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DOE OSTI2026

Microchannel-based Membrane-less Extraction of Li from Unconventional Lithium Sources & the Separation of REE

This final report provides an overview of the Project's entire duration, covering July 1, 2021 to December 31, 2023. It primarily focuses on the achievements, technological developments, and unique challenges the team faced while working on separating and extracting Lithium from produced waters. The project's primary aim was to create an integrated, high-throughput, membrane-less, and modular microfluidic platform that could extract Lithium from unconventional sources. We have successfully met all goals and milestones envisioned in the SOPO document. The most critical primary milestones, including the Go-No-Go milestone (refer to the Gantt chart in the Appendices), were successfully accomplished. We demonstrated phase separation (>90%) and extraction (>85%) performance in the MPSE using synthetic, and representative produced water composition feed at 50 ml/min total flow through MPSE 36. We have also performed a parametric study of the MPSE operations, beyond the scope of SOPO, exploring operating conditions of current and broader interest. The extended investigation of operational parameters is concurrent with our efforts to seek further development of the MPSE technology beyond the scope of the Project. Along these lines of development, we have made efforts to be responsive to DOE calls for technological developments of other types of resources (beyond PW) for the recovery of Critical Materials and higher TRL development (beyond TRL 4). During the work on this Project, we developed and implemented three innovative technical approaches that emerged from our efforts to successfully meet the Project milestones. The innovative & original technical approaches developed and implemented in this Project are now the contributions to process engineering that could be clearly credited to the Project. First, Convergent Design Approach is a comprehensive feedforward & feedback loop of four design phases: i) design for functionality, ii) design for manufacturing, iii) design for sustainability, and iv) design for market. Next was Process Intensification. A major aim of this Project was to create an innovative phase separation & extraction microscale-based technology for Li separation – thus the words microchannel-based in the Project title. A microscale-based technology is intrinsically in the center of the Process Intensification domain as defined by its unique principles. Therefore, Process Intensification was implicitly envisioned in the Project’s SOPO. Lastly, Time Scale Analysis is a novel tool for discovering the needs and directions of Process Intensification implementations in any process technology. This Project is fully credited for developing and implementing the three novel technical approaches mentioned above. These are general contributions to process engineering that emerged from this Project. Beyond the original SOPO scope, the OSU-U.Pitt research group utilized a Convergent Design methodology, integrating first-principles mathematical modeling with experimental validation on the Minimum Development Vehicle. By creating these Digital Twins, the team rapidly assessed manufacturing iterations to support TEA analysis. This framework further enabled the development of advanced Surface Modification Techniques, where hydrophobic and oleophobic coating strategies were optimized via Digital Twin tools and validated through rigorous 100-hour longevity testing. TEA Analysis: The closing efforts of this Project were focused on the TEA analysis. TEA analysis had two primary functions: i) enabling critical assessments of design variations withing 10 the Concurrent Design Approach, thus enabling evolution of the MPSE design to reach faster- better-cheaper alternatives; and ii) to create a bridge between the accomplishments of this Project and future projects of higher TRL, beyond TRL 6 level. It is important to note that the TEA model created in the Project stirred the technological solutions for the recovery of critical materials toward a vision of a very profitable modular plant that has unique zero-waste water discharge signature. More importantly, thanks to our experimental performance data and conservative assumptions, the TEA model predicts minimal technological and investment risks. Low cost of a modular unit of a nominal capacity of [1000 tons of Li 2 CO 3 /year] positions the MPSE based technology within the reach of community investors, thus offering a paradigm shift in the development of critical technologies. The project successfully navigated two primary challenges: solvent selection and manufacturing adaptation. Restricted by the SOPO to existing literature for lithium recovery, the team identified a critical need for a "material excellence program" to develop next-generation solvents, eventually concluding with a preliminary investigation into promising Ionic Liquids (ILs). Simultaneously, COVID-19 supply chain disruptions forced a pivot from traditional manufacturing to advanced additive methods at ATAMI-OSU. By transitioning from stainless steel to 3D-printed polymer substrates, the team achieved a transformative three-order-of- magnitude reduction in manufacturing costs and compressed prototyping timelines from several months to just two days. The MPSE technology offers significant energy, environmental, and economic advantages by overcoming the traditional bottlenecks of phase-separation hardware and contactor size. Unlike conventional mixer-settlers or membrane-based systems, MPSE operates without moving parts or fouling-prone membranes, achieving robust performance even with challenging, viscous, or particulate-heavy feeds. Key performance metrics include an energy intensity reduction of 5–50x (3–40 kJ/m 3 ) compared to incumbent technologies and a dramatic reduction of processing time to under 60 seconds, which drastically reduces the physical plant footprint. These technical efficiencies translate into superior economic outcomes; for a 100 t/year Li 2 CO 3 facility, implementing MPSE is projected to nearly halve contactor CAPEX (from $\$$6.08M to $\$$3.01M) and significantly increase the project's Net Present Value (NPV), derisking new investment and enabling distributed critical-mineral processing configurations. The commercialization of MPSE technology is being spearheaded by Vigsur Dynamics Inc., which has adopted a structured, parallel approach to technical and business development since its formation in January 2026. Following extensive customer discovery and engagement with the Oregon State University accelerator, Vigsur Dynamics is working to establish a business model that transitions from pilot demonstrations to modular hardware sales, ultimately aiming for a "build-own-operate" service strategy. Current technical milestones—including 100 hours of continuous operation, superior energy efficiency, and successful 6-unit modular scale-up— provide a foundation for this transition. Backed by ongoing IP licensing and a growing network of industrial and venture advisors, the company is actively de-risking the platform to replace conventional mixer-settler systems in the critical minerals market.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2001

Method and Apparatus for Monitoring of Daily Activity in Terms of Ground Reaction Forces

A device to record and analyze habitual daily activity in terms of the history of gait-related musculoskeletal loading is disclosed. The device consists of a pressure-sensing insole placed into the shoe or embedded in a shoe sole, which detects contact of the foot with the ground. The sensor is coupled to a portable battery-powered digital data logger clipped to the shoe or worn around the ankle or waist. During the course of normal daily activity, the system maintains a record of time-of-occurrence of all non-spurious foot-down and lift-off events. Off line, these data are filtered and converted to a history of foot-ground contact times, from which measures of cumulative musculoskeletal loading, average walking- and running-specific gait speed, total time spent walking and running, total number of walking steps and running steps, and total gait-related energy expenditure are estimated from empirical regressions of various gait parameters to the contact time reciprocal. Data are available as cumulative values or as daily averages by menu selection. The data provided by this device are useful for assessment of musculoskeletal and cardiovascular health and risk factors associated with habitual patterns of daily activity.

Whalen, Robert T.↗

NASA NTRSDate not supplied

Playing with DIRT: Building the Framework for a Comprehensive In-Situ Soil Materials Testing Database

Long-term, sustainable planetary exploration will require the ability to "live off the land," relying on In-Situ Resource Utilization (ISRU) and In-Situ Construction as core capabilities. Reduction of both risk and launch mass for lunar construction will require evaluating and comparing regolith materials for use as feedstocks suitable for in-situ beneficiation and fabrication of building components. These material assessment capabilities will inform lunar infrastructure design decisions, with co-benefits for terrestrial construction using in-situ materials. Current planetary construction technology development relies on lunar mapping and orbital data, Apollo-era sample analyses, current simulant inventories, and tests conducted using analog site soils. Requirements for lunar infrastructure design decisions and construction systems will be determined based on specific environmental conditions, mission architectures, and the materials available within traverse range of lunar feedstock processing depots. Critical for success is the capability to identify, evaluate and make effective use of a wide range of materials as they are found in-situ on the lunar surface. This paper discusses the development of a digital repository for data on soil and regolith properties, beginning with their structural performance in both cementitious and non-cementitious building material formulations. The Database for In-situ Resource Testing (DIRT) compiles a catalog of raw materials, additives, and formulations, with notations pertaining to material sources and preparation techniques entered via a web-based user interface. Design of consistent data schemas for site-sourced materials evaluation will facilitate linkage with relevant terrestrial and planetary materials databases while enabling guided data input via templates for participation by broader groups of collaborators. Results of these analyses are compiled in a centralized repository to generate insights applicable for regolith resources and landing sites yet to be precisely defined. Collection of thorough records of material characteristics, applications and performance will support innovative construction solutions not only for space infrastructure but for sustainable, resilient design in the terrestrial built environment.

Sarah Joey Seitz↗

DOE OSTI2025

Archival records housed at USTUR support radium dial worker dosimetry

The American radium dial worker (RDW) cohort of over 3200 persons is being revisited as part of the Million Person Study (MPS) to include a modern approach to RDW dosimetry. An exceptional source of data and contextualization in this project is an extensive collection of electronic records (digitized from existing microfilm and microfiche) housed at the United States Transuranium and Uranium Registries (USTUR). Although the type, extent, and quality (e.g. legibility) of record(s) varies between individuals, the remarkable occupational, medical and demographic data include in vivo radiation measurements (e.g. radon breath, whole body counts), autopsy results, medical records (including copies of radiographs), interviews over the years, and correspondence. Of particular dosimetric interest are the details of radiation measurements. For example, there are some instances where hand-written and transcribed values are both available, along with notes providing context for why a particular measurement in a series of measurements was chosen to assign an intake, or if there were concerns about a particular measurement. Born prior to 1935, RDW have nearly all passed away. Thus, the updated dosimetry, especially for the skeletal tissues, will allow the correlation of lifetime cumulative dose with radiation risk. Here we review typical information available in this collection of historical records and highlight some interesting finds. Additionally, we discuss the relevance to current and ongoing work related to updating the dosimetry of the RDW in the MPS, including providing an example of the usefulness of information contained in these records. The RDW cohort provides a unique historical perspective on occupational exposure to radium, making it a valuable dataset for understanding long-term health effects and improving current radiation protection standards.

Million Person Study↗

NASA NTRS2024

Clear Lake Volcanic Field Disasters: Creating a Deformation Record Using InSAR to Assess Hazards and Detect Volcanic Unrest in Clear Lake Volcanic Field

Clear Lake Volcanic Field (CLVF) in northern California is at a high threat potential for volcanic hazards. Eruptions leading to increased seismic activity could result in silicic domes, cinder cones, and flows that would be dangerous to the residential areas near the volcanic field. Remotely sensed Earth observations can reveal volcanic processes in the subsurface, which are essential to the timely monitoring of potential volcanic activity. In particular, Sentinel-1 C-band Synthetic Aperture Radar (C-SAR) and Digital Elevation Model (DEM) data capture relative surface deformation at unprecedented high spatial and temporal resolutions. Leveraging C-SAR and DEMs, we conducted interferometric analysis from January 2016 to December 2023. Our results demonstrate 1) the mean surface displacement velocity of the Clear Lake Volcanic Field is measured to undergo 5 to 10-centimeter scale deformation and shows a strong relationship with the surrounding faults, 2) apparent seasonal differences in rates of surface change, and 3) seismic activity associated with the geyser geothermal field has a strong association with cumulative surface displacement, with active fault zones having 2 to 5 cm of additional displacement. Results indicate that deformation is linked to deep pressure sources causing stresses on the surficial environment that should be considered in hazard mitigation. This study provides a baseline of historic deformation, aiding hazard analysts in communication efforts and streamlining decision-making for potential risks to region residents.

remote sensing↗

NASA NTRSDate not supplied

Creating a Deformation Time Series Utilizing InSAR to Assess Hazards and Detect Volcanic Unrest in Clear Lake Volcanic Field, California

According to the U.S Geological Survey, the Clear Lake Volcanic Field (CLVF) in northern California is at a high threat potential for volcanic hazards. Eruptions leading to increased seismic activity could result in silicic domes, cinder cones, and flows that would be dangerous to the residential areas near the volcanic field. Remotely sensed Earth observations can reveal volcanic processes in the subsurface, which are essential to the timely monitoring of potential volcanic activity. In particular, Sentinel-1 C-band Synthetic Aperture Radar (C-SAR) and Digital Elevation Model (DEM) data capture relative surface deformation at unprecedented high spatial and temporal resolutions. Leveraging C-SAR and DEMs, we conducted interferometric analysis from January 2016 to December 2023. Our results demonstrate 1) the mean surface displacement velocity of the Clear Lake Volcanic field is measured to undergo 5 to 10-centimeter scale deformation and shows a strong correlation with the surrounding faults, 2) apparent seasonal differences in rates of surface change, and 3) seismic activity associated with the geyser geothermal field has a strong correlation with cumulative surface displacement, with active fault zones having 2 to 5 cm of additional displacement. Results indicate that deformation is linked to deep pressure sources causing stresses on the surficial environment that should be considered in hazard mitigation. This study provides a baseline of historic deformation, aiding hazard analysts in communication efforts and streamlining decision-making for potential risks to region residents.

Ivan Tochimani-Hernandez↗

DOE OSTI2024

Enabling Digital Image Correlation for Deployment in the Hot Fuels Examination Facility

Digital image correlation (DIC) is a non-contact image-based technique for displacement and strain measurement. It is also a full-field method that can provide excellent spatial resolution. DIC has been widely used for measurements in many styles of mechanical tests and is desirable in part because of this flexibility to measure nearly any material across a range of time and length scales. Its ability to measure localized strain for tests and in environments not accessible to other strain measurement techniques makes it an ideal option for several mechanical test cases that exist in hot cell facilities such as the Hot Fuel Examination Facility (HFEF) at the Idaho National Laboratory (INL). However, DIC has not been demonstrated at HFEF, and several barriers to implementation in the hot cell environment exist. This report outlines the possible paths for deploying DIC at HFEF, weighing the technical advantages and risks with each path. It also discusses the steps which must be taken to add this capability to the suite of post-irradiation examination (PIE) techniques available at HFEF. Finally, it concludes with recommendations for the best method to perform DIC at the facility.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2014

Ka-Band Link Study and Analysis for a Mars Hybrid RF/Optical Software Defined Radio

The integrated radio and optical communications (iROC) project at the NASA Glenn Research Center (GRC) is investigating the feasibility of a hybrid RF and optical communication subsystem for future deep space missions. The hybrid communications subsystem enables the advancement of optical communications while simultaneously mitigating the risk of infusion by combining an experimental optical transmitter and telescope with a reliable Ka-band RF transmitter and antenna. The iROC communications subsystem seeks to maximize the total data return over the course of a potential 2-year mission in Mars orbit beginning in 2021. Although optical communication by itself offers potential for greater data return over RF, the reliable Ka-band link is also being designed for high data return capability in this hybrid system. A daily analysis of the RF link budget over the 2-year span is performed to optimize and provide detailed estimates of the RF data return. In particular, the bandwidth dependence of these data return estimates is analyzed for candidate waveforms. In this effort, a data return modeling tool was created to analyze candidate RF modulation and coding schemes with respect to their spectral efficiency, amplifier output power back-off, required digital to analog conversion (DAC) sampling rates, and support by ground receivers. A set of RF waveforms is recommended for use on the iROC platform.

communication↗

NASA NTRS2018

Multi-Scale Modeling of Low-Density Carbon-Phenolic Ablators

Protecting a spacecraft during atmospheric entry is one of highest risk factors that needs to be mitigated during design of a space exploration mission. At entry speeds from space, air turns into high-temperature plasma, and spacecraft Thermal Protection Systems (TPS) are needed to protect the vehicle payload. Modern successful material architectures of spacecraft shields use a porous carbon fiber substrate impregnated with phenolic as an ablator material. In the lecture, efforts to build a Predictive Material Modeling framework for porous ablators from micro-scale to macro-scale will be presented. Several numerical methods and techniques will be summarized that use voxelized images to compute geometrical properties of the porous substrate. These computed properties include porosity, specific surface area and tortuosity that are otherwise indirectly measured through experimental techniques. Direct simulation Monte Carlo (DSMC), a particle-based method for approximating the Boltzmann equation, is used to compute the permeability coefficient of the porous substrate based on its digitized representation. The method computes the flow within the microstructure, where the size of the pores may approach the mean-free-path of the flow. Finally, a high-fidelity model implemented in PATO (Porous-material Analysis Toolbox) is discussed, and some examples of ablative material response are presented, including for the first time 3D simulations of the full tiled heat shield for the Mars Science Laboratory (MSL) capsule.

Ablators↗

NASA NTRSDate not supplied

Core Stage TVC Systems Engineering Challenges in Reusing Heritage Hardware

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Core Auxiliary Power Unit (CAPU) is derived from the Orbiter Auxiliary Power Unit (APU). The Orbiter and Solid Rocket Booster APU turbines are powered by hot gas produced by catalyzed hydrazine decomposition. On the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. While direct reuse or slight modification of existing hardware may seem to be a triple-win for a program in cost, schedule, and technical risk mitigation, those benefits can only be realized when its degree of application in a new system is carefully and thoughtfully managed. The heritage hardware reuse should be prescribed within the heritage design capability and reuse environments must lie within the envelope of heritage qualification testing. Despite the significant test and flight experience of the Shuttle heritage hardware components, successful integration with the newly designed CS TVC components and incorporation into the stage design proved to be a challenge which required re-qualification of the heritage hardware as well as thorough integrated testing to support flight certification. Examples of the challenges that were overcome include: re-qualifying heritage hardware to survive new shock and vibration environments, certifying performance of extensively modified heritage hardware, regenerating design insight due to lack of available heritage vendor data, showing compliance to modern structural design standards, translation of heritage requirements for analog avionics to modern digital avionics, and interfacing heritage mechanical hardware with newly designed avionics. This paper is the second installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. This paper will discuss several engineering challenges encountered during the development process for SLS CS TVC and how they were successfully overcome to reach flight readiness.

Thrust Vector Control↗

NASA NTRSDate not supplied

Space Launch System: Core Stage Thrust Vector Control Systems Engineering Challenges in Reusing Heritage Hardware

Thrust Vector Control↗

DOE OSTI2025

Rancor-HUNTER: Using a Simulator Engine for Realistic Human Performance Modeling of Nuclear Power Operations

The Human Unimodel for Nuclear Technology to Enhance Reliability (HUNTER) is a software system to simulate human performance in support of human reliability analysis (HRA) in nuclear power plants. This paper summarizes recent work to integrate HUNTER with a plant simulator, namely the Rancor Microworld Simulator. Rancor is an offshoot of earlier work at Idaho National Laboratory (INL) to support plant modernization. The graphical software tools used to mimic digital human-system interface upgrades at INL’s Human Systems Simulation Laboratory were linked to the Rancor Microworld Simulator, an INL-developed simplified plant model. HUNTER becomes a “virtual operator” coupled to the Rancor simulator, thereby allowing a tight coupling between a digital human twin and a digital twin of the plant. Rancor-HUNTER may be run through Monte Carlo iterations across a dynamic range of performance shaping factors, thereby producing distributions of human performance in terms of procedure paths, errors instantiations, and task durations. This paper overviews the various unique features of Rancor-HUNTER and presents an example run of Rancor-HUNTER for a startup scenario.

99 - GENERAL AND MISCELLANEOUS↗

DOE OSTI2026

High-resolution mountain topography can inform global snow vulnerability estimates

Snow is changing globally. Computationally intensive snow reanalysis products and downscaled climate model projections allow for the estimation of historical and projected changes in snow over ∼4–10 km resolutions, but these resolutions are coarse relative to the scales needed for water supply and flood planning. Fine-scale digital elevation models (DEMs) are widely available but are underutilized to make first-order assessments of snow vulnerability. Here, we leverage DEMs at a 7.5 arc s (∼250 m) resolution, combining these with historical freezing level height estimates from ERA-5 to derive estimates of changes in the snow-receiving area (SRA) and its variability across global mountain ranges. Results show estimated SRA declines in 29% (1.9 million km2) of the global mountain area from 1982–2020; 66% of the mountainous areas had no change over the historical period. At +1.5 °C of warming relative to the pre-industrial control, global mountain SRA would decline by 9.5% (1.0 million km2) relative to recent conditions. This loss would be approximately doubled with +2 °C of warming. In a +4 °C warming scenario, an additional 34% (3.6 million km2) of SRA would be lost beyond the +2 °C case. Across individual mountain ranges, SRA losses can occur nonlinearly with warming, with some locations that have historically had relatively minor SRA losses at risk of substantially larger losses in warmer climates. Analysis using coarser-resolution DEMs can underestimate or overestimate SRA and its rate of loss, with the largest impacts in relatively warm, low-elevation mountain ranges. Results of this work provide estimates of projected loss in SRA at policy-relevant warming levels; inform the resolutions needed for process-based snow modeling; identify snow vulnerability hotspots; and provide a new integrated approach to snow vulnerability assessment that is achievable at global scales and highlights potential nonlinearities from recent trends to a variety of future warming scenarios.

climate, mountains↗

NASA NTRSDate not supplied

Utilization of Machine Learning Techniques for Managing the Tracking and Data Relay Satellite Constellation

National Aeronautics and Space Administration’s (NASA) Goddard Space Flight Center (GSFC) operates a constellation of ten geosynchronous Tracking and Data Relay Satellites (TDRS). The TDRS constellation consists of multiple geosynchronous communication relay satellites located around the equator so they can provide continual coverage of any mission in low earth orbit. The TDRS are located primarily in three oceanic regions around the earth. NASA’s White Sands Complex provides the ground communication support for TDRS located over the Atlantic and Pacific Oceans. Another TDRS ground station in Guam supports the TDRS over the Indian Ocean. With these satellites the TDRS network can provide continuous coverage of satellites in low-earth orbit. The NASA Space Network (SN) project office at GSFC manages the constellation of spacecraft. Major customers of the TDRS constellation include, but are not limited to, the International Space Station and the Hubble Space Telescope. The TDRS constellation has three generations of satellites and has been active for over 30 years providing reliable communication links between customer satellites and corresponding ground stations. However, one of the major concerns for TDRS, and in any space mission, is to ensure the health and safety of the spacecraft. Generally, engineers use telemetry data to monitor and analyze the performance and state of health of the spacecraft. Telemetry data contains hundreds of parameters that monitor each important component in the spacecraft, which can be utilized to recognize and characterize the behavior of the spacecraft. Each parameter contains considerable information to represent time-dependent properties of each spacecraft subsystem and component. During the entire life of a TDRS spacecraft, thousands of gigabytes of telemetry data are transmitted in real-time from the spacecraft to the ground station at the White Sands Complex in Las Cruces, New Mexico, and recorded as historical data sets for engineers to process and analyze the events that occurred on-orbit. These parameters contain the function of multiple spacecraft subsystems, such as the attitude control system (ACS), Thermal, Electrical Power Subsystem (EPS), etc. . The first and second generations have exceeded their required lifetime and NASA is keen to manage these spacecrafts carefully in order to maximize the remaining life using the spacecraft telemetry. The challenge is to know when the risk of losing a spacecraft in geosynchronous orbit exceeds the benefit of continued operations for customer support. In the TDRS fleet, the EPS is the most critical subsystem related to spacecraft operations. Failure of the EPS would strand a spacecraft in geosynchronous orbit. Since EPS provides power to the spacecraft, component failures ultimately lead to the inability to support the spacecraft loads and the communications payload. For instance, TDRS-8 has several anomalies in EPS including the Bus Voltage Limiter (BVL) shunt current, solar array loss of circuits, and failed battery cells. Any of these anomalies can cause critical issues to the spacecraft. Therefore, developing a system to analyze and perform early detection of a potential anomaly is an important issue in telemetry data analysis. In recent years, Telemetry Mining (TM) has been proposed to process telemetry data by using Data Mining (DM) techniques such as classification, clustering, regression and anomaly detection. Anomaly detection, also known as outlier detection, has been widely used in many data mining areas such as remote sensing, medical data processing and digital image processing. The goal of anomaly detection is to detect abnormal data, which contains a relatively low probability of occurrence among the entire data set. Early detection of anomalies is one of the most significant issues in managing the spacecraft configuration. If anomalies can be detected early enough, then the redundant resources can be used to extend the life of the operational spacecraft. We present an unsupervised anomaly detection method to process the EPS data extracted from TDRS-8. This is different from traditional analytical methods, which use telemetry data to illustrate behavior and physical meaning of each spacecraft component. TM connects multiple parameters as a vector and then conducts data analysis on this high dimension telemetry vector. This method is looking at the properties of a high dimensional vector that is able to consider the relationship between different parameters in the anomaly detection problem. This kind of method performs much better than the traditional limit checking method. In addition, we propose a new approach of real-time anomaly detection to process telemetry data in real-time, which can then be applied to spacecraft monitoring with high reliability, low cost and high accuracy.

Machine Learning (ML)↗

DOE OSTI2024

Assessment of a Grade 91 Steel Forging and Seamless Pipe Section After 141,000-Hours of Operation in a Superheat Outlet Header

In this work, two unique heats of 9Cr creep strength enhanced ferritic (CSEF) steels extracted from a retired superheat outlet header after 141,000 hours of service were evaluated. These two CSEF steels were a forging manufactured to SA-182 F91 (F91) reducer and a seamless pipe produced to SA-335 P91 (P91) pipe. Their creep deformation and fracture behavior were assessed using a lever arm creep frame integrated with in-situ high-temperature digital image correlation (DIC) system. Critical metallurgical and microstructure factors, including composition, service damage, grain matrix degradation, precipitates, and inclusions were quantitatively characterized to link the performance of the two service aged F91 and P91 CSEF steels. The creep test results show the F91 and P91 steels exhibit a large variation in creep strength and creep ductility. The F91 steel fractured at 572 hours while P91 steel fractured at 1,901 hours when subjected to a test condition of 650 °C and 100 MPa. The nominal creep strains at fracture were 12.5% (F91) and 14.5% (P91), respectively. The high-resolution DIC strain measurements reveal the local creep strain in F91 was about 50% while the local creep strain in P91 was >80%. The characterization results show that the F91 steel possessed pre-existing creep damage from its time in service, a higher fraction of inclusions, and a faster matrix grain coarsening rate. These features contribute to the observed reduction in performance for the F91 steel. The context for these findings, and the importance of metallurgical risk in an integrated life management approach will be emphasized.

Wang, Yiyu↗

DOE OSTI2025

Cybersecurity Considerations for Hydrogen Infrastructure in Airport Environments

This report explores key cybersecurity concerns and best practices within environments that serve as reference points for the development of hydrogen fueling infrastructure for aviation. This cybersecurity analysis leverages prior NREL studies: 1) hydrogen fueling station component validation to identify vulnerabilities and failure events documented in physical equipment, and 2) electric aircraft charging infrastructure analysis to explore primary cybersecurity vulnerabilities. It reviews the criticality of digitized technologies in sustaining hydrogen fuel production, storage, and fueling systems, noting cybersecurity concerns that are universal to power systems and industrial control systems in general. In considering cybersecurity vulnerabilities within a future landscape of hydrogen energy for aviation applications, a reference architecture was intended to reveal the points of connection between assets and the potential sensors that are vulnerable to manipulation in the event of compromised access or communication within a SCADA system. A generalized reference architecture can help stakeholders, engineers, or strategists understand connections, criticalities, and standard practices when it comes to designing and planning for new systems. There are several gaps to account for in assessing the future of hydrogen production, storage, and fueling for aviation. Engaging stakeholders, including aircraft manufacturers, electric utilities, site property owners, and local communities, will inform decision-making around site structure, operations, and resources for future hydrogen fueling infrastructure to understand operational needs and cybersecurity awareness. Cybersecurity mitigation strategy must consider physical attack vectors that emerge with the integration of hydrogen systems into existing airport security requirements. The cybersecurity risk assessment contained in this report is an entry point into potential future granular-level analyses to be conducted as part of hazard and risk assessments for safe aviation hydrogen infrastructure, determining how the scale of hydrogen fuel infrastructure for aviation impacts the volume of cyber attack vectors, and what, if any, are the vulnerabilities associated with different types of on-board hydrogen systems. In this nascent development phase, assessing how best to integrate cybersecurity practices into an evolving U.S. aviation landscape provides critical insights into building increased awareness and stakeholder engagement to support a cyber-resilient infrastructure.

08 HYDROGEN↗

NASA NTRS2007

NASA Tech Briefs, February 2007

Topics covered include: Calibration Test Set for a Phase-Comparison Digital Tracker; Wireless Acoustic Measurement System; Spiral Orbit Tribometer; Arrays of Miniature Microphones for Aeroacoustic Testing; Predicting Rocket or Jet Noise in Real Time; Computational Workbench for Multibody Dynamics; High-Power, High-Efficiency Ka-Band Space Traveling-Wave Tube; Gratings and Random Reflectors for Near-Infrared PIN Diodes; Optically Transparent Split-Ring Antennas for 1 to 10 GHz; Ice-Penetrating Robot for Scientific Exploration; Power-Amplifier Module for 145 to 165 GHz; Aerial Videography From Locally Launched Rockets; SiC Multi-Chip Power Modules as Power-System Building Blocks; Automated Design of Restraint Layer of an Inflatable Vessel; TMS for Instantiating a Knowledge Base With Incomplete Data; Simulating Flights of Future Launch Vehicles and Spacecraft; Control Code for Bearingless Switched- Reluctance Motor; Machine Aided Indexing and the NASA Thesaurus; Arbitrating Control of Control and Display Units; Web-Based Software for Managing Research; Driver Code for Adaptive Optics; Ceramic Paste for Patching High-Temperature Insulation; Fabrication of Polyimide-Matrix/Carbon and Boron-Fiber Tape; Protective Skins for Aerogel Monoliths; Code Assesses Risks Posed by Meteoroids and Orbital Debris; Asymmetric Bulkheads for Cylindrical Pressure Vessels; Self-Regulating Water-Separator System for Fuel Cells; Self-Advancing Step-Tap Drills; Array of Bolometers for Submillimeter- Wavelength Operation; Delta-Doped CCDs as Detector Arrays in Mass Spectrometers; Arrays of Bundles of Carbon Nanotubes as Field Emitters; Staggering Inflation To Stabilize Attitude of a Solar Sail; and Bare Conductive Tether for Decelerating a Spacecraft.

Source record↗

NASA NTRS2016

MoonDB: Restoration and Synthesis of Lunar Petrological and Geochemical Data

About 2,200 samples were collected from the Moon during the Apollo missions, forming a unique and irreplaceable legacy of the Apollo program. These samples, obtained at tremendous cost and great risk, are the only samples that have ever been returned by astronauts from the surface of another planetary body. These lunar samples have been curated at NASA Johnson Space Center and made available to the global research community. Over more than 45 years, a vast body of petrological, geochemical, and geochronological studies of these samples have been amassed, which helped to expand our understanding of the history and evolution of the Moon, the Earth itself, and the history of our entire solar system. Unfortunately, data from these studies are dispersed in the literature, often only available in analog format in older publications, and/or lacking sample metadata and analytical metadata (e.g., information about analytical procedure and data quality), which greatly limits their usage for new scientific endeavors. Even worse is that much lunar data have never been published, simply because no forum existed at the time (e.g., electronic supplements). Thousands of valuable analyses remain inaccessible, often preserved only in personal records, and are in danger of being lost forever, when investigators retire or pass away. Making these data and metadata publicly accessible in a digital format would dramatically help guide current and future research and eliminate duplicated analyses of precious lunar samples.

Lehnert, Kerstin A.↗