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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 433 records · Page 24

Signal Analysis of Gas Tungsten Arc Welds

Gas tungsten arc welding is a process in which the input parameters such as current, voltage and travel speed, can be easily controlled and/or monitored. However, weld quality is not solely a function of these parameters. An adaptive method of observing weld quality is desired to improve weld quality assurance. The use of dynamic electrical properties of the welding arc as a weld quality monitor was studied. The electrical properties of the arc are characterized by the current voltage transfer function. The hardware and software necessary to collect the data at a maximum rate of 45 kHz and to allow the off-line processing of this data are tested. The optimum input current waveform is determined. Bead-on-plate welds to observe such characteristics of the weld as the fundamental frequency of the puddle are studied. Future work is planned to observe changes of the arc response with changes in joint geometry, base metal chemistry, and shielding gas composition are discussed.

Eagar, T. W.↗

FY 2025 Multidimensional Data Correlation Platform: Unified Software Architecture for Advanced Materials and Manufacturing Technologies Data Management and Processing

The Advanced Materials and Manufacturing Technologies (AMMT) program continues to advance a data-driven approach to demonstrate the utility of additive manufacturing for fabricating components for nuclear applications. A key scientific goal is to leverage data to better understand manufacturing outcomes and thereby improve the performance, reliability, and lifespan of nuclear components. Ultimately, this effort supports the development of standards for certification and qualification of additively manufactured components, enabling broader industry adoption. In support of this objective, the AMMT program is building and deploying a data management platform to record, index, analyze, and make available the manufacturing data generated across the AMMT program. In FY 2023, the team conceptualized the architecture of the platform and, in FY 2024, deployed the first functional version at the Oak Ridge National Laboratory (ORNL) Manufacturing Demonstration Facility (MDF). In FY 2025, the platform was officially opened to all AMMT members. To enable this expansion, core modifications and enhancements were developed, including improvements to the user interface and workflows for data entry and retrieval. Most notably, robust security and access control mechanisms were implemented to protect data and manage information sharing. This effort featured a logging system, protected views, and controlled access mechanisms. This report documents these enhancements and the transition of the platform into program-wide use.

36 MATERIALS SCIENCE↗

Optimization of prefabricated component installation using a real-time evaluator (RTE) connection locating system

Prefabrication promises to industrialize the construction industry. By constructing elements within a manufacturing environment, producers can better control quality and maximize production efficiency. Since the major adoption of prefabrication, a wide variety of prefabricated components have been produced for varying applications such as new construction and exterior wall retrofits. While the production processes of these prefabricated components have seen much innovation, the installation process has remained relatively unchanged for decades. To innovate the installation process with modern technologies, a real-time evaluator (RTE) has been developed to reduce the installation cost of prefabricated components by reducing installation time, decreasing rework, and improving accuracy. The RTE uses developed software solutions with off-the-shelf hardware to assist erectors in completing an installation by measuring the real-time positions of connections and prefabricated components, providing installation guidance through a graphical user interface, and monitoring the accumulated installation errors. An overview of the RTE and proposed workflow is presented. A connection locating system that guides users in expediting the installation of connections is introduced. Laboratory experiments were conducted to determine the accuracy improvement and time savings of the RTE in installing connections for prefabricated components. RTE enabled a time saving of up to 37% compared to traditional connection installation methods using handheld measurement tools.

Hayes, Nolan↗

Report on the subpanel on remapping procedures

Problems associated with remapping procedures are defined and research tasks are proposed. It is noted that the remapping/rectification process could be significantly aided through engineering systems improvements in attitude control, with subsequent improvement in spacecraft ephemeris modeling accuracy. There is a need for state-of-the-art technology assessments prior to initiation of major programs, and the high potential return from well formulated testing of algorithms on selected data sets of actual and synthetic imagery. In addition, there is a need for tasks that incorporate standard photogrammetric methodology and formulas and that more fully utilize platform and calibration data from current and proposed sensors to reproject digital imagery. The impact of improved platform stability and integration of global positioning system measurements on reduced ground segment processing needs to be critically assessed. Also highlighted is the need for a substantial effort in the development of remapping software and systems that are modular and transportable.

Source record↗

Reducing the turnaround time for the Shuttle Orbiter main propulsion system at Kennedy Space Center

This paper presents steps currently being implemented to reduce the processing time of the Orbiter Main Propulsion System. Given the projected increase in launch rates of the Space Transportation System (STS) in the operational era, average turnaround time from arrival at Kennedy Space Center to subsequent launch will have to be significantly reduced. In many STS flows to date, a pacing system has been the Main Propulsion System consisting of the three Space Shuttle Main Engines (SSME's) and the Main Propulsion Subsystem (MPS) connecting the SSME's to the Orbiter/ground and Orbiter/External Tank interfaces. This paper summarizes procedural, hardware, software, and requirements changes being incorporated at Kennedy Space Center (KSC) to reduce the processing time required for the MPS/SSME systems. Specific examples from each category are cited to illustrate the impact of the improvements on MPS/SSME processing.

Bilardo, V. J., Jr.↗

Impact of flight systems integration on future aircraft design

Integrations trends in aircraft are discussed with an eye to manifestations in future aircraft designs through interdisciplinary technology integration. Current practices use software changes or small hardware fixes to solve problems late in the design process, e.g., low static stability to upgrade fuel efficiency. A total energy control system has been devised to integrate autopilot and autothrottle functions, thereby eliminating hardware, reducing the software, pilot workload, and cost, and improving flight efficiency and performance. Integrated active controls offer reduced weight and larger payloads for transport aircraft. The introduction of vectored thrust may eliminate horizontal and vertical stabilizers, and location of the thrust at the vehicle center of gravity can provide vertical takeoff and landing capabilities. It is suggested that further efforts will open a new discipline, aeroservoelasticity, and tests will become multidisciplinary, involving controls, aerodynamics, propulsion and structures.

Hood, R. V.↗

Data Services Upgrade: Perfecting the ISIS-I Topside Digital Ionogram Database

The ionospheric topside sounders of the International Satellites for Ionospheric Studies (ISIS) program were designed as analog systems. More than 16,000 of the original telemetry tapes from three satellites were used to produce topside digital ionograms, via an analog-to-digital (A/D) conversion process, suitable for modern analysis techniques. Unfortunately, many of the resulting digital topside ionogram files could not be auto-processed to produce topside Ne(h) profiles because of problems encountered during the A/D process. Software has been written to resolve these problems and here we report on (1) the first application of this software to a significant portion of the ISIS-1 digital topside-ionogram database, (2) software improvements motivated by this activity, (3) N(sub e)(h) profiles automatically produced from these corrected ISIS-1 digital ionogram files, and (4) the availability via the Virtual Wave Observatory (VWO) of the corrected ISIS-1 digital topside ionogram files for research. We will also demonstrate the use of these N(sub e)(h) profiles for making refinements in the International Reference Ionosphere (IRI) and in the determination of transition heights from Oxygen ion to Hydrogen ion.

topside ionosphere↗

Swift Mission Gyro Patch and Re-Calibration Without A Calibration Campaign

The Swift spacecraft has three Two-Axis-Rate-Assemblies (TARAs) (designated as TARA 1, TARA 2, and TARA 3, and generically referred to as gyros) which until March of 2024 were all used in rate estimation as an operational workaround (dubbed “corrector-gyro”) of a software defect discovered in 2007. TARA 1 performance degraded throughout 2023 and 2024, making it an unreliable rate source. It was determined that shifting TARA 1 to be the corrector-gyro and using mainly TARAs 2 and 3, with the existing flight software (FSW) defect, would not meet performance requirements for science operations. Rather the FSW was patched to remove the defect found in 2007. This patch was delivered by the vendor in 2009, but was not fully tested or installed at that time. A decision was made in 2024 to install the patch despite limited simulation and testing capabilities. The problem facing the team was to come up with a set of alignment parameters that would work with the new patch, using data from the spacecraft operating normally in the old configuration. Calibration activities would have been possible in either the old or new FSW configuration, but were ultimately deemed unnecessary, saving staff time and pre-serving time on the spacecraft for science data collection. This paper describes the old and new FSW configurations related to gyro processing and alignment, and how the raw gyro and star tracker data from normal operation were used with a multidimensional unconstrained nonlinear minimization in MATLAB (Nelder-Mead1) to produce a fully calibrated set of gyro alignment parameters compatible with the patched FSW. Flight data is presented showing that not only did the process work, it improved performance significantly, rivaling the best slew performance of the mission to date.

MATLAB↗

Minimum deltaV Burn Planning for the International Space Station Using a Hybrid Optimization Technique, Level 1

The International Space Station's (ISS) trajectory is coordinated and executed by the Trajectory Operations and Planning (TOPO) group at NASA's Johnson Space Center. TOPO group personnel routinely generate look-ahead trajectories for the ISS that incorporate translation burns needed to maintain its orbit over the next three to twelve months. The burns are modeled as in-plane, horizontal burns, and must meet operational trajectory constraints imposed by both NASA and the Russian Space Agency. In generating these trajectories, TOPO personnel must determine the number of burns to model, each burn's Time of Ignition (TIG), and magnitude (i.e. deltaV) that meet these constraints. The current process for targeting these burns is manually intensive, and does not take advantage of more modern techniques that can reduce the workload needed to find feasible burn solutions, i.e. solutions that simply meet the constraints, or provide optimal burn solutions that minimize the total DeltaV while simultaneously meeting the constraints. A two-level, hybrid optimization technique is proposed to find both feasible and globally optimal burn solutions for ISS trajectory planning. For optimal solutions, the technique breaks the optimization problem into two distinct sub-problems, one for choosing the optimal number of burns and each burn's optimal TIG, and the other for computing the minimum total deltaV burn solution that satisfies the trajectory constraints. Each of the two aforementioned levels uses a different optimization algorithm to solve one of the sub-problems, giving rise to a hybrid technique. Level 2, or the outer level, uses a genetic algorithm to select the number of burns and each burn's TIG. Level 1, or the inner level, uses the burn TIGs from Level 2 in a sequential quadratic programming (SQP) algorithm to compute a minimum total deltaV burn solution subject to the trajectory constraints. The total deltaV from Level 1 is then used as a fitness function by the genetic algorithm in Level 2 to select the number of burns and their TIGs for the next generation. In this manner, the two levels solve their respective sub-problems separately but collaboratively until a burn solution is found that globally minimizes the deltaV across the entire trajectory. Feasible solutions can also be found by simply using the SQP algorithm in Level 1 with a zero cost function. This paper discusses the formulation of the Level 1 sub-problem and the development of a prototype software tool to solve it. The Level 2 sub-problem will be discussed in a future work. Following the Level 1 formulation and solution, several look-ahead trajectory examples for the ISS are explored. In each case, the burn targeting results using the current process are compared against a feasible solution found using Level 1 in the proposed technique. Level 1 is then used to find a minimum deltaV solution given the fixed number of burns and burn TIGs. The optimal solution is compared with the previously found feasible solution to determine the deltaV (and therefore propellant) savings. The proposed technique seeks to both improve the current process for targeting ISS burns, and to add the capability to optimize ISS burns in a novel fashion. The optimal solutions found using this technique can potentially save hundreds of kilograms of propellant over the course of the ISS mission compared to feasible solutions alone. While the software tool being developed to implement this technique is specific to ISS, the concept is extensible to other long-duration, central-body orbiting missions that must perform orbit maintenance burns to meet operational trajectory constraints.

Brown, Aaron J.↗

Remote-Sensing Time Series Analysis, a Vegetation Monitoring Tool

The Time Series Product Tool (TSPT) is software, developed in MATLAB , which creates and displays high signal-to- noise Vegetation Indices imagery and other higher-level products derived from remotely sensed data. This tool enables automated, rapid, large-scale regional surveillance of crops, forests, and other vegetation. TSPT temporally processes high-revisit-rate satellite imagery produced by the Moderate Resolution Imaging Spectroradiometer (MODIS) and by other remote-sensing systems. Although MODIS imagery is acquired daily, cloudiness and other sources of noise can greatly reduce the effective temporal resolution. To improve cloud statistics, the TSPT combines MODIS data from multiple satellites (Aqua and Terra). The TSPT produces MODIS products as single time-frame and multitemporal change images, as time-series plots at a selected location, or as temporally processed image videos. Using the TSPT program, MODIS metadata is used to remove and/or correct bad and suspect data. Bad pixel removal, multiple satellite data fusion, and temporal processing techniques create high-quality plots and animated image video sequences that depict changes in vegetation greenness. This tool provides several temporal processing options not found in other comparable imaging software tools. Because the framework to generate and use other algorithms is established, small modifications to this tool will enable the use of a large range of remotely sensed data types. An effective remote-sensing crop monitoring system must be able to detect subtle changes in plant health in the earliest stages, before the effects of a disease outbreak or other adverse environmental conditions can become widespread and devastating. The integration of the time series analysis tool with ground-based information, soil types, crop types, meteorological data, and crop growth models in a Geographic Information System, could provide the foundation for a large-area crop-surveillance system that could identify a variety of plant phenomena and improve monitoring capabilities.

McKellip, Rodney↗

Calibration Issues and Operating System Requirements for Electron-Probe Microanalysis

Instrument purchase requirements and dialogue with manufacturers have established hardware parameters for alignment, stability, and reproducibility, which have helped improve the precision and accuracy of electron microprobe analysis (EPMA). The development of correction algorithms and the accurate solution to quantitative analysis problems requires the minimization of systematic errors and relies on internally consistent data sets. Improved hardware and computer systems have resulted in better automation of vacuum systems, stage and wavelength-dispersive spectrometer (WDS) mechanisms, and x-ray detector systems which have improved instrument stability and precision. Improved software now allows extended automated runs involving diverse setups and better integrates digital imaging and quantitative analysis. However, instrumental performance is not regularly maintained, as WDS are aligned and calibrated during installation but few laboratories appear to check and maintain this calibration. In particular, detector deadtime (DT) data is typically assumed rather than measured, due primarily to the difficulty and inconvenience of the measurement process. This is a source of fundamental systematic error in many microprobe laboratories and is unknown to the analyst, as the magnitude of DT correction is not listed in output by microprobe operating systems. The analyst must remain vigilant to deviations in instrumental alignment and calibration, and microprobe system software must conveniently verify the necessary parameters. Microanalysis of mission critical materials requires an ongoing demonstration of instrumental calibration. Possible approaches to improvements in instrument calibration, quality control, and accuracy will be discussed. Development of a set of core requirements based on discussions with users, researchers, and manufacturers can yield documents that improve and unify the methods by which instruments can be calibrated. These results can be used to continue improvements of EPMA.

Carpenter, P.↗

Fuzzy logic particle tracking velocimetry

Fuzzy logic has proven to be a simple and robust method for process control. Instead of requiring a complex model of the system, a user defined rule base is used to control the process. In this paper the principles of fuzzy logic control are applied to Particle Tracking Velocimetry (PTV). Two frames of digitally recorded, single exposure particle imagery are used as input. The fuzzy processor uses the local particle displacement information to determine the correct particle tracks. Fuzzy PTV is an improvement over traditional PTV techniques which typically require a sequence (greater than 2) of image frames for accurately tracking particles. The fuzzy processor executes in software on a PC without the use of specialized array or fuzzy logic processors. A pair of sample input images with roughly 300 particle images each, results in more than 200 velocity vectors in under 8 seconds of processing time.

Wernet, Mark P.↗

Software Quality Assurance for the MOOSE-Based Open-Source Multiphysics Code Cardinal - An Expanded CI Testing Suite

Cardinal is a wrapping of the GPU-oriented spectral element Computational Fluid Dynamics (CFD) code NekRS and the Monte Carlo particle transport code OpenMC within the Multiphysics Object-Oriented Simulation Environment (MOOSE). Cardinal provides high-resolution thermal-hydraulics and/or radiation transport feedback to MOOSE multiphysics simulations. Multiphysics feedback is implemented in a geometry-agnostic manner which eliminates the need for rigid one-to-one mappings. A generic data transfer implementation also allows NekRS and OpenMC to couple to any MOOSE application, enabling a broad set of multiphysics capabilities. Cardinal simulations can also leverage combinations of MPI, OpenMP, and GPU resources. Cardinal continuous development and improvement efforts have led to the software being considered as a high-fidelity design and licensing tool for key areas of nuclear reactor relevant physics, including neutron transport, fluid flow, heat transfer, and mechanical processes. The fast development and expansion of the software from a pure R&D framework towards its application in the nuclear industry and regulation require a focus on developing, enhancing and, maintaining Cardinal’s software quality through strict adherence to a Software Quality Assurance (SQA) framework and SQA program. To facilitate compliance with SQA standards, the Cardinal SQA Program has been initiated during Fiscal Year 2023 (FY23). During the development of the Cardinal SQA Program, multiple gaps have been identified. These gaps are primarily related to model verification and code pedigree as they relate to the use of Cardinal as a safety analysis tool. These gaps have been captured in a report published in 2023. A second report highlighted the progress made during Fiscal Year 2024 (FY24) and described Argonne’s effort to document and integrate software verification within Cardinal’s software development process. This report documents a snapshot of the verification test cases currently available for Cardinal and NekRS in their assimilation into a Continuous Integration (CI) platform. Following the CI practice permits the integrating of source code changes frequently and ensuring that the integrated codebase clears the verification testing for the software. It should be noted that the SQA program itself, including the program plans, procedures, configuration management, and testing strategies, need to be developed in a future step of this task.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Progress Towards NQA-1 for Cardinal in FY25

Cardinal is a wrapping of the GPU-oriented spectral element Computational Fluid Dynamics (CFD) code NekRS and the Monte Carlo particle transport code OpenMC within the Multiphysics Object-Oriented Simulation Environment (MOOSE). Cardinal provides high-resolution thermal-hydraulics and/or radiation transport feedback to MOOSE multiphysics simulations. Multiphysics feedback is implemented in a geometry-agnostic manner which eliminates the need for rigid one-to-one mappings. A generic data transfer implementation also allows NekRS and OpenMC to couple to any MOOSE application, enabling a broad set of multiphysics capabilities. Cardinal simulations can also leverage combinations of MPI, OpenMP, and GPU resources. Cardinal continuous development and improvement efforts have led to the software being considered as a high-fidelity design and licensing tool for key areas of nuclear reactor relevant physics, including neutron transport, fluid flow, heat transfer, and mechanical processes. The fast development and expansion of the software from a pure R&D framework towards its application in the nuclear industry and regulation require a focus on developing, enhancing,and maintaining Cardinal’s software quality through strict adherence to a Software Quality Assurance (SQA) framework and SQA program. To facilitate compliance with SQA standards, the Cardinal SQA Program was initiated during Fiscal Year 2023 (FY23). During the development of the Cardinal SQA Program, multiple gaps have been identified. These gaps are primarily related to model verification and code pedigree as they relate to the use of Cardinal as an analysis tool. These gaps were captured in a report published in 2023. A second report highlighted the progress made during Fiscal Year 2024 (FY24) and described Argonne’s effort to document and integrate software verification within Cardinal’s software development process. This report documents the progress made towards NQA-1 for Cardinal in the Fiscal Year 2025 (FY25). All cases in the expanded Continuous Integration (CI) suite of NekRS are included in this report which test the solvers and modules available in NekRS exhaustively. The NekRS tests are integrated with the Cardinal CI suite and made available in publicly accessible Github documentation. Following the CI practice permits integrating of source code changes frequently and ensuring that the integrated codebase clears the verification testing for the software. Also in this report is a brief overview of the development of the Cardinal Software Quality Assurance Plan (SQAP) that was done in FY25, though it should be noted that the rest of the documentation for the SQA program needs to be developed in a future step of this task.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Automated data acquisition technology development:Automated modeling and control development

This report documents the completion of, and improvements made to, the software developed for automated data acquisition and automated modeling and control development on the Texas Micro rackmounted PC's. This research was initiated because a need was identified by the Metal Processing Branch of NASA Marshall Space Flight Center for a mobile data acquisition and data analysis system, customized for welding measurement and calibration. Several hardware configurations were evaluated and a PC based system was chosen. The Welding Measurement System (WMS), is a dedicated instrument strickly for use of data acquisition and data analysis. In addition to the data acquisition functions described in this thesis, WMS also supports many functions associated with process control. The hardware and software requirements for an automated acquisition system for welding process parameters, welding equipment checkout, and welding process modeling were determined in 1992. From these recommendations, NASA purchased the necessary hardware and software. The new welding acquisition system is designed to collect welding parameter data and perform analysis to determine the voltage versus current arc-length relationship for VPPA welding. Once the results of this analysis are obtained, they can then be used to develop a RAIL function to control welding startup and shutdown without torch crashing.

Romine, Peter L.↗

Steering Aircraft Clear of Choppy Air

AeroTech Research (U.S.A.), Inc., a leader in turbulence-detection and warning systems, has been involved with NASA Aviation Safety research since 1998. AeroTech served as a contractor for the TPAWS government/industry development project, and was funded by NASA to develop the E-Turb Mode Radar algorithms and the TAPS software. (Other contributors to this project include the National Center for Atmospheric Research, the FAA, North Carolina State University, and the Research Triangle Institute.) The radar algorithms combine an aircraft's turbulenceresponse characteristics with radar measurements to determine the predicted turbulence loads the aircraft will experience, and present this information to the pilot. The TAPS software monitors and processes onboard aircraft sensor data; generates automatic reports when an aircraft encounters turbulence and a set turbulence threshold is exceeded; and then displays the reports and underlying information to ground personnel to improve situational awareness of the location and the severity of the turbulence encounter.

Source record↗

Reducing V&V Cost of Flight Critical Systems: Myth or Reality?

This paper presents an overview of NASA research program on the V&V of flight critical systems. Five years ago, NASA started an effort to reduce the cost and possibly increase the effectiveness of V&V for flight critical systems. It is the right time to take a look back and realize what progress has been made. This paper describes our overall approach and the tools introduced to address different phases of the software lifecycle. For example, we have improved testing by developing a statistical learning approach tor defining test cases. The tool automatically identifies possible unsafe conditions by analyzing outliers in output data; using an iterative learning process, it can then generate more test cases that represent potentially unsafe regions of operation. At the code level, we have developed and made available as open source a static analyzer for C and C++ programs called IKOS. We have shown that IKOS is very precise in the analysis of embedded C programs (very few false positives) and a bit less for regular C and C++ code. At the design level, in collaboration with our NRA partners, we have developed a suite of analysis tools for Simulink models. The analysis is done in a compositional framework for scalability.

Brat, Guillaume P.↗

DIVA/DeviceEditor v6.1.2

DIVA is an end-to-end DNA design and construction management platform that streamlines how researchers design, build, and receive sequence-verified DNA constructs. Through a web-based BioCAD interface (DeviceEditor), researchers independently design DNA constructs and submit them to a centralized queue with a single action. Designs progress transparently through standardized states which allow researchers to track status and access finished constructs via a central DNA repository. Submitted designs are reviewed by dedicated staff for feasibility and optimization, reducing costly failures and improving downstream execution. Automated DNA assembly software optimizes construction strategies by reusing existing parts where possible and sourcing synthetic DNA only when needed. Standardized, sequence-agnostic assembly methods enable many independent constructs to be built in parallel using lab automation, dramatically increasing throughput. High-throughput next-generation sequencing is used to verify construct accuracy, with flexible platforms selected based on task requirements. Throughout the process, detailed success and failure data are captured and analyzed, enabling continuous improvement of assembly protocols. Compared to traditional, manual DNA construction workflows, DIVA offers higher scalability, transparency, reproducibility, and data-driven optimization.

Plahar, Hector [Lawrence Berkeley National Laborat↗