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NASA NTRS2011

Common Bolted Joint Analysis Tool

Common Bolted Joint Analysis Tool (comBAT) is an Excel/VB-based bolted joint analysis/optimization program that lays out a systematic foundation for an inexperienced or seasoned analyst to determine fastener size, material, and assembly torque for a given design. Analysts are able to perform numerous what-if scenarios within minutes to arrive at an optimal solution. The program evaluates input design parameters, performs joint assembly checks, and steps through numerous calculations to arrive at several key margins of safety for each member in a joint. It also checks for joint gapping, provides fatigue calculations, and generates joint diagrams for a visual reference. Optimum fastener size and material, as well as correct torque, can then be provided. Analysis methodology, equations, and guidelines are provided throughout the solution sequence so that this program does not become a "black box:" for the analyst. There are built-in databases that reduce the legwork required by the analyst. Each step is clearly identified and results are provided in number format, as well as color-coded spelled-out words to draw user attention. The three key features of the software are robust technical content, innovative and user friendly I/O, and a large database. The program addresses every aspect of bolted joint analysis and proves to be an instructional tool at the same time. It saves analysis time, has intelligent messaging features, and catches operator errors in real time.

Imtiaz, Kauser↗

NASA NTRS2011

IONAC-Lite

The Interplanetary Overlay Net - working Protocol Accelerator (IONAC) described previously in The Inter - planetary Overlay Networking Protocol Accelerator (NPO-45584), NASA Tech Briefs, Vol. 32, No. 10, (October 2008) p. 106 (http://www.techbriefs.com/component/ content/article/3317) provides functions that implement the Delay Tolerant Networking (DTN) bundle protocol. New missions that require high-speed downlink-only use of DTN can now be accommodated by the unidirectional IONAC-Lite to support high data rate downlink mission applications. Due to constrained energy resources, a conventional software implementation of the DTN protocol can provide only limited throughput for any given reasonable energy consumption rate. The IONAC-Lite DTN Protocol Accelerator is able to reduce this energy consumption by an order of magnitude and increase the throughput capability by two orders of magnitude. In addition, a conventional DTN implementation requires a bundle database with a considerable storage requirement. In very high downlink datarate missions such as near-Earth radar science missions, the storage space utilization needs to be maximized for science data and minimized for communications protocol-related storage needs. The IONAC-Lite DTN Protocol Accelerator is implemented in a reconfigurable hardware device to accomplish exactly what s needed for high-throughput DTN downlink-only scenarios. The following are salient features of the IONAC-Lite implementation: An implementation of the Bundle Protocol for an environment that requires a very high rate bundle egress data rate. The C&DH (command and data handling) subsystem is also expected to be very constrained so the interaction with the C&DH processor and the temporary storage are minimized. Fully pipelined design so that bundle processing database is not required. Implements a lookup table-based approach to eliminate multi-pass processing requirement imposed by the Bundle Protocol header s length field structure and the SDNV (self-delimiting numeric value) data field formatting. 8-bit parallel datapath to support high data-rate missions. Reduced resource utilization implementation for missions that do not require custody transfer features. There was no known implementation of the DTN protocol in a field programmable gate array (FPGA) device prior to the current implementation. The combination of energy and performance optimization that embodies this design makes the work novel.

Torgerson, Jordan L.↗

NASA NTRS2000

Qualitative Discovery in Medical Databases

Implication rules have been used in uncertainty reasoning systems to confirm and draw hypotheses or conclusions. However a major bottleneck in developing such systems lies in the elicitation of these rules. This paper empirically examines the performance of evidential inferencing with implication networks generated using a rule induction tool called KAT. KAT utilizes an algorithm for the statistical analysis of empirical case data, and hence reduces the knowledge engineering efforts and biases in subjective implication certainty assignment. The paper describes several experiments in which real-world diagnostic problems were investigated; namely, medical diagnostics. In particular, it attempts to show that: (1) with a limited number of case samples, KAT is capable of inducing implication networks useful for making evidential inferences based on partial observations, and (2) observation driven by a network entropy optimization mechanism is effective in reducing the uncertainty of predicted events.

Maluf, David A.↗

NASA NTRS2003

Compressing Aviation Data in XML Format

Design, operations and maintenance activities in aviation involve analysis of variety of aviation data. This data is typically in disparate formats making it difficult to use with different software packages. Use of a self-describing and extensible standard called XML provides a solution to this interoperability problem. XML provides a standardized language for describing the contents of an information stream, performing the same kind of definitional role for Web content as a database schema performs for relational databases. XML data can be easily customized for display using Extensible Style Sheets (XSL). While self-describing nature of XML makes it easy to reuse, it also increases the size of data significantly. Therefore, transfemng a dataset in XML form can decrease throughput and increase data transfer time significantly. It also increases storage requirements significantly. A natural solution to the problem is to compress the data using suitable algorithm and transfer it in the compressed form. We found that XML-specific compressors such as Xmill and XMLPPM generally outperform traditional compressors. However, optimal use of Xmill requires of discovery of optimal options to use while running Xmill. This, in turn, depends on the nature of data used. Manual disc0ver.y of optimal setting can require an engineer to experiment for weeks. We have devised an XML compression advisory tool that can analyze sample data files and recommend what compression tool would work the best for this data and what are the optimal settings to be used with a XML compression tool.

Patel, Hemil↗

NASA NTRS1992

Astronomical data analysis software and systems I; Proceedings of the 1st Annual Conference, Tucson, AZ, Nov. 6-8, 1991

Consideration is given to a definition of a distribution format for X-ray data, the Einstein on-line system, the NASA/IPAC extragalactic database, COBE astronomical databases, Cosmic Background Explorer astronomical databases, the ADAM software environment, the Groningen Image Processing System, search for a common data model for astronomical data analysis systems, deconvolution for real and synthetic apertures, pitfalls in image reconstruction, a direct method for spectral and image restoration, and a discription of a Poisson imagery super resolution algorithm. Also discussed are multivariate statistics on HI and IRAS images, a faint object classification using neural networks, a matched filter for improving SNR of radio maps, automated aperture photometry of CCD images, interactive graphics interpreter, the ROSAT extreme ultra-violet sky survey, a quantitative study of optimal extraction, an automated analysis of spectra, applications of synthetic photometry, an algorithm for extra-solar planet system detection and data reduction facilities for the William Herschel telescope.

Worrall, Diana M.↗

NASA NTRS2010

Microstructure Modeling of 3rd Generation Disk Alloys

The objective of this program is to model, validate, and predict the precipitation microstructure evolution, using PrecipiCalc (QuesTek Innovations LLC) software, for 3rd generation Ni-based gas turbine disc superalloys during processing and service, with a set of logical and consistent experiments and characterizations. Furthermore, within this program, the originally research-oriented microstructure simulation tool will be further improved and implemented to be a useful and user-friendly engineering tool. In this report, the key accomplishment achieved during the second year (2008) of the program is summarized. The activities of this year include final selection of multicomponent thermodynamics and mobility databases, precipitate surface energy determination from nucleation experiment, multiscale comparison of predicted versus measured intragrain precipitation microstructure in quench samples showing good agreement, isothermal coarsening experiment and interaction of grain boundary and intergrain precipitates, primary microstructure of subsolvus treatment, and finally the software implementation plan for the third year of the project. In the following year, the calibrated models and simulation tools will be validated against an independently developed experimental data set, with actual disc heat treatment process conditions. Furthermore, software integration and implementation will be developed to provide material engineers valuable information in order to optimize the processing of the 3rd generation gas turbine disc alloys.

Jou, Herng-Jeng↗

NASA NTRS1993

A comparative evaluation plan for the Maintenance, Inventory, and Logistics Planning (MILP) System Human-Computer Interface (HCI)

The primary goal of this project was to develop a tailored and effective approach to the design and evaluation of the human-computer interface (HCI) to the Maintenance, Inventory and Logistics Planning (MILP) System in support of the Mission Operations Directorate (MOD). An additional task that was undertaken was to assist in the review of Ground Displays for Space Station Freedom (SSF) by attending the Ground Displays Interface Group (GDIG), and commenting on the preliminary design for these displays. Based upon data gathered over the 10 week period, this project has hypothesized that the proper HCI concept for navigating through maintenance databases for large space vehicles is one based upon a spatial, direct manipulation approach. This dialogue style can be then coupled with a traditional text-based DBMS, after the user has determined the general nature and location of the information needed. This conclusion is in contrast with the currently planned HCI for MILP which uses a traditional form-fill-in dialogue style for all data access and retrieval. In order to resolve this difference in HCI and dialogue styles, it is recommended that comparative evaluation be performed which combines the use of both subjective and objective metrics to determine the optimal (performance-wise) and preferred approach for end users. The proposed plan has been outlined in the previous paragraphs and is available in its entirety in the Technical Report associated with this project. Further, it is suggested that several of the more useful features of the Maintenance Operations Management System (MOMS), especially those developed by the end-users, be incorporated into MILP to save development time and money.

Overmyer, Scott P.↗

NASA NTRS1989

Development of a funding, cost, and spending model for satellite projects

The need for a predictive budget/funging model is obvious. The current models used by the Resource Analysis Office (RAO) are used to predict the total costs of satellite projects. An effort to extend the modeling capabilities from total budget analysis to total budget and budget outlays over time analysis was conducted. A statistical based and data driven methodology was used to derive and develop the model. Th budget data for the last 18 GSFC-sponsored satellite projects were analyzed and used to build a funding model which would describe the historical spending patterns. This raw data consisted of dollars spent in that specific year and their 1989 dollar equivalent. This data was converted to the standard format used by the RAO group and placed in a database. A simple statistical analysis was performed to calculate the gross statistics associated with project length and project cost ant the conditional statistics on project length and project cost. The modeling approach used is derived form the theory of embedded statistics which states that properly analyzed data will produce the underlying generating function. The process of funding large scale projects over extended periods of time is described by Life Cycle Cost Models (LCCM). The data was analyzed to find a model in the generic form of a LCCM. The model developed is based on a Weibull function whose parameters are found by both nonlinear optimization and nonlinear regression. In order to use this model it is necessary to transform the problem from a dollar/time space to a percentage of total budget/time space. This transformation is equivalent to moving to a probability space. By using the basic rules of probability, the validity of both the optimization and the regression steps are insured. This statistically significant model is then integrated and inverted. The resulting output represents a project schedule which relates the amount of money spent to the percentage of project completion.

Johnson, Jesse P.↗

NASA NTRS2005

Aerodynamic Parameter Estimation for the X-43A (Hyper-X) from Flight Data

Aerodynamic parameters were estimated based on flight data from the third flight of the X-43A hypersonic research vehicle, also called Hyper-X. Maneuvers were flown using multiple orthogonal phase-optimized sweep inputs applied as simultaneous control surface perturbations at Mach 8, 7, 6, 5, 4, and 3 during the vehicle descent. Aerodynamic parameters, consisting of non-dimensional longitudinal and lateral stability and control derivatives, were estimated from flight data at each Mach number. Multi-step inputs at nearly the same flight conditions were also flown to assess the prediction capability of the identified models. Prediction errors were found to be comparable in magnitude to the modeling errors, which indicates accurate modeling. Aerodynamic parameter estimates were plotted as a function of Mach number, and compared with estimates from the pre-flight aerodynamic database, which was based on wind-tunnel tests and computational fluid dynamics. Agreement between flight estimates and values computed from the aerodynamic database was excellent overall.

Morelli, Eugene A.↗

NASA NTRS2016

A Quasi-Global Approach to Improve Day-Time Satellite Surface Soil Moisture Anomalies through the Land Surface Temperature Input

Passive microwave observations from various spaceborne sensors have been linked to the soil moisture of the Earth's surface layer. A new generation of passive microwave sensors are dedicated to retrieving this variable and make observations in the single theoretically optimal L-band frequency (1-2 GHz). Previous generations of passive microwave sensors made observations in a range of higher frequencies, allowing for simultaneous estimation of additional variables required for solving the radiative transfer equation. One of these additional variables is land surface temperature, which plays a unique role in the radiative transfer equation and has an influence on the final quality of retrieved soil moisture anomalies. This study presents an optimization procedure for soil moisture retrievals through a quasi-global precipitation-based verification technique, the so-called Rvalue metric. Various land surface temperature scenarios were evaluated in which biases were added to an existing linear regression, specifically focusing on improving the skills to capture the temporal variability of soil moisture. We focus on the relative quality of the day-time (01:30 pm) observations from the Advanced Microwave Scanning Radiometer for Earth Observing System (AMSR-E), as these are theoretically most challenging due to the thermal equilibrium theory, and existing studies indicate that larger improvements are possible for these observations compared to their night-time (01:30 am) equivalent. Soil moisture data used in this study were retrieved through the Land Parameter Retrieval Model (LPRM), and in line with theory, both satellite paths show a unique and distinct degradation as a function of vegetation density. Both the ascending (01:30 pm) and descending (01:30 am) paths of the publicly available and widely used AMSR-E LPRM soil moisture products were used for benchmarking purposes. Several scenarios were employed in which the land surface temperature input for the radiative transfer was varied by imposing a bias on an existing regression. These scenarios were evaluated through the Rvalue technique, resulting in optimal bias values on top of this regression. In a next step, these optimal bias values were incorporated in order to re-calibrate the existing linear regression, resulting in a quasi-global uniform LST relation for day-time observations. In a final step, day-time soil moisture retrievals using the re-calibrated land surface temperature relation were again validated through the Rvalue technique. Results indicate an average increasing Rvalue of 16.5%, which indicates a better performance obtained through the re-calibration. This number was confirmed through an independent Triple Collocation verification over the same domain, demonstrating an average root mean square error reduction of 15.3%. Furthermore, a comparison against an extensive in situ database (679 stations) also indicates a generally higher quality for the re-calibrated dataset. Besides the improved day-time dataset, this study furthermore provides insights on the relative quality of soil moisture retrieved from AMSR-E's day- and night-time observations.

soil moisture↗

NASA NTRSDate not supplied

Quantifying the Sensitivity of Condition Incidence Parameters in the Evidence Library

One approach to quantifying spaceflight risk at NASA makes use event driven probabilistic techniques. The Medical Extensible Dynamic Probabilistic Risk Assessment Tool (MEDPRAT) is such a tool that estimates medical risk metrics via simulation and enables optimization of medical resources subject to mission constraints [1]. Previous analyses have informed medical set composition, exercise countermeasures, and water intake, where each analysis quantifies the risk associated with proposed variations in system design. As future mission profiles extend beyond Low-Earth Orbit (LEO) and lengthen in duration, understanding these risks and contributing factors is critical. MEDPRAT employs Monte Carlo sampling techniques to simulate missions and track the occurrence of medical events. These events follow fault-tree-like progressions through levels of severity and mitigation via medical treatment to many possible outcomes and these are reported throughout the mission. Making this possible, are the medical databases that contain evidence gathered by the Human Research Program (HRP). Quantifying the impact of uncertainty or variability in the input data is an important step in evaluating the credibility of modeling and simulation results. In this work, we investigate the sensitivity of medical risk metrics with respect to the condition incidence parameters within the Evidence Library (EL) [2] as the medical database input for MEDPRAT. The medical conditions, contained in the EL, are equipped with incidence rates that describe the likelihood that the condition will occur. These incidence rates reflect historical spaceflight data or when appropriate, terrestrial data. In this presentation, we will explore how uncertainty in these rates propagate to the medical risk described by MEDPRAT. These results identify the conditions and parameters with the largest contribution to medical risks.

Ian Lim↗

NASA NTRS2014

Tradespace Exploration of Distributed Propulsors for Advanced On-Demand Mobility Concepts

Combustion-based sources of shaft power tend to significantly penalize distributed propulsion concepts, but electric motors represent an opportunity to advance the use of integrated distributed propulsion on an aircraft. This enables use of propellers in nontraditional, non-thrust-centric applications, including wing lift augmentation, through propeller slipstream acceleration from distributed leading edge propellers, as well as wingtip cruise propulsors. Developing propellers for these applications challenges long-held constraints within propeller design, such as the notion of optimizing for maximum propulsive efficiency, or the use of constant-speed propellers for high-performance aircraft. This paper explores the design space of fixed-pitch propellers for use as (1) lift augmentation when distributed about a wing's leading edge, and (2) as fixed-pitch cruise propellers with significant thrust at reduced tip speeds for takeoff. A methodology is developed for evaluating the high-level trades for these types of propellers and is applied to the exploration of a NASA Distributed Electric Propulsion concept. The results show that the leading edge propellers have very high solidity and pitch well outside of the empirical database, and that the cruise propellers can be operated over a wide RPM range to ensure that thrust can still be produced at takeoff without the need for a pitch change mechanism. To minimize noise exposure to observers on the ground, both the leading edge and cruise propellers are designed for low tip-speed operation during takeoff, climb, and approach.

Borer, Nicholas K.↗

NASA NTRS2011

Noise of Embedded High Aspect Ratio Nozzles

A family of high aspect ratio nozzles were designed to provide a parametric database of canonical embedded propulsion concepts. Nozzle throat geometries with aspect ratios of 2:1, 4:1, and 8:1 were chosen, all with convergent nozzle areas. The transition from the typical round duct to the rectangular nozzle was designed very carefully to produce a flow at the nozzle exit that was uniform and free from swirl. Once the basic rectangular nozzles were designed, external features common to embedded propulsion systems were added: extended lower lip (a.k.a. bevel, aft deck), differing sidewalls, and chevrons. For the latter detailed Reynolds-averaged Navier-Stokes (RANS) computational fluid dynamics (CFD) simulations were made to predict the thrust performance and to optimize parameters such as bevel length, and chevron penetration and azimuthal curvature. Seventeen of these nozzles were fabricated at a scale providing a 2.13 inch diameter equivalent area throat." ! The seventeen nozzles were tested for far-field noise and a few data were presented here on the effect of aspect ratio, bevel length, and chevron count and penetration. The sound field of the 2:1 aspect ratio rectangular jet was very nearly axisymmetric, but the 4:1 and 8:1 were not, the noise on their minor axes being louder than the major axes. Adding bevel length increased the noise of these nozzles, especially on their minor axes, both toward the long and short sides of the beveled nozzle. Chevrons were only added to the 2:1 rectangular jet. Adding 4 chevrons per wide side produced some decrease at aft angles, but increased the high frequency noise at right angles to the jet flow. This trend increased with increasing chevron penetration. Doubling the number of chevrons while maintaining their penetration decreased these effects. Empirical models of the parametric effect of these nozzles were constructed and quantify the trends stated above." Because it is the objective of the Supersonics Project that future design work be done more by physics-based computations and less by experiments, several codes under development were evaluated against these test cases. Preliminary results show that the RANS-based code JeNo predicts the spectral directivity of the low aspect ratio jets well, but has no capability to predict the non-axisymmetry. An effort to address this limitations, used in the RANS-based code of Leib and Goldstein, overpredicted the impact of aspect ratio. The broadband shock noise code RISN, also limited to axisymmetric assumptions, did a good job of predicting the spectral directivity of underexpanded 2:1 cold jet case but was not as successful on high aspect ratio jets, particularly when they are hot. All results are preliminary because the underlying CFD has not been validated yet. An effort using a Large Eddy Simulation code by Stanford University predicted noise that agreed with experiments to within a few dB.

Bridges, James E.↗

NASA NTRS2022

On the Effects of Cloud Water Content on Passive Microwave Snowfall Retrievals

The Bayesian passive microwave retrievals of snowfall often rely on mathematical matching of the observed vectors of brightness temperature with an a priori database of precipitation profiles and their corresponding brightness temperatures. Mathematical proximity does not necessarily lead to consistent retrievals due to limited information content of passive microwave observations. This paper defines imposter (genuine) vectors of brightness temperature as those that are mathematically close but physically inconsistent (consistent) and characterizes them through the Silhouette Coefficient (SC) analysis. The Neyman–Pearson (NP) hypothesis testing is used to separate the imposter and genuine brightness temperatures based on their associated values of cloud ice (IWP) and liquid water path (LWP), given by coincidences of CloudSat Profiling Radar (CPR) and the Global Precipitation Measurement (GPM) Microwave Imager (GMI). The study determines thresholds for IWP and LWP that allow optimal identification of imposter brightness temperatures of non-snowing and snowing clouds, which can mislead the passive microwave retrieval algorithms to falsely detect or miss the snowfall events. It is demonstrated that emission signal of supercooled liquid water in snowing clouds can lead to improved passive microwave retrieval of snowfall and conditioning the retrievals to the cloud IWP and LWP can result in marginal correction of the snowfall detection probability; however, reduce the probability of false alarm by 6%–8% over sea ice and open oceans.

Snowfall↗

NASA NTRS2012

Highlights of TOMS Version 9 Total Ozone Algorithm

The fundamental basis of TOMS total ozone algorithm was developed some 45 years ago by Dave and Mateer. It was designed to estimate total ozone from satellite measurements of the backscattered UV radiances at few discrete wavelengths in the Huggins ozone absorption band (310-340 nm). Over the years, as the need for higher accuracy in measuring total ozone from space has increased, several improvements to the basic algorithms have been made. They include: better correction for the effects of aerosols and clouds, an improved method to account for the variation in shape of ozone profiles with season, latitude, and total ozone, and a multi-wavelength correction for remaining profile shape errors. These improvements have made it possible to retrieve total ozone with just 3 spectral channels of moderate spectral resolution (approx. 1 nm) with accuracy comparable to state-of-the-art spectral fitting algorithms like DOAS that require high spectral resolution measurements at large number of wavelengths. One of the deficiencies of the TOMS algorithm has been that it doesn't provide an error estimate. This is a particular problem in high latitudes when the profile shape errors become significant and vary with latitude, season, total ozone, and instrument viewing geometry. The primary objective of the TOMS V9 algorithm is to account for these effects in estimating the error bars. This is done by a straightforward implementation of the Rodgers optimum estimation method using a priori ozone profiles and their error covariances matrices constructed using Aura MLS and ozonesonde data. The algorithm produces a vertical ozone profile that contains 1-2.5 pieces of information (degrees of freedom of signal) depending upon solar zenith angle (SZA). The profile is integrated to obtain the total column. We provide information that shows the altitude range in which the profile is best determined by the measurements. One can use this information in data assimilation and analysis. A side benefit of this algorithm is that it is considerably simpler than the present algorithm that uses a database of 1512 profiles to retrieve total ozone. These profiles are tedious to construct and modify. Though conceptually similar to the SBUV V8 algorithm that was developed about a decade ago, the SBUV and TOMS V9 algorithms differ in detail. The TOMS algorithm uses 3 wavelengths to retrieve the profile while the SBUV algorithm uses 6-9 wavelengths, so TOMS provides less profile information. However both algorithms have comparable total ozone information and TOMS V9 can be easily adapted to use additional wavelengths from instruments like GOME, OMI and OMPS to provide better profile information at smaller SZAs. The other significant difference between the two algorithms is that while the SBUV algorithm has been optimized for deriving monthly zonal means by making an appropriate choice of the a priori error covariance matrix, the TOMS algorithm has been optimized for tracking short-term variability using month and latitude dependent covariance matrices.

Bhartia, Pawan↗

NASA NTRS2018

Rapid, Comprehensive, Mission Architecting at the Jet Propolusion Laboratory

One of the first multi-disciplinary optimization challenges a mission concept faces is finding an initial system level architecture that simultaneously satisfies the constraints of cost, the requirements of science, and the capabilities of engineering. Compounding this challenge, especially in the early formulation of an architecture, is communicating amongst all key stakeholders, in this multidimensional space of constraints and requirements, where the current architecture is not yet adequately defined, or if it is defined, where it is broken. Recently, a factor of two improvement in the speed of development of the engineering architecture, while also comprehensively considering scientific performance and cost, has been achieved through a single screen visualization dashboard (“S-Chart”), a cost allocation tool, segment level analogy databases and parametric relationships for segment technical capabilities and their technical (Size, Weight, Power, and Data) and financial (Cost) capabilities and/or accommodation requirements.

Nash, Alfred E.↗

NASA NTRSDate not supplied

Open-source Numerical Modeling of Solidification Cracking Susceptibility: Application to Refractory Alloy Systems

Introduction. Alloys such as aluminum, nickel-base, and austenitic stainless steels are susceptible to solidification cracking during welding and 3D printing. Compositional optimization is one method used to effectively mitigate solidification cracking of those alloy systems. With the surge in hypersonic and in-space propulsion activities, refractory metals (Nb, Mo, Ta, W, and Re) and their alloy derivatives are increasing in importance due to their extreme high melting point and retention of high-temperature strength; however, their chemistry was most typically optimized to promote ductility during mechanical operations such as drawing and forming. Welding of such alloys has been a challenge due to a number of issues including solidification cracking, atmospheric contamination (O, C, and N), as well as a shift in ductile-to-brittle transition to higher temperature following grain growth induced by welding. Compositional optimization of refractory alloys for solidification cracking resistance in particular is desirable as their usage increases with the advent of advanced manufacturing methods such as 3D printing. This work evaluates the effect of compositional variation in refractory metal systems on the solidification cracking susceptibility with the goals of optimizing existing alloys and joining process techniques, and formulating new alloys with increased solidification cracking resistance. Experimental Procedures. A python code was developed in a Jupyter notebook environment (Michael and Sowards, 2023) to facilitate the calculation of crack susceptibility index proposed by Kou (2015). Composition is entered as a single point, or as a 1-D or 2-D array. The notebook calls pycalphad (Otis and Liu, 2017 and Bocklund et al, 2020) to calculate the evolution of fraction solid as a function of temperature (under either Scheil or equilibrium assumptions) and then evaluates steepness of the fraction solid curve near the terminal stage of solidification to predict solidification cracking resistance. Open source thermodynamic databases available at online repositories are used (van de Walle). The process is setup in an automated fashion to generate plots that show variation in solidification cracking susceptibility according to composition on 1-D line plots or 2-D contour plots. The Jupyter notebook and crack susceptibility algorithm was also integrated with a widely used commercial CALPHAD code for validation and alloy exploration. Results and Discussion. The crack susceptibility model was first validated against a series of refractory alloy compositions evaluated in past work which utilized a specialized Varestraint test built inside a vacuum chamber environment (Lessman and Gold, 1971). The alloys tested in the Varestraint apparatus included T-111 (Ta-8W-2Hf), ASTAR-811C (Ta-8W-1Re-0.7Hf-0.025C), FS-85 (Nb-27Ta-10W-1Zr), T-222 (Ta-9.6W-2.4Hf-0.01C), Ta-10W, B-66 (Nb-5Mo-5V-1Zr), and SCb-291 (Nb-10W-10Ta). The initial test of the model showed a strong correlation with empirical Varestraint data, i.e., a Spearman rank correlation between model predictions and hot cracking measurements was observed to be greater than 0.8. Following the validation, a set of refractory metal binary mixtures was investigated to evaluate sensitivity of Nb, Mo, W, and Ta to C, N, and O content. A series of plots were produced that suggest ppmw ranges of C, N, and O where solidification cracking increases significantly and reaches a maximum. Also comparative ranking of each primary refractory metal to each interstitial was produced. For example C produces greater cracking response in Mo whereas O produces greater cracking response in Ta and Nb. Such compositional values have utility in setting limits on pickup of these interstitial elements during welding and printing rather than using a one-size-fits-all approach. Furthermore, the results have use in determining additive powder recycling requirements, which is especially pertinent for refractory metal powders due to their high cost compared to conventional alloys. Another application created thousands of hypothetical alloys within the nominal specified composition range of two widely used refractory alloys C103 (Nb-10Hf-1Ti) and TZM (Mo-0.5Ti-0.1Zr). The cracking index was calculated for the alloys and results were fed into machine learning regression techniques including Multiple Linear Regression, Ridge Regression, and Lasso Regression to determine relative potency each alloying element had on computed solidification cracking index. A series of linear equations were produced that relate composition of C103 and TZM to solidification cracking index. The crack susceptibility of C103 for example is described by an equation of the form: cracking index ~ O + 0.667*C + 0.635*N + 0.00037*Ta – 0.0008*Hf (in wt.%) From that equation, it is clear that O has strong propensity to induce solidification cracking. Interestingly, Hf is shown to reduce calculated cracking response. Finally, realizing the potential of this method to discover new refractory alloy formulations across the period table that have low solidification cracking sensitivity, the code was applied to new untested alloy systems including W-Zr-C, W-Ta-C, and others. Conclusions. In summary, an open source numerical method has been developed using Python code to calculate Kou’s crack susceptibility index. The method was applied to refractory metals which are inherently difficult to study from a weldability testing standpoint since inert shielding gas is not sufficient and welding is typically done in vacuum, especially in light of findings presented here where oxygen has profound influence on solidification cracking. This work revealed the effect of compositional variations on a series of refractory metals and showed the framework defined here will be useful in 1) the development of new alloys that have improved weldability and 3D printability, 2) placing compositional limits on existing alloys, and 3) ensuring adequate controls of manufacturing processes such as 3D printing where powder reuse is critical. Keywords. pycalphad; Python; refractory metals; solidification cracking. References. B. Bocklund et. al. (2020) http://doi.org/10.5281/zenodo.3630657. S. Kou. (2015) https://doi.org/10.1016/j.actamat.2015.01.034. G.G. Lessmann and R.E. Gold. Welding Journal, issue 1, pp. 1-s – 8-s (1971). F.N. Michael and J.W. Sowards. NASA/TM-20230002218 (2023). R. Otis and Z.-K. Liu. (2017) http://doi.org/10.5334/jors.140. A. Van de Wallle et. al. (2018) https://doi.org/10.1016/j.calphad.2018.04.003.

pycalphad↗

NASA NTRS1989

Design challenges for space bioreactors

The design of bioreactors for operation under conditions of microgravity presents problems and challenges. Absence of a significant body force such as gravity can have profound consequences for interfacial phenomena. Marangoni convection can no longer be overlooked. Many speculations on the advantages and benefits of microgravity can be found in the literature. Initial bioreactor research considerations for space applications had little regard for the suitability of the designs for conditions of microgravity. Bioreactors can be classified in terms of their function and type of operation. The complex interaction of parameters leading to optimal design and operation of a bioreactor is illustrated by the JSC mammalian cell culture system. The design of a bioreactor is strongly dependent upon its intended use as a production unit for cell mass and/or biologicals or as a research reactor for the study of cell growth and function. Therefore a variety of bioreactor configurations are presented in rapid summary. Following this, a rationale is presented for not attempting to derive key design parameters such as the oxygen transfer coefficient from ground-based data. A set of themes/objectives for flight experiments to develop the expertise for design of space bioreactors is then proposed for discussion. These experiments, carried out systematically, will provide a database from which engineering tools for space bioreactor design will be derived.

Seshan, P. K.↗