simulations of beam physics in linear induction accelerators

Flash radiography of hydrodynamic experiments driven by high explosives is a well-known diagnostic technique in use at many laboratories. At Los Alamos, the DualAxis Radiographic Hydrodynamic Test (DARHT) facility two linear induction electron accelerators (LIAs) make the bremsstrahlung radiographic source spots for point projection radiographs from orthogonal views. A new LIA, called Scorpius, is presently under development to advance this technology. To better understand electron-beam physics in these LIAs, numerical simulations are frequently performed with the objective of improving the radiography. At Los Alamos we frequently use the TRAK ray-trace and LSP particle-in-cell (PIC) codes to simulate the injector, and the XTR and LAMDA envelope/centroid codes along with LSP to simulate transport of the accelerated beam through the LIAs. The LIA simulations need the injected beam parameters as initial conditions for calculating beam transport and stability. The determination of these initial conditions is the topic of this note.

43 PARTICLE ACCELERATORS↗

Nondestructive Evaluation (NDE) of Cable Anomalies using Frequency Domain Reflectometry (FDR) and Spread Spectrum Time Domain Reflectometry (SSTDR)

This report presents a comparative assessment of the performance of frequency domain reflectometry (FDR) and spread spectrum time domain reflectometry (SSTDR) in detecting a wide range of electrical cable anomalies. All tests and results reported herein were performed at the PNNL Accelerated and Real-Time Environmental Nodal Assessment (ARENA) cable and motor test bed. The primary objective of this work was to evaluate the effectiveness of SSTDR, a fledgling cable monitoring technique that shows promise for application in online monitoring of energized cable systems, against FDR, an offline technique widely employed in the nuclear power plant (NPP) industry. FDR tests are becoming more widely used in nuclear power plant cable aging management and test programs – particularly for low voltage cables. FDR capabilities for these kinds of tests have been reported by PNNL and others. The FDR test is performed on de-energized cables by connecting the FDR instrument to two of the cable conductors, or one conductor and the shield. A broad band low voltage (< 5 V) chirp is introduced in the cable, and any reflected response is captured in the frequency domain. The captured reflection is then processed by performing an inverse Fourier transform to a time domain response which can then be converted to a distance response based on the cable velocity of propagation (VoP). SSTDR measurements are functionally similar to FDR measurements in that a broad-band voltage signal composed of a square or sine wave modulated pseudo-random sequence of chips (< 5 volts), is injected onto one of the cable conductors. The injected signal will experience partial energy reflection and transmission at each impedance discontinuity along the transmission line. Any reflected response is detected by computing a cross-correlation between the reflected signals and a delayed copy of the incident SSTDR signal. the time delay for the reflected signal to experience the best matched correlation with the incident signal, indicates the travel time for the signal to reach a change in impedance. By knowing this time delay and velocity of propagation (VoP) of the signal, one can compute the physical distance. A big advantage that SSTDR measurements have over other methods is the ability to be connected to energized or live wires (currently up to 1kV) thereby enabling online monitoring of cables. SSTDR has been used successfully in several applications, e.g., aircraft, rail, and photovoltaic systems. In this work FDR and SSTDR cable assessment techniques were used to characterize a variety of cable anomalies and faults including: (1) Presence or absence of a motor; (2) Ground faults and short circuit faults; (3) Moist environments and water ingress faults; (4) Accelerated thermal aging. Both shielded and non-shielded cables were evaluated in this report. Offline measurements were made using FDR and online measurements were made by SSTDR for a range of test scenarios. Based on the results across all cable anomalies evaluated in this study, FDR displayed high sensitivity towards cable condition assessment, while SSTDR showed promise for future application in monitoring NPP cable systems. However, further developments are suggested to improve the resolution and sensitivity of SSTDR towards faults and anomalies in low voltage cables.rt presents a comparative

42 ENGINEERING↗

Variable Acceleration Force Calibration System (VACS)

Conventionally, force balances have been calibrated manually, using a complex system of free hanging precision weights, bell cranks, and/or other mechanical components. Conventional methods may provide sufficient accuracy in some instances, but are often quite complex and labor-intensive, requiring three to four man-weeks to complete each full calibration. To ensure accuracy, gravity-based loading is typically utilized. However, this often causes difficulty when applying loads in three simultaneous, orthogonal axes. A complex system of levers, cranks, and cables must be used, introducing increased sources of systematic error, and significantly increasing the time and labor intensity required to complete the calibration. One aspect of the VACS is a method wherein the mass utilized for calibration is held constant, and the acceleration is changed to thereby generate relatively large forces with relatively small test masses. Multiple forces can be applied to a force balance without changing the test mass, and dynamic forces can be applied by rotation or oscillating acceleration. If rotational motion is utilized, a mass is rigidly attached to a force balance, and the mass is exposed to a rotational field. A large force can be applied by utilizing a large rotational velocity. A centrifuge or rotating table can be used to create the rotational field, and fixtures can be utilized to position the force balance. The acceleration may also be linear. For example, a table that moves linearly and accelerates in a sinusoidal manner may also be utilized. The test mass does not have to move in a path that is parallel to the ground, and no re-leveling is therefore required. Balance deflection corrections may be applied passively by monitoring the orientation of the force balance with a three-axis accelerometer package. Deflections are measured during each test run, and adjustments with respect to the true applied load can be made during the post-processing stage. This paper will present the development and testing of the VASC concept.

Rhew, Ray D.↗

Photon Irradiation Effects on the Enduray Vision System for Nuclear Inspections

Video cameras with greater radiation hardening are needed for the operation and remote handling of equipment in nuclear reactor inspection and refueling applications. Vega Wave Systems has developed a radiation-hardened vision system for nuclear energy applications. The program described in this report provided radiation-hardness testing of this vision system using the Argonne Low-Energy Accelerator Facility (LEAF). This report presents the results of irradiation tests performed on several of Vega Wave System’s cameras at dose rates ranging from 1 kGy/hr up to 10 kGy/hr and up to total doses of >500 kGy. The results were excellent, providing proof of the camera system’s immunity to radiation effects at all levels tested.

36 MATERIALS SCIENCE↗

A Summary of Airframe Results from a Fokker F28 Full-Scale Crash Test

On June 20, 2019, a full-scale crash test was conducted on a Fokker F28 MK1000 aircraft as a part of a joint NASA / Federal Aviation Administration (FAA) research effort to investigate the crashworthiness characteristics of a Transport Category Aircraft (TCA), as defined by 14 Code of Federal Regulations, Part 25. The test was conducted at NASA Langley Research Center’s Landing and Impact Research Facility and was the third in a test series to further understand TCA crashworthiness characteristics. The test article featured 24 Anthropomorphic Test Devices (ATDs, a.k.a. crash test dummies), and over 700 channels of instrumentation covering major aircraft structures such as the wings, tail, nose, cockpit and cabin, along with recording seat, overhead bin and ATD accelerations. Five different U.S. Government agencies collaborated on the test including: NASA, the FAA, the U.S. Army Research Laboratory, the National Transportation Safety Board (NTSB) and the National Highway Traffic Safety Administration (NHTSA). This report will covertest article build up, which includes weight and balance measurements and pre-test laser scans. It will also cover the events of the test, which includes the test sequence of events and post-test damage inspections. Finally, it will show airframe level accelerations at all positions measured, with discussion on correlation to the airframe damage witnessed. The test build up consisted of outfitting the main cabin section of the aircraft with 24 ATDs seated in 12 rows of seats, overhead mass and the under floor cargo area with foam representing the luggage. The main cabin also included all of the onboard data system pallets, which recorded711 channels of data from the test. All major portions of the aircraft were instrumented, including locations at the floor / frame junction locations in the cabin where the ATDs were located along with other major exterior components such as the nose, the tail, each engine cowling, and at overhead hat rack ballast locations. The aircraft impacted a soil surface at65.3 ft/s horizontal and 31.8 ft/s vertical velocities. The aircraft plowed through the soil and slid a distance of 32.5 feet from the initial impact location. There was a secondary impact occurring 0.9 s due to the “slap down” of the nose during the post-impact response. The duration of the event from impact to rest was1.62 seconds. There was major structural damage in the lower fuselage areas around the Wingbox and Aft Fuselage sections. The Aft Fuselage section deformation caused some cabin intrusion from the keel beams pushing the aft cabin floor into the cabin. Other structural deformations occurred around the tail and at transition regions in the aircraft structure; mainly in locations of differing overall stiffness. The data obtained showed average vertical accelerations between 12 and 16 g with spikes reaching almost 40 g at certain floor locations. Average horizontal accelerations were approximately 10 g for all floor locations measured with spikes reaching approximately 25 g in some locations. The report includes a full set of results on aircraft deformation and accelerations along with discussions as to the effect on the aircraft structure.

Justin D Littell↗

SPEL: Software tool for Porting E3SM Land Model with OpenACC in a Function Unit Test Framework

Most high-end computers adopt hybrid architecture, porting a large-scale scientific code onto accelerators is necessary. The paper presents a generic method for porting large-scale scientific code onto accelerators using compiler directives within a modularized function unit test platform. We have implemented the method and designed a software tool (SPEL) to port the E3SM Land Model (ELM) onto the GPUs in the Summit computer. SPEL automatically generates GPU-ready test modules for all ELM functions, such as CanopyFlux, SoilTemperature, and EcosystemDynamics. SPEL breaks the ELM into a collection of standalone unit test programs for easy code verification and further performance improvement. We further optimize several ELM test modules with advanced techniques, including memory reduction, reconstructed parallel loops, and asynchronous GPU kernel launch. We hope our study will inspire new toolkit developments that expedite large-scale scientific code porting with compiler directives.

Schwartz, Peter↗

Correct Initial Conditions for Simulations of Beam Physics in Linear Induction Accelerators

Flash radiography of hydrodynamic experiments driven by high explosives is a well-known diagnostic technique in use at many laboratories. At Los Alamos, the Dual Axis Radiographic Hydrodynamic Test (DARHT) facility two linear induction electron accelerators (LIAs) make the bremsstrahlung radiographic source spots for point projection radiographs from orthogonal views. A new LIA, called Scorpius, is presently under development to advance this technology. To better understand electron-beam physics in these LIAs, numerical simulations are frequently performed with the objective of improving the radiography. At Los Alamos we frequently use the TRAK ray-trace and LSP particle-in-cell (PIC) codes to simulate the injector, and the XTR and LAMDA envelope/centroid codes along with LSP to simulate transport of the accelerated beam through the LIAs. The LIA simulations need the injected beam parameters as initial conditions for calculating beam transport and stability. The determination of these initial conditions is the topic of this note.

43 PARTICLE ACCELERATORS↗

Advancing Conduction-Cooled 650 MHz SRF Technology for Industrial Accelerators at Fermilab's IARC

The National Nuclear Security Administration (NNSA) funds the Illinois Accelerator Research Center (IARC) at Fermilab in developing a high-power, conduction-cooled Superconducting Radio Frequency (SRF) accelerator tailored for industrial applications requiring robust and efficient operation. A 650 MHz, 1.6 MeV, 20 kW SRF accelerator is currently under development, employing a conduction cooling approach to simplify cryogenic requirements and enhance accessibility for industrial use. The accelerator’s control system is implemented on the Blinky Lite platform, selected for its open-source architecture, secure remote access capabilities, and operational flexibility—attributes advantageous for industrial deployment and sustained operation. A dedicated beamline is designed to measure essential beam parameters and test the integrated performance of the accelerator and control systems, thereby validating their operational readiness for intended applications

Ji, Y. [Fermilab] (ORCID:0000000233981752)↗

An initial framework for the rapid qualification of long-term creep rupture strength via microstructural modeling

This report describes the development and testing of a new method for extrapolating short-term creep rupture test data to predict long-term rupture strength. The goal of this work is to reduce the time required to qualify new materials for nuclear service by reducing the lead time required for dedicated, long-term material testing to establish key long-term material properties. The new approach described here uses a physics-based model to predict the long-term creep rupture strength of 316H stainless steel using only short-term test data. The key idea is to use Bayesian inference to find the statistical distribution of the model parameters that best explain the short-term rupture data. Because the model is physics-based these parameters are all microstructural quantities that can be measured through detailed material characterization experiments. The Bayesian prior distributions provide a means for incorporating this characterization data into the final model to improve the accuracy of the long-term model predictions. However, where such data is not available the process still produces an accurate model based on an uniformed prior. Our hypothesis is that this approach more accurately extrapolates the short-term test data when compared to current, empirical methods. The report proves this hypothesis using actual long-term rupture data available for 316H, including tests with rupture times greater than 200,000 hours. The general approach developed here could be applied to other materials and other time-dependent material properties. Applying this new technique to develop long-term qualified material properties, potentially in conjunction with other accelerated qualification approaches like staggered qualification test programs, could greatly reduce the time required to qualify new materials for nuclear service.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Advancing Conduction-Cooled 650 MHZ SRF Technology for Industrial Accelerators at Fermilab S IARC

The National Nuclear Security Administration (NNSA) funds the Illinois Accelerator Research Center (IARC) at Fermilab in developing a high-power, conduction-cooled Superconducting Radio Frequency (SRF) accelerator tailored for industrial applications requiring robust and efficient operation. A 650 MHz, 1.6 MeV, 20 kW SRF accelerator is currently under development, employing a conduction cooling approach to simplify cryogenic requirements and enhance accessibility for industrial use. The accelerator's control system is implemented on the Blinky Lite platform, selected for its open-source architecture, secure remote access capabilities, and operational flexibility attributes advantageous for industrial deployment and sustained operation. A dedicated beamline is designed to measure essential beam parameters and test the integrated performance of the accelerator and control systems, thereby validating their operational readiness for intended applications.

Ji, Yichen [Fermilab]↗

H2@Scale - Validating an Electrolysis System with High Output Pressure: Cooperative Research and Development Final Report, CRADA Number CRD-18-00741

Electrolysis has been a commercially available product for a while and electrolyzers have been a proven capability to provide additional benefits (e.g. controllable load for grid services) in addition to production of hydrogen. The hydrogen output is typically compressed for storage and dispensing. Compression adds cost and decreases system reliability. Honda’s electrolyzer systems have been developed to include electrochemical compression to leverage the production system itself for at least partial compression. In this project, the team will evaluate Honda’s PEM based electrochemical compression system. The system is capable of compressing hydrogen up to 70 MPa electrochemically. Validation testing is the next step to accelerate this technology into the marketplace, as the validation will provide needed data under a variety of operation conditions and controls. These operating conditions and controls are based on over a decade of NLR research and development with low-temperature electrolysis. The validation testing will include preparing NLR’s site for third party evaluation, benchmark testing of Honda’s stack and system, and simulating operation connected to renewables or in a grid service profile. NLR’s Energy System Integration Lab will be the location for the electrolyzer validation research and integrated into the Hydrogen Infrastructure Test & Research Facility (HITRF). This will build into the existing retail style hydrogen fueling station for a fully integrated experimental setup.

08 HYDROGEN↗