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DOE OSTI2024

Advanced Fuels Campaign Execution Plan

The Advanced Fuels Campaign (AFC) Execution Plan outlines the strategy, mission, scope, near-term and long-term goals, structure, and organization associated with nuclear fuels and materials research, development, and demonstration activities within the Department of Energy’s (DOE) Nuclear Fuel Cycle and Supply Chain (NFCSC) program. NFCSC has been given responsibility to identify and mature advanced fuel technologies for the DOE using a science-based approach, focused on developing a fundamental understanding of nuclear fuels and materials to drive development of integrated nuclear fuel and materials technology. This science-based approach combines theory, experiments, and multiscale modeling and simulation to achieve a predictive understanding of relevant behaviors ranging from fuel fabrication processes (and their resulting fuel microstructures) through fuel/cladding performance under irradiation (in contrast to more empirical, observation-based approaches frequently used in fuel performance modeling and fuel qualification). The traditional scope of AFC includes the evaluation and development of multiple fuel forms to support two fuel cycle options: once-through and full recycle. The word “fuel” is used generically to include conventional fuels, transmutation targets, and any associated cladding or duct materials. The once-through fuel cycle addresses advanced light water reactor fuels with enhanced performance, extended burnup, and reduced waste generation. In fiscal year (FY) 2012, AFC’s scope expanded to include research, development, and demonstration (RD&D) for light water reactor (LWR) fuels with enhanced accident tolerance. Fuel fabrication activities include the development of innovative methods to enhance process efficiencies, reduce waste, and improve control over as-fabricated fuel microstructural properties to achieve desired in-reactor performance. Using modern modeling and simulation approaches, the objective is to predict fresh fuel properties given the feedstock characteristics and fabrication process parameters. The performance-related activities include small-scale, in-reactor, and out-of-reactor phenomenological testing (distinct from, but synergistic with, integral prototypic testing) and extensive, quantitative characterization (focusing on characterization of fuel and cladding materials at the scale of microstructure) both before and after testing. Larger-scale, prototypic experiments are conducted in concert with phenomenological testing to drive a Fuel Development and Qualification program, incorporating a fundamental understanding of fuel behavior performance characteristics. Then, using the tools developed under the productive science-based approach, fuels will be optimized to meet specific performance requirements, thereby minimizing the need to repeatedly perform large-scale, integral experiments over a wide parametric range as a means of experimental exploration. Two significant initiatives are underway within AFC. First, a gap analysis completed in early FY 2019 identified critical irradiation testing needs that are lacking within the national light water reactor (LWR) fuels testbed since the shutdown of the Halden Reactor in 2018. The identified gaps are for instrumented, prototypic testing of LWR fuels, especially under boiling water reactor conditions, ramp conditions, and conditions leading to fuel failure; these needs exist for supporting current LWR fuels and their possible extension to higher burnups, but are especially urgent relative to near-term development and qualification of accident-tolerant fuels. Recommendations that resulted from the Halden Gap Analysis focused on enhancements at Advanced Test Reactor (ATR) and Transient Reactor Test Facility (TREAT) to fill gaps in testing capabilities relative to these needs. Second, a concerted effort to develop and demonstrate a systematic approach to accelerating the development, testing, and qualification of new fuel systems has been initiated. This is highlighted by a test strategy that combines the considerable advances in multiscale, mechanistic fuel modeling of recent years with a MiniFuel separate effects test program in the High Flux Isotope Reactor (HFIR) and a Fission Accelerated Steady-state Testing (FAST) semi-integral accelerated test program in ATR. This approach is being tested/demonstrated using the metallic fuel system, but if successful it is expected to be extensible to multiple fuel types and diverse applications. This document includes an overview of the NFCSC program, a definition of science-based development of nuclear fuels, near-term goals for Advanced LWR fuels (ALFs), and longer-term goals for Advanced Reactor Fuels (ARFs) RD&D. This includes the activities that will be conducted to achieve success toward the grand challenge, as well as the goals and milestones to be achieved over the next few decades of research and development. Long-term goals are based on the DOE Office of Nuclear Energ

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2009

Short Duration Bioastronautics Investigation 1904: Human Factors Assessment of Vibration Effects on Visual Performance during Launch

The primary objective of the Short Duration Bioastronautics Investigation (SDBI) 1904 was to determine visual performance limits during Shuttle operational vibration and g-loads, specifically through the determination of minimal usable font sizes using Orion-type display formats. Currently there is little to no data available to quantify human visual performance under the extreme g- and vibration conditions of launch. Existing data on shuttle vibration magnitude and frequency is incomplete and does not address human visual performance. There have been anecdotal reports of performance decrements from shuttle crews, but no structured data have been collected. Previous work by NASA on the effects of vibration and linear g-loads on human performance was conducted during the Gemini era, but these experiments were performed using displays and controls that are dramatically different than current concepts being considered by the Constellation Program. Recently, three investigations of visual performance under vibration have been completed at NASA Ames Research Center: the first examining whole-body vibration, the second employing whole-body vibration coupled with a sustained g-load, and a third examining the effects of peak versus extended duration vibration. However, all of these studies were conducted using only a single x-axis direction (eyeballs in/out). Estimates of thrust oscillations from the Constellation Ares-I first stage are driving the need for realistic human performance requirements. SDBI 1904 was an opportunity to address the need for requirements by conducting a highly focused and applied evaluation in a relevant spaceflight environment. The SDBI was a companion effort to Detailed Test Objective (DTO) 695, which measured shuttle seat accelerations (vibration) during ascent. Data from the SDBI will serve an important role in interpreting the DTO vibration data. Both SDBI 1904 and DTO 695 were low impact with respect to flight resources, and combined, they represent an efficient and focused problem solving approach. This project provided (a) immediate data for developing preliminary human performance vibration requirements; (b) flight validated inputs for ongoing and future ground-based research; and (c) preliminary information related to Orion display format design.

Thompson, Shelby↗

NASA NTRSDate not supplied

Sensorimotor Application of Proposed Methods to Combine the Effects of Multiple Countermeasures for PRisM

Risk associated with human systems is challenging to quantify but is critical for the mission planning and decision making required to enable future Lunar and Martian missions. To address this gap, the Crew Health and Performance-Probabilistic Risk Assessment (CHP-PRA) project is developing an integrated computational model for CHP mission risk. Much like how MEDPRAT is designed to allow medical resource trades informed by medical risk, CHP-PRA will enable analogous trades in human system risks across multiple CHP functions and capabilities. Human performance is one component of the risk intended to be captured by CHP-PRA through the Performance Risk Model (PRisM). The sensorimotor risk area provides a good frame of reference for investigating the structure of a performance model because most tasks that astronauts are expected to perform require input from the sensory system and/or movement/motor control. Additionally, sensorimotor countermeasures are an area of particular concern for NASA’s Human Research Program because of the increased sensorimotor risk associated with surface operations in Lunar and Martian missions. Thus, a tool that can quickly compare risk reductions of potential countermeasures would be beneficial in guiding research and development of effective countermeasures. In this proof of concept, we present a systematic way to combine multiple performance data sets for humans subjected to different countermeasures such that we can predict the countermeasure(s) that optimize astronaut performance on relevant tasks. PRisM assumes that both the tests that are used to measure countermeasure effectiveness (input data) and the tasks we use to represent astronaut performance, can be broken down and represented as a function/vector of the human systems required to perform that test/task. Through mathematical combination, test data are used to predict performance on astronaut tasks that use similar systems. We propose that when combining countermeasures evaluated using the same test, that only one value should be used to represent their combined effectiveness. We start our analysis with the assumption that two countermeasures together will perform better than each countermeasure individually. Our initial implementation of this framework compares various space motion sickness countermeasures and the most up to date analysis will be demonstrated at the IWS.

Caroline R Austin↗

NASA NTRS1991

Hoop column soil moisture spacecraft in low Earth orbit for global change monitoring

A subset of the total Global Change Technology Initiative instruments are required to be in low Earth, sunsynchronous orbits. There is one instrument, however, that requires its own specialized spacecraft; the Soil Moisture Microwave Radiometer (SMMR). The characteristic structure of the instrument is the 118 m hoop column support structure. The hoop is supported by an axially placed column. Tension cables support and shape an electromagnetically reflective mesh surface. The instrument is capable of detecting frequencies in the 1.4 GHz range (Soil Moisture and Sea Salinity). Three apertures are used to reduce the degree of paraboloid offset and improve the beam quality. The spacecraft configuration is determined by the instrument support requirements and the requirement that it can fit into the Titan IV cargo bay. The configuration is derived by cross referencing the instrument performance requirements with the performance of the spacecraft. The spacecraft design is similar with the Multi-mission Modular Spacecraft in terms of size and packaging. A description of the spacecraft's features will yield a summary of the technologies needed for the SMMR spacecraft.

Ferebee, Melvin J., Jr.↗

NASA NTRS2007

Initial Ares I Bending Filter Design

The Ares-I launch vehicle represents a challenging flex-body structural environment for control system design. Software filtering of the inertial sensor output will be required to ensure control system stability and adequate performance. This paper presents a design methodology employing numerical optimization to develop the Ares-I bending filters. The filter design methodology was based on a numerical constrained optimization approach to maximize stability margins while meeting performance requirements. The resulting bending filter designs achieved stability by adding lag to the first structural frequency and hence phase stabilizing the first Ares-I flex mode. To minimize rigid body performance impacts, a priority was placed via constraints in the optimization algorithm to minimize bandwidth decrease with the addition of the bending filters. The bending filters provided here have been demonstrated to provide a stable first stage control system in both the frequency domain and the MSFC MAVERIC time domain simulation.

Jang, Jiann-Woei↗

DOE OSTI2022

Development and Performance Evaluation of of Active Insulation Systems using Solid-State Thermal Switches

Traditional building envelopes have passive insulation systems that cannot respond to dynamic changes in the environment. An Active Insulation System (AIS) consists of Active Insulation Materials (AIMs), which dynamically vary the thermal conductivity of the insulation system. Several researchers have evaluated the impact of AIS on building thermal and energy performance by using simulation tools. Up to 70% savings in annual heating and cooling energy and significant reductions in peak demand have been predicted for some climates with wall systems employing AIS. Sensitivity studies have provided requirements for the AIS properties and control schemes that can lead to those savings. However, materials and assembly development have not yet achieved a cost-effective product that achieves the required performance. In this study, we present the process to develop an AIS that we will install in a test hut for their performance evaluation. Minimum performance criteria of the AIS system are developed based on Rmin/Rmax ratio, required time and efficiency to switch states and cost estimate. The next step carried out during this study is creating the concept to meet the requirements, predicting the performance by simulations, developing the experimental setup for bench-scale testing, and finally, constructing a full-scale wall assembly and monitoring the performance when exposed to natural weather conditions. The selected approach uses off-the-shelf products to create a materials system that can switch R-value between R~=1 ft2·°F·h/BTU (0.18 m2·K/W) and R~=7 ft2·°F·h/BTU (1.23 m2·K/W and have a switching time of less than one minute between R-high and R-low.

Iffa, Emishaw↗

NASA NTRS1989

Aspheric doublets and precision adjustable fold mirrors for 20 K operation in CLAES

A cooled, infrared spectrometer is required to operate in earth orbit. The spectrometer performance requirements are discussed to show how package volume constraints and the stressing environment of cryogenic operation affect the detailed design of spectrometer components such as relay imaging optics and fold mirrors. Design steps are described that were taken to insure that the spectrometer would perform well in orbit, with components that are easily manufactured, readily aligned and stable in operation. This design procedure has produced two components of special interest, fast doublets suitable for use at 20 K over the wavelength band from 3.5 to 12 microns, and fold mirrors that can be adjusted to arc second tolerances.

Zinky, William R.↗

NASA NTRS2005

The Systems Engineering Process for Human Support Technology Development

Systems engineering is designing and optimizing systems. This paper reviews the systems engineering process and indicates how it can be applied in the development of advanced human support systems. Systems engineering develops the performance requirements, subsystem specifications, and detailed designs needed to construct a desired system. Systems design is difficult, requiring both art and science and balancing human and technical considerations. The essential systems engineering activity is trading off and compromising between competing objectives such as performance and cost, schedule and risk. Systems engineering is not a complete independent process. It usually supports a system development project. This review emphasizes the NASA project management process as described in NASA Procedural Requirement (NPR) 7120.5B. The process is a top down phased approach that includes the most fundamental activities of systems engineering - requirements definition, systems analysis, and design. NPR 7120.5B also requires projects to perform the engineering analyses needed to ensure that the system will operate correctly with regard to reliability, safety, risk, cost, and human factors. We review the system development project process, the standard systems engineering design methodology, and some of the specialized systems analysis techniques. We will discuss how they could apply to advanced human support systems development. The purpose of advanced systems development is not directly to supply human space flight hardware, but rather to provide superior candidate systems that will be selected for implementation by future missions. The most direct application of systems engineering is in guiding the development of prototype and flight experiment hardware. However, anticipatory systems engineering of possible future flight systems would be useful in identifying the most promising development projects.

Jones, Harry↗

NASA NTRS2017

Update on Risk Reduction Activities for a Liquid Advanced Booster for NASA's Space Launch System

The stated goals of NASA's Research Announcement for the Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) are to reduce risks leading to an affordable Advanced Booster that meets the evolved capabilities of SLS and enable competition by mitigating targeted Advanced Booster risks to enhance SLS affordability. Dynetics, Inc. and Aerojet Rocketdyne (AR) formed a team to offer a wide-ranging set of risk reduction activities and full-scale, system-level demonstrations that support NASA's ABEDRR goals. During the ABEDRR effort, the Dynetics Team has modified flight-proven Apollo-Saturn F-1 engine components and subsystems to improve affordability and reliability (e.g., reduce parts counts, touch labor, or use lower cost manufacturing processes and materials). The team has built hardware to validate production costs and completed tests to demonstrate it can meet performance requirements. State-of-the-art manufacturing and processing techniques have been applied to the heritage F-1, resulting in a low recurring cost engine while retaining the benefits of Apollo-era experience. NASA test facilities have been used to perform low-cost risk-reduction engine testing. In early 2014, NASA and the Dynetics Team agreed to move additional large liquid oxygen/kerosene engine work under Dynetics' ABEDRR contract. Also led by AR, the objectives of this work are to demonstrate combustion stability and measure performance of a 500,000 lbf class Oxidizer-Rich Staged Combustion (ORSC) cycle main injector. A trade study was completed to investigate the feasibility, cost effectiveness, and technical maturity of a domestically-produced engine that could potentially both replace the RD-180 on Atlas V and satisfy NASA SLS payload-to-orbit requirements via an advanced booster application. Engine physical dimensions and performance parameters resulting from this study provide the system level requirements for the ORSC risk reduction test article. The test article is scheduled to complete fabrication and assembly soon and continue testing through late 2019. Dynetics has also designed, developed, and built innovative tank and structure assemblies using friction stir welding to leverage recent NASA investments in manufacturing tools, facilities, and processes, significantly reducing development and recurring costs. The full-scale cryotank assembly was used to verify the structural design and prove affordable processes. Dynetics performed hydrostatic and cryothermal proof tests on the assembly to verify the assembly meets performance requirements..

Crocker, Andrew M.↗

DOE OSTI2026

Establishing an acoustic-property relationship in laser powder bed fusion with machine learning

Quality control of Laser Powder Bed Fusion (PBF-LB) additively manufactured parts is an important hurdle inhibiting the technology’s use structural applications. Acoustic monitoring of the laser powder bed fusion process can detect defects in-situ that are known to degrade mechanical properties. However, processing-structure-property (PSP) relationships are required to extrapolate from detected defects to part performance. Here, this study explores how acoustics may be a suitable signature linking processing conditions to properties, thus effectively substituting for structure in the PSP relationship. Establishing such a relationship would enable a part’s mechanical performance to be directly predicted from its acoustic signature, reducing the need for destructive testing or microstructural analysis to ensure a part will meet performance requirements. One hundred CoCrFeMnNi high entropy alloy tensile bars were printed across 13 process conditions in a series of 6 prints. The acoustic signatures of these tensile bars were used to train machine learning models to predict each part’s mechanical properties. By using both process information and acoustic information to predict mechanical properties, yield strength was predicted 18% more accurately and ductility to failure was predicted 10% more accurately than is achieved when using duplicate parts to predict part performance. Finally, individual acoustic frequencies were investigated to determine why acoustic signatures improve mechanical property predictions and the potential physical origins of these signatures. This work demonstrates how blending acoustics, process information, and machine learning can provide in-situ diagnostics of mechanical properties and improve the reliability of the PBF-LB process.

Acoustic emission↗

NASA NTRS1990

Development of a preliminary high-angle-of-attack nose-down pitch control requirement for high-performance aircraft

The requirements for high-angle-of-attack nose-down pitch control for advanced high-performance aircraft are discussed. Background information on fundamental factors that influence and, to a large extent, determine the high angle-of-attack nose-down control requirement is briefly reviewed. Guidelines currently proposed by other sources which attempt to define these requirements are discussed. A requirement based on NASA analysis of the characteristics of existing relaxed static stability (RSS) aircraft is presented. This analysis could provide the basis for a preliminary design guide.

Nguyen, Luat T.↗

NASA NTRS1985

Astrophysical payload accommodation on the space station

Surveys of potential space station astrophysics payload requirements and existing point mount design concepts were performed to identify potential design approaches for accommodating astrophysics instruments from space station. Most existing instrument pointing systems were designed for operation from the space shuttle and it is unlikely that they will sustain their performance requirements when exposed to the space station disturbance environment. The technology exists or is becoming available so that precision pointing can be provided from the space station manned core. Development of a disturbance insensitive pointing mount is the key to providing a generic system for space station. It is recommended that the MSFC Suspended Experiment Mount concept be investigated for use as part of a generic pointing mount for space station. Availability of a shirtsleeve module for instrument change out, maintenance and repair is desirable from the user's point of view. Addition of a shirtsleeve module on space station would require a major program commitment.

Woods, B. P.↗

NASA NTRS1985

Polymer, metal and ceramic matrix composites for advanced aircraft engine applications

Advanced aircraft engine research within NASA Lewis is being focused on propulsion systems for subsonic, supersonic, and hypersonic aircraft. Each of these flight regimes requires different types of engines, but all require advanced materials to meet their goals of performance, thrust-to-weight ratio, and fuel efficiency. The high strength/weight and stiffness/weight properties of resin, metal, and ceramic matrix composites will play an increasingly key role in meeting these performance requirements. At NASA Lewis, research is ongoing to apply graphite/polyimide composites to engine components and to develop polymer matrices with higher operating temperature capabilities. Metal matrix composites, using magnesium, aluminum, titanium, and superalloy matrices, are being developed for application to static and rotating engine components, as well as for space applications, over a broad temperature range. Ceramic matrix composites are also being examined to increase the toughness and reliability of ceramics for application to high-temperature engine structures and components.

Mcdanels, D. L.↗

NASA NTRS1986

Polymer, metal, and ceramic matrix composites for advanced aircraft engine applications

Mcdanels, D. L.↗

NASA NTRS1995

Performance Thresholds for Application of MEMS Inertial Sensors in Space

We review types of inertial sensors available and current usage of inertial sensors in space and the performance requirements for these applications. We then assess the performance available from micro-electro-mechanical systems (MEMS) devices, both in the near and far term. Opportunities for the application of these devices are identified. A key point is that although the performance available from MEMS inertial sensors is significantly lower than that achieved by existing macroscopic devices (at least in the near term), the low cost, low size, and power of the MEMS devices opens up a number of applications. In particular, we show that there are substantial benefits to using MEMS devices to provide vibration, and for some missions, attitude sensing. In addition, augmentation for global positioning system (GPS) navigation systems holds much promise.

Smit, Geoffrey N.↗

NASA NTRS2001

STEP-AIRSEDS System Engineering Support

This report summarizes and highlights the activities in support of the Space Transportation using Electrodynamic Propulsion Atmospheric Ionospheric Research Small Expendable Deployer Satellite (STEP-AIRSEDS) Project for the period of May 16, 2000 through September 28, 2001. The Alpha Technology, Inc. was tasked to provide support to the MSFC (Marshall Space Flight Center) in requirements development and in verification activities. Specifically, the Alpha Technology, Inc. task was to: (1) develop and maintain the STEP-AIRSEDS Project System Requirements Database; (2) develop and maintain the STEP-AIRSEDS requirements verification definition and planning support database; (3) perform requirements flow down analysis of STEP-AIRSEDS Project System Requirements to TMTC (The Michigan Technic Corporation) Level IV Requirements; (4) provide system engineering guidance to the Project as needed; (5) provide guidance to TMTC in preparation of Level IV Requirements; and (6) provide support to STEP-AIRSEDS meetings, reviews, and telecons as needed.

Rowell, Tom↗

NASA NTRS1998

Automated System Checkout to Support Predictive Maintenance for the Reusable Launch Vehicle

The Propulsion Checkout and Control System (PCCS) is a predictive maintenance software system. The real-time checkout procedures and diagnostics are designed to detect components that need maintenance based on their condition, rather than using more conventional approaches such as scheduled or reliability centered maintenance. Predictive maintenance can reduce turn-around time and cost and increase safety as compared to conventional maintenance approaches. Real-time sensor validation, limit checking, statistical anomaly detection, and failure prediction based on simulation models are employed. Multi-signal models, useful for testability analysis during system design, are used during the operational phase to detect and isolate degraded or failed components. The TEAMS-RT real-time diagnostic engine was developed to utilize the multi-signal models by Qualtech Systems, Inc. Capability of predicting the maintenance condition was successfully demonstrated with a variety of data, from simulation to actual operation on the Integrated Propulsion Technology Demonstrator (IPTD) at Marshall Space Flight Center (MSFC). Playback of IPTD valve actuations for feature recognition updates identified an otherwise undetectable Main Propulsion System 12 inch prevalve degradation. The algorithms were loaded into the Propulsion Checkout and Control System for further development and are the first known application of predictive Integrated Vehicle Health Management to an operational cryogenic testbed. The software performed successfully in real-time, meeting the required performance goal of 1 second cycle time.

Patterson-Hine, Ann↗

NASA NTRS2004

Einstein Inflationary Probe (EIP)

I will discuss plans to develop a concept for the Einstein Inflation Probe: a mission to detect gravity waves from inflation via the unique signature they impart to the cosmic microwave background (CMB) polarization. A sensitive CMB polarization satellite may be the only way to probe physics at the grand-unified theory (GUT) scale, exceeding by 12 orders of magnitude the energies studied at the Large Hadron Collider. A detection of gravity waves would represent a remarkable confirmation of the inflationary paradigm and set the energy scale at which inflation occurred when the universe was a fraction of a second old. Even a strong upper limit to the gravity wave amplitude would be significant, ruling out many common models of inflation, and pointing to inflation occurring at much lower energy, if at all. Measuring gravity waves via the CMB polarization will be challenging. We will undertake a comprehensive study to identify the critical scientific requirements for the mission and their derived instrumental performance requirements. At the core of the study will be an assessment of what is scientifically and experimentally optimal within the scope and purpose of the Einstein Inflation Probe.

Hinshaw, Gary↗