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At least 415 records · Page 23

Design Methods, Tools, and Data for Ceramic Solar Receivers Year 1 Continuation Report

This report describes the first year of work on a project to develop the methods, tools, and data required to analyze high temperature ceramic Concentrating Solar Power (CSP) components. This first year focused on developing the methods and data required for a time-independent assessment of potential components, focusing in particular on ceramic solar receivers. The report describes both model development and testing work focused on accomplishing this goal. Our overall conclusion is that high temperature ceramic CSP components are viable and could provide a means to overcome the expected low reliability and short service life for equivalent components constructed from Ni-based superalloys. Based on the results reported here, we recommend the project continue to Phase II which will develop more sophisticated, realistic models for time-dependent failure of ceramics operating in expected CSP component conditions and develop the time-dependent ceramic test data needed to parameterize these models, using commercial SiC as a reference material.

14 SOLAR ENERGY↗

NASA Fundamental Remote Sensing Science Research Program

The NASA Fundamental Remote Sensing Research Program is described. The program provides a dynamic scientific base which is continually broadened and from which future applied research and development can draw support. In particular, the overall objectives and current studies of the scene radiation and atmospheric effect characterization (SRAEC) project are reviewed. The SRAEC research can be generically structured into four types of activities including observation of phenomena, empirical characterization, analytical modeling, and scene radiation analysis and synthesis. The first three activities are the means by which the goal of scene radiation analysis and synthesis is achieved, and thus are considered priority activities during the early phases of the current project. Scene radiation analysis refers to the extraction of information describing the biogeophysical attributes of the scene from the spectral, spatial, and temporal radiance characteristics of the scene including the atmosphere. Scene radiation synthesis is the generation of realistic spectral, spatial, and temporal radiance values for a scene with a given set of biogeophysical attributes and atmospheric conditions.

Source record↗

Prediction and Assessment of Reynolds Number Sensitivities Associated with Wing Leading-Edge Radius Variations

The primary objectives of this study were to expand the data base showing the effects of LE radius distribution and corresponding . sensitivity to Rn at subsonic and transonic conditions, and to assess the predictive capability of CFD for these effects. Several key elements led to the initiation of this project: 1) the necessity of meeting multipoint design requirements to enable a viable HSCT, 2) the demonstration that blunt supersonic leading-edges can be associated with performance gain at supersonic speeds , and 3) limited data. A test of a modified Reference H model with the TCA planform and 2 LE radius distributions was performed in the NTF, in addition to Navier-Stokes analysis for an additional 3 LE radius distributions. Results indicate that there is a tremendous potential to improve high-lift performance through the use of a blunt LE across the span given an integrated, fully optimized design, and that low Rn data alone is probably not sufficient to demonstrate the benefit.

Wahls, Richard A.↗

Prediction and Assessment of Reynolds Number Sensitivities Associated with Wing Leading-Edge Radius Variations

The primary objectives of this study were to expand the data base showing the effects of LE radius distribution and corresponding sensitivity to Rn at subsonic and transonic conditions, and to assess the predictive capability of CFD for these effects. Several key elements led to the initiation of this project: 1) the necessity of meeting multipoint design requirements to enable a viable HSCT, 2) the demonstration that blunt supersonic leading-edges can be associated with performance gain at supersonic speeds , and 3) limited data. A test of a modified Reference H model with the TCA planform and 2 LE radius distributions was performed in the NTF, in addition to Navier-Stokes analysis for an additional 3 LE radius distributions. Results indicate that there is a tremendous potential to improve high-lift performance through the use of a blunt LE across the span given an integrated, fully optimized design, and that low Rn data alone is probably not sufficient to demonstrate the benefit.

Wahls, Richard A.↗

NREL Stratus - Enabling Workflows to Fuse Data Streams, Modeling, Simulation, and Machine Learning

Integrating cloud services into advanced computing facilities provides significant new capabilities over focusing solely on traditional high performance computing (HPC) workloads. This brings complementary capabilities as well as enabling new focused roles for HPC. They are especially potent for workflows that fuse data streams, modeling and simulation ('modsim') and machine learning. A key challenge to adopting a hybrid edge-cloud-HPC model is to align optimal capability, data, and user intent on the right resources for each step in a workflow.?The NREL Stratus service provides a basis for this: Stratus layers capabilities needed to make?cloud services accessible to a lab-based scientific community on commercial offerings, and; currently supports upwards of 200 projects ranging from IOT integration to traditional modeling and simulation. This provides a real-world inventory of scientific workflow elements. A growing knowledge base enables placing these elements appropriately between the edge, cloud, and traditional HPC. This paper outlines a vision via reference architecture and the application of that architecture in a typical workflow highlighting multiple components: sensor data intake, cleaning and transforming (edge/cloud suitable); generation of synthetic data through modsim, computationally heavy ML training and hyperparameter optimization (HPC suitable), and; inference and deployment (cloud ideal). Every step in such a workflow involves a cost-benefit analysis regarding the data movement, computational efficiency, availability, latency, and resource capabilities. The reference architecture and examples outlined allow for understanding new opportunities in the context of emerging workflows that combine IOT, cloud, and HPC to bolster scientific productivity.

AI↗

28 NREL Stratus - Enabling Workflows to Fuse Data Streams, Modeling, Simulation, and Machine Learning: Preprint

Integrating cloud services into advanced computing facilities provides significant new capabilities over focusing solely on traditional high performance computing (HPC) workloads. This brings complementary capabilities as well as enabling new focused roles for HPC. They are especially potent for workflows that fuse data streams, modeling and simulation ('modsim') and machine learning. A key challenge to adopting a hybrid edge-cloud-HPC model is to align optimal capability, data, and user intent on the right resources for each step in a workflow.?The NREL Stratus service provides a basis for this: Stratus layers capabilities needed to make?cloud services accessible to a lab-based scientific community on commercial offerings, and; currently supports upwards of 200 projects ranging from IOT integration to traditional modeling and simulation. This provides a real-world inventory of scientific workflow elements. A growing knowledge base enables placing these elements appropriately between the edge, cloud, and traditional HPC. This paper outlines a vision via reference architecture and the application of that architecture in a typical workflow highlighting multiple components: sensor data intake, cleaning and transforming (edge/cloud suitable); generation of synthetic data through modsim, computationally heavy ML training and hyperparameter optimization (HPC suitable), and; inference and deployment (cloud ideal). Every step in such a workflow involves a cost-benefit analysis regarding the data movement, computational efficiency, availability, latency, and resource capabilities. The reference architecture and examples outlined allow for understanding new opportunities in the context of emerging workflows that combine IOT, cloud, and HPC to bolster scientific productivity.

AI↗

Data for "Divergent urban land trajectories under alternative population projections within the shared socioeconomic pathways"

Datasets supporting findings and visualizations behind McManamay et al. (2024) Divergent urban land trajectories under alternative population projections within the shared socioeconomic pathways. Environmental Research Letters, DOI: 10.1088/1748-9326/ad2eec Using a spatial modeling experiment at high resolution (1-km), this study compared how two alternative US population projections, varying in the spatially explicit nature of demographic patterns and migration, affect urban land dynamics simulated by the Spatially Explicit, Long-term, Empirical City development (SELECT) model for SSP2, SSP3, and SSP5. The numerical experiment, inputs and outputs are fully described in McManamay et al. (2024). The datasets summarize SELECT model simulations within urban areas and rural areas of the conterminous United States. For code to reproduce the results, please refer to https://github.com/IMMM-SFA/mcmanamay_etal_2024_erl Please refer to the README file provided in Files for more details. Descriptions of the datasets are provided below. Dataset(s) Descriptions: Urban_Land_delta_UA_County.csv: Urban land area for original (default) population, updated population, and urban land delta (difference between the two) according to Shared Socioeconomic Pathways (SSPs) and year. Urban land is summarized for U.S. counties (FIPS code) and urban areas (GEOID) as unique areas within various counties. JO_Gao_pop_ufdelta.csv: Comparison of population differences and urban land differences between the origial (default) and updated population projections. City_Case_studies.csv: Differences in urban land areas arising from different population projections summarized for selected cities (Atlanta, Los Angeles, Houston, and New York) and their surrounding rural areas UA_county_FID.zip: Zipped folder of .tiff file depicting unique combination of urban areas and US counties used for summarizing urban land differences in urban and rural areas based on different population projections. ULD_clusters.zip: Zipped folder of .csv files depicting normalized changes in urban land delta (difference in urban land arising from population projections) and the respective Ward's hierarchical clusters, which group urban and rural areas based on similarities in temporal trends. Urban_Percent_change_2100.zip: Zipped folder of .csv files depicting percent changes in urban land area for year 2100 based on differences in the original (default) population and updated population. Each file is for SSPs and urban or rural areas.

Land↗

Stress Birth and Death: Disruptive Computational Mechanics and Novel Diagnostics for Fluid-to-Solid Transitions

Many materials of interest to Sandia transition from fluid to solid or have regions of both phases coexisting simultaneously. Currently there are, unfortunately, no material models that can accurately predict this material response. This is relevant to applications that "birth stress" related to geoscience, nuclear safety, manufacturing, energy production and bioscience. Accurately capturing solidification and residual stress enables fully predictive simulations of the evolving front shape or final product. Accurately resolving flow of proppants or blood could reduce environmental impact or lead to better treatments for heart attacks, thrombosis, or aneurism. We will address a science question in this proposal: When does residual stress develop during the critical transition from liquid to solid and how does it affect material deformation? Our hypothesis is that these early phases of stress development are critical to predictive simulation of material performance, net shape, and aging. In this project, we use advanced constitutive models with yield stress to represent both fluid and solid behavior simultaneously. The report provides an abbreviated description of the results from our LDRD "Stress Birth and Death: Disruptive Computational Mechanics and Novel Diagnostics for Fluid-to-Solid Transitions," since we have written four papers that document the work in detail and which we reference. We give highlights of the work and describe the gravitationally driven flow visualization experiment on a model yield stress fluid, Carbopol, at various concentrations and flow rates. We were able to collapse the data on a single master curve by showing it was self-similar. We also describe the Carbopol rheology and the constitutive equations of interest including the Bingham-Carreau-Yasuda model, the Saramito model, and the HB-Saramito model including parameter estimation for the shear and oscillatory rheology. We present several computational models including the 3D moving mesh simulations of both the Saramito models and Bingham-Carreau-Yasuda (BCY) model. We also show results from the BCY model using a 3D level set method and two different ways of handling reduced order Hele-Shaw modeling for generalized Newtonian fluids. We present some first ever two-dimensional results for the modified Jeffries Kamani-Donley-Rogers constitutive equation developed during this project. We include some recent results with a successful Saramito-level set coupling that allows us to tackle problems with complex geometries like mold filling in a thin gap with an obstacle, without the need for remeshing or remapping. We report on some experiments for curing systems where fluorescent particles are used to track material flow. These experiments were carried out in an oven on Sylgard 184 as a model polymerizing system. We conclude the report with a summary of accomplishments and some thoughts on follow-on work.

36 MATERIALS SCIENCE↗

Space power distribution system technology. Volume 1: Reference EPS design

The multihundred kilowatt electrical power aspects of a mannable space platform in low Earth orbit is analyzed from a cost and technology viewpoint. At the projected orbital altitudes, Shuttle launch and servicing are technically and economically viable. Power generation is specified as photovoltaic consistent with projected planning. The cost models and trades are based upon a zero interest rate (the government taxes concurrently as required), constant dollars (1980), and costs derived in the first half of 1980. Space platform utilization of up to 30 years is evaluated to fully understand the impact of resupply and replacement as satellite missions are extended. Such lifetimes are potentially realizable with Shuttle servicing capability and are economically desirable.

Decker, D. K.↗

Applying a Multisector Scenario Framework to Evaluate Past and Future Public Surface Water Supply Infrastructure Strategies in Texas

Datasets supporting the index model and scenario analysis used in evaluating surface water supply strategies across different water system types in Texas. These data underpin the scenario development and application of five key indicators: Water Availability Index (WAI), Water Quality Index (WQI), Energy Requirement Index (ERI), Water Treatment Cost (WTC), and Water Infrastructure Cost (WIC). The datasets are organized by system type—stream reaches (flowlines), waterbodies, and reservoirs—and include both raw and standardized index values. The integrated datasets also provide scenario classifications (original and adjusted) based on infrastructure and planning priorities, enabling comparison across Shared Socioeconomic Pathways (SSPs). Additional strategy-level data are included to support evaluation of state-level new reservoir projects in relation to cost and availability tradeoffs. Please refer to the README file provided in Files for more details. Descriptions of the datasets are provided below. Dataset(s) Descriptions Folder: Index_model_database.zip Subfolder: Stream_reach.zip Fl_wf.csv, Fl_wq.csv, Fl_er.csv, Fl_wf_wtcUV.csv, Fl_wf_wtcnoUV.csv, Fl_allfac_wic1.csv, Fl_allfac_wic2.csvDatasets for computing WAI, WQI, ERI, WTC, and WIC for surface water systems classified as stream reaches (flowlines). Subfolder: Waterbody.zip Wb_wf.csv, Wb_wq.csv, Wb_er.csv, Wb_wf_wtcUV.csv, Wb_wf_wtcnoUV.csv, Wb_allfac_wic1.csv, Wb_allfac_wic2.csvEquivalent index model datasets for waterbodies, reflecting hydrologic and infrastructure attributes specific to impounded natural systems. Subfolder: Reservoir.zip Rs_wf.csv, Rs_wq.csv, Rs_er.csv, Rs_wf_wtcUV.csv, Rs_wf_wtcnoUV.csv, Rs_allfac_wic1.csv, Rs_allfac_wic2.csvIndex model datasets specific to regulated reservoir systems, incorporating both resource indicators and cost parameters. Folder: Integrated data.zip combined_merged_data.csv, combined_merged_data_scenario.csvDatasets integrating index model indicators (both raw and scaled) with scenario classifications, including adjustments reflecting SSP-aligned transitions and planning shifts. Folder: Additional data.zip wai_supplystrat_wic_merged.csvCurated dataset capturing proposed major reservoir-based municipal water supply strategies in Texas. Integrates site-level planning data with estimated capital infrastructure costs and water availability scores for comparative assessment.

geospatial↗

Moving beyond post hoc explainable artificial intelligence: a perspective paper on lessons learned from dynamical climate modeling

AI models are criticized as being black boxes, potentially subjecting climate science to greater uncertainty. Explainable artificial intelligence (XAI) has been proposed to probe AI models and increase trust. In this review and perspective paper, we suggest that, in addition to using XAI methods, AI researchers in climate science can learn from past successes in the development of physics-based dynamical climate models. Dynamical models are complex but have gained trust because their successes and failures can sometimes be attributed to specific components or sub-models, such as when model bias is explained by pointing to a particular parameterization. We propose three types of understanding as a basis to evaluate trust in dynamical and AI models alike: (1) instrumental understanding, which is obtained when a model has passed a functional test; (2) statistical understanding, obtained when researchers can make sense of the modeling results using statistical techniques to identify input–output relationships; and (3) component-level understanding, which refers to modelers' ability to point to specific model components or parts in the model architecture as the culprit for erratic model behaviors or as the crucial reason why the model functions well. We demonstrate how component-level understanding has been sought and achieved via climate model intercomparison projects over the past several decades. Such component-level understanding routinely leads to model improvements and may also serve as a template for thinking about AI-driven climate science. Currently, XAI methods can help explain the behaviors of AI models by focusing on the mapping between input and output, thereby increasing the statistical understanding of AI models. Yet, to further increase our understanding of AI models, we will have to build AI models that have interpretable components amenable to component-level understanding. We give recent examples from the AI climate science literature to highlight some recent, albeit limited, successes in achieving component-level understanding and thereby explaining model behavior. The merit of such interpretable AI models is that they serve as a stronger basis for trust in climate modeling and, by extension, downstream uses of climate model data.

54 ENVIRONMENTAL SCIENCES↗

Electrification Futures Study Flexible Load Profiles

This data set includes hourly profiles for flexible load developed for the Electrification Futures Study (EFS). The load profiles represent projected end-use electricity demand that is assumed to be flexible (i.e., can be shifted throughout a day) for various scenarios of flexibility (Base, Enhanced), electrification (Reference, Medium, High), and technology advancement (Slow, Moderate, Rapid), and were developed as inputs into the ReEDS model. The quantity of flexible load is estimated using assumptions on the level of flexibility and customer participation within each subsector modeled in the EFS. Detailed assumptions and modeling implementation will be documented in ongoing EFS analyses. Flexible load profiles are provided for a subset of years (2018, 2020, 2024, 2030, 2040, 2050) and are aggregated to the state and sector level. Total electricity load profiles can be found in a related EFS data set (https://dx.doi.org/10.7799/1593122). NOTE: Due to the file size, Mac users may experience issues decompressing the zip files using the Mac Archive Utility. In those cases, decompressing using the command line is recommended. - Mai, Trieu, Paige Jadun, Jeffrey Logan, Colin McMillan, Matteo Muratori, Daniel Steinberg, Laura Vimmerstedt, Ryan Jones, Benjamin Haley, and Brent Nelson. 2018. Electrification Futures Study: Scenarios of Electric Technology Adoption and Power Consumption for the United States. National Renewable Energy Laboratory. NREL/TP-6A20-71500. https://doi.org/10.2172/1459351. - Murphy, Caitlin, Trieu Mai, Yinong Sun, Paige Jadun, Matteo Muratori, Brent Nelson, Ryan Jones. Forthcoming. Electrification Futures Study: Scenarios of Power System Evolution and Infrastructure Development for the United States. National Renewable Energy Laboratory. - Sun, Yinong, Paige Jadun, Brent Nelson, Matteo Muratori, Caitlin Murphy, Jeffrey Logan, and Trieu Mai. Forthcoming. Electrification Futures Study: Methodological Approaches for Assessing Long-Term Power System Impacts of End-Use Electrification. National Renewable Energy Laboratory.

buildings↗

Software Engineering Laboratory (SEL) relationships, models, and management rules

Over 50 individual Software Engineering Laboratory (SEL) research results, extracted from a review of published SEL documentation, that can be applied directly to managing software development projects are captured. Four basic categories of results are defined and discussed - environment profiles, relationships, models, and management rules. In each category, research results are presented as a single page that summarizes the individual result, lists potential uses of the result by managers, and references the original SEL documentation where the result was found. The document serves as a concise reference summary of applicable research for SEL managers.

Decker, William↗

The Mathematics of Navigating the Solar System

In navigating spacecraft throughout the solar system, the space navigator relies on three academic disciplines - optimization, estimation, and control - that work on mathematical models of the real world. Thus, the navigator determines the flight path that will consume propellant and other resources in an efficient manner, determines where the craft is and predicts where it will go, and transfers it onto the optimal trajectory that meets operational and mission constraints. Mission requirements, for example, demand that observational measurements be made with sufficient precision that relativity must be modeled in collecting and fitting (the estimation process) the data, and propagating the trajectory. Thousands of parameters are now determined in near real-time to model the gravitational forces acting on a spacecraft in the vicinity of an irregularly shaped body. Completing these tasks requires mathematical models, analyses, and processing techniques. Newton, Gauss, Lambert, Legendre, and others are justly famous for their contributions to the mathematics of these tasks. More recently, graduate students participated in research to update the gravity model of the Saturnian system, including higher order gravity harmonics, tidal effects, and the influence of the rings. This investigation was conducted for the Cassini project to incorporate new trajectory modeling features in the navigation software. The resulting trajectory model will be used in navigating the 4-year tour of the Saturnian satellites. Also, undergraduate students are determining the ephemerides (locations versus time) of asteroids that will be used as reference objects in navigating the New Millennium's Deep Space 1 spacecraft autonomously.

Hintz, Gerald↗

Assurance Equations: A Cost and Criticality Model for Optimizing Quality Assurance Surveillance

The cost of quality vs cost of failure correction has been a long-running topic of discussion within the Aerospace community. It leads directly to concepts of “risk tolerance”, and risk-based decision-making. It would be valuable if there was a way to compute the optimal investment in customer-executed quality assurance activities using defect significance with respect to performance objectives, the activities’ defect detection effectiveness, and the cost-penalty for late discovery of impactful defects. This optimization is particularly of interest to projects whose budget constraints significantly limit their risk management options.The cost to fix defects (i.e., failure correction) escalates as the project matures. There have been studies attempting to determine the relative cost of fixing defects discovered during various phases of a project life cycle with important implications, all of which suggest growth factors are large. The commonly referred to 1:10:100 rule represents a cost multiplier for repair/rework across the Design to Fab to Test hardware development phases. Cost premiums for QA activities also accumulate when they are treated as mandatory (due to schedule drag) or are performed later than their assigned phase.This paper describes the modeling of development phase -dependencies in the conduct of typical customer-executed quality assurance activities. Our initial modeling encompasses:• Distinct phases of the production lifecycle• Multiple kinds of Defects, each with some a-priori likelihood of being present• Each defect’s impact on performance Objectives for a type of hardware• The cost and efficacy of assurance techniques at detecting such Defects• The costs of fixing those Defects detected in a given phase of the production lifecycleThe model captures assurance activities’ abilities to Detect defects. Upon detection it is assumed that the Defect is immediately fixed. Defects that “escape” detection by some activity may thereafter be detected by a later activity, but by then the cost of fixing the Defect may have escalated. Defects are related to the performance Objectives they would detract from, were those Defects to remain present in the operating system.We have constructed and are exploring, a model that relates the importance of hardware system elements to mission objectives, the impact of types of Defects on those hardware types, the cost of customer-executed assurance activities (i.e., supplier controls) and their effectiveness towards reducing an impactful quality escape, and the cost of Defect correction across production phase. We describe the approach taken to select the key model aspects, why they are relevant to our NASA mission, and our efforts to populate it with relevant and contemporary data. We use a notional example to illustrate model design and function.

Plante, Jeannette↗

RESCue Model (RESCue Experiment and Model) [SWR-24-84]

The Renewable Energy and Storage Cybersecurity Research (RESCue) project is a collaborative effort aimed at securing the rapidly growing deployment of transmission-connected hybrid renewable energy systems, consisting of a combination of wind, solar, and/or energy storage equipment, against escalating cyber threats. This project brings together major original equipment manufacturers (OEMs) of wind, solar, and energy storage, along with major asset owners and DOE National Laboratories, to collectively identify cyber threats, assess risks, and develop robust cybersecurity strategies and solutions. The development of hybrid reference architectures has provided comprehensive blueprints for the secure design and integration of hybrid renewable energy systems, accounting for their unique characteristics and interdependencies. Additionally, NREL has created a cyber-resilient design framework that integrates cybersecurity considerations from the start of the system lifecycle, ensuring security is "baked in" from the initial design phase. The research thrusts for the project included (i) development of hybrid reference architectures and (ii) a cyber-resilient design framework for hybrid energy systems. The reference architectures has provided comprehensive blueprints for the secure design and integration of hybrid renewable energy systems, accounting for their unique characteristics and interdependencies. Additionally, NREL has created a cyber-resilient design framework that integrates cybersecurity considerations from the start of the system lifecycle, ensuring security is "baked in" from the initial design phase. A demonstration experiment was developed for one of the architectures using NREL's Cyber Range resources. This experiment configuration, deployable using open-source tools, is provided here in this repository. Additional models were developed for the wind and solar architectures as well, however the configurations for only the Energy Storage scenario are provided here: https://www.nrel.gov/docs/fy24osti/89921.pdf

Hasandka, Adarsh↗

A Flexible Parameterization for Shortwave and Longwave Optical Properties of Ice Crystals and Derived Bulk Optical Properties for Climate Models

We provide a parameterization of the extinction efficiency, single scattering albedo and asymmetry parameter of single ice crystals with any combination of particle volume, projected area, component aspect ratio and crystal distortion at any wavelength between 0.2 and 100 mm. The paramerization is an extension of the one previously published by van Diedenhoven et al. (2014, https://doi.org/10.1175/JAS-D-13-0205.1). In addition, the parameterized optical properties are integrated over size distributions yielding bulk extinction efficiencies, single scattering albedos and asymmetry parameters for large ranges of effective radii, particle component aspect ratios and crystal distortion values. The parameterization of single particle optical properties is evaluated with a reference database. The bulk optical properties are evaluated against the ice model selected for the Moderate Resolution Imaging Spectroradiometer (MODIS) Collection 6 products, for which accurate optical properties are available. Mean absolute errors in parameterized extinction efficiency, asymmetry parameter and single scattering albedo are shown to be 0.0272, 0.00890 and 0.00468, respectively for shortwave wavelengths, while they are 0.0641, 0.0368 and 0.0200 in the longwave. Shortwave and longwave asymmetry parameter and single scattering albedos are shown to vary strongly with particle component aspect ratio and distortion, resulting in substantial variation in shortwave fluxes, but relatively small variations in longwave cloud emissivity. The parameterization and bulk optical properties are made publicly available.

Bastiaan Van Diedenhoven↗

A Combined Computational, Experimental, and Technology Development Approach to In-Space Laser Manufacturing Maturation at NASA Marshall Space Flight Center

In-space manufacturing (ISM) is emerging as a field vital to continued access and capabilities in the space environment. NASA Marshall Space Flight Center (MSFC) is advancing the frontier of in-space laser manufacturing (ISLM) techniques through work initially focused on maturing laser beam welding (LBW) and laser forming (LF) for use in space. Such techniques proffer the ability to assemble and join structures in space from sheet metal or other stock – extant satellites, in situ resource utilization of Lunar regolith, etc. – by forming to desired shapes and then joining via in-space welding (ISW). ISLM processes are useful for assembly, joining, modification, and repair of structures in free space and on the Lunar surface such as large observatories, antennas, trusses, blast/thermal/radiation shields, pressure vessels, and more. However, these techniques are not yet qualified & certified (Q&C) for regular application in space. It would be prohibitively expensive, laborious, and time-consuming to perform Q&C via traditional experimental approaches as data collection & experimentation in space is resource-intensive. As such, benchmark experiments and focused, properly instrumented technology demonstration efforts in space can collect sufficient data that – when combined with verified computational models in an integrated computational materials engineering (ICME) approach – can validate ICME tools capable of translating more readily obtained ground data to in-space, in situ, computationally informed Q&C of ISLM techniques. Several ISLM projects at MSFC are obtaining the data required to validate ICME tools through both ground and flight experiments. A parabolic flight experiment of LBW under vacuum is manifested for August 2024, including both microgravity and Lunar gravity profiles. This collaboration with the Ohio State University is investigating common aerospace alloys such as 316L stainless steel, 2219 aluminum alloy, and Ti64 titanium alloy. In situ data collection includes videography, thermography, and reference thermocouples to build a thermal model of the welds. This will elucidate the relevant physics when combined with post-flight microstructural examination and mechanical testing. MSFC is also progressing towards a suborbital flight experiment of LBW under vacuum, which could provide reams of data on ISW during sustained, high-quality reduced gravity. The effect of combined thermal (cryogenic and high-temperature) and vacuum exposure on both LBW (NASA-funded) and LF (DARPA-funded) is being investigated through ground experiments. In addition to the copious data collected during these ground experiments, ruggedization of LBW hardware will also be pursued. The datasets from these experiments will be used to validate computational models which will inform future ISLM efforts in an ICME framework. A variety of techniques across lengths scales, from CALPHAD-driven thermodynamics & kinetics to phase field modeling of solidification to kinetic Monte Carlo simulations of grain evolution at the mesoscale, will be employed to accelerate the infusion and eventual Q&C of LBW and LF for use in space. The development of data-driven surrogate models to bridge ground to flight experiments and thereby reduce the need for resource-intensive experiments in space will also be investigated. These ICME techniques, surrogate models, and datasets from ground testing can also be employed to advance manufacturing in terrestrial environments.

in-space welding↗