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NASA NTRS2009

Maneuver Automation Software

The Maneuver Automation Software (MAS) automates the process of generating commands for maneuvers to keep the spacecraft of the Cassini-Huygens mission on a predetermined prime mission trajectory. Before MAS became available, a team of approximately 10 members had to work about two weeks to design, test, and implement each maneuver in a process that involved running many maneuver-related application programs and then serially handing off data products to other parts of the team. MAS enables a three-member team to design, test, and implement a maneuver in about one-half hour after Navigation has process-tracking data. MAS accepts more than 60 parameters and 22 files as input directly from users. MAS consists of Practical Extraction and Reporting Language (PERL) scripts that link, sequence, and execute the maneuver- related application programs: "Pushing a single button" on a graphical user interface causes MAS to run navigation programs that design a maneuver; programs that create sequences of commands to execute the maneuver on the spacecraft; and a program that generates predictions about maneuver performance and generates reports and other files that enable users to quickly review and verify the maneuver design. MAS can also generate presentation materials, initiate electronic command request forms, and archive all data products for future reference.

Uffelman, Hal↗
NASA NTRS2006

Instruments for Reading Direct-Marked Data-Matrix Symbols

Improved optoelectronic instruments (specially configured digital cameras) for reading direct-marked data-matrix symbols on the surfaces of optically reflective objects (including specularly reflective ones) are undergoing development. Data-matrix symbols are two-dimensional binary patterns that are used, like common bar codes, for automated identification of objects. The first data-matrix symbols were checkerboard-like patterns of black-and-white rectangles, typically existing in the forms of paint, ink, or detachable labels. The major advantage of direct marking (the marks are more durable than are painted or printed symbols or detachable labels) is offset by a major disadvantage (the marks generated by some marking methods do not provide sufficient contrast to be readable by optoelectronic instruments designed to read black-and-white data-matrix symbols). Heretofore, elaborate lighting, lensing, and software schemes have been tried in efforts to solve the contrast problem in direct-mark matrix- symbol readers. In comparison with prior readers based on those schemes, the readers now undergoing development are expected to be more effective while costing less. All of the prior direct-mark matrix-symbol readers are designed to be aimed perpendicularly to marked target surfaces, and they tolerate very little angular offset. However, the reader now undergoing development not only tolerates angular offset but depends on angular offset as a means of obtaining the needed contrast, as described below. The prototype reader (see Figure 1) includes an electronic camera in the form of a charge-coupled-device (CCD) image detector equipped with a telecentric lens. It also includes a source of collimated visible light and a source of collimated infrared light for illuminating a target. The visible and infrared illumination complement each other: the visible illumination is more useful for aiming the reader toward a target, while the infrared illumination is more useful for reading symbols on highly reflective surfaces. By use of beam splitters, the visible and infrared collimated lights are introduced along the optical path of the telecentric lens, so that the target is illuminated and viewed from the same direction.

Schramm, Harry F.↗
NASA NTRS2009

NASA Tech Briefs, May 2009

Topics covered include: Valve-"Health"-Monitoring System; Microstrip Antenna for Remote Sensing of Soil Moisture and Sea Surface Salinity; Biomedical Wireless Ambulatory Crew Monitor; Wireless Avionics Packet to Support Fault Tolerance for Flight Applications; Aerobot Autonomy Architecture; Submillimeter Confocal Imaging Active Module; Traveling-Wave Maser for 32 GHz; System Synchronizes Recordings from Separated Video Cameras; Piecewise-Planar Parabolic Reflectarray Antenna; Reducing Interference in ATC Voice Communication; EOS MLS Level 1B Data Processing, Version 2.2; Auto-Generated Semantic Processing Services; Geospatial Authentication; Maneuver Automation Software; Event Driven Messaging with Role-Based Subscriptions; Estimating Relative Positions of Outer-Space Structures; Fabricating PFPE Membranes for Capillary Electrophoresis; Linear Actuator Has Long Stroke and High Resolution; Installing a Test Tap on a Metal Battery Case; Fabricating PFPE Membranes for Microfluidic Valves and Pumps; Room-Temperature-Cured Copolymers for Lithium Battery Gel Electrolytes; Catalysts for Efficient Production of Carbon Nanotubes; Amorphous Silk Fibroin Membranes for Separation of CO2; "Zero-Mass" Noninvasive Pressure Transducers; Radial-Electric-Field Piezoelectric Diaphragm Pumps; Ejector-Enhanced, Pulsed, Pressure-Gain Combustor; Suppressing Ghost Diffraction in E-Beam-Written Gratings; Target-Tracking Camera for a Metrology System; Polarimetric Imaging using Two Photoelastic Modulators; Miniature Wide-Angle Lens for Small-Pixel Electronic Camera; Modal Filters for Infrared Interferometry; Mo(3)Sb(7-x)Te(x) for Thermoelectric Power Generation; Two-Dimensional Quantum Model of a Nanotransistor; Scanning Miniature Microscopes without Lenses; Manipulating Neutral Atoms in Chip-Based Magnetic Traps; Expansion Compression Contacts for Thermoelectric Legs; Processing Electromyographic Signals to Recognize Words; Physical Principle for Generation of Randomness; DSN Beowulf Cluster-Based VLBI Correlator; Hybrid NN/SVM Computational System for Optimizing Designs; Criteria for Modeling in LES of Multicomponent Fuel Flow; Computerized Machine for Cutting Space Shuttle Thermal Tiles; Orbiting Depot and Reusable Lander for Lunar Transportation; FPGA-Based Networked Phasemeter for a Heterodyne Interferometer; Aquarius Digital Processing Unit; Three-Dimensional Optical Coherence Tomography; Benchtop Antigen Detection Technique using Nanofiltration and Fluorescent Dyes; Isolation of Precursor Cells from Waste Solid Fat Tissue; Identification of Bacteria and Determination of Biological Indicators; Further Development of Scaffolds for Regeneration of Nerves; Chemically Assisted Photocatalytic Oxidation System; Use of Atomic Oxygen for Increased Water Contact Angles of Various Polymers for Biomedical Applications; Crashworthy Seats Would Afford Superior Protection; Open-Access, Low-Magnetic-Field MRI System for Lung Research; Microfluidic Mixing Technology for a Universal Health Sensor; Microfluidic Extraction of Biomarkers using Water as Solvent; Microwell Arrays for Studying Many Individual Cells; Droplet-Based Production of Liposomes; and Identifying and Inactivating Bacterial Spores

Source record↗
DOE OSTI2025

Traffic Control via Connected and Automated Vehicles (CAVs): An Open-Road Field Experiment with 100 CAVs

The CIRCLES project aims to reduce instabilities in traffic flow, which are naturally occurring phenomena due to human driving behavior. Also called “phantom jams” or “stop-and-go waves,” these instabilities are a significant source of wasted energy. Toward this goal, the CIRCLES project designed a control system, referred to as the MegaController by the CIRCLES team, that could be deployed in real traffic. Our field experiment, the MegaVanderTest (MVT), leveraged a heterogeneous fleet of 100 longitudinally controlled vehicles as Lagrangian traffic actuators, each of which ran a controller with the architecture described in this article. The MegaController is a hierarchical control architecture that consists of two main layers. The upper layer is called the Speed Planner and is a centralized optimal control algorithm. It assigns speed targets to the vehicles, conveyed through the LTE cellular network. The lower layer is a control layer, running on each vehicle. It performs local actuation by overriding the stock adaptive cruise controller, using the stock onboard sensors. The Speed Planner ingests live data feeds provided by third parties as well as data from our own control vehicles and uses both to perform the speed assignment. The architecture of the Speed Planner allows for the modular use of standard control techniques, such as optimal control, model predictive control (MPC), kernel methods, and others. The architecture of the local controller allows for the flexible implementation of local controllers. Corresponding techniques include deep reinforcement learning (RL), MPC, and explicit controllers. Depending on the vehicle architecture, all onboard sensing data can be accessed by the local controllers or only some. Likewise, control inputs vary across different automakers, with inputs ranging from torque or acceleration requests for some cars to electronic selection of adaptive cruise control (ACC) setpoints in others. The proposed architecture technically allows for the combination of all possible settings proposed previously, that is {Speed Planner algorithms} × {local Vehicle Controller algorithms} × {full or partial sensing} × {torque or speed control}. As a result, most configurations were tested throughout the ramp up to the MegaVandertest (MVT).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
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 NTRS2002

Solid Freeform Fabrication: An Enabling Technology for Future Space Missions

The emerging class of direct manufacturing processes known as Solid Freeform Fabrication (SFF) employs a focused energy beam and metal feedstock to build structural parts directly from computer aided design (CAD) data. Some variations on existing SFF techniques have potential for application in space for a variety of different missions. This paper will focus on three different applications ranging from near to far term to demonstrate the widespread potential of this technology for space-based applications. One application is the on-orbit construction of large space structures, on the order of tens of meters to a kilometer in size. Such structures are too large to launch intact even in a deployable design; their extreme size necessitates assembly or erection of such structures in space. A low-earth orbiting satellite with a SFF system employing a high-energy beam for high deposition rates could be employed to construct large space structures using feedstock launched from Earth. A second potential application is a small, multifunctional system that could be used by astronauts on long-duration human exploration missions to manufacture spare parts. Supportability of human exploration missions is essential, and a SFF system would provide flexibility in the ability to repair or fabricate any part that may be damaged or broken during the mission. The system envisioned would also have machining and welding capabilities to increase its utility on a mission where mass and volume are extremely limited. A third example of an SFF application in space is a miniaturized automated system for structural health monitoring and repair. If damage is detected using a low power beam scan, the beam power can be increased to perform repairs within the spacecraft or satellite structure without the requirement of human interaction or commands. Due to low gravity environment for all of these applications, wire feedstock is preferred to powder from a containment, handling, and safety standpoint. The energy beams may be either electron beam or laser, and the developments required for either energy source to achieve success in these applications will be discussed.

Taminger, Karen M. B.↗
DOE OSTI2025

Electrochemically Mediated Au–C(sp 2 ) Anchors for Molecular Electronics

Terminal anchor groups play a key role in the stability and electronic properties of molecular junctions. Single molecule junctions typically consist of two preinstalled terminal anchors linking organic molecules to metal electrodes. Here, in this work, we show that p -terphenyl derivatives containing only a single terminal anchor show conductance features similar to junctions with two preinstalled terminal anchors. A set of p -terphenyl derivatives with one terminal anchor was prepared using automated chemical synthesis and characterized using single molecule electronics experiments, molecular dynamics (MD) simulations, bulk electrochemistry and spectroscopy, and nonequilibrium Green’s function-density functional theory (NEGF-DFT) calculations. Our results show that 4-amino- p -terphenyl (PPP) and related analogs exhibit a well-defined high conductance state that is diminished or absent in other p-terphenyl derivatives lacking a preinstalled amine terminal anchor or fluorine or methyl substitutions at the terminal para position. However, a low conductance state is observed in all amino- p -terphenyl derivatives with one preinstalled anchor due to molecular junctions formed by noncovalent dimeric π–π stacking interactions. The observed high conductance state diminishes upon the addition of reducing agents and is restored upon the addition of an oxidizing agent. Our results suggest that the high conductance state arises due to Au–C(sp 2 ) bond formation facilitated by a single electron oxidation event at the electrode surface. A series of control experiments with different anchor groups shows that primary amines play a key role in forming Au–C bonds for molecular junctions. Overall, these results suggest that Au–C bond formation gives rise to high conductance pathways in organic molecules containing only one preinstalled terminal anchor. Insights from this work can be leveraged in the design of molecular electronic devices, particularly in understanding the mechanisms of molecular binding and junction formation.

charge transport↗
DOE OSTI2024

"Traffic Control via Connected and Automated Vehicles: An Open-Road Field Experiment with 100 CAVs"

The CIRCLES project aims to reduce instabilities in traffic flow, which are naturally occurring phenomena due to human driving behavior. These "phantom jams" or "stop-and-go waves,"are a significant source of wasted energy. Toward this goal, the CIRCLES project designed a control system referred to as the MegaController by the CIRCLES team, that could be deployed in real traffic. Our field experiment leveraged a heterogeneous fleet of 100 longitudinally-controlled vehicles as Lagrangian traffic actuators, each of which ran a controller with the architecture described in this paper. The MegaController is a hierarchical control architecture, which consists of two main layers. The upper layer is called Speed Planner, and is a centralized optimal control algorithm. It assigns speed targets to the vehicles, conveyed through the LTE cellular network. The lower layer is a control layer, running on each vehicle. It performs local actuation by overriding the stock adaptive cruise controller, using the stock on-board sensors. The Speed Planner ingests live data feeds provided by third parties, as well as data from our own control vehicles, and uses both to perform the speed assignment. The architecture of the speed planner allows for modular use of standard control techniques, such as optimal control, model predictive control, kernel methods and others, including Deep RL, model predictive control and explicit controllers. Depending on the vehicle architecture, all onboard sensing data can be accessed by the local controllers, or only some. Control inputs vary across different automakers, with inputs ranging from torque or acceleration requests for some cars, and electronic selection of ACC set points in others. The proposed architecture allows for the combination of all possible settings proposed above. Most configurations were tested throughout the ramp up to the MegaVandertest.

Lee, Jonathan↗
DOE OSTI2023

Design and Development of a High Fidelity Cyber-Physical Testbed

In order to ensure that future critical infrastructure systems are resilient to various types of such advanced and persistent threats, it is important to develop and integrate tailored solutions that holistically address cyber-attack detection and mitigation in a timely manner such that adverse system impacts that impact a large population are avoided. Further, it is essential to create environments that allow control, protection and communication to exist within a realistic environment to analyze the effects of adverse conditions and system operating modes. This project aims to establish a high-fidelity testbed environment for modeling and simulating a single microgrid all the way up to a network of microgrids along with baseline controls, protection, and associated cyber communication. This is an important activity because accurately modeling and simulating the various power-electronics-based DERs and loads in a microgrid is critical to adequately capturing their behaviors over a wide range of off-normal conditions, as well as to evaluate the resilience of the system using the developed controls. The work presented in this report focuses on the process of building this high-fidelity testbed and the associated experimentation it enables. The model enables the creation of high-fidelity use cases and associated datasets that have been used extensively within the initiative to study resilience and support novel control development and prototyping. The work heavily leverages existing capability that is part of the high-fidelity cyber-physical system experimentation lab to create a power hardware-in-the-loop setup. The report also details the creation of an automated model building platform that can enable high-fidelity real-time models to be built without much effort allowing existing low-fidelity models to be analyzed in higher fidelity. Lastly, the report also discusses efforts center around scaling to large complex power system models to make the experimentation more effective.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Opportunities for Process Intensification with Membranes to Promote Circular Economy Development for Critical Minerals

Critical minerals are essential to the future of clean energy, especially energy storage, electric vehicles, and advanced electronics. In this paper, we argue that process systems engineering (PSE) paradigms provide essential frameworks for enhancing the sustainability and efficiency of critical mineral processing pathways. As a concrete example, we review challenges and opportu-nities across material-to-infrastructure scales for process intensification (PI) with membranes. Within critical mineral processing, there is a need to reduce environmental impact, especially con-cerning chemical reagent usage. Feed concentrations and product demand variability require flex-ible, intensified processes. Further, unique feedstocks require unique processes (i.e., no one-size-fits-all recycling or refining system exists). Membrane materials span a vast design space that allows significant optimization. Therefore, there is a need to rapidly identify the best opportunities for membrane implementation, thus informing materials optimization with process and infrastructure scale performance targets. Finally, scale-up must be accelerated and de-risked across the materials-to-process levels to fully realize the opportunity presented by membranes, thereby fostering the development of a circular economy for critical minerals. Tackling these challenges requires integrating efforts across diverse disciplines. We advocate for a holistic molecular-to-systems perspective for fully realizing PI with membranes to address sustainability challenges in critical mineral processing. The opportunities for PI with membranes are excellent applications for emerging research in machine learning, data science, automation, and optimization.

Dougher, Molly↗
DOE OSTI2023

A rule-free workflow for the automated generation of databases from scientific literature

Abstract In recent times, transformer networks have achieved state-of-the-art performance in a wide range of natural language processing tasks. Here we present a workflow based on the fine-tuning of BERT models for different downstream tasks, which results in the automated extraction of structured information from unstructured natural language in scientific literature. Contrary to existing methods for the automated extraction of structured compound-property relations from similar sources, our workflow does not rely on the definition of intricate grammar rules. Hence, it can be adapted to a new task without requiring extensive implementation efforts and knowledge. We test our data-extraction workflow by automatically generating a database for Curie temperatures and one for band gaps. These are then compared with manually curated datasets and with those obtained with a state-of-the-art rule-based method. Furthermore, in order to showcase the practical utility of the automatically extracted data in a material-design workflow, we employ them to construct machine-learning models to predict Curie temperatures and band gaps. In general, we find that, although more noisy, automatically extracted datasets can grow fast in volume and that such volume partially compensates for the inaccuracy in downstream tasks.

36 MATERIALS SCIENCE↗
NASA NTRS1993

Development of far infrared detection techniques

This grant supports the development of a variety of advanced far infrared detection techniques that will be used in future NASA missions such as the Space Infrared Telescope Facility (SIRTF). These studies span the wavelength region of 30-200 microns and include development of focal planes and electronics that would utilize them. Efforts reported here represent collaborations among the University of Arizona's Steward Observatory; Lawrence Berkeley Laboratories (LBL); and the University of California at Berkeley. The overall goal of this program is to demonstrate extremely high performance detectors for low background applications between 30-200 microns. For the 40-120 micron region, the program is developing a 32x32 filled detector array. Previous work has demonstrated the required performance with a Z-Plane array architecture; we are now upgrading construction facilities and techniques to increase yields and reliability. We have completed the initial tradeoff analysis for the interconnects between the detectors and and readouts. We found satisfactory performance for both Flex-Cable and Tape Automated Bonding (TAB) devices, but analysis showed that an all-sapphire device would not meet our requirements. In addition, the effort continued to develop readouts that can operate close to the detector element temperature; success would substantially improve the manufacturability of the arrays. For the 100-200 micron range, previous work has demonstrated good performance with individual detector elements of stressed Ge:Ga; current efforts are to increase the quantum efficiency of these devices. Work continues to discover how to construct an alternate type of long wave detector, Ge:B Blocked Impurity Band devices. Following descoping of SIRTF, we are closing out the bolometer and refrigerator development. We documented the optical designs and approaches developed previously to meet the specific requirements of these detector types in terms of modulation of the signals for good photometric behavior within the constraints of a compact and self-contained cryogenic instrument. Further study was initiated for the Band 3 optical train, where we have concerns about complexity and the manufacturability of one component.

Rieke, George↗
NASA NTRS2003

Software With Strong Ties to Space

TieFlow is a simple but powerful business process improvement solution. It can automate and simplify any generic or industry-specific work process, helping organizations to transform work inefficiencies and internal operations involving people, paper, and procedures into a streamlined, well-organized, electronicbased process. TieFlow increases business productivity by improving process cycle times. The software can expedite generic processes in the areas of product design and development, purchase orders, expense reports, benefits enrollment, budgeting, hiring, and sales. It can also shore up vertical market processes such as claims processing, loan application and processing, health care administration, contract management, and advertising agency traffic. The processes can be easily and rapidly captured in a graphical manner and enforced together with rules pertaining to assignments that need to be performed. Aside from boosting productivity, TieFlow also reduces organizational costs and errors. TieFlow was developed with Small Business Innovation Research (SBIR) assistance from Johnson. The SBIR support entitles all Federal Government agencies to utilize the TieFlow software technology free of charge. Tietronix emphasizes that TieFlow is an outstanding workflow resource that could produce dramatic productivity and cost improvements for all agencies, just as it has done and continues to do for NASA. The Space Agency is currently using the software throughout several mission-critical offices, including the Mission Operations Directorate and the Flight Director s Office, for worldwide participation of authorized users in NASA processes. At the Flight Director s Office, TieFlow allows personnel to electronically submit and review changes to the flight rules carried out during missions.

Source record↗
NASA NTRS2007

Design and Data Management System

The Design and Data Management System (DDMS) was developed to automate the NASA Engineering Order (EO) and Engineering Change Request (ECR) processes at the Propulsion Test Facilities at Stennis Space Center for efficient and effective Configuration Management (CM). Prior to the development of DDMS, the CM system was a manual, paper-based system that required an EO or ECR submitter to walk the changes through the acceptance process to obtain necessary approval signatures. This approval process could take up to two weeks, and was subject to a variety of human errors. The process also requires that the CM office make copies and distribute them to the Configuration Control Board members for review prior to meetings. At any point, there was a potential for an error or loss of the change records, meaning the configuration of record was not accurate. The new Web-based DDMS eliminates unnecessary copies, reduces the time needed to distribute the paperwork, reduces time to gain the necessary signatures, and prevents the variety of errors inherent in the previous manual system. After implementation of the DDMS, all EOs and ECRs can be automatically checked prior to submittal to ensure that the documentation is complete and accurate. Much of the configuration information can be documented in the DDMS through pull-down forms to ensure consistent entries by the engineers and technicians in the field. The software also can electronically route the documents through the signature process to obtain the necessary approvals needed for work authorization. The workflow of the system allows for backups and timestamps that determine the correct routing and completion of all required authorizations in a more timely manner, as well as assuring the quality and accuracy of the configuration documents.

Messer, Elizabeth↗
DOE OSTI2025

Tailoring composition and deformation modes at the microstructural level for next generation low-cost high-strength austenitic stainless steels

The objective of this project is to enable deliberate development of cost-effective, hydrogen resistant alloys by establishing detailed relationships specific to the effects of alloy composition, short-range order (SRO), and microsegregation in the presence of hydrogen on the transition between homogeneous deformation and localized plasticity in shear bands. In collaboration with the International Institute for Carbon-Neutral Energy Research, I2CNER, at Kyushu University in Japan, we conceptualized, designed, and manufactured four austenitic alloys that maintain corrosion resistance and ensure lower cost relative to baseline commercial alloys. The mechanical properties and deformation modes of the novel alloys (KU alloys) were assessed in the presence of hydrogen (H). Correlations between composition and performance revealed that two of the KU alloys are suitable replacements for 316 steel, while another is a viable replacement for 304 steel at room temperature. We found that, in the presence of other austenite stabilizing elements namely Mn and N, replacing Ni with Cu does not lead to martensite formation as has been previously reported.1–3 Furthermore, we found that the addition of Cu leads to an earlier onset of multiple slip resulting in an relative earlier onset of a higher work hardening rate (WHR). Greater understanding of the relationships between alloy composition and SRO required the development of a novel advanced electron diffraction methodology to characterize SRO in complex FCC alloys. This innovative approach, which combines fluctuation and correlation analyses of diffuse-scattering signals, successfully differentiated between SRO and long-range ordering (LRO). Further investigations into annealed austenitic stainless steels could provide insights into manipulating SRO and its effects on material properties. Atomistic simulations provided understanding of SRO behavior that was difficult to capture experimentally. This project created the first spin cluster expansion model that is able to capture and describe SRO effects in Fe-Ni-Cr FCC alloys, accounting for the non-negligible effects of magnetism. An automated computational workflow was established to provide reliable predictions of SRO in Fe-Ni-Cr austenitic alloys, both with and without the presence of H atoms. Analysis of the propensity for SRO in Fe-Ni-Cr alloys revealed that H tends to cluster with specific, well-defined SRO domains. The computational framework is general purpose and can be extended to realistic stainless steels across diverse composition ranges. With confidence that SRO is possible in austenitic stainless steels, we developed a discrete dislocation finite element code to understand the interaction of dislocations with SRO in the presence of H. By incorporating H effects on the dislocation emission and SRO stress field we show that the critical stress for the dislocation pileup to breakthrough the SRO domain decreases in the presence of H, which directly contributes localized deformation at the macroscale. Through the simulation of a uniaxial tension test, we demonstrated that H-induced weakening of SRO stress field and H-enhanced dislocation emission can lead to the onset of shear localization at lower macroscopic strains. As a whole, this project identified three novel alloys that show improvements in performance and cost efficiency for H-facing applications by studying correlations between alloy chemistry and deformation behavior. We also made significant advancements to experimental and computational methodologies necessary to study the chemistry and distribution of SRO across a range of alloys, which in turn allowed us to demonstrate how deformation mechanisms change due to the contributions of SRO in austenitic alloys in the presence of H. The combined advancements in fundamental understanding with novel alloy development in this project has increased the viability of next generation H-technologies for the broader public through accessible low-cost alloys and accelerated development towards future H-infrastructure.

08 HYDROGEN↗
DOE OSTI2022

Use of Machine Learning on PMU Data for Transmission System Fault Analysis

Synchrophasor technology has been used for monitoring, control, and protection of bulk power system for over 10 years. Deployment of phasor measurement units (PMUs) in the USA power system has surpassed 3000 units installed in the transmission substations as stand-alone intelligent electronic devices (IEDs) or as a software add-on to other devices such as digital protective relays (DPRs) or digital fault recorders (DFRs). By now, thousands of terabytes of PMU data may have been captured and stored by various transmission system operators (TSOs) and independent system operators (ISOs). This creates an opportunity to deploy advanced machine learning (ML) techniques to detect and classify faults recorded by PMUs automatically to be used by the system operators for rapid, critical decision-making when manual analysis of the past or unfolding events is not feasible. In this paper we offer a brief background on how the automated fault analysis may be done using DPR and/or DFR data, and compare some of the legacy approaches to the new ML approaches in the context of the system-wide PMU recordings. We then offer insights from developing practical ML solutions that have been applied on field recordings captured by close to 450 PMUs from all three US interconnections (Western, Eastern and ERCOT) over two years (2016-2017). We identify and illustrate ML challenges we addressed: inaccurate data, data with scarce and temporally imprecise fault labels, data recorded by PMUs sparsely located at substations resulting in the fault records taken afar from the ends of the faulted lines, data containing only positive sequence values, and data taken at different voltage levels. We then illustrate the ML model results for fault analysis under different application scenarios. The novelty of this study is not only in the design, implementation, and performance analysis of the ML algorithms, but also in the use of advanced fault modelling and simulation approaches to improve the training results when developing supervised ML models for fault detection and classification. Extensive simulations of faults were conducted on a 14-bus power system to create a training dataset with over 1400 accurately labelled faults. This dataset was applied to enhance the accuracy of fault detection and classification of machine learning-based models trained with small number of labelled faults in large datasets recorded in the grid interconnections ranging from 5,000 to 70,000 buses.

Synchrophasors, Machine Learning, Fault Analysis, ↗
DOE OSTI2025

Myna: Connecting powder bed fusion build data to simulation tools for digital twin applications

Additive manufacturing (AM), as a digital process, can generate a detailed digital thread linking a part’s design and manufacturing to its operational performance. As AM systems advance, an increasing amount of process data is stored in manufacturing databases. In principle, this data can be utilized by simulation-based digital twin approaches, such as real-time process control and asynchronous post-processing guidance. However, few tools currently exist for systematically integrating digital thread data with computational tools. Here, in this study, we propose a software package, called Myna, for connecting data from powder bed fusion processes to simulation tools. The utility of such a platform is demonstrated using build data from the Oak Ridge National Laboratory Manufacturing Demonstration Facility “Peregrine v2023-10” public dataset to automatically configure and run 54 semi-analytical 3DThesis melt pool simulations, 78 numerical Additive FOAM melt pool simulations, and 3 ExaCA microstructure simulations. The simulated, spatially registered microstructures are then compared directly with electron backscatter diffraction characterization of the corresponding as-built part locations. The resulting simulated microstructure showed variation as a function of process parameters, particularly stripe width; however, the experimental data had little variation between the microstructure texture and grain size resulting from different processing conditions. Analysis of the discrepancies suggest that it is possible a two-phase ferritic-austenitic solidification model is needed to accurately predict grain size and texture for certain stainless steel 316L feedstock compositions under powder bed fusion conditions, providing direction for future research. As illustrated here, due to the number and complexity of the simulations involved in AM process-structure–property predictions, automated methods to connect process data and simulations will remain necessary tools for testing hypotheses and implementing digital twin applications.

Knapp, Gerald L. [Oak Ridge National Laboratory (O↗
NASA NTRS2016

Investigating the Simulink Auto-Coding Process

Model based program design is the most clear and direct way to develop algorithms and programs for interfacing with hardware. While coding "by hand" results in a more tailored product, the ever-growing size and complexity of modern-day applications can cause the project work load to quickly become unreasonable for one programmer. This has generally been addressed by splitting the product into separate modules to allow multiple developers to work in parallel on the same project, however this introduces new potentials for errors in the process. The fluidity, reliability and robustness of the code relies on the abilities of the programmers to communicate their methods to one another; furthermore, multiple programmers invites multiple potentially differing coding styles into the same product, which can cause a loss of readability or even module incompatibility. Fortunately, Mathworks has implemented an auto-coding feature that allows programmers to design their algorithms through the use of models and diagrams in the graphical programming environment Simulink, allowing the designer to visually determine what the hardware is to do. From here, the auto-coding feature handles converting the project into another programming language. This type of approach allows the designer to clearly see how the software will be directing the hardware without the need to try and interpret large amounts of code. In addition, it speeds up the programming process, minimizing the amount of man-hours spent on a single project, thus reducing the chance of human error as well as project turnover time. One such project that has benefited from the auto-coding procedure is Ramses, a portion of the GNC flight software on-board Orion that has been implemented primarily in Simulink. Currently, however, auto-coding Ramses into C++ requires 5 hours of code generation time. This causes issues if the tool ever needs to be debugged, as this code generation will need to occur with each edit to any part of the program; additionally, this is lost time that could be spent testing and analyzing the code. This is one of the more prominent issues with the auto-coding process, and while much information is available with regard to optimizing Simulink designs to produce efficient and reliable C++ code, not much research has been made public on how to reduce the code generation time. It is of interest to develop some insight as to what causes code generation times to be so significant, and determine if there are architecture guidelines or a desirable auto-coding configuration set to assist in streamlining this step of the design process for particular applications. To address the issue at hand, the Simulink coder was studied at a foundational level. For each different component type made available by the software, the features, auto-code generation time, and the format of the generated code were analyzed and documented. Tools were developed and documented to expedite these studies, particularly in the area of automating sequential builds to ensure accurate data was obtained. Next, the Ramses model was examined in an attempt to determine the composition and the types of technologies used in the model. This enabled the development of a model that uses similar technologies, but takes a fraction of the time to auto-code to reduce the turnaround time for experimentation. Lastly, the model was used to run a wide array of experiments and collect data to obtain knowledge about where to search for bottlenecks in the Ramses model. The resulting contributions of the overall effort consist of an experimental model for further investigation into the subject, as well as several automation tools to assist in analyzing the model, and a reference document offering insight to the auto-coding process, including documentation of the tools used in the model analysis, data illustrating some potential problem areas in the auto-coding process, and recommendations on areas or practices in the current Ramses model that should be further investigated. Several skills were required to be built up over the course of the internship project. First and foremost, my Simulink skills have improved drastically, as much of my experience had been modeling electronic circuits as opposed to software models. Furthermore, I am now comfortable working with the Simulink Auto-coder, a tool I had never used until this summer; this tool also tested my critical thinking and C++ knowledge as I had to interpret the C++ code it was generating and attempt to understand how the Simulink model affected the generated code. I had come into the internship with a solid understanding of Matlab code, but had done very little in using it to automate tasks, particularly Simulink tasks; along the same lines, I had rarely used shell script to automate and interface with programs, which I gained a fair amount of experience with this summer, including how to use regular expression. Lastly, soft-skills are an area everyone can continuously improve on; having never worked with NASA engineers, which to me seem to be a completely different breed than what I am used to (commercial electronic engineers), I learned to utilize the wealth of knowledge present at JSC. I wish I had come into the internship knowing exactly how helpful everyone in my branch would be, as I would have picked up on this sooner. I hope that having gained such a strong foundation in Simulink over this summer will open the opportunity to return to work on this project, or potentially other opportunities within the division. The idea of leaving a project I devoted ten weeks to is a hard one to cope with, so having the chance to pick up where I left off sounds appealing; alternatively, I am interested to see if there are any opening in the future that would allow me to work on a project that is more in-line with my research in estimation algorithms. Regardless, this summer has been a milestone in my professional career, and I hope this has started a long-term relationship between JSC and myself. I really enjoy the thought of building on my experience here over future summers while I work to complete my PhD at Missouri University of Science and Technology.

Gualdoni, Matthew J.↗