Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “mission lifetime”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

14 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

The Impact of the 8–10 March 2012 Geomagnetic Storm on Inner Zone Protons as Measured by Van Allen Probes

The Relativistic Electron Proton Telescope (REPT) instrument on the Van Allen Probes observed a double-peaked inner zone proton population throughout the 7 year lifetime of the mission. M. Hudson et al. (2023) showed that a strong SEP event accompanied by a CME-shock in early March 2012 provided the Solar Energetic Proton (SEP) source for the higher L trapped proton population, which then diffused radially inward to be observed by REPT at L = 2. The study followed trajectories of SEP protons launched isotropically from a sphere at 7 Re for 2.5 hr in fields calculated by the LFM-RCM global MHD model, which includes electric fields needed to model the transport and trapping of the protons by the shock, and then a radial diffusion simulation was run for 2 years using the result from the test-particle simulation as the initial condition. The simulation result was compared with REPT measurement in November 2013 and showed reasonable agreement. However, the simulation overestimated the Phase Space Density by a factor of four due to lack of field line curvature scattering during the storm in the model. In this study, a test-particle simulation is performed for 2 days following the injection and trapping of protons in March 2012 using TS05 fields to simulate the field line curvature scattering of the trapped SEP due to the buildup of the ring current during the geomagnetic storm. The resulting sample distribution was then weighted using the flux at the end of the two-hour MHD-test particle simulation. A radial diffusion simulation is then run using the initial profile that included the loss effect, with improved comparison with REPT measurements after 2 years.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2024

Rapid Predictions of Part Lifetimes in Corrosive Environments, Corrosion

Corrosion challenges persist throughout SNL’s mission areas. The primary difficulty lies in the fact that corrosion typically manifests as isolated, rare events, making preemptive identification exceedingly difficult. Our current strategy for addressing corrosion issues, such as anomalies and SFIs, is similarly isolated and reactive. This method is costly, time-consuming, heavily dependent on a limited number of experts, and offers minimal understanding of the overall damage distribution within the stockpile. This technical challenge is not unique to corrosion but is also prevalent in other material aging phenomena, such as tin-whisker growth in lead-free solder and fatigue failure of springs.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Reliability Assessment of Cooling Fans for PV Inverters: Testing, Modeling, and Case Studies

The reliability of photovoltaic (PV) inverters is critical for long-term solar system performance, with cooling fan failures frequently leading to costly downtime. While much research exists on general cooling fan reliability, little attention has been given to fans operating within PV inverters and their unique environmental challenges. Here, this article proposes a comprehensive methodology to address this gap. First, a failure mode and effects analysis is performed on fans to identify the key failure mechanisms in PV applications, their corresponding stressors, and the models necessary for lifetime prediction. Second, an accelerated life test is designed and conducted to collect valuable experimental data for PV inverter fans in a reasonable amount of time. Third, a mathematical conversion of dynamic mission profiles into effective constant stress levels is derived. Fourth, case studies are given, showcasing lifetime estimates that account for geographic variations in mission profile data. The results demonstrate that this integrated approach leads to an accurate reliability assessment for PV inverter cooling fans.

accelerated life testing (ALT)↗
DOE OSTI2025

In situ Detection of Plasma Induced Surface Interaction based on Deep Learning based Visual Diagnostics (Technical Report)

It is characteristic for many plasma devices to undergo plasma-material interaction leading to surface erosion. These processes, often not easily detectable, lead to changes in device performance and lifespan. State-of-the-art lifetime tests and wear experiments require over 1000s hours. A self-consistent model for accurately predicting the erosion's effects is not available. In situ detection of these processes is not a trivial task since the surface variations at the early stages have a micron scale. Such limitations not only restrict testing and prediction capabilities but also slow the development of new thrusters and limit mission duration. To address these challenges, an in-situ diagnostic for real-time erosion assessment has been developed, aiming to expedite lifetime testing and broaden experimental campaigns. Several works were dedicated to real-time and in situ monitoring of material erosion during plasma exposure using laser holography, microscopy, and with telemicroscopes. However, the applicability of these approaches is limited due to complexity, cost and less flexibility as they often require placing diagnostic equipment inside the vacuum chamber. In collaboration with Princeton Collaborative Research Facility (PCRF), Princeton Plasma Physics Laboratory (PPPL), a new diagnostic approach is developed, where geometry modifications to the ceramic channel walls were introduced that would result in accelerated channel erosion. We employed Long-distance microscope (LDM) imagery, combined with Deep-Learning based Shape from focus or depth from focus (DFF or SFF) approach, that provides an accessible and cost-effective solution. LDM employs focus variation techniques to continuously capture multiple images of the target object at distinct focal planes. DFF, an optical focus variation method, generates a 3D topographical surface depth map from a sequence of variably focused images. Combined with the developed diagnostic, this approach offers a controllable means to study erosion under accelerated conditions. In this work, we develop Neural Network-based DFF algorithm applicable for LDM data to quantitatively evaluate plasma induced surface modification from LDM data. Next, we develop Deep Learning-based super-resolution depth map image reconstruction technique to increase the resolution of depth maps obtained from DFF algorithm to improve the accuracy of erosion measurements. Thirdly, we develop several image processing techniques to remove noise and improve the quality of depth map image. Here we report the results of initial tests for this approach. An experimental setup designed and built in PPPL was employed that consists of a 3-cm gridded ion source that produces a neutralized argon beam with energies up to 600 eV. A hexagonal boron nitride (h-BN) ceramic target, designed based on computational predictions, was used. Tests were conducted to reconstruct the complex geometry of the target under the lighting conditions of the operated ion source.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Predicting Cislunar Orbit Lifetimes from Initial Orbital Elements

The volume of space between Earth’s geosynchronous orbit out to the Moon’s sphere of influence, including the lunar Lagrange points, is crucial for the successful planning and execution of space missions, but not fully understood dynamically. This region is a part of cislunar space. Trajectories through cislunar space are influenced by the gravitational forces of the Sun, Earth, Moon, and other Solar System planets leading to typically unpredictable and chaotic trajectory behavior. It is therefore difficult to predict the stability of an trajectory through cislunar space from a set of initial conditions or orbital elements. We simulate one million cislunar orbits to train a self-organizing map (SOM) to cluster the trajectories and orbits into families based on how long they remain stable within the cislunar space. Using the trained SOM, we are able to predict the stable lifetime of a trajectory through cislunar space from a set of initial orbital elements to within an accuracy of 10% for 8% of simulated trajectories and within 50% for 43% of the simulated trajectories. Clustering in the SOM suggests that a variety of trajectory morphologies have similar lifetimes. Once trained, the SOM can predict the stable lifetime of a given cislunar trajectory within milliseconds. The methods developed in this work enable the rapid identification of stable cislunar orbits and trajectories that could be used for future space exploration. Moreover, the developed SOM method can generate orbital and trajectory lifetime estimates from minimal observational data, such as a single two line element, making it useful for early warning systems and large-scale sensor network operations.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

Time-delayed gamma-ray signatures of heavy axions from core-collapse supernovae

Heavy axions that couple to both quantum electrodynamics and quantum chromodynamics with masses on the order of MeV–GeV and high-scale decay constants in excess of ∼ 10 8 GeV may arise generically in, e.g., axiverse constructions. In this work we provide the most sensitive search to date for the existence of such heavy axions using Fermi-LAT data toward four recent supernovae (SN): Cassiopea A, SN1987A, SN2023ixf, and SN2024ggi. We account for heavy axion production in the proto-neutron-star cores through nuclear and electromagnetic processes and then the subsequent decay of the axions into photons. While previous works have searched for gamma rays from SN1987A using the Solar Maximum Mission that observed SN1987A during the SN itself, we show that using Fermi Large Area Telescope data provides an approximately 5 orders of magnitude improvement in flux sensitivity for axions with lifetimes larger than around 10 yrs. We find no evidence for heavy axions and exclude large regions of previously unexplored parameter space.

Axions↗
DOE OSTI2026

Collaborative Approach to Identify Degradation Mechanisms and Validate Aging Protocols for a Diverse Set of DAC Materials (TCF Base Technology-Specific Final Report)

This work supports the mission of the U.S. Department of Energy to promote American energy leadership, technological innovation, and economic growth through the development of technologies for cost effective carbon capture. While capture technologies can provide carbon dioxide for enhanced oil recovery, many capture materials suffer from oxidative, hydrolytic and/or thermal degradation which leads to capacity loss and unwanted emissions such as ammonia. Short lifetimes increase operational costs and cost studies suffer from uncertainty because the true lifetimes of many capture materials are unknown. In this study, a suite of capture materials were studied to quantify their degradation, provide insight into the mechanisms that lead to their uptake loss and provide validated accelerated aging protocols for industry.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Virtual Inspection of Advanced Manufacturing via Process-Scale Digital Twins (Abbreviated Report)

Inspection and certification comprise the most significant bottlenecks in advanced manufacturing for NNSA applications, often requiring far more time and resources than the fabrication of the parts themselves. Traditional methods, such as manual review and X-ray computed tomography, are not only slow and costly, but also struggle to provide a clear connection between manufacturing instructions and the final performance of critical components. This gap limits both the agility and assurance needed to support the modernization and safety of the United States nuclear stockpile. In response, our Strategic Initiative established a digital twin framework that integrates realtime process monitoring, automated data analysis, and immersive virtual reality collaboration into a unified inspection pipeline. By leveraging data from sensors, machine instructions, and imaging, we created high-fidelity virtual models of manufactured parts that could be rapidly analyzed and certified. This approach was first demonstrated with Direct Ink Write, and then extended to other manufacturing settings, including conventional (or “subtractive”) manufacturing and to predict the end of life performance of parts per the aging and lifetimes programs. The result is a transformational capability: inspection times have been reduced by a factor of 120,000 without loss of accuracy and while simultaneously improving traceability and confidence in part quality. This framework not only streamlines certification for critical applications, but also positions the national security enterprise to respond more flexibly to emerging challenges, supporting agile manufacturing and digital engineering practices across a broad range of mission-relevant domains.

42 ENGINEERING↗
DOE OSTI2025

Resolve instrument onboard the X-Ray Imaging and Spectroscopy Mission

We present an overview of the design and in-flight performance of the Resolve soft X-ray spectrometer on the X-Ray Imaging and Spectroscopy Mission that was successfully launched on September 7, 2023, on a JAXA H-IIA rocket from the Tanegashima Space Center of Japan. The instrument has a 36-pixel array of microcalorimeters, 35 of which are at the focus of a high-throughput grazing-incidence X-ray mirror. The instrument has achieved its required operational base temperature of 0.05 K and a spectral resolution of 4.5 eV (FWHM) at 6 keV. The cooling chain was designed to provide a lifetime of at least 3 years in orbit and operate with and without liquid helium to provide redundancy and the longest operational lifetime for the instrument. Early indications are that the cryogen lifetime may reach 6 years with a cryogen-free mode thereafter. A series of onboard X-ray calibration sources produces energy scale calibration lines simultaneously while observing celestial sources. The overall design and in-flight performance of Resolve are described.

Astronomy and AstroPhysics↗
DOE OSTI2025

Pre- and post-launch operation of the Resolve soft X-ray spectrometer onboard the XRISM satellite

Resolve is a high-resolution X-ray spectrometer onboard the X-Ray Imaging and Spectroscopy Mission (XRISM), launched on September 6 (UT), 2023. The Resolve has performed better than its required spectral resolution (7 eV at full width at half maximum at 6 keV), both on the ground and in orbit, and has been confirmed to have comparable performance to the soft X-ray spectrometer onboard the ASTRO-H (Hitomi) satellite. The focal plane is composed of an array of microcalorimeter detectors operated at 50 mK to achieve the required energy resolution, and the cooling system is designed to satisfy the lifetime requirement of over 3 years. The focal plane and cooling system are contained in a vacuum-insulated dewar. The cooling system is equipped with a two-stage adiabatic demagnetization refrigerator (ADR) that uses superfluid liquid helium (LHe) as its heat sink. The system includes a third ADR stage that can be used to provide the heat sink when the helium is exhausted. A Joule–Thomson cooler and several two-stage Stirling coolers are used to reduce the heat load on the LHe. During pre-launch operations, we carried out a superfluid LHe top-off operation. The resultant amount of LHe onboard Resolve was over 35 L before launch, which is sufficient to meet the lifetime requirement. During post-launch operation, the LHe vent valve was opened 5 min after launch during rocket acceleration, and the cryocoolers were turned on after several orbits, as planned, which established stable cooling within the dewar. Pre- and post-launch operations for the Resolve instrument were planned around multiple constraints from launch vehicle operations; all were successfully completed, and the launch requirements were fully met.

X-Ray Imaging and Spectroscopy Mission↗
DOE OSTI2025

Computational Fluid Dynamics Simulations of Glass Vitrification Refractory Coupon Tests

The Waste Treatment and Immobilization Plant (WTP) at the Hanford site is nearing the start of the Direct-Feed Low-Activity Waste (DFLAW) operations. DFLAW is destined to convert a pretreated low activity waste portion of the 56 million gallons of tank waste into a stable solid glass. In the subsequent decade completion of the high-level waste (HLW) facility is anticipated. Sustained operational missions of both LAW and HLW melter facilities are expected over multiple decades. In high-temperature glass melters, the refractory lining corrodes over time, which could potentially be an issue for longer term operations, this refractory corrosion is higher at the level of the glass-air interface due to surface tension driven flow. The glass viscosity, melt pool temperature, and glass chemical composition can impact the rate at which the refractory corrodes. This rate is important to quantify for the various waste glasses to be produced at the WTP since the integrity of the refractory should not be a limiting factor affecting the lifetime of the melter. To this end, a series of glasses representative of the first batches of waste glass produced by the WTP will be melted in small-scale crucibles with Monofrax® K-3 coupons inserted. The corrosion of the K-3 will be measured in the melt and at the meltline (or neckline). A model for the corrosion rate will be constructed and implemented into a previously developed framework for a computational fluid dynamics (CFD) model of the full-scale WTP. To assist with experimental design and validate the implementation of the model in the full-scale melter, CFD simulations of the small-scale crucible tests were performed. The bubbling that occurs in the small-scale crucible is initially validated here with a model that uses silicone oil at room temperature. The viscosity of the oil ranges from 1 to 100 Pa•s, which corresponds to operating glass pool temperatures near 1150 °C down to idling temperatures near 950 °C. The simulation results show good agreement with the bubble sizes that form during experiments. CFD modeling of the crucible setup was used to determine bubbling characteristics to match the range of near-wall velocities expected in the full-scale WTP. This study presents the initial CFD modeling results, corrosion testing plan, and some preliminary corrosion samples with an outline for the next steps for the development of the corrosion model.

Abboud, Alexander W. [Idaho National Lab]↗
DOE OSTI2026

PV Lifetime Project - 2025 NLR Annual Report

DOE's PV Lifetime project was initiated in 2016 with the goal of accurately characterizing the early-life evolution of photovoltaic (PV) field performance. Different PV cell and module technologies result in different initial degradation rates due to effects like light-induced degradation (LID) and light and elevated temperature-induced degradation (LeTID). To accurately characterize the initial field degradation of maximum power (Pmp) requires the use of high-accuracy indoor IV curve measurements at standard test conditions. Therefore, PV modules involved in this study are removed from the field once or twice per year and brought indoors for measurement under constant temperature and irradiance conditions. Overall annual degradation rates are as follows: our first modules to be deployed (Jinko, Trina, QCells) have annual median degradation rate between -0.4%/yr and -0.5%/yr mainly concentrated in the first year. Mission Solar, LG and Panasonic modules are all displaying modest degradation, better than -0.3% / year. Indeed, Mission Solar fielded modules degraded less than their control modules which remain indoors and un-exposed. This is also true for the LONGi monofacial modules, which had some field degradation, but not as much as the degradation of the indoor control modules. The LONGi bifacial modules on the other hand have degraded more in the field than their monofacial counterparts, although still a modest amount (-0.4 %/yr). Of the four newest module types in the study, only one has had better than average degradation. REC360NP2 (N-type TOPCon) had a slight performance increase over the first year and a half of field deployment. For the other three new module types (plus one older module type), degradation was more rapid. In our study of 16 module types, four have demonstrated degradation faster than -1%/yr: two N-type Heterojunction, one PERC bifacial and one PERC shingled module. The two heterojunction modules in our study are degrading the most rapidly. Sunpreme n-HIT bifacial modules are showing a loss rate around -1.5%/yr, for over -10% total to date. This is largely attributed to loss in front-side Isc. This is distinct from the REC 405AA-Pure modules which have degraded -6.8% in only a year and a half, for an annualized decline of -3.9 %/yr. For this module type, the decline is roughly half in Voc, with the remaining split between FF and Isc. Of the remaining two module types, Prism Solar PERC bifacial has declined -5% total since 2019, although this loss appears to have stabilized in the most recent measurement. The Solaria PowerX-400R Shingled module type has also lost around -3.2% in the first 1.5 years of field deployment. It remains to be seen if these losses will continue with time.

14 SOLAR ENERGY↗
DOE OSTI2025

MATHUSLA: An External Long-Lived Particle Detector to Maximize the Discovery Potential of the HL-LHC

We present the current status of the MATHUSLA (MAssive Timing Hodoscope for Ultra-Stable neutraL pArticles) long-lived particle (LLP) detector at the HL-LHC, covering the design, fabrication and installation at CERN Point 5. MATHUSLA40 is a 40 m-scale detector with an air-filled decay volume that is instrumented with scintillator tracking detectors, to be located near CMS. Its large size, close proximity to the CMS interaction point and about 100 m of rock shielding from LHC backgrounds allows it to detect LLP production rates and lifetimes that are one to two orders of magnitude beyond the ultimate reach of the LHC main detectors. This provides unique sensitivity to many LLP signals that are highly theoretically motivated, due to their connection to the hierarchy problem, the nature of dark matter, and baryogenesis. Data taking is projected to commence with the start of HL-LHC operations. We summarize the new 40m design for the detector that was recently presented in the MATHUSLA Conceptual Design Report, alongside new realistic background and signal simulations that demonstrate high efficiency for the main target LLP signals in a background-free HL-LHC search. We argue that MATHUSLA's uniquely robust expansion of the HL-LHC physics reach is a crucial ingredient in CERN's mission to search for new physics and characterize the Higgs boson with precision.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

The aluminium-26 distribution in a cosmological simulation of a Milky Way-type Galaxy

Context . The 1.8 MeV γ -rays corresponding to the decay of the radioactive isotope 26 Al (with a half-life of 0.72 Myr ) have been observed by the SPI detector on the INTEGRAL spacecraft and extensively used as a tracer of star formation and current nucleosynthetic activity in the Milky Way Galaxy. Further information is encoded in the observation related to the higher 26 Al content found in regions of the Galaxy with the highest line-of-sight (LoS) velocity relative to an observer located in the Solar System. However, this feature remains unexplained. Aims . We ran a cosmological “zoom-in” chemodynamical simulation of a Milky Way-type galaxy, including the production and decays of radioactive nuclei in a fully self-consistent way. We then analyzed the results to follow the evolution of 26 Al throughout the lifetime of the simulated galaxy to provide a new method for interpreting the 26 Al observations. Methods . We included the massive star sources of 26 Al in the Galaxy and its radioactive decay into a state-of-the-art galactic chemical evolution model, coupled with cosmological growth and hydrodynamics. This approach allowed us to follow the spatial and temporal evolution of the 26 Al content in the simulated galaxy. Results . Our results are in agreement with the observations with respect to the fact that gas particles in the simulation with relatively higher 26 Al content also have the highest LoS velocities. On the other hand, gas particles with relatively lower 26 Al content (i.e., not bright enough to be observed) generally display the lowest LoS velocities. However, this result is not conclusive because the overall rotational velocity of our simulated galaxy is higher than that observed for cold CO gas in the Milky Way Galaxy. Furthermore, we found no significant correlation between gas temperature, rotational velocity, and 26 Al content at any given radius. We also found the presence of transient 26 Al-rich spots at low LoS velocities and we show that one such spot had been captured by the INTEGRAL/SPI data. Based on our model, we present a prediction for the detection of 1.8 MeV γ -rays by the future COSI mission. We find that according to our model, the new instrument will be able to observe similar 26 Al-emission patterns to those seen by INTEGRAL/SPI.

Wehmeyer, B. (ORCID:0009000254149292)↗