Search NASA⌕ Search

SEARCH · Search NASA

Results for “Complex industrial process”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Regulating Gas Transport in Molecularly Engineered Polymer Membranes (Final Technical Report)

Energy-efficient separation processes are essential for a wide range of applications ranging from clean fuels (e.g., hydrogen purification) and petroleum refining (e.g., natural gas processing) to water purification and carbon capture. Membrane-mediated separations have shown tremendous promise in providing high productivity and high separation efficiency at significantly lower energy consumption, e.g., up to 90% less energy cost than traditional thermally driven processes such as distillation. Polymeric membranes–the dominant separation membrane materials–have yet to reach their full potential due to their limitations in long-term durability (e.g., productivity loss over the period of their lifetime due to physical aging) or insufficient stability under harsh conditions (e.g., high temperature, chemically complex feeds). This research seeks to establish a new paradigm in polymer membrane material design by harnessing crosslinked model networks with well-defined yet finely tailorable microstructure to facilitate fast and selective gas transport and simultaneously enhance membrane stability. Unlike traditional randomly crosslinked polymers, which suffer from structural inconsistencies and consequently suboptimal gas separation performance, crosslinked model network membranes prepared via a precisely controlled end-linking process enables the creation of previously unattainable microstructure tunability, which, in turn, results in versatile crosslinked membranes with high separation performance that meet the needs of various challenging gas separations. Using model network framework as a fundamental tool by applying this concept in diverse polymer categories, this work has led to the development of various innovative crosslinked membrane structures such as unimodal, bimodal and clustered model networks. These advanced crosslinked polymer membranes not only demonstrate exceptional gas separation performance that significantly outperform existing randomly crosslinked membranes, but also possess excellent long-term durability and robust stability under complex operating conditions. From a fundamental perspective, results from this research provide critical mechanistic insights into gas separation in crosslinked polymer membranes, addressing key knowledge gaps and opening new avenues for membrane design to meet various separation needs. The new membrane materials produced from this research enable the use of polymeric membranes for high temperature gas separations, offering substantial energy and cost savings by eliminating the need for repeated cooling-heating cycles in industrial processes.

02 PETROLEUM↗
DOE OSTI2020

There’s plenty of room at the top

Richard Feynman’s famous words, “there’s plenty of room at the bottom,” referred to the opportunities for revolutionizing the electronics industry by developing the science and technology of how to manufacture very small components (sub-micron to nanometer sized features). In additive manufacturing (AM), the opposite may be true: There’s plenty of room at the top. AM’s strength is in the low volume production of complex components, which is demanded in big industries such as oil and gas, construction, tooling, wind and water turbines, and infrastructure. Is AM’s ‘big’ future in the manufacture of large structures? Here, this special issue surveys the technical challenges and enormous opportunities associated with large scale additive manufacturing while discussing the materials, processes and applications that are enabled by scaling to much larger structures, much faster speeds and lower manufacturing costs. The authors believe that, if Professor Feynman was alive, he’d say “There’s plenty of room at the top.”

36 MATERIALS SCIENCE↗
DOE OSTI2021

A Redundancy-Guided Approach for the Hazard Analysis of Digital Instrumentation and Control Systems in Advanced Nuclear Power Plants

We report digital instrumentation and control (I&C) upgrades are a vital research area for the nuclear industry. Despite their performance benefits, deployment of digital I&C in nuclear power plants (NPPs) has been limited. Digital I&C systems exhibit complex failure modes including common cause failures (CCFs), which can be difficult to identify. This paper describes the development of a redundancy-guided application of the Systems-Theoretic Process Analysis and fault tree analysis for the hazard analysis of digital I&C in advanced NPPs. The resulting Redundancy-Guided Systems-Theoretic Hazard Analysis (RESHA) is applied for the case study of a representative state-of-the-art digital reactor trip system. The analysis qualitatively and systematically identifies the most critical CCFs and other hazards of digital I&C systems. Ultimately, the RESHA can help researchers make informed decisions for how, and to what degree, defensive measures such as redundancy, diversity, and defense in depth can be used to mitigate or eliminate the potential hazards of digital I&C systems.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

The Effect of Flocculent, Dispersants, and Binder on Wet-laid Process for Recycled Glass Fiber/PA6 Composite

The papermaking industry has been using the wet-laid process to suspend paper pulp-derived fibers in water and drain the solution through a forming mesh. This process has recently been adopted to produce non-woven, wet-laid fiber-reinforced polymer matrix composite mats. The mats can be postmolded into different complex shapes using compression molding or related processes. The objective of this study was to produce composite panels from wet-laid mats and observe the effect of chemicals used during the process on the mechanical and thermal characteristics of the resulting composite. Two sets of mats were processed using recycled glass fiber with Polyamide 6 (PA6). Flocculent, dispersant and binder (poly(vinyl alcohol) (PVOH)) were added to one of the mats, and the second mat was processed without these chemicals. The addition of these chemicals enhanced the fiber distribution and reduced processing defects in the mats. This was reflected in the mechanical properties of the final product. It was noticed that the flocculent, dispersant and binder volatilized during the compression molding step. Furthermore, the additives were found not to affect the thermal properties of the consolidated part.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Creation of the NaSCoRD Database

This report was written as part of a United States Department of Energy (DOE), Office of Nuclear Energy, Advanced Reactor Technologies program funded project to re-create the capabilities of the legacy Centralized Reliability Database Organization (CREDO) database. The CREDO database provided a record of component design and performance documentation across various systems that used sodium as a working fluid. Regaining this capability will allow the DOE complex and the domestic sodium reactor industry to better understand how previous systems were designed and built for use in improving the design and operations of future loops. The contents of this report include: overview of the current state of domestic sodium reliability databases; summary of the ongoing effort to improve, understand, and process the CREDO information; summary of the initial efforts to develop a unified sodium reliability database called the Sodium System Component Reliability Database (NaSCoRD); and explain both how potential users can access the domestic sodium reliability databases and the type of information that can be accessed from these databases.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗
DOE OSTI2018

Born Qualified Grand Challenge LDRD Final Report

This SAND report fulfills the final report requirement for the Born Qualified Grand Challenge LDRD. Born Qualified was funded from FY16-FY18 with a total budget of ~$13M over the 3 years of funding. Overall 70+ staff, Post Docs, and students supported this project over its lifetime. The driver for Born Qualified was using Additive Manufacturing (AM) to change the qualification paradigm for low volume, high value, high consequence, complex parts that are common in high-risk industries such as ND, defense, energy, aerospace, and medical. AM offers the opportunity to transform design, manufacturing, and qualification with its unique capabilities. AM is a disruptive technology, allowing the capability to simultaneously create part and material while tightly controlling and monitoring the manufacturing process at the voxel level, with the inherent flexibility and agility in printing layer-by-layer. AM enables the possibility of measuring critical material and part parameters during manufacturing, thus changing the way we collect data, assess performance, and accept or qualify parts. It provides an opportunity to shift from the current iterative design-build-test qualification paradigm using traditional manufacturing processes to design-by-predictivity where requirements are addressed concurrently and rapidly. The new qualification paradigm driven by AM provides the opportunity to predict performance probabilistically, to optimally control the manufacturing process, and to implement accelerated cycles of learning. Exploiting these capabilities to realize a new uncertainty quantification-driven qualification that is rapid, flexible, and practical is the focus of this effort.

36 MATERIALS SCIENCE↗
NASA NTRS1983

Conceptual design of a data reduction system

A telemetry data processing system was defined of the Data Reduction. Data reduction activities in support of the developmental flights of the Space Shuttle were used as references against which requirements are assessed in general terms. A conceptual system design believed to offer significant throughput for the anticipated types of data reduction activities is presented. The design identifies the use of a large, intermediate data store as a key element in a complex of high speed, single purpose processors, each of which performs predesignated, repetitive operations on either raw or partially processed data. The recommended approach to implement the design concept is to adopt an established interface standard and rely heavily on mature or promising technologies which are considered main stream of the integrated circuit industry. The design system concept, is believed to be implementable without reliance on exotic devices and/or operational procedures. Numerical methods were employed to examine the feasibility of digital discrimination of FDM composite signals, and of eliminating line frequency noises in data measurements.

Source record↗
NASA NTRS1995

A summary of computational experience at GE Aircraft Engines for complex turbulent flows in gas turbines

This viewgraph presentation summarizes some CFD experience at GE Aircraft Engines for flows in the primary gaspath of a gas turbine engine and in turbine blade cooling passages. It is concluded that application of the standard k-epsilon turbulence model with wall functions is not adequate for accurate CFD simulation of aerodynamic performance and heat transfer in the primary gas path of a gas turbine engine. New models are required in the near-wall region which include more physics than wall functions. The two-layer modeling approach appears attractive because of its computational complexity. In addition, improved CFD simulation of film cooling and turbine blade internal cooling passages will require anisotropic turbulence models. New turbulence models must be practical in order to have a significant impact on the engine design process. A coordinated turbulence modeling effort between NASA centers would be beneficial to the gas turbine industry.

Zerkle, Ronald D.↗
NASA NTRS2008

On Convergence of Development Costs and Cost Models for Complex Spaceflight Instrument Electronics

Development costs of a few recent spaceflight instrument electrical and electronics subsystems have diverged from respective heritage cost model predictions. The cost models used are Grass Roots, Price-H and Parametric Model. These cost models originated in the military and industry around 1970 and were successfully adopted and patched by NASA on a mission-by-mission basis for years. However, the complexity of new instruments recently changed rapidly by orders of magnitude. This is most obvious in the complexity of representative spaceflight instrument electronics' data system. It is now required to perform intermediate processing of digitized data apart from conventional processing of science phenomenon signals from multiple detectors. This involves on-board instrument formatting of computational operands from row data for example, images), multi-million operations per second on large volumes of data in reconfigurable hardware (in addition to processing on a general purpose imbedded or standalone instrument flight computer), as well as making decisions for on-board system adaptation and resource reconfiguration. The instrument data system is now tasked to perform more functions, such as forming packets and instrument-level data compression of more than one data stream, which are traditionally performed by the spacecraft command and data handling system. It is furthermore required that the electronics box for new complex instruments is developed for one-digit watt power consumption, small size and that it is light-weight, and delivers super-computing capabilities. The conflict between the actual development cost of newer complex instruments and its electronics components' heritage cost model predictions seems to be irreconcilable. This conflict and an approach to its resolution are addressed in this paper by determining the complexity parameters, complexity index, and their use in enhanced cost model.

Kizhner, Semion↗
NASA NTRS2022

National Campaign (NC)-1 Strategic Conflict Management Simulation (X4) Final Report

Urban Air Mobility (UAM) enables highly automated, cooperative, passenger or cargo-carrying air transportation services in and around urban areas. UAM is a subset of the Advanced Air Mobility (AAM) concept under development by the National Aeronautics and Space Administration (NASA), the Federal Aviation Administration (FAA), and industry. The Strategic Conflict Management (SCM) Simulation, dubbed “X4”, was conducted between July 2021 and June 2022 by NASA with the FAA and industry to evolve the Provider of Services for UAM (PSU) that will be needed to ensure initial UAM operations can scale in the National Airspace System (NAS). The FAA UAM Concept of Operations (ConOps) v1 [1] served as an initial guiding document for the X4 airspace management system design to ensure the architecture supports testing of services provided by third-party service providers. To that end, the X4 architecture leveraged concepts and technologies developed for Unmanned Aircraft System (UAS) Traffic Management (UTM) while also developing and testing new capabilities and services needed for UAM. The architecture included an initial prototype of the FAA-Industry Exchange Protocol (FIDXP), third-party services such as the PSUs, and Discovery and Synchronization Service (DSS), and other new services such as Demand-Capacity Balancing (DCB) to facilitate UAM strategic conflict management. During X4, NASA led discussions and collaborated with seven industry airspace partners to develop initial airspace management concepts for UAM that drove what would be tested and evaluated during the simulations. The initial capabilities defined for PSU leveraged UTM UAS Service Supplier (USS) as a starting point and evolved to meet UAM requirements. These discussions were also an opportunity for NASA to collaborate with industry to develop a set of initial Community-Based Rules (CBRs). These CBRs enabled how UAM traffic would be cooperatively managed among UAM operators. The collaborative, iterative process of developing CBRs with industry during X4 provided insight into the challenges involved and identified the need for a suitable and effective forum for future CBR development. In parallel with these discussions, NASA conducted a series of seven software sprints and two collaborative simulations with the airspace partners that built up in complexity. Over the course of the year, all seven partners successfully completed all the sprints by demonstrating the required capabilities. They also participated in the two collaborative simulations to demonstrate how multiple PSUs could work together in a collaborative, more complex environment with higher traffic density. The X4 simulation accomplished NASA's objectives and helped advance the development of the seven participating PSUs. The lessons learned provided insight into key elements of the UAM Notional Architecture from the FAA ConOps v1 [1] and UTM technologies when applied to UAM: - Having a Concept of Use (ConUse) defined prior to the activity would accelerate the time and effort from concept development to testing. - While the UAM Notional Architecture provided a starting point for a federated architecture that support services provided by third-party providers, the USS and PSU differed in their capability definitions for operational intent submission and sharing, conformance monitoring, airspace authorization, strategic conflict management, airspace constraints and dynamic replanning. - While existing DSS developed for UTM provided a way for PSU and other UAM services (such as DCB) to discover relevant operations from each other, additional complexity and challenges were found during X4 testing and illuminated the need for a more suitable solution for UAM. Industry can leverage the results of this demonstration to accelerate UAM requirements, CBRs, and standards development. The FAA and other government municipalities and agencies will be able to leverage results to inform future policies and identify additional gaps that require further analysis, moving toward operationalization of UAM.

Urban Air Mobility↗
DOE OSTI2018

Control of Ionomer Distribution in Roll-to-Roll Coated Fuel Cell Catalyst Layers

Fuel cell catalyst layers are a complex mixture of catalyst particles and ion-conducting polymers. The performance of catalyst layers is highly dependent on microstructure, which must balance proton and electron conduction with gas transport. As fuel cells transition from the laboratory to industrial production for vehicles and other applications, there is a need to understand how manufacturing processes impact the microstructure and, ultimately, the performance of catalyst layers. In this work, we have focused on the roll-to-roll coating of catalyst layers for proton exchange membrane fuel cells. The catalyst layers are responsible for the electrochemical reactions that enable power production. In these devices the catalyst is commonly a Pt nanoparticle supported on porous carbon blacks. The ion conducting polymer, or ionomer, is typically a perfluorosulfonic acid. The most common being Nafion. To fabricate the catalyst layer, the catalyst particles are dispersed in an ink with the ionomer and cast to form the catalyst layer. Commonly, laboratory samples are prepared using spray coating or hand painting, which effectively coat many thin layers to achieve the desired catalyst layer thickness. This creates catalyst layers with uniform distributions of materials throughout the thickness of the full catalyst layer. In contrast, roll-to-roll methods, like slot die, gravure or screen printing, coat the catalyst layer as a single wet film. As the film dries, ink constituents are able to segregate, leading to a heterogeneous distribution of materials through the thickness of the layer. It is also known that the choice of solvent and drying rate can affect the morphology of the catalyst layer. Thus, there is a need to understand how ink formulation and the drying process influence the distribution of materials and catalyst layer morphology. Here, we have explored the influence of solvent and drying rate on morphology of roll-to-roll coated catalyst layers. We show the development of the Kelvin probe method as a rapid screening technique for qualitative analysis of ionomer distribution. We also utilize nano X-ray computed tomography to visualize electrode structure and to quantify particle-size and pore-size distributions, thickness-dependent ionomer distribution, tortuosity, and effective transport properties. We find that solvent has a strong influence on ionomer distribution, with less of an effect on porosity. Conversely, drying temperature has a strong influence on porosity, but less influence on ionomer distribution. Finally, we utilize in situ fuel cell performance testing and other advanced diagnostics to quantify the impact of catalyst layer properties on fuel cell performance and demonstrate that roll-to-roll coating is capable of coating high performance catalyst layers in multi-meter lengths.

14 SOLAR ENERGY↗
DOE OSTI2019

Demonstration of Integrated Hazard Analysis for Digital Reactor Trip Systems

Digital instrumentation and control (I&C) upgrades are a vital research area for nuclear industry. Despite their performance benefits, deployment of digital I&C in nuclear power plants (NPPs) has been limited. Digital I&C systems exhibit complex failure modes including common cause failures (CCFs) which can be difficult to identify. This paper describes the development of a redundancy-guided application of the Systems-Theoretic Process Analysis (STPA) and Fault Tree Analysis (FTA) for the hazard analysis of digital I&C in advanced NPPs. The resulting Redundancy-guided System-theoretic Hazard Analysis (RESHA) is applied for the case study of a representative state-of-the-art digital reactor trip system. The analysis qualitatively and systematically identifies the most critical CCFs and other hazards of digital I&C systems. Ultimately, RESHA can help researchers make informed decisions for how, and to what degree, defensive measures such as redundancy, diversity, and defense-in-depth can be used to mitigate or eliminate the potential hazards of digital I&C systems.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

Nuclear Decontamination Evolution and Revolution - 20349

Decontamination, one of the oldest practices in the nuclear industry, is about to change. While no single approach to decontamination is appropriate in all situations, decontamination of highly contaminated surfaces is historically viewed as difficult and/or marginally effective and fixatives and strippable coatings are often called on to manage time sensitive contamination control issues. The deferral of proper decontamination can lead to accumulated concentrations of radioactive material increasing the risk of cross-contamination of workers and equipment while also increasing radiation levels, which further discourages decontamination. The results of the subject testing demonstrate that superior decontamination factors are readily achievable and the ALARA benefit of decontamination is viable through advanced decontamination technologies in conjunction with innovative application techniques. The collateral benefits will save countless radiological man-hours and personnel radiological exposure. The appropriate use of radiological decontamination techniques can prevent or limit the adverse effects of highly radioactive contamination in the work area. High levels of radiological contamination are typically associated with some of the most physically demanding work in the nuclear industry. Additionally, working in highly contaminated environments increases the risk of exposure to elevated levels of airborne radioactivity and radiation from the source term of the contamination, particularly in hard to reach areas or complex equipment. Veolia's Alaron Nuclear Services (Alaron), a fully integrated nuclear facility, has provided the nuclear industry waste treatment, consolidation, repackaging, and broad decontamination services for almost 35 years. In looking at solutions for its customers, as well as for their own facility, Alaron has recently collaborated with Environmental Alternatives, Inc. (EAI), which has provided innovative solutions addressing difficult nuclear decontamination and industrial cleaning challenges since 1989. This broad range of experience along with the products to support the work created an ideal partner for Alaron's needs at their facility. The benefits of collaboration were immediately recognizable to the management of both companies although the decontamination challenge was significant. Due to the nature of the services offered, contamination at the Alaron facility is routine. The recent decontamination experience at Alaron utilized an innovative surfactant process that quickly produces remarkably higher decontamination factors for both removable surface contamination and fixed contamination. Considering the time to decontaminate areas historically designated for high radiological hazard work, the results from this decontamination effort not only reduced contamination levels but also significantly lowered exposure rates in the working environment. The relative ease with which the surfactant is applied, combined with extraordinary decontamination test results, indicates the potential to alter current radiological work processes in a way that improves worker comfort, and removes radiological engineering barriers, allowing Alaron to complete complex radiological tasks more efficiently and effectively. In a series of two simple applications of the decontamination agent to contaminated high bay vertical surfaces, as well as a variety of horizontal and vertical surfaces with variable porousness and surface sealants, there was an overall reduction in removable contamination of approximately 73% with a reduction in area dose of approximately 93%. The results indicate additional reduction in fixed contamination with application of the surfactant. These values are much higher than experienced with more traditional decontamination agents. In conjunction with demonstrating EAI's surfactant on room surfaces, additional studies were conducted on complex geometry equipment including waste processing equipment, tools, and heavily contaminated parts normally handled from Alaron's customers. Evaluations were made with straight application of EAI's surfactant as well as adding additional techniques to the treatment which afforded revolutionary improvements in the levels of contamination removed. Successful decontamination with up to 95% reduction in removable contamination with just one application were demonstrated in several of the trials. This paper outlines the planned approach to use this technology, the variety of surfaces and equipment treated, and the results of the decontamination efforts. Furthermore, this paper discusses options for pretreatment of certain heavily contaminated equipment prior to employees handling and/or working with the equipment. The potential for dose saving and the reduced risk of cross-contamination with the added benefit of lower PPE requirements, produces an enormous potential for cost and time savings. Attendees will benefit from Alaron's experiences and more fully understand the capabilities of EAI's decontamination process. With the variety of contamination agents, forms and surfaces on which the technology was demonstrated, the information will be valuable to a broad cross-section of industry users. The significance of this report demonstrates superior decontamination factors are achievable utilizing the next evolution of decontamination technology and that the ALARA benefits of decontamination are available through advanced and modern decontamination efforts. The collateral benefits will save countless radiological man-hours and valuable personnel radiological exposure. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Advanced dismantling techniques applied in an industrial project for the dismantling of highly activated equipment - 15446

Commissioned in 1958 on the CEA nuclear site of Marcoule (France) and shut down in 1997, the former UP1 plant was dedicated to reprocess the spent fuel from G1, G2 and G3 GCR reactors. Since 1998, a wide program for cleaning-up and dismantling the plant has been developed in order to dismantle the process equipment, eliminate any radiological risk in all buildings concerned and remove all the resulting waste. Major technical challenges are related to the wide range of complex components and equipment in the facilities such as chemical dissolvers, extractor batteries, evaporators, tanks; and to a high risk of exposure, due to the presence of fission products. To address these challenges, CEA led R and D programs to develop advanced tools for complex dismantling projects: immersive virtual reality, laser cutting techniques, special remote-controlled arms combining dexterity and high resistance to irradiation The purpose of this paper is to provide an overview of a practical implementation and to show first results of these advanced techniques on a real case: the dismantling of dissolver's equipment from the dissolution workshop of UP1 plant. ONET Technologies has been chosen by CEA to design, build and operate the overall dismantling and waste treatment system for this project. ONET Technologies designed two main subsystems to meet all the requirements for this project: first, the 'Remotely-Operated Handling and Cutting Unit' and second the 'Waste Extraction and Conditioning Unit' and the combining innovative technologies. During the design phase, the 'Immersive Virtual Reality' has been used to qualify the kinematics in the final environment and the preliminary dismantling scenario. Following a first R and D program of CEA regarding the laser cutting technique applied to nuclear decommissioning, ONET Technologies and CEA realized elementary inactive tests based on a 6 kW Nd-Yag laser source to qualify the cutting performance according to material and thickness. Main objective was to meet the safety criteria and to check the physical characteristics of waste resulting from the laser cutting operation. The Remotely-Operated Handling and Cutting Unit was equipped with a MAESTRO manipulator, resulting from ten years of research and development cooperation between CEA and Cybernetix. This manipulator, a 6 axis hydraulic manipulator-arm specifically designed to work in harsh environment, entered in its industrial phase. ONET Technologies was responsible for the overall system integration, confinement and performance. A comprehensive qualification program in real conditions has been driven during 2014. The dismantling scenario was tested with a mockup at a full scale of dissolver equipment and confirmed at this stage the expected level of performance and safety. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1993

Making tomorrow's mistakes today: Evolutionary prototyping for risk reduction and shorter development time

In the early days of JPL's solar system exploration, each spacecraft mission required its own dedicated data system with all software applications written in the mainframe's native assembly language. Although these early telemetry processing systems were a triumph of engineering in their day, since that time the computer industry has advanced to the point where it is now advantageous to replace these systems with more modern technology. The Space Flight Operations Center (SFOC) Prototype group was established in 1985 as a workstation and software laboratory. The charter of the lab was to determine if it was possible to construct a multimission telemetry processing system using commercial, off-the-shelf computers that communicated via networks. The staff of the lab mirrored that of a typical skunk works operation -- a small, multi-disciplinary team with a great deal of autonomy that could get complex tasks done quickly. In an effort to determine which approaches would be useful, the prototype group experimented with all types of operating systems, inter-process communication mechanisms, network protocols, packet size parameters. Out of that pioneering work came the confidence that a multi-mission telemetry processing system could be built using high-level languages running in a heterogeneous, networked workstation environment. Experience revealed that the operating systems on all nodes should be similar (i.e., all VMS or all PC-DOS or all UNIX), and that a unique Data Transport Subsystem tool needed to be built to address the incompatibilities of network standards, byte ordering, and socket buffering. The advantages of building a telemetry processing system based on emerging industry standards were numerous: by employing these standards, we would no longer be locked into a single vendor. When new technology came to market which offered ten times the performance at one eighth the cost, it would be possible to attach the new machine to the network, re-compile the application code, and run. In addition, we would no longer be plagued with lack of manufacturer support when we encountered obscure bugs. And maybe, hopefully, the eternal elusive goal of software portability across different vendors' platforms would finally be available. Some highlights of our prototyping efforts are described.

Friedman, Gary↗
DOE OSTI2026

Improved manufacturability of vacuum thermoforming molds by segmentation

Thin polymer shell components used in consumer goods, the automotive industry, and marine applications are often produced by thermoforming. Depending on the quantity of parts, molding processes can increase throughput significantly when compared to processes such as milling or additive manufacturing. One disadvantage to mold-based manufacturing methods, however, is that molds must be produced to form the required geometry. Mold production is often complex and requires a large capital investment. For large-scale molding processes, mold production is sometimes complicated by the requirement for large working volume machine tools which are capable of machining the cavities to the appropriate tolerances for the selected molding process. Here, this paper focuses on a segmented design for a large draw ratio (>3:1 molded surface area to sheet surface area) thermoforming mold and a cost-benefit analysis of segmentation versus monolithic design. Discussion of the thermoforming tests are included. The primary goals were to improve manufacturability and reduce the overall cost of the mold.

Manufacturability↗
DOE OSTI2018

Surface Quality after High-Speed Grinding

In producing machine parts from the hard materials used today in the military–industrial complex, attainment of the required precision is difficult and sometimes unfeasible unless finishing operations are employed. In general, finishing operations are expensive and slow and they require highly skilled workers and specialized equipment. That considerably increases the production costs. Finishing operations can only be eliminated if the cutters used in the prior machining processes ensure satisfactory surface quality. However, that is not always the case, on account of bluntness of the tool. In the present work, attention focuses on the precision that may be attained in machining key components made of hard materials when using high-quality hard-alloy cutters produced by ultrahigh-speed grinding.

42 ENGINEERING↗
DOE OSTI2016

An Overview of P450 Enzymes: Opportunity and Challenges in Industrial Applications

Cytochrome P450 enzymes (P450s) containing a heme-iron center, are biocatalysts from all kingdoms, involvedin a large variety of reactions. Their potential in catalyzing a broad range of substrates makes perfect candidates for biotechnology applications and the production of high-value compounds. Biocatalytic reactions performed by P450s have a great interest in the pharmaceutical industry, fine chemicals, cosmetics, and for bioremediation procedures. However, the complex nature of this protein is still a major hurdle in the prospect of using their promising ability for expanding the number of industrial applications. Multiple approaches of protein engineering are currently conducted to improve activity, stability and/or substrate specificity for a given reaction. Furthermore, in combination with the appropriate biocatalyst, a suitable bioengineering process is a key step in the implementation of P450s at the industrial scale.

09 BIOMASS FUELS↗