Design and Development Assessment
An assessment methodology is described and illustrated.
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An assessment methodology is described and illustrated.
As compared to conventional nuclear reactors, microreactors have the potential to significantly reduce construction timelines and capital costs, decreasing the barriers for advanced nuclear reactor technologies. However, the lower power output of these microreactors (typically < 20 MWe) creates challenging economics if operation and maintenance costs cannot be sufficiently reduced. The compact size of these designs presents an opportunity for comprehensive in-situ structural health monitoring to provide real-time feedback in order to reduce operational costs associated with maintenance and downtime. Many microreactor concepts use graphite for both in-core neutron moderation and as a structural material, which has typically required some form of periodic and laborious inspection. This report provides a description and assessment of recent work with graphite to couple acoustic-based experimental measurements and characterization with machine learning models to mature structural health monitoring capabilities and generate benefits for the nuclear microreactor industry. With resilient embedded sensors in development in other programs funded by the US Department of Energy’s Office of Nuclear Energy and elsewhere, the work described herein builds upon previously funded efforts to mature non-destructive testing technology that relates measured vibrational signatures to structural changes, using a combination of new experimental measurements and machine learning processing. Building on past successful demonstrations of predictive workflows to identify structural changes in a hexagonal stainless steel test article with excellent acoustic propagation, we first performed baseline characterization on graphite samples with canonical geometries to ensure compatibility and confidence in the applied techniques for a material with distinctly different mechanical properties. In contrast to efforts in previous years, we worked exclusively with unidirectional vibration data that is more comparable to those expected from the existing embedded sensor technologies which are suitable for deployment in a reactor setting. Established acoustic and modern machine-learning-based characterization approaches were applied to the resulting datasets from these simple geometries. Both approaches were found to be highly capable of detecting even small geometric irregularities amongst nominally identical samples. As such, we then moved to testing these approaches for detection of artificial local stress perturbations introduced into a more complex geometry: a hexagonal block with drilled holes. A main outcome of this work is that a generalizable ML workflow can be used to detect and predict the characteristics of small artificial anomalies in a graphite component with a relevant geometry. While this work was performed using surficial vibration data, we expect the approach to be flexible and viable for other monitoring scenarios, such as those with different arrangements or types of sensor arrays. As compared to previously funded efforts, an existing ML workflow based on neural networks was enhanced through the addition of recently developed Fourier neural operators. As applied to previously collected and new vibration datasets, prediction accuracies of anomaly characterizations were greatly improved with minimal added computational cost. As trained on small durations of vibration data (tens of seconds) collected over a realistic number of locations, the model was able to reliably determine the presence of a subtle stress anomaly and begin to provide location estimates. Such an approach is likely to be viable for more relevant reactor damage scenarios for graphite components, such as progressive crack growth or creep.
This report discusses testing of a bi-axial woven panel consisting of high-strength webbings that represent a portion of the structural restraint layer of an inflatable space structure. Inflatable softgoods vessels are being researched for human space missions as possible habitats, airlocks and tunnel elements. Understanding the complex behavior of the softgoods restraint layer and maturing finite element analysis capabilities to model these structures is critical to their successful implementation. The primary goal of this research is to study the load-up and load distribution in a weave of webbings, before and after the loss of tension in one of the webbings. In addition, a key objective is to evaluate the ability to convert strains measured via photogrammetry using digital image correlation to loads in the weave. The report gives an introduction and objectives for the test program and a description of the test fixture, setup and procedure. This is followed by a section focusing on the test data and associated discussion. To streamline presentation of the data, one focus case is detailed in the main text. (Comprehensive data set can be found in Appendix A for the three remaining test cases.) In addition to the load and time histories for one case, summary charts and tables that incorporate data from all four test cases are provided. The concluding remarks include major findings, lessons learned and recommendations for future work. Appendix B provides complementary full-field strain results when considering the existing woven webbing data as a fabric. These types of results could inform models intended for global representation. Appendix C contains a description from a series of exploratory instrumented hammer tap tests and results on the weave. These tests describe an area of research for the biaxial test fixture beyond the current testing studying the propagation and detection of vibrations in a tensioned weave that has applications in impact and damage detection.
Maturation and validation of predictive modeling capabilities for plume-surface interaction, and the effects caused by the impingement of rocket engine exhaust on surface regolith, require relevant, highly characterized ground test data. The multi-phase nature of this problem poses challenges to ground testing across physical scaling, test environments and techniques, and diagnostics. NASA has developed a Physics Focused Ground Test (PFGT) of plume-surface interaction to address this need. The PFGT is a subscale, inert-gas experiment at Mars- and Lunar-relevant ambient pressure conditions that will provide critical data for model validation of cratering, ejecta, and plume physics. In this test, the ambient pressure in a vacuum chamber will be varied, along with the height of a supersonic nozzle above a surface, and the mass flow rate through the nozzle. Testing will be performed on a range of regolith simulants of varying composition and will also include instrumented impingement plate tests in place of regolith simulant to characterize gas-only plume physics. Novel high-speed visual diagnostics will capture temporal data on crater formation and ejecta dynamics, and planar laser-induced fluorescence diagnostics will capture plume structure and behavior. This paper will present an overview of the data collected during this test – for both the cratering and ejecta testing and the gas-only plume physics testing. Emphasis will be placed on trends, effects, and interactions observed in the data across the test parameter space.
Maturation and validation of predictive modeling capabilities for plume-surface interactions and their effects requires relevant, highly characterized ground test data. The National Aeronautics and Space Administration has developed a test bed for these behaviors under its Game Changing Developments Plume Surface Interactions project, and has undertaken testing at the Marshall Space Flight Center to address critical data needs. This manuscript provides a high-level overview of the testing and its associated data.
As part of the Game Changing Development (GCD) Program, funded by NASA’s Space Technology Mission Directorate (STMD), the development of simulation capability for the prediction of extra-terrestrial Plume Surface Interaction (PSI) environments has been undertaken by the Fluid Dynamics Branch at NASA/MSFC. The Predictive Simulation Capability (PSC) Element is focused on creating simulation capability for the reliable and accurate prediction of PSI in Martian (~650 Pa) and Lunar (vacuum) ambient environments. In addition to the predictive simulation capability, the GCD Program also contains a companion Ground Testing Element for development of focused datasets for validation of predictive capability as well as a Flight-focused Instrumentation Element. This paper will present the status of implementing and maturing particle-particle interaction constituent physics models essential in simulating the landing surface granular material flow under PSI effects. This gas-particle multi-phase interaction modeling of plume impingement flow on the extra-terrestrial soil material is performed with the Gas-Granular Flow Solver (GGFS) addressed in a companion paper. The response of regolith particle flow induced by lander PSI requires accurate representation of the regolith granular material fluidic behavior and gas-granular interactions. The lunar regolith, as the extreme example, is poorly sorted with broad particle size distributions and large fines content. It has significant cohesion, due to interlocking particle shapes for the very jagged particles. The combination of particle shape and size distribution has been identified as major drivers in the complex particle flow response and resulting crater shape characteristics of extraterrestrial granular material. Constituent models for spherical particles can be formulated directly from particle kinetics theory. Complex particle shapes can be modeled by gluing together elemental spherical shapes into composite particles, requiring a Discrete Element Model (DEM) particle kinetics modeling approach to extract data and formulate constituent models. Mixture constituent models for poly-disperse mixtures (i.e, containing distribution of particle sizes) have recently been developed. The required non-spherical particle mixture granular material response closure models are then obtained through small-scale unit physics DEM simulations for the range of particle shapes, mixtures and packing densities. The granular material response closure models are then implemented in the Eulerian granular flow formulation. This DEM-based constituent model extraction process and formulation of poly-disperse particle mixtures has been successfully developed by small business and academic partners in the development of the Gas-Granular Flow Solver (GGFS) simulation program simulation framework. The currently implemented capabilities have reached the capability level of modeling bi-disperse, non-spherical particle mixtures is being continuously extended towards computational modeling of full range irregular particle mixtures. Under the GCD project, this technology is being further developed, transferred to NASA analysts, and matured towards application readiness. The predictive simulation capability team under the GCD project has acquired the modeling tools and processes of the DEM based constituent model formulation from the GGFS development team and is developing the capability to replicate the existing process. This is the first important step towards the ability of the NASA team to independently perform such model development in a production setting. Further efforts are underway to migrate the DEM based model simulation process performed with the academic based tools to more capable Open Source, highly parallelized simulation tools for efficient operation on NASA HPC assets. Evaluation of the currently implemented (such as mono-disperse and bi-disperse spherical and irregular shape particle constituent model applications) and continuously evolving full-range particle physics models in the GGFS tool is performed by the NASA team to advance application readiness of the simulations. Application testing for complex PSI erosions and cratering scenarios such as the Apollo LM is performed for axi-symmetric and full 3D simulations to aid the tool developers in achieving practical application readiness for NASA projects. Important validation and application testing will further be performed against experimental data generated under the GCD PSI project experimental component.
This report details model development, theory, and a literature review focusing on the emission of contaminants on solid substrates in fires. This is the final report from a 2-year Nuclear Safety Research and Development (NSRD) project. The work represents progress towards a goal of having modeling and simulation capabilities that are sufficiently mature and accurate that they can be utilized in place of physical tests for determining safe handling practices. At present, the guidelines for safety are largely empirically based, derived from a survey of existing datasets. This particular report details the development, verification and calibration of a number of code improvements that have been implemented in the SIERRA suite of codes, and the application of those codes to three different experimental scenarios that have been subject of prior tests. The first scenario involves a contaminated PMMA slab, which is exposed to heat. The modeling involved a novel method for simulating the viscous diffusion of the particles in the slab. The second scenario involved a small pool fire of contaminated combustible liquid mimicking historical tests and finds that the release of contaminants has a high functionality with the height of the liquid in the container. The third scenario involves the burning of a contaminated tray of shredded cellulose. A novel release mechanism was formulated based on predicted progress of the decomposition of the cellulose, and while the model was found to result in release that can be tuned to match the experiments, some modifications to the model are desirable to achieve quantitative accuracy.
The evolving landscape of cybersecurity necessitates a paradigm shift to a Zero Trust (ZT) model, which assumes breaches and continuously verifies trust. This approach reshapes how trust boundaries are established, focusing on identities, devices, networks, applications, and data, rather than solely relying on perimeter defenses such as firewalls. Central to this transformation is the National Institute of Standards and Technology's (NIST) Special Publication 800-207, outlining the Zero Trust Architecture (ZTA), along with Executive Order 14028, which mandates federal agencies to adopt ZT principles. Complementary to these efforts, the Cybersecurity and Infrastructure Security Agency (CISA) developed the Zero Trust Maturity Model (ZTMM), providing a framework with five pillars and three cross-cutting capabilities to guide agencies toward enhanced cybersecurity maturity. In support of these initiatives, the DHS Countering Weapons of Mass Destruction Office (CWMD) is applying ZT principles to secure Chemical, Biological, Radiological, and Nuclear (CBRN) detection systems. Recognizing the diverse deployment models and network connectivity of these systems—from stationary, non-networked units to mobile, cloud-connected devices—the Pacific Northwest National Laboratory (PNNL) is developing cybersecurity scenarios specifically for CBRN environments. These scenarios examine various configurations and technological capabilities, offering insights into the application of ZTMM pillars in enhancing the security postures of CBRN devices. The cybersecurity scenarios presented by PNNL are hypothetical, crafted to explore theoretical situations and stimulate discussion on the potential use or compromise of CBRN detection systems in varied contexts. These narratives are illustrative and do not reference any real events or actual networks. Instead, they employ generalized reference models to highlight concepts and potential issues within CBRN security, focusing on how Zero Trust strategies can be adapted to address these challenges effectively.
A modular structured system of computer programs is presented utilizing earth and ocean dynamical data keyed to finitely defined parameters. The model is an assemblage of mathematical algorithms with an inherent capability of maturation with progressive improvements in observational data frequencies, accuracies and scopes. The Eom in its present state is a first-order approach to a geophysical model of the earth's dynamics.
High-fidelity computational fluid dynamics (CFD) simulations have so far only played exploratory and supporting roles in the study and qualification of parachutes for planetary entry. The last few years have seen the maturation of coupled computational methods that are capable of modeling the complex fluid-structure interactions between a parachute canopy and the supersonic flow in the wake of an entry vehicle in flight conditions. One of the primary goals of these methods is to predict the peak opening load experienced by the parachute during inflation. The Launch, Ascent, and Vehicle Aerodynamics (LAVA)team is developing efficient, high-fidelity numerical methods to perform such challenging fluid-structure interaction simulations. A loose coupling approach is used to advance the solutions of a Cartesian ghost cell immersed boundary method CFD solver and a finite element computational structural dynamics (CSD) solver in space and time. The coupled solver is employed to simulate the ASPIRE SR01 flight test, where a build-to-print version of the Mars Science Laboratory parachute was inflated in supersonic conditions in the upper terrestrial atmosphere. The simulations conducted in the current paper predict a peak opening load that is within 10% of that from the flight test. Grid convergence with respect to the volume and structural domains is demonstrated, and less than 1% variation in the peak opening load is predicted between all grid resolutions.
The last few years have seen a marked increase in the sophistication of models of the solar corona. This has been brought about by a confluence of three key elements. First, the collection of high-resolution observations of the Sun, both in space and time, has grown tremendously. The SOHO (Solar Heliospheric Observatory) mission is providing additional correlated high-resolution magnetic, white-light and spectroscopic observations. Second, the power and availability of supercomputers has made two- and three-dimensional modeling routine. Third, the sophistication of the models themselves, both in their geometrical realism and in the detailed physics that has been included, has improved significantly. The support from our current Space Physics Theory grant has allowed us to exploit this confluence of capabilities. We have carried out direct comparisons between observations and models of the solar corona. The agreement between simulated coronal structure and observations has verified that the models are mature enough for detailed analysis, as we will describe. The development of this capability is especially timely, since observations obtained from three space missions that are underway (Ulysses, WIND and SOHO) offer an opportunity for significant advances in our understanding of the corona and heliosphere. Through this interplay of observations and theory we can improve our understanding of the Sun. Our achievements thus far include progress modeling the large-scale structure of the solar corona, three-dimensional models of active region fields, development of emerging flux and current, formation and evolution of coronal loops, and coronal heating by current filaments.
The NASA Human Research Program’s (HRP) Exploration Medical Capability (ExMC) Element is utilizing a Model Based Systems Engineering (MBSE) approach to enhance the development of systems engineering products that will be used to advance medical system designs for exploration missions beyond Low Earth Orbit. In support of future missions, the team is capturing content such as system behaviors, functional decompositions, architecture, system requirements and interfaces, and recommendations for clinical capabilities and resources in Systems Modeling Language (SysML) models. As these products mature, SysML models provide a way for ExMC to capture relationships among the various products, which includes supporting more integrated and multi-faceted views of future medical systems. In addition to using SysML models, HRP and ExMC are developing supplementary tools to support two key functions: 1) prioritizing current and future research activities for exploration missions in an objective manner; and 2) enabling risk-informed and evidence-based trade space analysis for future space vehicles, missions, and systems. This paper will discuss the long-term HRP and ExMC vision for the larger ecosystem of tools, which include dynamic Probabilistic Risk Assessment (PRA) capabilities, additional SysML models, a database of system component options, and data visualizations. It also includes a review of an initial Pilot Project focused on enabling medical system trade studies utilizing data that is coordinated across tools for consistent outputs (e.g., mission risk metrics that are associated with medical system mass values and medical conditions addressed). This first Pilot Project demonstrated successful operating procedures and integration across tools. Finally, the paper will also cover a second Pilot Project that utilizes tool enhancements such as medical system optimization capabilities, post-processing, and visualization of generated data for subject matter expert review, and increased integration amongst the tools themselves.
The NASA Human Research Program's (HRP) Exploration Medical Capability (ExMC) Element is utilizing a Model Based Systems Engineering (MBSE) approach to enhance the development of systems engineering products that will be used to advance medical system designs for exploration missions beyond Low Earth Orbit. In support of future missions, the team is capturing content such as system behaviors, functional decompositions, architecture, system requirements and interfaces, and recommendations for clinical capabilities and resources in Systems Modeling Language (SysML) models. As these products mature, SysML models provide a way for ExMC to capture relationships among the various products, which includes supporting more integrated and multi-faceted views of future medical systems. In addition to using SysML models, HRP and ExMC are developing supplementary tools to support two key functions: 1) prioritizing current and future research activities for exploration missions in an objective manner; and 2) enabling risk-informed and evidence-based trade space analysis for future space vehicles, missions, and systems. This paper will discuss the long-term HRP and ExMC vision for the larger ecosystem of tools, which include dynamic Probabilistic Risk Assessment (PRA) capabilities, additional SysML models, a database of system component options, and data visualizations. It also includes a review of an initial Pilot Project focused on enabling medical system trade studies utilizing data that is coordinated across tools for consistent outputs (e.g., mission risk metrics that are associated with medical system mass values and medical conditions addressed). This first Pilot Project demonstrated successful operating procedures and integration across tools. Finally, the paper will also cover a second Pilot Project that utilizes tool enhancements such as medical system optimization capabilities, post-processing, and visualization of generated data for subject matter expert review, and increased integration amongst the tools themselves.
Digital engineering (DE) and integrated computational materials engineering (ICME) are widely recognized as critical enablers of faster, more affordable, and more reliable aerospace systems. However, many organizations have struggled to realize the promised return on investment (ROI) from digital initiatives. A primary reason is the absence of a shared, decision-focused framework that distinguishes simple digitization of existing workflows from true digital transformation that fundamentally changes how engineering decisions are made. This paper introduces an ICME capability maturity framework that fills this gap. The framework defines six cumulative ICME capability maturity levels (CMLs), explicitly tied to decision authority, engineering integration, optimization, and uncertainty management across material, process, structure, and performance scales. It is designed to complement established readiness metrics such as technology readiness levels (TRLs), manufacturing readiness levels (MRLs), and integration readiness levels (IRLs), by addressing a missing dimension: the conditions required for model-informed decision authority across scales. A unifying figure and capability table illustrate the six-level ICME Capability Maturity Framework, showing how organizations progress from digitization—with limited or negative ROI—to true digital transformation, where ICME-enabled workflows deliver measurable improvements in decision quality, cycle time, risk reduction, and reuse. The framework is intended for both technical practitioners and executive leadership, providing a common language to assess current state, guide roadmaps, align software ecosystem investments, and set realistic expectations for digital transformation outcomes. A regulatory-relevant statement clarifying the relationship between ICME capability and existing certification frameworks is provided.
As part of the Game Changing Development (GCD) Program funded by NASA’s Space Technology Mission Directorate (STMD), the development of simulation capability for the prediction of extra-terrestrial plume surface interaction (PSI) environments has been undertaken by the Fluid Dynamics Branch at NASA/MSFC. The Predictive Simulation Capability (PSC) Element is focused on creating simulation capability for the reliable and accurate prediction of PSI in Martian (~650 Pa) and Lunar (vacuum) ambient environments. In this paper, an overview and brief status on one area of capability development through this GCD PSI project, capturing the effects of mixed continuum/rarefied flow on crater development and ejecta sheets, is presented with respect to capability enhancements, predictive tool maturation, and validation of the Loci/GGFS tool against PSI data in Martian and Lunar environments. Axisymmetric modeling, overset mesh/moving mesh, and multiple-species mixture modeling capabilities are verified against Loci/CHEM, and a demonstration of the capabilities is presented for the Apollo Lunar Module.
Crop models are useful tools for simulating agricultural systems that require continued model development and testing to increase their robustness and improve how they describe our current understanding of processes. Coordinated and “blind” evaluation of multiple models using same protocols and experimental datasets provides unique opportunities to further improve models and enhance their reliability. For soybean [Glycine max (L.) Merr.], there has been limited coordinated multi-model evaluations for the simulation of in-season plant growth dynamics. We evaluated ten dynamic soybean crop models for their simulation of in-season plant growth using data from five experiments conducted in Argentina, Brazil, France, and USA. We evaluated models after a Blind (using only phenology data) and a Full calibration (with in-season and end-of-season variables). Calibration reduced model uncertainty by reducing standard bias for the simulation of in-season variables (biomass, leaf, pod, and stem weights, and leaf area index, LAI). However, we found that most models had difficulty in reproducing leaf growth dynamics, with normalized root mean squared error (nRMSE) of 56% for leaf weight and 43% for LAI (across locations and models after Full calibration). Models with different levels of complexity and experience were capable of simulating final seed yield at maturity with reasonable accuracy (nRMSE of 8–31% after Full calibration). However, the nRMSE for pod weight (of 17–64% after Full calibration) was two-fold larger than that of seed yield. Moreover, the models differed in how they simulated timing from sowing to beginning seed growth (47–93 days) and effective seed filling period (18–54 days), owing to model structural differences in defining the reproductive developmental stages. Overall, we identified the following processes that can benefit from further model improvement: leaf expansion and senescence, reproductive phenology, and partitioning to reproductive growth. Simulation of pod wall tissue and individual seed cohorts is another aspect that many models currently lack. Model improvement can benefit from high-temporal resolution experimental datasets that concurrently account for phenology, plant growth, and partitioning. Further, we recommend collecting reproductive phenology in the field consistent with actual dry matter allocation to organs in the models and collecting multiple observations of seed and pod weight to aid model improvement for simulation of seed growth and yield formation.
The purpose of this paper is to review existing smart manufacturing (SM) maturity models' dimensions and maturity levels to assess their applicability and drawbacks. There are many maturity models available but many of them have not been validated or do not provide a useful guide or tool for applications. This gap creates the need for a review of the existing maturity model's applicability. Nineteen peer-reviewed maturity models related to “Digital Transformation,” “Industry 4.0” or “Smart Manufacturing” were selected based on a systematic literature review and five consulting firm models were selected based on the author's industry knowledge. The chosen models were analyzed to determine 10 categories of dimensions. Then they are assessed on a 1–5 scale for how applicable they are in the 10 categories of dimensions. The five “consulting firm” models have a first-mover advantage, are more widely used in industry and are more applicable, but some require payment, and they lack published details and validation. The 19 “peer reviewed” models are not as widely used, lack awareness in the industry and are not as easy to apply because of no web tool for self-assessment, but they are improving. The categories defined to characterize the models and facilitate comparisons for users include “Information Technology (IT) and Cyber-Physical System (CPS) and Data,” “Strategy and Organization,” “Supply Chain and Logistics,” “Products and Services,” “Culture and Employees,” “Technology and Capabilities,” “Customer and Market,” “Cybersecurity and Risk,” “Leadership and Management” and “Governance and Compliance.” The analyzed maturity models were particularly weak in the areas of cybersecurity, leadership and governance. Researchers and practitioners can use this review with consideration of their specific needs to determine if a maturity model is applicable or if a new model needs to be developed. The review can also aid in the development of maturity models through the discussion of each of the dimension categories. Finally, compared to existing reviews of SM maturity models, this research determines comprehensive dimension categories and focuses on applicability and drawbacks.
A vital part of the licensing process for advanced (non-LWR) nuclear reactor developers in the United States is the assessment of the reactor’s source term, i.e., the potential release of radionuclides from the reactor system to the environment during normal operations and accident sequences. In comparison to source term assessments which follow a bounding approach with conservative assumptions, a mechanistic approach to modeling radionuclide transport, which realistically accounts for transport and retention phenomena, is expected to be used for advanced reactor systems. As the designs of advanced reactors increase in maturity and progress towards licensing, there is a need to advance modeling and simulation capabilities in analyzing the mechanistic source term (MST) of a prospective reactor concept. In the present work, a survey is provided of existing computational capabilities for the modeling of advanced reactors MSTs. The following reactors are considered: high temperature gas reactors (HTGR); molten salt reactors (MSR) which include salt-fueled reactors and fluoride salt-cooled high temperature reactors (FHR); and sodium- and lead-cooled fast reactors (SFR, LFR). A review of relevant codes which may be useful in providing information to MST analyses is also completed, including codes that have been used for source term analyses of LWRs, as well as those being developed for other aspects of advanced reactor system modeling such as reactor physics, thermal hydraulics, and chemistry. A discussion of MST modeling capabilities for each reactor type is provided with additional focus on important phenomena and functional requirements. Additionally, a comprehensive survey is provided of tools for consequence modeling such as atmospheric transport and dispersion (ATD).