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NASA NTRS1996

Validation of bonded composite doubler technology through application oriented structural testing

One of the major thrusts established under the FAA's National Aging Aircraft Research Program is to foster new technologies associated with civil aircraft maintenance. Recent DOD and other government developments in the use of bonded composite patches on metal structures has supported the need for research and validation of such doubler applications on U.S. certificated airplanes. Composite patching is a rapidly maturing technology which shows promise of cost savings on aging aircraft. Sandia Labs is conducting a proof-of-concept project with Delta Air Lines, Lockheed Martin, Textron, and the FAA which seeks to remove any remaining obstacles to the approved use of composite doublers. By focusing on a specific commercial aircraft application - reinforcement of the L-1011 door frame - and encompassing all 'cradle-to-grave' tasks such as design, analysis, installation, and inspection, this program is designed to prove the capabilities of composite doublers. This paper reports on a series of structural tests which have been conducted on coupons and subsize test articles. Tension-tension fatigue and residual strength tests attempted to grow engineered flaws in coupons with composite doublers bonded to aluminum skin. Also, structures which modeled key aspects of the door corner installation were subjected to extreme tension, shear, and bending loads. In this manner it was possible to study strain fields in and around the Lockheed-designed composite doubler using realistic aircraft load scenarios and to assess the potential for interply delaminations and disbonds between the aluminum and the laminate. The data acquired was also used to validate finite element models (FEM) and associated Damage Tolerance Analyses.

Roach, Dennis↗

NASA NTRSDate not supplied

NASA Advanced Reconfigurable Electrified Aircraft Laboratory (AREAL)

The rapid maturation of electrified aircraft and the underlying technologies has outpaced the development of corresponding standards and guidelines. This is especially true with respect to the design and test of high voltage power systems and equipment. To expedite the development of these standards and guidelines, the National Aeronautics and Space Administration (NASA) Revolutionary Vertical Lift Technology (RVLT) Project has designed and built the Advanced Reconfigurable Electrified Aircraft Laboratory (AREAL). AREAL is a 200 kW High Voltage DC (HVDC) test facility that can be reconfigured to test various electrical power system (EPS) architectures and/or different types of Utilization Equipment (UE). This paper will cover AREAL and its capabilities, the testing planned within AREAL, and how the tests performed within AREAL will inform developing HVDC Power System standards, test methods and guidelines, and models.

Aerospace↗

NASA NTRSDate not supplied

Functional Volume Assessment of an Early Version of the Mars Transit Habitat

During the summer of 2020, the NASA Mars Architecture Team (MAT) conducted a functional volume assessment of the Transit Habitat (TH). The TH has evolved substantially since that time and the current TH does not share the same internal configuration, but the insights gained from the assessment remain relevant. In virtually all architectures involving chemical, electric, or nuclear propulsion, the majority of the crew mission is spent aboard the TH. The Earth to Mars transit durations may vary from architecture to architecture, but all are on the order of hundreds of days, regardless of whether an opposition or conjunction class trajectory is selected, and regardless of whether the propulsion system is chemical, electric, or nuclear. Thus, the TH must provide capabilities appropriate to a very long duration. So, despite significant changes in the current Mars architecture over the past few years, this evaluation still provides useful recommendations in the form of habitability guidance that can be applied to current and future TH concepts. This assessment had six primary objectives: provide a sanity check to the BOC-derived TH layout; understand if we can fit the hardware and functional tasks in the volume; provide a high-level assessment of how aggressive the layout is; generate a list of challenges or assumptions necessary to make it work; generate a list of future work to refine understanding; and identify proposed requirements. All of this information is critical to drive habitat sizing studies and key architecture decisions. It was clear that a human-in-the-loop (HITL) evaluation of some kind would be necessary, but several challenges were immediately identified. The most information could be gleaned from a Desert Research and Technology Studies (DRATS) type of mission operations test (MOT), but the TH concept was too low fidelity to construct the type of prototype necessary to conduct a MOT, nor were their financial resources to do so. The next best option – and really the one most appropriate for the BOC’s stage of maturity – is a Virtual Reality (VR) walk-through evaluation. However, NASA was in a shutdown state due to the COVID-19 pandemic and the VR labs were inaccessible. As a result, a tabletop evaluation was created, using .jpg imagery from the ECM CAD model along with Excel-based datasheets. High-level crew living and working functions within the habitat were identified for evaluation. Questionnaires using Likert scales assessed acceptability of habitat functions and sim quality – the degree to which the function was represented in CAD. This enabled the evaluation to be conducted by personnel working remotely. Each function was evaluated individually along with several overarching habitability parameters and vehicle subsystems. The results of this evaluation are discussed, including methodological challenges and rating challenges. Acceptability results are discussed for functions that the participants were able to rate and participant comments for functions that could not be related are also described. Final conclusions are described, including challenges or assumptions needed to make the TH design acceptable, future work needed to refine understanding of the TH, and proposed habitat requirements based on test data.

Transit Habitat↗

DOE OSTI2022

Interspecific variation in the timing and magnitude of hydraulic redistribution in a forest with distinct water sources

Trees regulate water availability among their rooting strata through a nocturnal, passive transference of water known as hydraulic redistribution (HR). This study investigates differences in HR and groundwater use among common canopy species in longleaf pine (Pinus palustris Mill., Pinaceae) woodlands and explores environmental factors influencing HR. HR was estimated by sap flux of lateral roots and main stems of three mature canopy species (P. palustris, Quercus laevis Walter., Fagaceae and Quercus margarettae Ashe., Fagaceae). We used δ18O and δD of xylem water, soil water, and groundwater to determine water source. Finally, we related HR to environmental factors (Temperature, VWC, VPD) to better understand controls of HR dynamics. Pinus palustris had higher water use than either Quercus species, and also redistributed significantly more water as a nocturnal subsidy. HR fluxes were inversely related with mean nightly temperature and independent of shallow soil moisture. Stable isotope mixing models, based on δ 18 O and δD, indicated that all species have access to groundwater, but utilized shallow soil water in differing amounts when available. In systems with strong water potential gradients among soil strata, any species with access to a groundwater source is likely capable of HR; however, the magnitude of HR varies significantly by species, even among closely related taxa.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Feasibility of Using Fourier Neural Operators for 3D Elastic Seismic Simulations

Seismic simulations in three-dimensional (3D) Earth models are important in many of the seismological applications related to our lab’s mission, however, accurate high-fidelity simulations are computationally costly. We investigated the capabilities of the newly developed Fourier Neural Operator (FNO) to solve the 3D elastic wave equations for seismic simulations. We generated simulation data for training the FNO model, and analyzed its performance on various test cases, such as the performance with different number of training data, different resolutions, and on more canonical structures. We found the FNO model can reproduce 3D seismic simulations with high accuracy and ~169 times faster on a small spatial grid size of 16 x 16 x16. When applied on higher resolution data, we found that transfer learning with fine-tuning on a small amount of data achieves reasonable results. This feasibility study showed promising results for using FNO’s for 3D seismic simulations and represents the foundation of further research to develop this into a more mature approach for different seismological applications. The potential impact of this project will provide techniques for large-scale or real-time applications of solving PEDs in support of national lab’s programs.

58 GEOSCIENCES↗

NASA NTRS2004

Advanced Diagnostic System on Earth Observing One

In this infusion experiment, the Livingstone 2 (L2) model-based diagnosis engine, developed by the Computational Sciences division at NASA Ames Research Center, has been uploaded to the Earth Observing One (EO-1) satellite. L2 is integrated with the Autonomous Sciencecraft Experiment (ASE) which provides an on-board planning capability and a software bridge to the spacecraft's 1773 data bus. Using a model of the spacecraft subsystems, L2 predicts nominal state transitions initiated by control commands, monitors the spacecraft sensors, and, in the case of failure, isolates the fault based on the discrepant observations. Fault detection and isolation is done by determining a set of component modes, including most likely failures, which satisfy the current observations. All mode transitions and diagnoses are telemetered to the ground for analysis. The initial L2 model is scoped to EO-1's imaging instruments and solid state recorder. Diagnostic scenarios for EO-1's nominal imaging timeline are demonstrated by injecting simulated faults on-board the spacecraft. The solid state recorder stores the science images and also hosts: the experiment software. The main objective of the experiment is to mature the L2 technology to Technology Readiness Level (TRL) 7. Experiment results are presented, as well as a discussion of the challenging technical issues encountered. Future extensions may explore coordination with the planner, and model-based ground operations.

Hayden, Sandra C.↗

NASA NTRS2015

Experimental and Computational Sonic Boom Assessment of Lockheed-Martin N+2 Low Boom Models

Flight at speeds greater than the speed of sound is not permitted over land, primarily because of the noise and structural damage caused by sonic boom pressure waves of supersonic aircraft. Mitigation of sonic boom is a key focus area of the High Speed Project under NASA's Fundamental Aeronautics Program. The project is focusing on technologies to enable future civilian aircraft to fly efficiently with reduced sonic boom, engine and aircraft noise, and emissions. A major objective of the project is to improve both computational and experimental capabilities for design of low-boom, high-efficiency aircraft. NASA and industry partners are developing improved wind tunnel testing techniques and new pressure instrumentation to measure the weak sonic boom pressure signatures of modern vehicle concepts. In parallel, computational methods are being developed to provide rapid design and analysis of supersonic aircraft with improved meshing techniques that provide efficient, robust, and accurate on- and off-body pressures at several body lengths from vehicles with very low sonic boom overpressures. The maturity of these critical parallel efforts is necessary before low-boom flight can be demonstrated and commercial supersonic flight can be realized.

Cliff, Susan E.↗

NASA NTRSDate not supplied

Lunar Search & Rescue Applications of Lunar GNSS

Accurate lunar navigation and timing knowledge provides for the development of safety-critical services in the cislunar and lunar surface domain. Currently under development, the Goddard Space Flight Center’s (GSFC) Search and Rescue Mission Office is investigating and integrating search and rescue (SAR) capability into planned and future lunar communication and navigation interfaces. Lunar Search and Rescue (LunaSAR) development has a stated end-goal for assured, reliable, and timely indication of distress events for a wide variety of lunar surface users, including government-sponsored, commercial, and international users. LunaSAR performance requirements are modelled after the current terrestrial Cospas-Sarsat distress notification system, leveraging an internationally robust global navigation satellite system (GNSS) ecosystem as a core element of survivor locating capability. This presentation will discuss NASA’s work to develop user-focused distress messaging capabilities including infusion of example sensor data for triggering of automated distress alerts coupled with location-tagging. Additionally, the presentation will examine overall message structures, rotating fields for use in bi-directional distress messaging, and specific use cases based on NASA’s lunar exploration and lunar communication relay architectures. Modelling and simulation of LunaSAR use by individual lunar explorers will be discussed, based on notional industry and government design reference missions and mission considerations. Results from GSFC-funded Internal Research and Development (IRAD) efforts will be detailed, including successful distress message formulation simulating the ingestion of example legacy space suit telemetry fields. Hardware-in-the-loop testing using high-reliability software defined radio (SDR) modules serve as an example of IRAD successes and the framework for technical requirements. Architectural development and technical evolution from 2020 to 2021 included alignment of LunaSAR distress waveforms with ongoing NASA LunaNet interoperability development, as well as engagement with NASA Lunar Spectrum authorities for allocation of UHF-band distress frequencies on the lunar surface. S-Band and UHF-band transmission characteristics will be detailed, along with band-specific applications of each emission type. Additionally, examples of ingestion and formatting of GNSS signals (using historical terrestrial National Marine Electronics Association-formatted GNSS data) will be detailed, underscoring lunar user needs for a common lunar GNSS receiver output message framework. Maturity and ability to support evolving lunar exploration goals has been demonstrated and will be detailed, with maturity gaps such as position, navigation, and timing (PNT) and lunar reference frames identified within the context of distress message generation. Provision of LunaSAR services for lunar surface users represents a new era of ensured safety for lunar explorers and builds off of forty years of the Cospas-Sarsat program, underscoring the importance of lunar GNSS for safety-critical applications and growing interest in safe, reliable lunar surface operations. Enabled by new GNSS systems being developed by government and industry partners, NASA will continue to evolve and integrate lunar GNSS types into distress message generation, with a focus on compact and efficient message transmission over various lunar communication links. When fielded, LunaSAR will be the first dedicated search and rescue notification system employed on another celestial body. Robust lunar navigation and timing services form the core of LunaSAR capabilities, allowing for system syncing with time-dominant sensors, and high-accuracy location of those in distress while engaged in lunar surface activities.

Search and Rescue↗

NASA NTRS2019

eddy Users Manual

eddy is a collection of tools - nonlinear solvers, meshing, post-processing, visualization, optimization, etc. - for performing scale-resolving simulations of multi-physics applications. The framework is designed to enable advanced R&D on a variety of topics by leveraging a mature capability for scale resolving simulations, and simultaneously be an appropriate tool for application analysis and support. Currently, eddy is at a relatively low technical readiness level (TRL), and users and developers should maintain appropriate expectations. The technical details behind eddy are outlined in several publications which can be consulted for more information [1–10]. The solvers are built around an unstructured high-order capability, and heavily utilize the tensor product sum-factorization approach for efficiency. The unsteady formulation utilizes a fully implicit space-time approach with a matrix-free Newton- Krylov method. A primitive steady-state solver is available for testing purposes, but is not expected to converge for all but simple verification cases. The Navier-Stokes fluid solvers do not support either RANS or hybrid-RANS capability, only LES and wall-modeled LES approaches. All of the solvers within eddy support three modes of operation: a primal solve of the full nonlinear problem, and two linearization approaches of the primal solve - the ad joint and the tangent solution. Details on how to select and use these three modes are outlined in Sec. 3.

Murman, Scott M.↗

NASA NTRSDate not supplied

A Concept of Operations (ConOps) of an In-time Aviation Safety Management System (IASMS) for Advanced Air Mobility (AAM)

The growth of new emerging operations involving Advanced Air Mobility (AAM) necessitates developing a perspective for an In-time Aviation Safety Management System (IASMS). This perspective advances from the National Academies report on IASMS and its recommendation for developing a Concept of Operations (ConOps) for IASMS. A ConOps has been developed for In-time System-Wide Safety Assurance (ISSA) from which the IASMS ConOps pivots to provide a robust scope commensurate with the broad vision defined by the National Academies. The IASMS ConOps focuses on emerging operations and spans innovations in Unmanned Aircraft System (UAS) and an increasingly complex ecosystem comprised of a widening mix of vehicles and technologies, Urban Air Mobility (UAM) with industry-federated services, traditional operations, as well as new supersonic aircraft and space launch systems.The challenge for the IASMS ConOps is to be broad to encompass innovations in the coming years and decades while agile to ensure levels of safety compatible with operational and certification requirements of the National Airspace System (NAS). The IASMS ConOps interweaves increasing complexity of operational safety capabilities and unlocking UAS Maturity Levels (UMLs). The relationships between increased complexity of automation and automated systems, fewer operators who are not as traditionally higher skilled, more complex operational environments, and aviation operations management with mixed aircraft and equipage pose a multi-dimensional space for IASMS capabilities essential for safety assurance and risk management. Instantiating IASMS capabilities and how they would be integral to AAM operations and increasing maturity of UAM could be accomplished through a series of Safety Demonstrators. These Safety Demonstrators could provide increased understanding and insight into use of controls for risk mitigation, means of compliance for certification, and operational experience with safety services such as in relation to contingency management. The IASMS capabilities can be viewed as initially residing with the vehicle, airspace, and Supplemental Data Service Provider (SDSP). For example, vehicle capabilities include communications including the command and control link, Remote Identification (ID), conflict advisory/alerting, and UAS system monitoring. These capabilities monitor and assess data such as battery health, aircraft state, and human performance. Complexity of ISAMS capabilities depends on a number of factors. These factors are intendedonly as a notional categorization with the purpose being to reflect the complexity of the AAM ecosystem that would drive up the complexity of ISSA capabilities including systems, sensors, models, standards, and controls. Factors could include the Vehicle Flight Management, Environment, Airspace, and Contingency Management. Each of these factors can be comprised of multiple sub-factors that contribute to increasing complexity. For example, Airspace at a lower level of complexity could be dedicated to UTM operations that are unmonitored, and at a higher level of complexity could involve mixed UTM and ATM operations. The IASMS concept includes safety services that provide data and information to different participants in AAM. The roles and responsibilities of participants can be defined using the Responsible-Accountable-Consulted-Informed (RACI) analysis. For example, for the safety service involving the Remote ID, the Operator would be accountable for providing the data, the Vehicle would be responsible for transmitting it, and the USS, SDSP, Vertiports, FIMS (FAA), and Public Entities such as safety services would be informed by receiving the data. The IASMS ConOps identifies the capabilities needed for risk mitigation and safety assurance in the increasingly complex national airspace. The ConOps serves as a pathway for engaging with industry to gain operational experience including through the Safety Demonstrator series, the RACI analysis, and operational complexity factors. The ConOps serves to integrate these different perspectives to build a cohesive and cogent approach to an AAM safety management system.

In-Time Aviation Safety Management System↗

NASA NTRSDate not supplied

Design of a Subscale, Inert Gas Test for Plume-Surface Interactions in a Reduced Pressure Environment

Rocket plume-surface interaction is a multi-phase, complex discipline characterized by plume flow physics, erosion physics, and ejecta dynamics. To provide critical data for the validation of predictive modeling capabilities, an inert-gas, subscale ground test has been designed, with one test phase focused on cratering and ejecta and another test phase focused on plume structure and behavior. Using a supersonic, heated N2 jet impinging onto six different mechanical regolith simulants, visual data on the temporal evolution of cratering and ejecta are collected in a vacuum chamber at ambient pressures ranging from 600 Pa down to approximately 7 Pa. Using the same N2 jet impinging onto an instrumented plate, NO planar laser-induced fluorescence data are obtained at lower ambient pressures for the validation of both continuum and rarefied gas-phase physics. This paper discusses the design of this test and data products, with emphasis on the cratering and ejecta experiments, along with the physical scaling, challenges, and relevance of these data to the maturation of the plume-surface interaction discipline.

Ashley M Korzun↗

NASA NTRS1999

High-Performance Bipropellant Engine

TRW, under contract to the NASA Lewis Research Center, has successfully completed over 10 000 sec of testing of a rhenium thrust chamber manufactured via a new-generation powder metallurgy. High performance was achieved for two different propellants, N2O4- N2H4 and N2O4 -MMH. TRW conducted 44 tests with N2O4-N2H4, accumulating 5230 sec of operating time with maximum burn times of 600 sec and a specific impulse Isp of 333 sec. Seventeen tests were conducted with N2O4-MMH for an additional 4789 sec and a maximum Isp of 324 sec, with a maximum firing duration of 700 sec. Together, the 61 tests totalled 10 019 sec of operating time, with the chamber remaining in excellent condition. Of these tests, 11 lasted 600 to 700 sec. The performance of radiation-cooled rocket engines is limited by their operating temperature. For the past two to three decades, the majority of radiation-cooled rockets were composed of a high-temperature niobium alloy (C103) with a disilicide oxide coating (R512) for oxidation resistance. The R512 coating practically limits the operating temperature to 1370 C. For the Earth-storable bipropellants commonly used in satellite and spacecraft propulsion systems, a significant amount of fuel film cooling is needed. The large film-cooling requirement extracts a large penalty in performance from incomplete mixing and combustion. A material system with a higher temperature capability has been matured to the point where engines are being readied for flight, particularly the 100-lb-thrust class engine. This system has powder rhenium (Re) as a substrate material with an iridium (Ir) oxidation-resistant coating. Again, the operating temperature is limited by the coating; however, Ir is capable of long-life operation at 2200 C. For Earth-storable bipropellants, this allows for the virtual elimination of fuel film cooling (some film cooling is used for thermal control of the head end). This has resulted in significant increases in specific impulse performance (15 to 20 sec). To determine the merits of a powder rhenium thrust chamber, Lewis On-Board Propulsion Branch directed TRW (under the Space Storable Rocket Technology Program and the High Pressure Earth Storable Rocket Technology Program) to design, fabricate, and test an engineering model to serve as a technology demonstrator.

Biaglow, James A.↗

NASA NTRS2018

Assurance of Model-Based Fault Diagnosis

Autonomy is an increasingly important technology for robotic scientific and commercial spacecraft. An important motivation for developing onboard autonomy is to enable quick response to dynamic environment and situations, including fault conditions that a spacecraft may encounter. The reliability of such autonomous capabilities depends on the quality of their knowledge of a spacecraft’s health state. Model-based approaches to fault management, i.e. model-based fault diagnosis (MBFD), is one approach to continuously verify correct behavior in addition to diagnosing symptoms to estimate the spacecraft’s health state. The proper functioning of MBFD is dependent on 1) the quality of the model that is analyzed and compared to the outputs of onboard sensors to estimate the system’s health state, and 2) the correct functioning of the diagnosis engine that interrogates the model and compares its analysis to observed system behavior. We are currently developing Verification and Validation (V&V) approaches to provide the necessary confidence that MBFD systems are correctly estimating the health of on-board spacecraft components and systems. Our work is intended to narrow the gap between the rapidly maturing field of ModelBased System Engineering (including MBFD) and the less-well understood area of identifying and applying appropriate V&V techniques to MBFD. Our effort is investigating three areas: 1) developing V&V techniques for the diagnostic model, 2) developing V&V techniques for the diagnostic engine in isolation, and 3) developing V&V techniques for the diagnostic engine and model in combination. This paper describes the work we have completed in the first area. We describe our approach to selecting a system to be represented by a model, the approach to modeling the system, the verification approach we developed for the model, and the results of the verification activity. We conclude with a description of the work remaining in the last two areas, which will be addressed over the next two years.

Chung, Seung↗

NASA NTRSDate not supplied

Three Dimensionally Woven Mid-Density Carbon Phenolic (3MDCP) is a Novel Single Piece Ablative TPS for Extreme Entry Environments

Three Dimensionally Woven Mid-Density Carbon Phenolic (3MDCP) is robust, single piece, carbon phenolic ablative thermal protection system under development at NASA Ames Research Center initially for the Mars Sample Return Earth Entry System (MSR EES). The MSR EES requirements drove the need for TPS with no seams, capable of surviving the highest entry conditions for any NASA Earth return capsule with heat fluxes >2000 W/cm2 and pressures >1.5 atmospheres. To produce 3MDCP required development of new weaving infrastructure to enable weaving of preforms large enough to form into a single piece heatshield. It required development of forming techniques to transform a flat woven panel into a sphere cone shape and enhanced infusion processes to support larger scale infusion of resin into the formed preforms. A rigorous performance testing campaign was conducted to develop and validate the materials thermal response model used to determine the required material thickness and to demonstrate the material can survive the extreme entry conditions. The end of the development effort (end of FY26) will result in a TPS at Technical Readiness Level (TRL) 6 and Manufacturing Readiness Level (MRL) 6+ for the MSR EES mission and a mature system ready to support other missions. This poster will provide a snapshot of where 3MDCP is in its development phase.

Ablator↗

NASA NTRS2005

Automated Conflict Resolution For Air Traffic Control

The ability to detect and resolve conflicts automatically is considered to be an essential requirement for the next generation air traffic control system. While systems for automated conflict detection have been used operationally by controllers for more than 20 years, automated resolution systems have so far not reached the level of maturity required for operational deployment. Analytical models and algorithms for automated resolution have been traffic conditions to demonstrate that they can handle the complete spectrum of conflict situations encountered in actual operations. The resolution algorithm described in this paper was formulated to meet the performance requirements of the Automated Airspace Concept (AAC). The AAC, which was described in a recent paper [1], is a candidate for the next generation air traffic control system. The AAC's performance objectives are to increase safety and airspace capacity and to accommodate user preferences in flight operations to the greatest extent possible. In the AAC, resolution trajectories are generated by an automation system on the ground and sent to the aircraft autonomously via data link .The algorithm generating the trajectories must take into account the performance characteristics of the aircraft, the route structure of the airway system, and be capable of resolving all types of conflicts for properly equipped aircraft without requiring supervision and approval by a controller. Furthermore, the resolution trajectories should be compatible with the clearances, vectors and flight plan amendments that controllers customarily issue to pilots in resolving conflicts. The algorithm described herein, although formulated specifically to meet the needs of the AAC, provides a generic engine for resolving conflicts. Thus, it can be incorporated into any operational concept that requires a method for automated resolution, including concepts for autonomous air to air resolution.

Erzberger, Heinz↗

NASA NTRS2009

The Need for Technology Maturity of Any Advanced Capability to Achieve Better Life Cycle Cost (LCC)

Programs such as space transportation systems are developed and deployed only rarely, and they have long development schedules and large development and life cycle costs (LCC). They have not historically had their LCC predicted well and have only had an effort to control the DDT&E phase of the programs. One of the factors driving the predictability, and thus control, of the LCC of a program is the maturity of the technologies incorporated in the program. If the technologies incorporated are less mature (as measured by their Technology Readiness Level - TRL), then the LCC not only increases but the degree of increase is difficult to predict. Consequently, new programs avoid incorporating technologies unless they are quite mature, generally TRL greater than or equal to 7 (system prototype demonstrated in a space environment) to allow better predictability of the DDT&E phase costs unless there is no alternative. On the other hand, technology development programs rarely develop technologies beyond TRL 6 (system/subsystem model or prototype demonstrated in a relevant environment). Currently the lack of development funds beyond TRL 6 and the major funding required for full scale development leave little or no funding available to prototype TRL 6 concepts so that hardware would be in the ready mode for safe, reliable and cost effective incorporation. The net effect is that each new program either incorporates little new technology or has longer development schedules and costs, and higher LCC, than planned. This paper presents methods to ensure that advanced technologies are incorporated into future programs while providing a greater accuracy of predicting their LCC. One method is having a dedicated organization to develop X-series vehicles or separate prototypes carried on other vehicles. The question of whether such an organization should be independent of NASA and/or have an independent funding source is discussed. Other methods are also discussed. How to make the choice of which technologies to pursue to the prototype level is also discussed since, to achieve better LCC, first the selection of the appropriate technologies.

Robinson, John W.↗

DOE OSTI2020

HPC4Mfg with Carbon Inc.

Continuous Liquid Interface Production (CLIP) is poised to bring additive manufacturing to multiple American manufacturing sectors owing to its unique combination of rapid print speeds and material options that resemble injection molding thermoplastics. In spite of these benefits, CLIP is still a maturing process. To improve our understanding and control of the process, this project developed a multi-physics computational model that encompasses the coupled chemical-physical processes of photopolymerization and fluid flow to predict part outcomes. A physically predictive model can enable rapid optimization of CLIP and reduce the current cycle time and waste associated with optimization by four-fold. Ultimately, this effort will help open the U.S. $400B plastic manufacturing industry to the key benefits of additive manufacturing, namely mass customization, unlimited design space, and a cost- and energy-effective path to mainstream manufacturing. In the course of the project we produced a model which coupled fluid-flow, species transport, and photochemistry to model the Carbon CLIP process. As the development proceeded, we validated the code against theory and experiments. The resulting code was transferred to Carbon, and we expect it to be a useful part of their modeling capability. Future work includes improvements to the fluid solver’s robustness and performance, along with the addition of additional physics models.

42 ENGINEERING↗

DOE OSTI2021

Development of a Multi-physics Model to Optimize Continuous Liquid Interface Production (CLIP) for Additive Manufacturing (Carbon3D HPC4Mfg Final Report)

36 MATERIALS SCIENCE↗