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DOE OSTI2024

Mechanical Performance of Additively Manufactured ODS 316L and 316H Stainless Steels

This work package within the Advanced Materials and Manufacturing Technologies (AMMT) program focused on the mechanical and microstructural characterization of oxide dispersion strengthened (ODS) stainless steels produced using advanced manufacturing techniques. The research aimed to identify an accelerated development path for ODS alloys by integrating additive manufacturing (AM) technologies with recent advancements in ODS materials and traditional manufacturing methods. For FY 24, the research specifically targeted exploring an accelerated development path for ODS alloys by combining AM technologies with these advancements. Novel AM and post-build processing routes were developed for ODS austenitic alloys, including Fe-Cr-Ni alloys such as 316L and 316H. Electron microscopy and mechanical characterizations were conducted to evaluate the impact of process variables on microstructure and properties, with the goal of optimizing these properties economically. Traditionally, producing ODS alloys involves multi-day, high-energy mechanical milling of alloy powder with yttria powder, followed by milled-powder consolidation through extrusion or other methods, and additional thermomechanical processing (TMP) for property control. To overcome the challenges associated with this complex and costly approach, we propose exploring alternative, cost-effective processing routes that emphasize AM and traditional TMP methods. The new processing routes for ODS alloys have achieved significantly higher strengths—several times greater than those of wrought stainless steels—while maintaining substantial ductility and fracture toughness. This report outlines the novel and economical AM-based processing routes for ODS austenitic alloys, combined with post-build TMPs, and discusses the mechanical and microstructural characteristics of the developed materials.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Improving the Freight Productivity of a Heavy-Duty, Battery Electric Truck by Intelligent Energy Management

This project aimed to enhance the range and reduce the operating costs of battery electric Class 8 trucks traveling over 250 miles daily. This was achieved through the development and implementation of an intelligent-Energy Management System (i-EMS) that leverages vehicle and operations data, physics-aware machine learning algorithms, and vehicle-to-cloud (V2C) connectivity. The project hypothesized that advanced machine learning algorithms and real-time data analytics could significantly improve the energy efficiency and range of these trucks. Key objectives included developing a physics-aware machine learning algorithm, implementing an i-EMS with V2C connectivity and physics-aware spatial data analytics (PSDA), and validating the system’s effectiveness with fleet partners HEB Companies and Murphy Logistics. Extensive data collection from vehicle operations, including vehicle characteristics, road conditions, and payload, was conducted. A machine learning algorithm was developed to predict energy consumption and enable proactive decision-making. The i-EMS was implemented on two Volvo VNR BEVs, with operators receiving charging and routing recommendations. Charging stations were installed at depot locations in Texas and Minnesota, with an additional on-route charger in Minnesota. Significant findings included a 14% range improvement for Murphy Logistics on a highway-driving eco-route and a 22% range improvement for HEB Companies on a city-driving eco-route. The i-EMS utilized rule-based methods and physics-based algorithms to predict and reduce energy consumption, with real-time monitoring and analysis through V2C connectivity enabling proactive decision-making. The project demonstrated the feasibility and economic viability of battery electric Class 8 trucks for long-haul operations, showcasing the potential of physics-aware machine learning in optimizing energy management. The successful implementation of the i-EMS in real-world scenarios validates its practical application and effectiveness, paving the way for the widespread adoption of battery electric vehicles in the freight transportation industry.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Entropy Analysis of FPGA Interconnect and Switch Matrices for Physical Unclonable Functions

Random variations in microelectronic circuit structures represent the source of entropy for physical unclonable functions (PUFs). In this paper, we investigate delay variations that occur through the routing network and switch matrices of a field-programmable gate array (FPGA). The delay variations are isolated from other components of the programmable logic, e.g., look-up tables (LUTs), flip-flops (FFs), etc., using a feature of Xilinx FPGAs called dynamic partial reconfiguration (DPR). A set of partial designs is created to fix the placement of a time-to-digital converter (TDC) and supporting infrastructure to enable the path delays through the target interconnect and switch matrices to be extracted by subtracting out common-mode delay components. Delay variations are analyzed in the different levels of routing resources available within FPGAs, i.e., local routing and across-chip routing. Data are collected from a set of Xilinx Zynq 7010 devices, and a statistical analysis of within-die variations in delay through a set of the randomly-generated and hand-crafted interconnects is presented.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1974

Road guide to geological points of interest on the island of Hawaii

This road guide briefly describes the points of geologic interest along the main roads on Hawaii. It begins at Hilo and proceeds around the island in a clockwise direction on State Route 11 to Kailua, then returns to Hilo on State Route 19 to Hilo via Waimea, with side excursions on the other principal roads. Minimum excursion time is two days, allowing only very brief time for the various stops. The return to Hilo from Waimea can be made via Route 19 along the Hamakua Coast (wet, leeward side of island, displaying typical tropical erosion) or via Route 20 over the Humuula Saddle (high, relatively dry and cool; young volcanic features).

Stearns, H. T.↗

NASA NTRS1980

Study of advanced communications satellite systems based on SS-FDMA

A satellite communication system based on the use of a multiple, contiguous beam satellite antenna and frequency division multiple access (FDMA) is studied. Emphasis is on the evaluation of the feasibility of SS (satellite switching) FDMA technology, particularly the multiple, contiguous beam antenna, the onboard switch and channelization, and on methods to overcome the effects of severe Ka band fading caused by precipitation. This technology is evaluated and plans for technology development and evaluation are given. The application of SS-FDMA to domestic satellite communications is also evaluated. Due to the potentially low cost Earth stations, SS-FDMA is particularly attractive for thin route applications up to several hundred kilobits per second, and offers the potential for competing with terrestrial facilities at low data rates and over short routes. The onboard switch also provides added route flexibility for heavy route systems. The key beneficial SS-FDMA strategy is to simplify and thus reduce the cost of the direct access Earth station at the expense of increased satellite complexity.

Kiesling, J.↗

NASA NTRS1981

Evaluation of Microwave Landing System (MLS) effect on the delivery performance of a fixed-path metering and spacing system

Metering and spacing (M & S) system's algorithms described assume an aircraft two dimensional are navigation capability. The three navigation systems compared were: very high frequency omnidirectional range/distance measuring equipment (VOR/DME) and ILS, VOR/DME and + or - 40 MLS, and VOR/DME and + or - 60 MLS. Other factors studied were M & S tentative schedule point location, route geometry effects, and approach gate location effects. Summarized results are: the MLS offers some improvement over VOR/DME and ILS if all approach routes contain computer assisted turns; pilot reaction to moving the gate closer to the runway threshold may adversely affect M & S performance; and coupling en route metering to terminal scheduling transfers most of the terminal holding to more full efficient, higher altitude en route delay.

Credeur, L.↗

NASA NTRS1982

Existing wind observation network

A real time wind observations of which the purpose is fuel efficient flight planning and air traffic control is discussed. The possibilities of travelling several ways, including a great circle route, a more or less straightline route and following wind circulation patterns was investigated. It is found that the longest route actually uses the least fuel, some 14% less than the great circle route. It is suggested that improving the observation system has an enormous potential and probably could easily pay for itself in a year. The profiler instrumentation is developed. Some broad characteristics of the instrumentation and of the program are shown. The instrumentation can function in clear air as well as cloudy air.

David E. Winer↗

NASA NTRS1985

Universal Cable Brackets

Concept allows routing easily changed. No custom hardware required in concept. Instead, standard brackets cut to length and installed at selected locations along cable route. If cable route is changed, brackets simply moved to new locations. Concept for "universal" cable brackets make it easy to route electrical cable around and through virtually any structure.

Vanvalkenburgh, C.↗

NASA NTRS1990

A network flow model for load balancing in circuit-switched multicomputers

In multicomputers that utilize circuit switching or wormhole routing, communication overhead depends largely on link contention - the variation due to distance between nodes is negligible. This has a major impact on the load balancing problem. In this case, there are some nodes with excess load (sources) and others with deficit load (sinks) and it is required to find a matching of sources to sinks that avoids contention. The problem is made complex by the hardwired routing on currently available machines: the user can control only which nodes communicate but not how the messages are routed. Network flow models of message flow in the mesh and the hypercube were developed to solve this problem. The crucial property of these models is the correspondence between minimum cost flows and correctly routed messages. To solve a given load balancing problem, a minimum cost flow algorithm is applied to the network. This permits one to determine efficiently a maximum contention free matching of sources to sinks which, in turn, tells one how much of the given imbalance can be eliminated without contention.

Bokhari, Shahid H.↗

NASA NTRS1990

A description and evaluation of TIMER: A time-based terminal flow-control concept

A description of a time-based ATC concept called TIMER (Traffic Intelligence for the Management of Efficient Runway-scheduling) and the results of a fast time and real time computer evaluation are presented. The concept was designed to improve the efficiency of extended terminal area operations (en route approach, transition, and terminal flight to the runway). TIMER integrates en route metering, fuel efficient cruise and profile descents, terminal sequencing and spacing together with computer-generated controller aids, in order to fully use runway capacity and improve efficiency of delay absorption. The concept, by using simplified aircraft models, accommodates both 4-D and non 4-D equipped aircraft and is designed for integration into the manual, voice linked ATC system in an evolutionary manner and still be able to accommodate proposed system upgrade features such as data link and further ground automation. Fast time and real time computer simulation results identify and show the effects and interactions of such key variables as horizon of control, metering fix and final approach delivery time errors, aircraft separation requirements, delay discounting, wind, flight technical error, and knowledge of aircraft final approach speed. The current ATC system has a runway interarrival-error standard deviation of approx. 26 seconds. Simulation results indicate that, with computer aiding, the runway interarrival-error standard deviation for non 4-D equipped traffic can be reduced to the region of 8 to 12 seconds if expected final approach speed is known; however, the reduction is only in the region of 16 to 20 seconds if expected final approach speed is unknown. Another major finding is that en route metering fix delivery-error standard deviation should be kept to less than a number somewhere between 35 to 45 seconds to achieve full runway capacity. This requirement implies the need for either airborne automation or assistance to the controller since the current manual performance in today's en route metering environment is in the order of 1.5 minutes.

Credeur, Leonard↗

NASA NTRS1990

Long-range vertical propagation

Development of the advanced turboprop has led to concerns about en route noise. Advanced turboprops generate low-frequency, periodic noise signatures at relatively high levels. As demonstrated in a flight test of NASA Lewis Research Center's Propfan Test Assessment (PTA) airplane in Alabama in October 1987, the noise of an advanced turboprop operating at cruise altitudes can be audible on the ground. The assessment of the en route noise issue is difficult due to the variability in received noise levels caused by atmospheric propagation and the uncertainty in predicting community response to the relatively low-level en route noise, as compared to noise associated with airport operations. The En Route Noise Test was designed to address the atmospheric propagation of advanced turboprop noise from cruise altitudes and consisted of measuring the noise of an advance turboprop at cruise in close proximity to the turboprop and on the ground. Measured and predicted ground noise levels are presented.

Willshire, William L., Jr.↗

NASA NTRS1992

Economic benefits of supersonic overland operation

Environmental concerns are likely to impose some restrictions on the next generation of supersonic commercial transport. There is a global concern over the effects of engine emissions on the ozone layer which protects life on Earth from ultraviolet radiation. There is also some concern over community noise. The High Speed Civil Transport (HSCT) must meet at least the current subsonic noise certification standards to be compatible with the future subsonic fleet. Concerns over sonic boom represent another environmental and marketing challenge to the HSCT program. The most attractive feature of the supersonic transport is speed, which offers the traveling public significant time-savings on long range routes. The sonic boom issue represents a major environmental and economic challenge as well. Supersonic operation overland produces the most desirable economic results. However, unacceptable overland sonic boom raise levels may force HSCT to use subsonic speeds overland. These environmental and economic challenges are likely to impose some restrictions on supersonic operation, thus introducing major changes to existing route structures and future supersonic network composition. The current subsonic route structure may have to be altered for supersonic transports to avoid sensitive areas in the stratosphere or to minimize overland flight tracks. It is important to examine the alternative route structure and the impact of these restrictions on the economic viability of the overall supersonic operation. Future market potential for HSCT fleets must be large enough to enable engine and airframe manufacturers to build the plane at a cost that provides them with an attractive return on investment and to sell it at a price that allows the airlines to operate with a reasonable margin of profit. Subsonic overland operation of a supersonic aircraft hinders its economic viability. Ways to increase the market potential of supersonic operation are described.

Metwally, Munir↗

NASA NTRS1993

A network flow model for load balancing in circuit-switched multicomputers

Bokhari, Shahid H.↗

NASA NTRS1998

Surface Hydrology in Global River Basins in the Off-Line Land-Surface GEOS Assimilation (OLGA) System

Land surface hydrology for the Off-line Land-surface GEOS Analysis (OLGA) system and Goddard Earth Observing System (GEOS-1) Data Assimilation System (DAS) has been examined using a river routing model. The GEOS-1 DAS land-surface parameterization is very simple, using an energy balance prediction of surface temperature and prescribed soil water. OLGA uses near-surface atmospheric data from the GEOS-1 DAS to drive a more comprehensive parameterization of the land-surface physics. The two global systems are evaluated using a global river routing model. The river routing model uses climatologic surface runoff from each system to simulate the river discharge from global river basins, which can be compared to climatologic river discharge. Due to the soil hydrology, the OLGA system shows a general improvement in the simulation of river discharge compared to the GEOS-1 DAS. Snowmelt processes included in OLGA also have a positive effect on the annual cycle of river discharge and source runoff. Preliminary tests of a coupled land-atmosphere model indicate improvements to the hydrologic cycle compared to the uncoupled system. The river routing model has provided a useful tool in the evaluation of the GCM hydrologic cycle, and has helped quantify the influence of the more advanced land surface model.

Bosilovich, Michael G.↗

NASA NTRS2000

Corrosion Issues for Ceramics in Gas Turbines

The requirements for hot-gas-path materials in gas turbine engines are demanding. These materials must maintain high strength and creep resistance in a particularly aggressive environment. A typical gas turbine environment involves high temperatures, rapid gas flow rates, high pressures, and a complex mixture of aggressive gases. Figure 26.1 illustrates the requirements for components of an aircraft engine and critical issues [1]. Currently, heat engines are constructed of metal alloys, which meet these requirements within strict temperature limits. In order to extend these temperature limits, ceramic materials have been considered as potential engine materials, due to their high melting points and stability at high temperatures. These materials include oxides, carbides, borides, and nitrides. Interest in using these materials in engines appears to have begun in the 1940s with BeO-based porcelains [2]. During the 1950s, the efforts shifted to cermets. These were carbide-based materials intended to exploit the best properties of metals and ceramics. During the 1960s and 1970s, the silicon-based ceramics silicon carbide (SiC) and silicon nitride (Si3N4) were extensively developed. Although the desirable high-temperature properties of SiC and Si3N4 had long been known, consolidation of powders into component-sized bodies required the development of a series of specialized processing routes [3]. For SiC, the major consolidation routes are reaction bonding, hot-pressing, and sintering. The use of boron and carbon as additives which enable sintering was a particularly noteworthy advance [4]. For Si3N4 the major consolidation routes are reaction bonding and hot pressing [5]. Reaction-bonding involves nitridation of silicon powder. Hot pressing involves addition of various refractory oxides, such as magnesia (MgO), alumina (Al2O3), and yttria (y2O3). Variations on these processes include a number of routes including Hot Isostatic Pressing (HIP), gas-pressure sintering, sinter-HIPing, and Encapsulation-HIPing. It is important to note that each process involves the addition of secondary elements, which later were shown to dramatically influence oxidation and corrosion behavior. As dense bodies of silicon-based ceramics became more readily available, their desirable high temperature properties were confirmed. These materials retained strength to very high temperatures (i.e. 1300-1400 C). Further, they were lightweight and made from abundant materials. SiC and Si3N4 therefore emerged as leading ceramic candidates for components in heat engines, designed to operate at higher temperatures for better performance and fuel efficiency. The first US programs for ceramics in heat engines have been reviewed [6]. Selected programs on ceramic engine parts are summarized here in regard to their contributions to understanding the corrosion behavior of a heat engine environment.

Jacobson, Nathan S.↗

NASA NTRS1998

Steps Towards the Integration of Conflict Resolution with Metering and Scheduling

NASA Ames Research Center is developing decision support tool technology for air traffic controllers to improve the efficiency and capacity of National Airspace System. The goal is to provide technology, tools and procedures that result in the highest possible level of user preferred trajectories whenever possible with safe and efficient traffic management when necessary. The work is being conducted under the NASA Advanced Air Transportation Technology Program in cooperation with the FAA through the Inter-Agency Integrated Product Team. The objective is to develop technology and procedures that lead towards a seamless integration of conflict resolution with metering and scheduling for arrival aircraft and en route aircraft that are under metering restrictions. A requirement is that the integration incorporate user preferred trajectories. The ultimate goal is the implementation and validation of the Descent Advisor (DA) concept which provides clearance advisories to a sector controller that simultaneously meet metering constraints, are conflict free, incorporate a user preferred (e.g., minimum fuel) descent profile, and generally require no further corrective clearance as the aircraft transitions from en route cruise into the TRACON. The DA concept may also be applied to en route aircraft under metering constraints, e.g., miles-in-trail. To achieve the DA concept a stepwise development and field evaluation is anticipated. This paper addresses the initial steps towards implementation of the DA. The Traffic Management Advisor (TMA) computes arrival time sequence and required delay information for display to the sector controller during periods when arrivals must be metered due to landing rate restrictions at the airport. The Initial Conflict Probe (ICP) compares trajectory predictions for all aircraft and alerts the controller when any two aircraft are predicted to violate separation standards (5 mi. and 2000 ft. in en route airspace). ICP also includes a trial planning function allowing the controller to develop and check a separate "what if" trajectory for conflict resolution. TMA and ICP currently operate independent of one another and have separate controller displays. The TMA meter list is on the radar controller's plan view display. The ICP is still under development, but the current concept calls for a list of predicted conflicts at the data controller position. The research described herein address two steps towards the implementation of DA. The first is to develop a concept for integrated display of conflict and metering information on a controller's display. The objective is to provide the controller with situational awareness of one problem while he develops a solution to the other. The next step is to expand the concept for display of automated clearance advisories for one problem (e.g., metering) which take into account the other problems (e.g., conflicts). Information to be communicated between TMA and ICP to facilitate' manual or automated advisories is being identified as the concept matures. In order to study the ICP/TMA integration concept the CTAS conflict probe capability has been adapted to Ft. Worth Center. The system is being validated in the laboratory with all-track data and for non -interference with TMA, TMA is already running as a daily use prototype at Ft. Worth Center. A laboratory prototype system has been developed under the CTAS baseline which combines conflict and metering information on a common user interface. Elements of the user interface are shown in Figure 1. In this simple illustration the user sees the simultaneous effect of a trial plan on meter fix delay and conflict status. Delay information is shown in the aircraft flight data block, the meter list, and the TMA timeline. Experience during Descent Advisor development and observations at Ft. Worth Center high and low attitude arrival sectors during metering suggests that manual trial planning will be unworkable during rush periods due to high controller workload.

McNally, B. David↗

NASA NTRS1998

The Future of Air Traffic Management

A system for the control of terminal area traffic to improve productivity, referred to as the Center-TRACON Automation System (CTAS), is being developed at NASA's Ames Research Center under a joint program with the FAA. CTAS consists of a set of integrated tools that provide computer-generated advisories for en-route and terminal area controllers. The premise behind the design of CTAS has been that successful planning of traffic requires accurate trajectory prediction. Data bases consisting of representative aircraft performance models, airline preferred operational procedures and a three dimensional wind model support the trajectory prediction. The research effort has been the design of a set of automation tools that make use of this trajectory prediction capability to assist controllers in overall management of traffic. The first tool, the Traffic Management Advisor (TMA), provides the overall flow management between the en route and terminal areas. A second tool, the Final Approach Spacing Tool (FAST) provides terminal area controllers with sequence and runway advisories to allow optimal use of the runways. The TMA and FAST are now being used in daily operations at Dallas/Ft. Worth airport. Additional activities include the development of several other tools. These include: 1) the En Route Descent Advisor that assist the en route controller in issuing conflict free descents and ascents; 2) the extension of FAST to include speed and heading advisories and the Expedite Departure Path (EDP) that assists the terminal controller in management of departures; and 3) the Collaborative Arrival Planner (CAP) that will assist the airlines in operational decision making. The purpose of this presentation is to review the CTAS concept and to present the results of recent field tests. The paper will first discuss the overall concept and then discuss the status of the individual tools.

Denery, Dallas G.↗

NASA NTRS2003

Airborne Conflict Management within Confined Airspace in a Piloted Simulation of DAG-TM Autonomous Aircraft Operations

A human-in-the-loop experiment was performed at the NASA Langley Research Center to study the feasibility of Distributed Air/Ground Traffic Management (DAG-TM) autonomous aircraft operations in highly constrained airspace. The airspace was constrained by a pair of special use airspace (SUA) regions on either side of the pilot s planned route. The available airspace was further varied by changing the separation standard for lateral separation between 3 nm and 5 nm. The pilot had to maneuver through the corridor between the SUA s, avoid other traffic and meet flow management constraints. Traffic flow management (TFM) constraints were imposed as a required time of arrival and crossing altitude at an en route fix. This is a follow-up study to work presented at the 4th USA/Europe Air Traffic Management R&D Seminar in December 2001. Nearly all of the pilots were able to meet their TFM constraints while maintaining adequate separation from other traffic. In only 3 out of 59 runs were the pilots unable to meet their required time of arrival. Two loss of separation cases are studied and it is found that the pilots need conflict prevention information presented in a clearer manner. No degradation of performance or safety was seen between the wide and narrow corridors. Although this was not a thorough study of the consequences of reducing the en route lateral separation, nothing was found that would refute the feasibility of reducing the separation requirement from 5 nm to 3 nm. The creation of additional, second-generation conflicts is also investigated. Two resolution methods were offered to the pilots: strategic and tactical. The strategic method is a closed-loop alteration to the Flight Management System (FMS) active route that considers other traffic as well as TFM constraints. The tactical resolutions are short-term resolutions that leave avoiding other traffic conflicts and meeting the TFM constraints to the pilot. Those that made use of the strategic tools avoided additional conflicts, whereas, those making tactical maneuvers often caused additional conflicts. Many of these second-generation conflicts could be avoided by improved conflict prevention tools that clearly present to the pilot which maneuver choices will result in a conflict-free path. These results, together with previously reported studies, continue to support the feasibility of autonomous aircraft operations.

Barmore, Bryan↗