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DOE OSTI2021

U.S. Manufacturing Water Use Data and Estimates: Current State, Limitations, and Future Needs for Supporting Manufacturing Research and Development

Water is essential to manufacturing operations; without it, many facilities could not operate or meet production demands. Physical, reputational, and regulatory risks to water supplies compounded by climate change-induced impacts on hydrological conditions threaten the adequacy of water supplies for manufacturing. Manufacturing water use has not been a major focus of either water or manufacturing-related research. Research and development (R&D) aimed at helping manufacturers use water more sustainably and adapt to changing water conditions is needed to ensure a thriving sector and economy. However, the ability to identify R&D needs is severely limited due to a lack of current, statistically representative data on manufacturing water use and its environmental implications. In this Perspective, we outline four key questions to inform R&D on manufacturing use and highlight how the current state of water data in the United States does not support the adequate investigation of these questions. We make recommendations for the water data characteristics needed to explore the research questions and knowledgeably inform R&D on manufacturing water use.

McCall, James↗

DOE OSTI2022

Safety Analysis for the Versatile Test Reactor Conceptual Design

Safety analysis simulations have been carried out using the SAS4A/SASSYS-1 safety analysis code system to update the baseline set of results for the Versatile Test Reactor conceptual design. Results from a previous revision of this work provided input for the Conceptual Safety Design Report summarizing the overall safety basis for the VTR. This work will also support future analyses that will be required for Chapter 13, “Accident Analysis,” of a preliminary safety analysis report. A number of transients have been evaluated based on categories of postulated accident sequences suggested for consideration in NUREG-1537. Ultimately, the full spectrum of event initiators and subsequent accident sequences will be defined through a probabilistic risk assessment of the plant design following the implementation of the Licensing Modernization Project guidelines as described in the VTR Safety Design Strategy. Since that process is ongoing, the present analysis addresses several transients that are expected to be bounding accident scenarios that represent the three key ways to perturb a reactor: through changes to the core inlet temperature, mass flow rate, or reactivity. These correspond to a loss of heat sink (LOHS), loss of flow (LOF) or station blackout (SBO), and transient overpower (TOP), respectively. Both Protected and Unprotected versions of these transients have been evaluated, along with additional transients that include transient overpower with one stuck rod, pump coast-down failures, seismic events, and overcooling events. At the current stage of design, transient simulation results for the Versatile Test Reactor indicate that large safety margins exist for many event initiators. However, several “enabling” assumptions have been made, in terms of both design features and design limits, in order to perform the analyses; and these assumptions will need to be revised as the design matures. In addition, a larger spectrum of events needs to be evaluated as part of the on-going probabilistic risk assessment process.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

Selective NMR observation of the SEI–metal interface by dynamic nuclear polarisation from lithium metal

While lithium metal represents the ultimate high-energy-density battery anode material, its use is limited by dendrite formation and associated safety risks, motivating studies of the solid–electrolyte interphase layer that forms on the lithium, which is key in controlling lithium metal deposition. Dynamic nuclear polarisation enhanced NMR can provide important structural information; however, typical exogenous dynamic nuclear polarisation experiments, in which organic radicals are added to the sample, require cryogenic sample cooling and are not selective for the interface between the metal and the solid–electrolyte interphase. Here we instead exploit the conduction electrons of lithium metal to achieve an order of magnitude hyperpolarisation at room temperature. We enhance the 7 Li, 1 H and 19 F NMR spectra of solid–electrolyte interphase species selectively, revealing their chemical nature and spatial distribution. These experiments pave the way for more ambitious room temperature in situ dynamic nuclear polarisation studies of batteries and the selective enhancement of metal–solid interfaces in a wider range of systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2018

Cross-Cutting Computational Modeling Project: Integrative Modeling Approach

A wide range of computational models and analyses have been applied to spaceflight risk assessment and countermeasure development. The benefits of using computational modeling to enhance Human Research Program (HRP) goals include the ability to mathematically represent physiological systems, integrate multiple, discrete experimental measures, span multiple temporal and spatial scales, determine important factors within the system and provide estimates of unmeasurable quantities. In the area of application, computational models provide a means of developing simulations to test hypotheses, determining key factors of the system to aid experimental design and bridging gaps in sparse data by mathematically simulating large populations. Specifically, computational models and their supporting analysis tools have the proven potential to integrate analyses of risk factors to enhance mission planning and preparation capabilities and to inform spacecraft design and countermeasure development. Appropriately applied, computational models may allow intelligent, unbiased physiological parameter assessment to enable hypothesis testing and model based design of experiments. HRP recently formed the Computational Modeling Project (CMP), managed out of Glenn Research Center, as a cross-cutting activity aimed at leveraging the growing power and acceptance of computational modeling in informing clinical, physiological, and biological studies. This presentation will provide an overview of the challenges and opportunities in implementing various forms of computational models in support of the HRPs path to risk reduction.

biomechanics↗

DOE OSTI2025

Failure Analysis–Informed Risk Assessment Framework for Geological Carbon Storage Using Numerical Simulation and Machine Learning

Geological carbon storage (GCS) is recognized as a critical technology for achieving large-scale reductions in anthropogenic carbon dioxide (CO 2 ) emissions. Ensuring long-term containment and safety requires robust risk assessment frameworks that account for geological uncertainty and identify potential failure scenarios. Among various indicators, the area of review (AoR) serves as a key metric for evaluating storage performance, regulatory compliance, and monitoring design, as it delineates the spatial extent impacted by pressure buildup and plume migration. However, conventional AoR-based risk assessments typically perturb parameters within narrow uncertainty bounds, potentially overlooking rare but high-impact events arising from extreme geological conditions. In this study, we present a failure analysis–informed risk assessment framework for large-scale GCS projects to improve site prescreening and monitoring design. A suite of 300 numerical simulations was generated using stochastic geological models that vary five key parameters: net-to-gross ratio, anisotropy azimuth, porosity multiplier, permeability multiplier, and vertical-to-horizontal permeability ratio. Among these, 200 realizations represent normal geological uncertainty, while 100 additional cases explore extreme yet plausible conditions for failure-case analysis. The AoR was simulated and computed from pressure and CO 2 saturation fields, where the baseline AoR boundary, representing the extent predicted under typical geological uncertainty, was defined as the union of 200 normal-range simulations, and failure was identified when extreme-range cases exceeded this baseline. Results show that incorporating broader parameter uncertainty produces significantly larger AoR extents, underscoring the potential underestimation of risk under conventional uncertainty ranges. Furthermore, spatial probability maps derived from failure-induced AoR exceedance identify regions requiring enhanced monitoring attention. Various machine learning (ML)–based classifiers were developed to predict failure occurrence from geological parameters, with the random forest model achieving the highest performance (F1-score of 0.986). Consistent findings from correlation coefficient, feature importance, and Sobol sensitivity analyses reveal that low net-to-gross ratios and permeability multipliers are the dominant risk drivers, reflecting reduced reservoir connectivity and limited pressure dissipation. Altogether, these results provide a novel framework for risk-informed site prescreening and monitoring design that explicitly considers rare but high-impact geological scenarios in GCS projects.

25 ENERGY STORAGE↗

NASA NTRS2015

Hyperbolic Rendezvous at Mars: Risk Assessments and Mitigation Strategies

Given the current interest in the use of flyby trajectories for human Mars exploration, a key requirement is the capability to execute hyperbolic rendezvous. Hyperbolic rendezvous is used to transport crew from a Mars centered orbit, to a transiting Earth bound habitat that does a flyby. Representative cases are taken from future potential missions of this type, and a thorough sensitivity analysis of the hyperbolic rendezvous phase is performed. This includes early engine cutoff, missed burn times, and burn misalignment. A finite burn engine model is applied that assumes the hyperbolic rendezvous phase is done with at least two burns.

Jedrey, Ricky↗

DOE OSTI2024

Multi-Source Machine Learning and Thermoplastics Enhanced Aerostructure Manufacturing (mTEAM)

RTX Technology Research Center (RTRC), together with Collins Aerospace (Collins) and Oak Ridge National Laboratory (ORNL) has developed an Artificial Intelligence (AI) / Machine Learning (ML) guided solution to advance the manufacturing and assembly of high performance and lightweight thermoplastic composite (TPC) aerospace products. The solution aims to lower risk, cost and lead time for induction heating based welding and consolidation processes for TPC structure. The cost and lead time of part and material specific process development for induction welding (IW) and induction consolidation will be reduced by replacing traditional empirical methods with optimization methods that merge AI/ML and physics-based process simulations and process experiments with sensing and controls. TPC-IW process development is empirical in nature, and uncertainties in material & process behavior exist near & far from the induction coil. Physics-based simulations can be leveraged directly for process optimization but can be too computationally expensive to run in high fidelity and real time to do robust process optimization. The key impact of successful TPC induction consolidation and welding is cost & lead time reduction for part & material specific consolidation and welding recipes. This is an enabler for more rapid deployment of TPC structures via joining assembly, which can reduce energy & cost intensive usage of autoclaves & ovens. The solution aimed to advance the U.S. Department of Energy’s interests in using thermoplastics and automation in composite manufacturing for improvement of products for existing markets via increased production speeds, reduced costs, and lowered use of energy. Welded TPC structures can offer significant weight & energy savings for high-value commercial aerospace & industrial applications compared to metal & thermoset composite structures assembled by mechanical fastening and/or adhesive bonding. The project was organized into two Budget Periods. Budget Period 1 (BP1) was 15 months and its goal was to perform ML process optimization framework development & deployment on lab-coupon aerostructure components. A Go/No-Go Review was performed at the end of BP1 to verify fulfilment of key tasks & milestones to justify a Go Decision to move into the next Budget Period. Budget Period 2 (BP2) was 12 months and its goal was the deployment of the ML framework for ML process optimization of pilot industrial scale aerostructure components. The overall project aim was to develop & demonstrate ML-enhanced modeling framework that learns process-property mapping from multiple data sources at different fidelities. During BP1, the team accomplished key tasks & milestones to demonstrate the concept of multi-source ML for TPC aerostructure consolidation and assembly. First, the team completed documentation of induction based TPC heating requirements including baseline metrics to compare measured results against. Next the team completed demonstration of data generation from physics-based simulations for ML surrogate model generation and demonstrated the integration of physics-based simulation data into multi-source AI/ML algorithms. In parallel, the team established the lab-coupon scale induction welding system and completed a process to label and reduce generated data from physics-based simulation and experiments for ML surrogate models to enable multi-source ML model training & testing. To complete BP1, the team integrated physics-based simulation data and experimental data into multi-source ML algorithms. This was based on the team completing ML deployment of the induction welding on a lab system at RTRC and AI/ML deployment on existing induction welding line at Collins. ORNL visited both Collins and RTRC sites to witness the TPC induction welding process. Then, ORNL designed and constructed a new version of their vision-based sensing system better adapted to acquire process signals of the TPC induction welding process for process anomaly and defect detection. In BP2, the team accomplished key tasks & milestones to scale up multi-source ML for TPC aerostructure consolidation and assembly from the lab-coupon scale to the pilot-industrial scale. In BP2, the team demonstrated real time anomaly & defect detection via experiments performed by ORNL & RTRC. The team completed ML-optimization heating trials for TPC induction consolidation at Collins, and the team confirmed pilot industrial scale experimental data from Collins was compatible with the developed ML pipeline from RTRC. The team completed sub-element scale ML process optimization demonstration at RTRC, where the team leveraged RTRC’s robotic TPC welding setup to de-risk the ML process optimization by performing ML analysis of recorded temperatures to account for complex part features. Then, the team applied its ML-derived control strategies and ML process optimization framework at Collins to the pilot-industrial scale on a demo skin-stiffener part representative of a nacelle aerostructure fan cowl section. The key innovation is the AI/ML framework enabling effective process development of high performance, lightweight, energy efficient TPCs for composite aircraft structures.

36 MATERIALS SCIENCE↗

NASA NTRS2016

Asteroid Redirect Mission (ARM) Formulation Assessment and Support Team (FAST) Final Report

The Asteroid Redirect Mission (ARM) Formulation Assessment and Support Team (FAST) was a two-month effort, chartered by NASA, to provide timely inputs for mission requirement formulation in support of the Asteroid Redirect Robotic Mission (ARRM) Requirements Closure Technical Interchange Meeting held December 15-16, 2015, to assist in developing an initial list of potential mission investigations, and to provide input on potential hosted payloads and partnerships. The FAST explored several aspects of potential science benefits and knowledge gain from the ARM. Expertise from the science, engineering, and technology communities was represented in exploring lines of inquiry related to key characteristics of the ARRM reference target asteroid (2008 EV5) for engineering design purposes. Specific areas of interest included target origin, spatial distribution and size of boulders, surface geotechnical properties, boulder physical properties, and considerations for boulder handling, crew safety, and containment. In order to increase knowledge gain potential from the mission, opportunities for partnerships and accompanying payloads were also investigated. Potential investigations could be conducted to reduce mission risks and increase knowledge return in the areas of science, planetary defense, asteroid resources and in-situ resource utilization, and capability and technology demonstrations. This report represents the FASTâ€"TM"s final product for the ARM.

Mazanek, Daniel D.↗

NASA NTRS2020

Assessment of Extremes in Global Precipitation Products: How Reliable Are They?

Global gridded precipitation products have proven essential for many applications ranging from hydrological modeling and climate model validation to natural hazard risk assessment. They provide a global picture of how precipitation varies across time and space, specifically in regions where ground-based observations are scarce. While the application of global precipitation products has become widespread, there is limited knowledge on how well these products represent the magnitude and frequency of extreme precipitation—the key features in triggering flood hazards. Here, five global precipitation datasets (MSWEP, CFSR, CPC, PERSIANN-CDR, and WFDEI) are compared to each other and to surface observations. The spatial variability of relatively high precipitation events (tail heaviness) and the resulting discrepancy among datasets in the predicted precipitation return levels were evaluated for the time period 1979–2017. The analysis shows that 1) these products do not provide a consistent representation of the behavior of extremes as quantified by the tail heaviness, 2) there is strong spatial variability in the tail index, 3) the spatial patterns of the tail heaviness generally match the Köppen–Geiger climate classification, and 4) the predicted return levels for 100 and 1000 years differ significantly among the gridded products. More generally, our findings reveal shortcomings of global precipitation products in representing extremes and highlight that there is no single global product that performs best for all regions and climates.

Risk assessment↗

NASA NTRS1994

Galactic cosmic ray composition and energy spectra

Galactic cosmic ray nuclei represent a significant risk to long-duration spaceflight outside the magnetosphere. We review briefly existing measurements of the composition and energy spectra of heavy cosmic ray nuclei, pointing out which species and energy ranges are most critical to assessing cosmic ray risks for spaceflight. Key data sets are identified and a table of cosmic ray abundances is presented for elements from H to Ni (Z = 1 to 28). Because of the 22-year nature of the solar modulation cycle, data from the approaching 1998 solar minimum is especially important to reducing uncertainties in the cosmic ray radiation hazard. It is recommended that efforts to model this hazard take advantage of approaches that have been developed to model the astrophysical aspects of cosmic rays.

Mewaldt, R. A.↗

NASA NTRSDate not supplied

Controls for Electrified Aircraft Propulsion

Advanced electrified aircraft propulsion (EAP) concepts with integrated power, propulsion, and thermal systems require the development of equally sophisticated controllers to fly safe and efficient missions. Hybrid electric aircraft utilize electric machines mechanically coupled to the engine shafts to extract and insert power for a variety of purposes. Additionally, electric machines may drive propulsive fans pulling from a combination of on-board energy storage devices and engine extracted power. NASA’s investment in hybrid electric aircraft hardware-in-the-loop testing enables controls research on representative engine models using a novel emulation and scaling methodology. High-voltage, high-power electrical powertrain presents several technical risks at altitude. High-power requires high efficiency to minimize losses. Superconducting electric machines and power distribution research at NASA has identified key challenges with potential controls solutions. These risks necessitate the development of controllers robust to model uncertainty, disturbances, and fault conditions. System health management and fault detection schemes play an important role in a multi-layer controls approach that utilizes a supervisor which oversees inner loops for the highly coupled power, propulsion, and thermal systems. Such a supervisory controller enables coordinates energy transfer between engines, energy storage devices, electric machines, propulsors, and heat exchangers. Existing methods have shown an improvement in engine operability using the hybrid electric powertrain.

Halle E Buescher↗

DOE OSTI2024

An Integrated Framework for Risk Assessment of Safety-related Digital Instrumentation and Control Systems in Nuclear Power Plants: Methodology Advancement and Application

This report documents activities performed by Idaho National Laboratory (INL) during fiscal year (FY) 2024 for the U.S. Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program, Risk Informed Systems Analysis (RISA) Pathway, Digital Instrumentation and Control (DI&C) Risk Assessment project. The goal of the RISA Pathway is to optimize safety margins and minimize uncertainties to achieve economic efficiencies while maintaining high levels of safety. This is accomplished by providing scientific basis to better represent safety margins and factors that contribute to cost and safety, and by developing new technologies that reduce operating costs. The research efforts for FY 2024 encompass methodology refinement and exploration. The efforts include: (1) The implementation of a natural language processing tool to expedite key aspects of the reliability analysis methods developed by INL; (2) advances to support intersystem CCF analysis by providing guidance for and identification of coupling mechanisms that may contribute to CCF; (3) the investigation of how generative artificial intelligence tools can aid in hazard analysis and diversity and defense in depth (i.e., D3) assessments; (4) Industry collaboration, allowing the demonstration of and INL's risk assessment tools to support risk assessment of DI&C systems at early and late stages of development; (4) a roadmap for the development of a software for each of INL's risk assessment tools; (5) The development of a theory and methodology manual for a risk quantification methodology; (6) the development of a reliability analysis for machine learning (ML)-integrated control systems.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRSDate not supplied

Production of Flight Instruments for Multi-Satellite Constellations

Recent National Academy of Science Decadal Surveys in space and Earth-science have called for simultaneous, distributed multi-point measurements in and from space, requiring constellations of small spacecraft. Small satellites have demonstrated their utility for enabling high-quality science measurements and observations. NASA missions have leveraged advances in sensor miniaturization, technology innovations, and new small satellite mission architectures to enable meaningful measurement-based scientific investigations that operate on small satellites and that are responsive to science objectives described in National Academy of Science Decadal Surveys. The advent of high capability small spacecraft enables consideration of science missions involving multiple small spacecraft, constellations of a few or many for simultaneous distributed in situ observations or remote observations from a variety of viewpoints. The central challenge for fielding instrumented space-flight constellations is to provide the required multiple sets of fully verified and calibrated instrument hardware, software, and operational processes from within a one-off project-based scientific space flight culture. Although there are numerous commercial entities providing “off-the shelf” spacecraft and avionics, the challenge lies in the multi-unit production of the uniquely targeted instrumentation necessary to perform the specific measurements required for a particular science investigation. Traditionally, the cost of such instrumentation has represented a significant portion of the hardware cost for a mission and posed the highest risk area for implementation. A shift in paradigm from large science platforms to constellations of smaller satellites drives the challenge to build instruments in a quasi-production environment. This paper describes key aspects of, and challenges encountered in the development program for the successful production of instruments for the Fast-Plasma Investigation (FPI) instrument suite of 64 flight plasma spectrometers and supporting electronics on the NASA Magnetospheric Multiscale (MMS) 4 satellite constellation mission. Although the MMS mission was not composed of small satellites, there are key aspects of the instrument production that apply directly to constellations of small satellites.

Arthur D Jacques↗

NASA NTRSDate not supplied

Production of Flight Instruments for Multi-Satellite Constellations

Arthur D Jacques↗

DOE OSTI2020

Pumped Storage Hydropower FAST Commissioning Technical Analysis

This report was developed in tandem with the Furthering Advancements to Shorten Time (FAST) to Commissioning PSH Challenge and represents the underlying technical analysis that informed the competition. Lead by Oak Ridge National Laboratory, the report is designed to address barriers and solutions to PSH development by establishing baseline project development knowledge, defining key aspects of project development, and identifying opportunities to reduce project timelines, costs, and risks. The document’s scope includes post-licensing activities and excludes factors related to permitting or licensing.

13 HYDRO ENERGY↗

NASA NTRS2004

Application of Recommended Design Practices for Conceptual Nuclear Fusion Space Propulsion Systems

An AIAA Special Project Report was recently produced by AIAA's Nuclear and Future Flight Propulsion Technical Committee and is currently in peer review. The Report provides recommended design practices for conceptual engineering studies of nuclear fusion space propulsion systems. Discussion and recommendations are made on key topics including design reference missions, degree of technological extrapolation and concomitant risk, thoroughness in calculating mass properties (nominal mass properties, weight-growth contingency and propellant margins, and specific impulse), and thoroughness in calculating power generation and usage (power-flow, power contingencies, specific power). The report represents a general consensus of the nuclear fusion space propulsion system conceptual design community and proposes 15 recommendations. This paper expands on the Report by providing specific examples illustrating how to apply each of the recommendations.

Williams, Craig H.↗

NASA NTRS1986

Implementation of and Ada real-time executive: A case study

Current Ada language implementations and runtime environments are immature, unproven and are a key risk area for real-time embedded computer system (ECS). A test-case environment is provided in which the concerns of the real-time, ECS community are addressed. A priority driven executive is selected to be implemented in the Ada programming language. The model selected is representative of real-time executives tailored for embedded systems used missile, spacecraft, and avionics applications. An Ada-based design methodology is utilized, and two designs are considered. The first of these designs requires the use of vendor supplied runtime and tasking support. An alternative high-level design is also considered for an implementation requiring no vendor supplied runtime or tasking support. The former approach is carried through to implementation.

Laird, James D.↗

NASA NTRS2023

Risk Assessment for Asteroid Impact Threat Scenarios

Asteroid impacts can cause a wide range of damage through multiple potential hazards, from localized blast waves or thermal radiation, to tsunami inundation, to global climatic effects. The level of risk posed by these hazards depends not only upon their extent and severity, but also upon the likelihood of the various damage ranges. Some consequences may be more moderate but very likely, while others may be unlikely but catastrophic. Evaluating the risk from these hazards involves substantial uncertainties across all aspects of the problem, including the properties of the asteroid itself, the specifics of its entry, and the complex high-energy damage physics involved. NASA’s Asteroid Threat Assessment Project performs Probabilistic Asteroid Impact Risk (PAIR) assessments that use fast-running entry and hazard models to evaluate millions of impact cases representing the distributions of these many uncertain parameters. This paper presents current probabilistic asteroid impact risk assessment modeling tools and approaches used for evaluating specific asteroid impact threat cases. We give an overview of the current PAIR model used to support impact threat scenarios and discuss some of the key applications of these assessment in supporting response decisions and planetary defense preparedness. We then present the results and key findings from the recent 2023 PDC hypothetical impact exercise as an example of the primary types of risk results and metrics being developed to inform and support those mitigation and response decisions.

SMD↗