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NASA NTRS2014

Crack Growth Behavior in the Threshold Region for High Cycle Fatigue Loading

This paper describes the results of a research program conducted to improve the understanding of fatigue crack growth rate behavior in the threshold growth rate region and to answer a question on the validity of threshold region test data. The validity question relates to the view held by some experimentalists that using the ASTM load shedding test method does not produce valid threshold test results and material properties. The question involves the fanning behavior observed in threshold region of da/dN plots for some materials in which the low R-ratio data fans out from the high R-ratio data. This fanning behavior or elevation of threshold values in the low R-ratio tests is generally assumed to be caused by an increase in crack closure in the low R-ratio tests. Also, the increase in crack closure is assumed by some experimentalists to result from using the ASTM load shedding test procedure. The belief is that this procedure induces load history effects which cause remote closure from plasticity and/or roughness changes in the surface morphology. However, experimental studies performed by the authors have shown that the increase in crack closure is a result of extensive crack tip bifurcations that can occur in some materials, particularly in aluminum alloys, when the crack tip cyclic yield zone size becomes less than the grain size of the alloy. This behavior is related to the high stacking fault energy (SFE) property of aluminum alloys which results in easier slip characteristics. Therefore, the fanning behavior which occurs in aluminum alloys is a function of intrinsic dislocation property of the alloy, and therefore, the fanned data does represent the true threshold properties of the material. However, for the corrosion sensitive steel alloys tested in laboratory air, the occurrence of fanning results from fretting corrosion at the crack tips, and these results should not be considered to be representative of valid threshold properties because the fanning is eliminated when testing is performed in dry air.

Forman, R. G.↗

DOE OSTI2026

Science Uses Deployment Operations-Advanced Wireless: Exploring Open Radio Access Network Technologies for Energy Science

Open Radio Access Network is emerging as a solution to the increasing demand for more flexible, cost-effective, and advanced mobile network infrastructures. This evolution is driven by advancements in wireless technologies and the growing complexity of deploying and managing these networks. O-RAN represents a significant shift in wireless technology, building upon the 3rd Generation Partnership Project framework to foster openness, flexibility, and interoperability. By decoupling hardware and software components, Open Radio Access Network enables a multi-vendor ecosystem that encourages innovation and diverse solutions. Open Radio Access Network's potential extends beyond traditional wireless applications, with growing interest in its role in advancing energy systems, particularly in the context of smart grids, microgrids, and the integration of renewable energy sources. While the role of open-wireless technologies in driving energy transformation is increasingly recognized, further exploration is needed. Vendors and utilities are investigating how Open Radio Access Network technologies can optimize energy use cases and improve the performance of 5G and beyond applications. This report outlines efforts under the Science Uses Deployment Operations Advance Wireless project, a collaboration between the National Laboratory of the Rockies' Cybersecurity Research Center, Argonne National Laboratory, Lawrence Berkeley National Laboratory, and the Department of Energy's Energy Science Network research and operations staff. The focus of this project is on due diligence, through testing and evaluation, preparing for the deployment of advanced wireless infrastructure for scientific use cases, with an emphasis on Open Radio Access Network technology, its components, integrations, and its ability to support vertical stack application across the energy sector. Additionally, the report highlights the value cases for utilities, underscoring how adopting open wireless standards can accelerate the evolution of energy systems, foster innovation, and improve the integration of critical energy technologies.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1997

Fuel Cell Power Plant Initiative: Preliminary Design of a Fixed-Base LFP/SOFC Power System - Volume 2

This report documents the preliminary design for a military fixed-base power system of 3 MWe nominal capacity using Westinghouse's tubular Solid Oxide Fuel Cell [SOFC] and Haldor Topsoe's logistic fuels processor [LFP]. The LFP provides to the fuel cell a methane rich sulfur free fuel stream derived from either DF-2 diesel fuel, or JP-8 turbine fuel. Fuel cells are electrochemical devices that directly convert the chemical energy contained in fuels such as hydrogen, natural gas, or coal gas into electricity at high efficiency with no intermediate heat engine or dynamo. The SOFC is distinguished from other fuel cell types by its solid state ceramic structure and its high operating temperature, nominally 1000'C. The SOFC pioneered by Westinghouse has a tubular geometry closed at one end. A power generation stack is formed by aggregating many cells in an ordered array. The Westinghouse stack design is distinguished from other fuel cell stacks by the complete absence of high integrity seals between cell elements, cells, and between stack and manifolds. Further, the reformer for natural gas [predominantly methane] and the stack are thermally and hydraulically integrated with no requirement for process water. The technical viability of combining the tubular SOFC and a logistic fuels processor was demonstrated at 27 kWe scale in a test program sponsored by the Advanced Research Projects Agency [ARPA) and carried out at the Southern California Edison's [SCE] Highgrove generating station near San Bernardino, California in 1994/95. The LFP was a breadboard design supplied by Haldor Topsoe, Inc. under subcontract to Westinghouse. The test program was completely successful. The LFP fueled the SOFC for 766 hours on JP-8 and 1555 hours of DF-2. In addition, the fuel cell operated for 3261 hours on pipeline natural gas. Over the 5582 hours of operation, the SOFC generated 118 MVVH of electricity with no perceptible degradation in performance. The LFP processed military specification JP-8 and DF-2 removing the sulfur and reforming these liquid fuels to a methane rich gaseous fuel. Results of this program are documented in a companion report titled 'Final Report-Solid Oxide Fuel Cell/ Logistic Fuels Processor 27 kWe Power System'.

Veyo, S.E.↗

NASA NTRS2002

Ion Storage Tests with the High Performance Antimatter Trap (HiPAT)

The NASA/Marshall Space Flight Centers (NASA/MSFC) Propulsion Research Center (PRC) is evaluating an antiproton storage system, referred to as the High Performance Antiproton Trap (HiPAT). This interest stems from the sheer energy represented by matter/antimatter annihilation process with has an energy density approximately 10 order of magnitude above that of chemical propellants. In other terms, one gram of antiprotons contains the equivalent energy of approximately 23 space shuttle external tanks or ET's (each ET contains roughly 740,000 kgs of fuel and oxidizer). This incredible source of stored energy, if harnessed, would be an enabling technology for deep space mission where both spacecraft weight and propulsion performance are key to satisfying aggressive mission requirements. The HiPAT hardware consists of a 4 Tesla superconductor system, an ultra high vacuum test section (vacuum approaching 10(exp -12) torr), and a high voltage confinement electrode system (up to 20 kvolts operation). The current laboratory layout is illustrated. The HiPAT designed objectives included storage of up to 1 trillion antiprotons with corresponding lifetimes approaching 18 days. To date, testing has centered on the storage of positive hydrogen ions produced in situ by a stream of high-energy electrons that passes through the trapping region. However, due to space charge issues and electron beam compression as it passes through the HiPAT central field, current ion production is limited to less then 50,000 ions. Ion lifetime was determined by counting particle populations at the end of various storage time intervals. Particle detection was accomplished by destructively expelling the ions against a micro-channel plate located just outside the traps magnetic field. The effect of radio frequency (RF) stabilization on the lifetime of trapped particles was also examined. This technique, referred to as a rotating wall, made use of a segmented electrode located near the center of the trap on which various phases of a particular frequency were applied. Various experiments were performed illustrating the ability of an RF drive to both prolong and reduced the lifetimes of various ion species depending on the selected frequency. HiPAT is now being reconfigured for testing with an ion source that will provide both positive and negative hydrogen ions from an external source. This ion system shall provide higher fill capacity (order of million of ions per shot), stacking of multiple shots, and injection schemes typical of a realistic antiproton delivery system.

Martin, James J.↗

NASA NTRSDate not supplied

AmesDT: Digital Twin and Autonomy Validation Environment

A simulation of NASA Ames Research Center was developed to provide a common testbed for multiple areas of research within the Intelligent Systems Division, primarily related to verification and validation of autonomous technologies, machine learning, and digital twin systems. AmesSim corresponds a physical rover that is capable of navigation in the real-world environment; in this way, the same experiments can be run in both settings, with the same software and hardware stacks in the loop. The simulation is built in Unreal Engine 4 and uses the AirSim plugin for API convenience. Several custom modifications allow deterministic, faster-than-realtime execution, which enables consistent testing of on-line algorithms and large-scale data collection. This paper describes the architecture and capabilities of the simulation and discusses development challenge.

simulation↗

NASA NTRS2011

Rad-Hard, Miniaturized, Scalable, High-Voltage Switching Module for Power Applications Rad-Hard, Miniaturized

A paper discusses the successful development of a miniaturized radiation hardened high-voltage switching module operating at 2.5 kV suitable for space application. The high-voltage architecture was designed, fabricated, and tested using a commercial process that uses a unique combination of 0.25 micrometer CMOS (complementary metal oxide semiconductor) transistors and high-voltage lateral DMOS (diffusion metal oxide semiconductor) device with high breakdown voltage (greater than 650 V). The high-voltage requirements are achieved by stacking a number of DMOS devices within one module, while two modules can be placed in series to achieve higher voltages. Besides the high-voltage requirements, a second generation prototype is currently being developed to provide improved switching capabilities (rise time and fall time for full range of target voltages and currents), the ability to scale the output voltage to a desired value with good accuracy (few percent) up to 10 kV, to cover a wide range of high-voltage applications. In addition, to ensure miniaturization, long life, and high reliability, the assemblies will require intensive high-voltage electrostatic modeling (optimized E-field distribution throughout the module) to complete the proposed packaging approach and test the applicability of using advanced materials in a space-like environment (temperature and pressure) to help prevent potential arcing and corona due to high field regions. Finally, a single-event effect evaluation would have to be performed and single-event mitigation methods implemented at the design and system level or developed to ensure complete radiation hardness of the module.

Adell, Philippe C.↗

NASA NTRS2019

Assembling and Testing NASA’s Space Launch System for First Flight

NASA is planning its next step toward human expansion into the solar system. The Space Launch System (SLS) (Figure 1) is a critical enabling component of that expansion. SLS payloads for its early missions include the Orion crew vehicle and components for Gateway, a lunar outpost orbiting the Moon that will facilitate research, technology and partnerships for eventual Mars missions. All major core stage hardware for test and flight completed structural manufacturing in 2018. The major components for the first flight vehicle are complete or approaching completion of internal equipment installation. The core stage forward join operation is also complete. The 10 booster segments needed for first flight have been cast and are ready to ship to NASA’s Kennedy Space Center (KSC) for mating and stacking. The four RS-25 core stage engines completed processing at NASA’s Stennis Space Center (SSC) and are ready for core stage integration. The Orion Stage Adapter (OSA) joined the Interim Cryogenic Propulsion Stage (ICPS) at KSC to await the rest of SLS flight hardware. Production and preparation of hardware for the second mission is also underway. Looking ahead to a busy 2019, liquid oxygen (LOX) tank, liquid hydrogen (LH2) tank and intertank structural testing will take place. This paper will discuss the current and planned status of SLS development in context of NASA’s overall exploration plans.

Askin, Bruce R.↗

DOE OSTI2025

Galaxy cluster profiles: a Gaussian mixture model approach to halo miscentering

Measurements of the galaxy density and weak-lensing profiles of galaxy clusters typically rely on an assumed cluster center, which is taken to be the brightest cluster galaxy or other proxies for the true halo center defined as the minimum in the potential well. Departure of the assumed cluster center from the true halo center bias the resultant profile measurements, an effect known as miscentering bias. Currently, miscentering is typically modeled in stacked profiles of clusters with a two parameter model. We use an alternate approach in which the profiles of individual clusters are used with the corresponding likelihood computed using a Gaussian mixture model. We test the approach using halos and the corresponding subhalo profiles from the IllustrisTNG hydrodynamic simulations. We obtain significantly improved estimates of the miscentering parameters for both 3D and projected 2D profiles relevant for imaging surveys. We discuss applications to upcoming cosmological surveys. Our Python package for the Gaussian mixture model is publicly available at https://github.com/KyleMiller1/Halo-Miscentering-Mixture-Model.

Bayesian reasoning↗

DOE OSTI2025

Exponential Backoff and Its Security Implications for Safety-Critical OT Protocols over TCP/IP Networks

The convergence of Operational Technology (OT) and Information Technology (IT) networks has become increasingly prevalent with the growth of Industrial Internet of Things (IIoT) applications. This shift, while enabling enhanced automation, remote monitoring, and data sharing, also introduces new challenges related to communication latency and cybersecurity. Oftentimes, legacy OT protocols were adapted to the TCP/IP stack without an extensive review of the ramifications to their robustness, performance, or safety objectives. To further accommodate the IT/OT convergence, protocol gateways were introduced to facilitate the migration from serial protocols to TCP/IP protocol stacks within modern IT/OT infrastructure. However, they often introduce additional vulnerabilities by exposing traditionally isolated protocols to external threats. This study investigates the security and reliability implications of migrating serial protocols to TCP/IP stacks and the impact of protocol gateways, utilizing two widely used OT protocols: Modbus TCP and DNP3. Our protocol analysis finds a significant safety-critical vulnerability resulting from this migration, and our subsequent tests clearly demonstrate its presence and impact. A multi-tiered testbed, consisting of both physical and emulated components, is used to evaluate protocol performance and the effects of device-specific implementation flaws. Through this analysis of specifications and behaviors during communication interruptions, we identify critical differences in fault handling and the impact on time-sensitive data delivery. The findings highlight how reliance on lower-level IT protocols can undermine OT system resilience, and they inform the development of mitigation strategies to enhance the robustness of industrial communication networks.

DNP3↗

NASA NTRS1991

Final prototype of magnetically suspended flywheel energy storage system

A prototype of a 500 Wh magnetically suspended flywheel energy storage system was designed, built, and tested. The authors present the work done and include the following: (1) a final design of the magnetic bearing, control system, and motor/generator, (2) construction of a prototype system consisting of the magnetic bearing stack, flywheel, motor, container, and display module, and (3) experimental results for the magnetic bearings, motor, and the entire system. The successful completion of the prototype system has achieved: (1) manufacture of tight tolerance bearings, (2) stability and spin above the first critical frequency, (3) use of inside sensors to eliminate runout problems, and (4) integration of the motor and magnetic bearings.

Anand, D. K.↗

NASA NTRS1993

Effect of boundary conditions and panel geometry on the response of laminated panels subjected to transverse pressure loads

The behavior of thin laminated flat and curved panels subjected to transverse pressure and inplane loads is considered. The effects of panel geometry, boundary conditions and laminate stacking sequence on the response of panels subjected to transverse pressure loads up to 12.4 N/sq cm is presented. The response of thin laminated panels is evaluated analytically and selected results are compared with test data. A parametric study of the deformation and strain responses of panels with radius of curvature ranging from 20 to 305 cm is presented. The combination of inplane tensile and pressure loads is also considered.

Jegley, Dawn C.↗

NASA NTRS2005

On the Interaction and Coalescence if Spherical Blast Waves

The scaling and similarity laws concerning the propagation of isolated spherical blast waves are briefly reviewed. Both point source explosions and high pressure gas explosions are considered. Test data on blast overpressure from the interaction and coalescence of spherical blast waves emanating from explosives in the form of shaped charges of different strength placed in the vicinity of a solid propellant stack are presented. These data are discussed with regard to the scaling laws concerning the decay of blast overpressure. The results point out the possibility of detecting source explosions from far-field pressure measurements.

Kandula, Max↗

NASA NTRSDate not supplied

Automated Ply-By-Ply Lamination and in-Situ Consolidation of Dry Carbon Fiber Non-Crimp Fabrics for High-Rate Aircraft Manufacturing of Structural Aircraft Components

NASA’s Hi-Rate Composites Aircraft Manufacturing (HiCAM) program addresses market needs to advance structural aircraft composite manufacturing technologies to significantly increase production rates. Dry, non-crimp fabric (NCF) carbon materials infused with advanced resin systems offer a promising solution to these manufacturing demands. Northrop Grumman’s Automated Stiffener Forming (ASF) technology has been adapted for ply-by-ply, in-situ processing of NCF materials. The modular ASF process accommodates flexibility in the laminate stacking, while allowing for ply drops, ply additions, and yaw, pitch, and roll in the laminate geometry. To adapt the ASF process for NCF materials, heating technologies and roller compaction processes were designed and tested on representative structural aircraft part geometries. Key success criteria for the ASF process with NCF materials is forming quality and preform compaction. Trials were performed with multiple NCF materials: unidirectional up to quad-axial formats. The NCF constituents, veils, stitching, and binders, were evaluated with the ASF process. The material performance in the ASF process and the resulting preform quality are presented.

dry carbon fiber materials↗

NASA NTRSDate not supplied

Automated Ply-By-Ply Lamination and in-Situ Consolidation of Dry Carbon Fiber Non-Crimp Fabrics for High-Rate Aircraft Manufacturing of Structural Aircraft Components

dry carbon fiber materials↗

NASA NTRS2026

Smart Process Planning for Automated Fiber Placement

Many industries, including aerospace, automotive, wind energy, maritime, and sporting goods, rely on strong, lightweight materials called composites. These materials are made by layering fibers, which can come in the form of narrow strips or wider sheets, and setting them in a polymer matrix. One of the most advanced ways to make these parts is through automated fiber placement, where a machine lays down the fibers in precise patterns. This method can create very efficient and strong designs, but it is complex, expensive, and often depends heavily on the experience of skilled engineers. Today, the design, manufacturing, and inspection stages of composite production are usually handled separately. This separation means that important information, such as how a part will be built or what defects might occur, is not always shared between stages. As a result, parts may not be as lightweight, strong, or defect-free as possible, and the process can take longer and cost more. This research develops a smart process planning system that connects design, manufacturing, and inspection into one continuous process. Built as software that works with existing tools, the system can automatically plan how the fibers are placed, predicting and reducing defects while improving both manufacturability and strength. The system optimizes not only individual layers but also how defects are distributed across all layers, preventing them from stacking up in ways that weaken the final part. It also uses inspection results from completed parts to improve future designs, creating a feedback loop where each stage informs the others. The system was tested by designing a composite panel using this new approach and comparing it to a panel made with state-of-the-art manual planning methods. The results showed that the system could intentionally control where defects appeared and increase the efficiency of the planning process. By unifying design, manufacturing, and inspection, this research shows a way to make advanced composite manufacturing more efficient, consistent, and cost-effective. This approach lowers the barrier to using automated fiber placement and opens the door for its wider adoption not only in aerospace but also in industries such as automotive, wind energy, maritime, and sporting goods, where strong and lightweight structures are essential.

Computer-Aided Process Planning↗

NASA NTRS2000

Analysis and Test of a Proton Exchange Membrane Fuel Cell Power System for Space Power Applications

An effort is underway to develop a prototype Proton Exchange Membrane (PEM) Fuel Cell breadboard system for fuhlre space applications. This prototype will be used to develop a comprehensive design basis for a space-rated PEM fuel cell powerplant. The prototype system includes reactant pressure regulators, ejector-based reactant pumps, a 4-kW fuel cell stack and cooling system, and a passive, membranebased oxygen / water separator. A computer model is being developed concurrently to analytically predict fluid flow in the oxidant reactant system. Fuel cells have historically played an important role in human-rated spacecraft. The Gemini and Apollo spacecraft used fuel cells for vehicle electrical power. The Space Shuttle currently uses three Alkaline Fuel Cell Powerplants (AFCP) to generate all of the vehicle's 15-20kW electrical power. Engineers at the Johnson Space Center have leveraged off the development effort ongoing in the commercial arena to develop PEM fuel cel ls for terrestrial uses. The prototype design originated from efforts to develop a PEM fuel cell replacement for the current Space Shuttle AFCP' s. In order to improve on the life and an already excellent hi storical record of reliability and safety, three subsystems were focused on. These were the fuel cell stack itself, the reactant circulation devices, and reactant / product water separator. PEM fuel cell stack performance is already demonstrating the potential for greater than four times the useful life of the current Shuttle's AFCP. Reactant pumping for product water removal has historically been accomplished with mechanical pumps. Ejectors offer an effective means of reactant pumping as well as the potential for weight reduction, control simplification, and long life. Centrifugal water separation is used on the current AFCP. A passive, membrane-based water separator offers compatibility with the micro-gravity environment of space, and the potential for control simplification, elimination of moving parts in an oxygen environment, and long life. The prototype system has been assembled from components that have previously been tested and evaluated at the component level. Preliminary data obtained from tests performed with the prototype system, as well as other published data, has been used to validate the analytical component models. These components have been incorporated into an integrated oxidant fluid system model. Results obtained from both the performance tests and the analytical model are presented.

Vasquez, Arturo↗

NASA NTRS1989

HOMAR: A computer code for generating homotopic grids using algebraic relations: User's manual

A computer code for fast automatic generation of quasi-three-dimensional grid systems for aerospace configurations is described. The code employs a homotopic method to algebraically generate two-dimensional grids in cross-sectional planes, which are stacked to produce a three-dimensional grid system. Implementation of the algebraic equivalents of the homotopic relations for generating body geometries and grids are explained. Procedures for controlling grid orthogonality and distortion are described. Test cases with description and specification of inputs are presented in detail. The FORTRAN computer program and notes on implementation and use are included.

Moitra, Anutosh↗

NASA NTRS1991

Some Recent Studies With the Solid-Ionomer Electrochemical Capacitor

Giner, Inc., has developed a high-energy-density, all-solid-ionomer electro-chemical capacitor, completely free of liquid electrolyte. The novel features of this device include: (1) a three-dimensional metal oxide-particulate-ionomer composite electrode structure and (2) a unitized repeating cell element. The composite electrode structures are bonded to opposite sides of a thin sheet of a solid proton-conducting ionomer membrane and form an integrally bonded membrane and electrode assembly (MEA). Individual MEAs can be stacked in series as bipolar elements to form a multiple cell device. The discharge characteristics and energy storage properties of these devices are described. Typical capacitance measured for a unit cell is 1 F/cm. Life testing of a multicell capacitor on an intermittent basis has shown that, over a 10,000-hour period, the capacitance and resistance of the cell has remained invariant. There has been no maintenance required on the device since it was fabricated. Other multicell units of shorter life duration have exhibited similar reliable performance characteristics. Recent work has focused on increasing the capacitance of the unitized structure and improving the low-temperature characteristics. The approaches and experimental results will be presented. Some possible advanced NASA applications for these unique all-solid-ionomer devices will be discussed.

Sarangapani, S.↗