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DOE OSTI2024

HYDRODYNAMIC TESTING OF ZIRCALOY TO STEEL HUB COUPLINGS FOR USE IN ADVANCED TEST REACTOR I-LOOP TUBE

The ATR I-positions' isolation from the flux trap region provides an opportunity for a test facility that could create conditions representative of commercial light water reactors. Such a facility requires piping couplings and joints that withstand extreme thermal and pressure cycling. Also, transitioning from steel to zircaloy piping inside the reactor vessel allows the neutronic properties of zircaloy to be leveraged while using cost-effective stainless steel outside of the core. Grayloc-style hub couplings will act as transition points between stainless steel piping and zircaloy piping inside the reactor vessel. These couplings have not been sufficiently tested for leakage where there is a transition between materials. This transition is a concern because the thermal expansion coefficients of the materials differ. Seal integrity between the two components may be greatly affected by thermal expansion at the connection. Thus, the effect of thermal cycling must be assessed. Thermal and pressure cycling and hydrodynamic testing will be conducted to verify seal integrity of the steel to zircaloy hub coupling when subjected to ATR conditions.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS2012

The Effect of Faster Engine Response on the Lateral Directional Control of a Damaged Aircraft

The integration of flight control and propulsion control has been a much discussed topic, especially for emergencies where the engines may be able to help stabilize and safely land a damaged aircraft. Previous research has shown that for the engines to be effective as flight control actuators, the response time to throttle commands must be improved. Other work has developed control modes that accept a higher risk of engine failure in exchange for improved engine response during an emergency. In this effort, a nonlinear engine model (the Commercial Modular Aero-Propulsion System Simulation 40k) has been integrated with a nonlinear airframe model (the Generic Transport Model) in order to evaluate the use of enhanced-response engines as alternative yaw rate control effectors. Tests of disturbance rejection and command tracking were used to determine the impact of the engines on the aircraft's dynamical behavior. Three engine control enhancements that improve the response time of the engine were implemented and tested in the integrated simulation. The enhancements were shown to increase the engine s effectiveness as a yaw rate control effector when used in an automatic feedback loop. The improvement is highly dependent upon flight condition; the airframe behavior is markedly improved at low altitude, low speed conditions, and relatively unchanged at high altitude, high speed.

May, Ryan D.↗

NASA NTRS1977

Ion engine auxiliary propulsion applications and integration study

The benefits derived from application of the 8-cm mercury electron bombardment ion thruster were assessed. Two specific spacecraft missions were studied. A thruster was tested to provide additional needed information on its efflux characteristics and interactive effects. A Users Manual was then prepared describing how to integrate the thruster for auxiliary propulsion on geosynchronous satellites. By incorporating ion engines on an advanced communications mission, the weight available for added payload increases by about 82 kg (181 lb) for a 100 kg (2200 lb) satellite which otherwise uses electrothermal hydrazine. Ion engines can be integrated into a high performance propulsion module that is compatible with the multimission modular spacecraft and can be used for both geosynchronous and low earth orbit applications. The low disturbance torques introduced by the ion engines permit accurate spacecraft pointing with the payload in operation during thrusting periods. The feasibility of using the thruster's neutralizer assembly for neutralization of differentially charged spacecraft surfaces at geosynchronous altitude was demonstrated during the testing program.

S. Zafran↗

NASA NTRS2003

Changes in Polymeric Tether Properties Due to Atomic Oxygen

The Propulsive Small Expendable Deployer System (ProSEDS) mission is designed to provide an on-orbit demonstration of the electrodynamic propulsion capabilities of tethers in space. The ProSEDS experiment will be a secondary payload on a Delta II unmanned expendable booster. A 5-km conductive tether is attached to the Delta II second stage and collects current fiom the low Earth orbit (LEO) plasma to facilitate de-orbit of the spent stage. The conductive tether is attached to a 10-km non-conductive tether, which is then attached to an endmass containing several scientific instruments. Atomic oxygen (AO) erodes most organic materials. As the orbit of the Delta II second stage decas, the AO flux (atoms/sq cm sec) increases. A nominal AO fluence of 1 x l0(exp 21) atoms/sq cm was agreed upon by the investigators as an adequate level for evaluating the performance of the tether materials. A test series was performed to determine the effect of atomic oxygen (AO) on the mechanical integrity and possible strength loss of ProSEDS tether materials. The tether materials in this study were Dyneema, an ultra-high molecular weight polyethylene material used as the non-conducting portion of the ProSEDS tether, and the Kevlar core strength fiber used in the conductive tether. Samples of Dyneema and Kevlar were exposed to various levels of atomic oxygen up to 1.07 x 10(exp 21) atoms/sq cm in the Marshall Space Flight Center Atomic Oxygen Beam Facility (AOBF). Changes in mass were noted after AO exposure. The tethers were then tensile-tested until failure. AO affected both the Dyneema and Kevlar tether material strength. Dyneema exposed to 1.07 x 10(exp 21) atoms/sq cm of atomic oxygen failed due to normal handling when removed fiom the AOBF and was not tensile-tested. Another test series was performed to determine the effect of AO on the electrical properties of the ProSEDS conductive tether. The conductive tether consists of seven individually coated strands of 28 AWG 1350-0 aluminum wire. The conductive coating, developed by Triton Systems, Inc., is a mix of polyanaline and COR, a clear AO-resistant polymer.

Finckenor, Miria M.↗

NASA NTRS1994

Multi-lab comparison on R-curve methodologies: Alloy 2024-T3

In an effort to determine an optimum method for ranking the fracture toughness of developmental aluminum alloys for High Speed Civil Transport applications, five labs performed K and/or J based fracture tests on aluminum alloy 2024-T3. Two material thicknesses were examined: 0.063 in. and 0.125 in. Middle crack tension and compact tension specimens were excised from 60 in. wide middle crack tension panels which had been previously tested at Boeing. The crack resistance curves generated were compared to the R-curves from 60 in. wide specimens. The experimental program indicated that effective stress intensity from secant compliance based crack length and stress intensity calculated from J-integral testing were equivalent. In addition, comparison of different specimen sizes and configurations indicated that standard validity requirements for compact tension specimens may be overly restrictive.

Reynolds, Anthony P.↗

NASA NTRS2003

Capabilities of the Materials Contamination Team at Marshall Space Flight Center

The Materials Contamination Team at the Marshall Space Flight Center (MSFC) has been recognized for its contributions supporting the National Aeronautics and Space Administration (NASA) spacecraft development programs. These programs include the Reusable Solid Rocket Motor (RSRM), Chandra X-Ray Observatory, and the International Space Station (ISS). The Environmental Effects Group, with the Materials Contamination Team and the Space Environmental Effects Team has been an integral part of NASA's success by the testing, evaluation, and qualification of materials, hardware, and processes. This paper focuses on the capabilities of the Materials Contamination Team. The Materials Contamination Team's realm of responsibility includes establishing contamination control during all phases of hardware development, including design, manufacturing, assembly, test, transportation, launch site processing, on-orbit exposure, return, and refurbishment. The team continues its mission of reducing the risk of equipment failure due to molecular or particulate contamination. Contamination is a concern in the Space Shuttle with sensitive bond-lines and reactive fluid (liquid oxygen) compatibility as well as for spacecraft with sensitive optics, such as Hubble Space Telescope and Chandra X-ray Observatory. The Materials Contamination Team has a variety of facilities and instrumentation capable of contaminant detection, identification, and monitoring. The team addresses material applications dealing with environments, including production facilities, clean rooms, and on-orbit exposure. The optically stimulated electron emission (OSEE) system, the Ultraviolet (UV) fluorescence (UVF) surface contamination detection, and the Surface Optics Corporation 400 (SOC 400) portable hand-held Fourier Transform Infrared (FTIR) spectrometer are state-of-the-art tools for in-process molecular contamination detection. The team of engineers and technicians also develop contamination calibration standards and evaluate new surface cleanliness inspection technologies. The team utilizes facilities for on-orbit simulation testing of materials for outgassing and molecular film deposition characteristics in the presence of space environmental effects, such as Atomic Oxygen (AO) and UV radiation exposure. The Materials Contamination Team maintains databases for process materials as well as outgassing and optical compatibility test results for specific environments.

Burns, Howard↗

NASA NTRS2013

Probing Aircraft Flight Test Hazard Mitigation for the Alternative Fuel Effects on Contrails & Cruise Emissions (ACCESS) Research Team

The Alternative Fuel Effects on Contrails & Cruise Emissions (ACCESS) Project Integration Manager requested in July 2012 that the NASA Engineering and Safety Center (NESC) form a team to independently assess aircraft structural failure hazards associated with the ACCESS experiment and to identify potential flight test hazard mitigations to ensure flight safety. The ACCESS Project Integration Manager subsequently requested that the assessment scope be focused predominantly on structural failure risks to the aircraft empennage raft empennage.

Kelly, Michael J.↗

DOE OSTI2025

Plug-in Electric Vehicle Charging Response Characterization for Grid Integration: Implications for Smart Charge Management

The rapid expansion of plug-in electric vehicles (PEVs) has created a unique challenge for electrical grids due to their significant power demand. At the same time, PEVs also create a unique opportunity to ease their own burden on the power grid, as they create a growing fleet of distributed energy resources capable of providing grid services such as demand response, frequency regulation, and renewable balancing. For aggregators and grid operators to effectively integrate PEVs into grid management, it is essential to first understand and characterize how they would respond in such situations. This study examines 25 models of PEVs across 25 makes, spanning model years from 2013 to 2025, to characterize their responses to the basic controls used in vehicle-grid integration (VGI): stopping, starting, and modulating the charge rate. Each vehicle was tested in a controlled laboratory setting to evaluate its performance in response to varying the maximum allowable current via the SAE J1772 control pilot signal, as well as its response to wake-up commands outlined in SAE J1772. Results show measurable differences across vehicle makes in the accuracy, latency, and precision with which PEVs respond to changes in ampacity, as well as varying sleep and wake-up behavior. The test results show that all vehicles respond to changes in ampacity, though with varying accuracy, precision, latency, and resolution. Wake-up behavior also differs across makes and models. These findings indicate that effective grid integration strategies must account for these differences. The results provide a foundation for understanding current vehicle behavior and advancing smart-charging methods while also highlighting the need for further testing, broader standardization, and manufacturer collaboration to ensure the successful integration of PEVs into the electrical grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

Modeling Transverse Space Charge effects in IOTA with pyORBIT

The role and mitigation of space charge effects are important aspects of the beam physics research to be performed at the Integrable Optics Test Accelerator (IOTA) at Fermilab. The impact of nonlinear integrability (partial and complete) on space charge driven incoherent and coherent resonances will be a new feature of this accelerator and has the potential to influence the design of future low energy proton synchrotrons. In this report we model transverse space charge effects using the PIC code pyORBIT. First we benchmark the single particle tracking results against MADX with checks on symplecticity, tune footprints, and dynamic aperture in a partially integrable lattice realized with a special octupole string insert. Our space charge calculations begin with an examination of the 4D symplecticity. Short term tracking is done first with the initial bare lattice and then with a matching of the rms values with space charge. Next, we explore slow initialization of charge as a technique to establish steady state and reduce emittance growth and beam loss following injection into a mismatched lattice. We establish values of space charge simulation parameters so as to ensure numerical convergence. Finally, we compare the simulated space charge induced tune shifts and footprints against theory.

43 PARTICLE ACCELERATORS↗

DOE OSTI2025

Thermal modulation of nonlinear ultrasonic waves for nondestructive evaluation of elastic materials

Temperature variation is often considered an undesirable factor in ultrasonic testing, as wave velocity is highly sensitive to thermal fluctuations. However, completely eliminating the temperature effect is difficult, particularly in tests requiring precise velocity measurements. Recently, a method called Thermal Modulation of Nonlinear Ultrasonics (TMNL) has been developed. Instead of eliminating the thermal effect, the TMNL method leverages the temperature variation as a driving force to stimulate the nonlinear response of the medium and modulate the ultrasonic waves propagating in it. These modulated waves can then be used to evaluate the nonlinear behaviours of the test medium. This paper presents a focused review of the TMNL technique, including its theoretical foundations, particularly the conceptual challenges in integrating thermal effects into classical acoustoelastic theory, and recent applications in non-destructive evaluation (NDE). Three case studies are presented to demonstrate TMNL’s application in detecting microcracking in concrete, assessing ageing in polymer materials, and enabling temperature compensation in acoustoelastic tests. In conclusion, the review also summarises related studies, including photothermal crack modulation, and discusses current limitations and future directions of TMNL in elastic media.

NDE↗

NASA NTRS1985

High Reynolds number tests of a NASA SC(3)-0712(B) airfoil in the Langley 0.3-meter transonic cryogenic tunnel

A wind tunnel investigation of a NASA 12-percent-thick, advanced-technology supercritical airfoil was conducted in the Langley 0.3-Meter Transonic Cryogenic Tunnel (TCT). This investigation represents another in the series of NASA/U.S. industry two-dimensional airfoil studies to be completed in the Advanced Technology Airfoil Tests program. Test temperature was varied from 220 K to 96 K at pressures ranging from 1.2 to 4.3 atm. Mach number was varied from 0.60 to 0.80. These variables provided a Reynolds number range from 4,400,000 to 40,000,000 based on a 15.24-cm (6.0-in.) airfoil chord. This investigation was designed to test a NASA advanced-technology airfoil from low to flight-equivalent Reynolds numbers, provide experience in cryogenic wind tunnel model design and testing techniques, and demonstrate the suitability of the 0.3-m TCT as an airfoil test facility. The aerodynamic results are presented as integrated force and moment coefficients and pressure distributions. Data are included which demonstrate the effects of fixed transition, Mach number, and Reynolds number on the aerodynamic characteristics. Also included are remarks on the model design, the model structural integrity, and the overall test experience.

Johnson, W. G., Jr.↗

NASA NTRS2004

Crash Simulation of a Boeing 737 Fuselage Section Vertical Drop Test

A 30-ft/s vertical drop test of a fuselage section of a Boeing 737 aircraft was conducted in October of 1999 at the FAA Technical Center in Atlantic City, NJ. This test was performed to evaluate the structural integrity of a conformable auxiliary fuel tank mounted beneath the floor and to determine its effect on the impact response of the airframe structure and the occupants. The test data were used to compare with a finite element simulation of the fuselage structure and to gain a better understanding of the impact physics through analytical/experimental correlation. To perform this simulation, a full-scale 3-dimensional finite element model of the fuselage section was developed using the explicit, nonlinear transient-dynamic finite element code, MSC.Dytran. The emphasis of the simulation was to predict the structural deformation and floor-level acceleration responses obtained from the drop test of the B737 fuselage section with the auxiliary fuel tank.

Fasanella, Edwin L.↗

DOE OSTI2022

Using Information Automation and Human Technology Integration to Implement Integrated Operations for Nuclear

The purpose of the research effort described in this report is to develop and demonstrate an approach to the design and implementation of advanced, automated systems intended to increase operational efficiencies at nuclear power plants. In particular, we describe methods for considering human-technology integration (HTI) issues throughout the various phases of system design, test, and implementation and how these considerations help promote effective design. This research project will develop planning tools and comprehensive guidance on how HTI principles and methods, in combination with information automation technologies, can enable effective data integration and coordination for full nuclear plant modernization. Specifically, this research project will develop an approach to automate the mapping of data from plant systems and processes to application needs, thereby significantly reducing the amount of human workload currently required for the execution of these tasks. In addition to developing an automated solution as a replacement for these tasks, this research will also analyze digitalization’s effectiveness in reducing operational costs of compliance related activities. Compliance activities are estimated to account for as much as 50% of operations and maintenance (i.e., non-fuel and non-capital) costs of plant operation.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Sulfurized Polyacrylonitrile (SPAN): Changes in Mechanical Properties during Electrochemical Lithiation

Sulfurized polyacrylonitrile (SPAN) is a promising material for stable lithium-sulfur (Li-S) batteries that can potentially satisfy the demand for high-density energy storage devices for electric vehicles (EVs). However, important physical and chemical properties of the SPAN cathode material are not yet well understood. For example, the SPAN mechanical behavior that depends on the structure and chemistry of the material generated during synthesis, and the mechanical response evolution during battery discharge have been scarcely investigated. This work addresses the effects of electrochemical lithiation on the SPAN mechanical integrity via uniaxial tensile loading tests using molecular dynamics with the ReaxFF potential. Here, we evaluate the volume expansion, Young’s modulus, yield strength, and ultimate tensile strength with increasing lithium contents. Our results show how the degree of graphitization of the carbonized skeleton impacts the SPAN ability to withstand the volume expansion-induced structural stresses upon lithiation. We describe the fracture mechanisms and find out a ductility loss with increasing lithium contents

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1972

Metal aircraft structural elements reinforced with graphite filamentary composites

Strain compatibility equations are used to evaluate the thermal stresses existing when unidirectional graphite composites are bonded to aluminum structures. Based on thermal stresses and optimum placement of the composite, skin-stringer aluminum panels are optimized for minimum weight compression panels with selective composite reinforcement. Composite reinforced skin-stringer panels are thermal cycled to determine the effect of thermal fatigue on structural integrity. Both cycled and uncycled panels are tested in compression and tension. Test results are correlated with predicted loads. Use of filamentary graphite composites is an efficient method of reinforcing metal structures, but care must be taken to minimize thermal stresses.

Berg, K. R.↗

NASA NTRS1985

Latchup in CMOS Integrated Circuits

Sensitivity to ion beams is studied. Latchup effect subject of paper presenting results of testing 19 types of complementary metal-oxide semiconductor (CMOS) chips from six manufacturers. Report gives details of sensitivity of chips to latchup caused by argon and krypton ion beams. Identifies parasitic npnp paths and proides latchup cross section and qualitative explanation of latchup sensitivity for each chip type.

Soliman, K. A.↗

NASA NTRS1992

NASA lunar surface habitat and remote exploration demonstration project

The Human Exploration Demonstration Project (HEDP) conducted by the NASA Ames Research Center to develop technological integration and demonstration capabilities for lunar and Mars space missions is described. The development of safe, effective, and reliable systems requires that independently engineered subsystems be fully integrated and tested under realistic conditions. The primary objective of the HEDP is demonstration of various aspects of human exploration and habitation on extraterrestrial surfaces. Some of the technologies to be demonstrated are also applicable to unmanned precursor mission functions. It is concluded that the HEDP will provide a unique opportunity to address a broad spectrum of advanced mission operations by bridging between the early requirements for robotic systems with control at earth-based workstations.

Clearwater, Yvonne A.↗

NASA NTRS2006

High-Resolution Millimeter Wave Detection of Vertical Cracks in the Space Shuttle External Tank (ET) Spray-on-Foam Insulation (SOFI)

Space Shuttle Columbia's catastrophic failure has been attributed to a piece of spray-on-foam insulation (SOFI) that was dislodged from the external tank (ET) and struck the leading edge of the left wing. A piece of SOFI was also dislodged in the Space Shuttle Discovery's flight in 2005 and recently a crack was detected in its ET foam prior to its successful launch. Millimeter wave nondestructive testing methods have been considered as potential effective inspection tools for evaluating the integrity of the SOFI. Recently, in a specific investigation into the potential of these methods for detecting vertical cracks in SOFI was explored using a focused millimeter wave reflectometer at 150 GHz. The results showed the capability of these methods for detecting tight vertical cracks (also as a function of crack opening dimension) in exposed SOFI panels and while covered by a piece of SOFI ramp simulating a more realistic and challenging situation. Some crack-like anomalies were also detected in a blind SOFI panel. This paper presents the background for these techniques as well as representative images of the vertical crack in the SOFI panel, crack-like anomalies in the blind panel and a discussion of the practical attributes of these inspection methods.

Kharkovsky, S.↗