Results for “model-based development” — Page 32

NASA NTRS2023

An MBSE Approach for Developing an Autonomous Rover Platform

The proliferation of increasingly autonomous systems calls for new ways to address how safety is assured. As these systems become more advanced and complex, it becomes more important to model and prototype autonomous functions at the systems level and the functions that assure they are operating safely and as expected. To that effect, researchers at the National Aeronautics and Space Administration (NASA) 's Robust Software Engineering (RSE) group are working on prototyping a Research Autonomous Vehicle, commonly referred to as R-RAV. The R-RAV is an autonomous rover platform designed to act as a case study for assured autonomy research. Moreover, an overarching goal is for the R-RAV to serve as a training ground for other mission projects. In this paper, we will detail how we have used a Model-Based Systems Engineering (MBSE) approach to model a prototype of the R-RAV and test and verify its different functionalities.

MBSE↗

NASA NTRS2022

A Systems Model for System-Wide Safety Safety Demonstrator (SD-1): Wildfire Response Operations

The aim of this internship-based project was to contribute to the ongoing development of a systems model for System-Wide Safety’s first Technical Challenge 5 (TC5) series Safety Demonstrator (SD-1), which will be a demonstration of an In-Time Aviation Safety Management System (IASMS) in emerging wildfire response operations. Using Models-Based Systems Engineering (MBSE) principles to develop the model, I organized and traced previously collected stakeholder needs from the Spring 2022 NASA System-Wide Safety Wildland Firefighting Operations Virtual Workshop (https://nari.arc.nasa.gov/sws-wildfire) to system elements, creating connections which can be used in the future by the project engineers to identify and address requirements gaps throughout the system design process. I also identified and modeled preliminary use case scenarios for aerial assets in the demonstrator and, building on previously produced preliminary high-level models of the 8 SD-1 Services, Functions, and Capabilities (SFCs) and their IASMS data flows, worked to model the Real-Time Risk Assessment (RTRA) tool as an implementation of Risk Assessment and Management that can take in multiple sets of data monitored by SFCs. Project deliverables include stakeholder requirements tables and matrices and systems model diagrams produced with MagicDraw software in the SysML Systems Modeling Language, with eventual plans to connect model diagrams to a Department of Defense Operational Viewpoint (OV-1) graphic, a high-level operational concept graphic that will be used to visualize the SD-1 scenarioin a future phase. The system model serves to provide a common understanding of the scope of and activities necessary for the completion of SD-1,and traces how stakeholder needs are to be addressed.

model-based systems engineering↗

NASA NTRSDate not supplied

Additive Manufacturing Model-Based Process Metrics: Reduced Order Modeling of the Laser Powder Bed Fusion Process

The multi-scale and complex process of printing additively manufactured (AM) parts can have unexpected, but predictable, build conditions that result in material microstructure variability. In this work, we describe a fully parallel reduced order modeling approach that has been developed to evaluate the evolution of AM processes, termed the AM moment measure method. This method couples the known sequence of the AM process with a physically informed nearest neighbors’ calculation to map the conditions of a part-scale build. The result is a map of the build that is derived directly from build files or in-situ process monitoring sensors. The methodology and terminology of the approach will be described, and computed build maps will be calculated and compared for various laser powder bed fusion (LPBF) builds of Ti-6Al-4V. Such comparative results develop understanding of how the sequential process actions can affect the LPBF-AM build quality and microstructure variability.

Laser Powder Bed Fusion↗

NASA NTRSDate not supplied

Evaluation of Precision Landing Performance Using A Generalized Aerospace Simulation in Simulink Framework

NASA’s science and exploration goals to return to the Moon and beyond will need to perform precision landings to place humans and cargo supplies near places of scientific interest, surface resources, or pre-established basecamps. With the maturation of new navigation technology, such as terrain relative navigation, precision landing is now feasible, enabling new exploration sites, such as the lunar poles. However, verification of precision landing performance becomes crucial since not reaching the designated landing site would have a high risk of loss of mission. Therefore, having a high-fidelity simulation platform to evaluate six degrees of freedom vehicle performance during high-risk phases of flight such landing is a fundamental part of the system verification and risk reduction. The NASA Marshall Space Flight Center has developed the GeneraLized Aerospace Simulation in Simulink® (GLASS) tool which incorporates guidance, navigation, and control algorithms, as well as vehicle and environmental models, such as gravity, vehicle mass properties, navigation sensors, propulsion, and terrain models. GLASS uses the MathWorks® Simulink® environment which provides a model-based design framework that allows the incorporation of vehicle models in a modular architecture. The Simulink® environment provides seamless integration with all the MathWorks® capabilities and toolboxes, such as control design toolboxes and Simscape™ Multibody™ dynamics toolbox. The MathWorks® environment also allows for guidance, navigation, and control algorithms to be auto coded in C language, enabling quick software and hardware in the loop testing. This paper provides an overview of GLASS capabilities for analyzing precision landing performance, including navigation trades applied to a NASA human lander reference design architecture.

Guidance↗

NASA NTRS2023

JWST Observations of the Enigmatic Y Dwarf WISE 1828+2650: I. Limits to a Binary Companion

The Y-dwarf WISE 1828+2650 is one of the coldest known Brown Dwarfs with an effective temperature of ~300 K. Located at a distance of just 10 pc, previous model-based estimates suggest WISE 1828+2650 has a mass of ~5-10 M J , making it a valuable laboratory for understanding the formation, evolution and physical characteristics of gas giant planets. However, previous photometry and spectroscopy have presented a puzzle with the near-impossibility of simultaneously fitting both the short (0.9-2.0 μm) and long wavelength (3-5 μm) data. A potential solution to this problem has been the suggestion that WISE 1828+2650 is a binary system whose composite spectrum might provide a better match to the data. Alternatively, new models being developed to fit JWST/NIRSpec and MIRI spectroscopy might provide new insights. This article describes JWST/NIRCam observations of WISE 1828+2650 in 6 filters to address the binarity question and to provide new photometry to be used in model fitting. We also report Adaptive Optics imaging with the Keck 10 m telescope. We find no evidence for multiplicity for a companion beyond 0.5 AU with either JWST or Keck. Companion articles will present low and high resolution spectra of WISE 1828 obtained with both NIRSpec and MIRI.

Infrared spectroscopy↗

NASA NTRS2022

A Model-Based Approach for Europa Lander Mission Concept Exploration

This study investigates the usage of a system model as a means to capture concept formulation for a potentialmission. Efforts are underway at JPL to explore thearchitectural and system concepts for a lander on Europa.Executing a mission on the surface of Europa poses uniquechallenges that will require the lander to operate with onboardautonomy that is more sophisticated than systems previouslyoperated by JPL. Current tasks to explore surface missionconcepts intend to identify concepts that enable a high degree ofonboard autonomy as well as identify the issues and technicallimitations that restrict autonomy. The Europa lander missionconcept team is developing a system model to support thisexploration.The results of this study highlight how executable systemmodeling and the associated engineering environment may beapplied to pre-project conceptual exploration. The applicationof system modeling has resulted in a central system model thatprecisely describes the concepts formulated by the EuropaLander Mission Concept Team. Documentation in the form ofdiagrams and narrative has been directly generated from thesystem model and accessible by team members in a webapplication. The executability of the system model enablesvarious analyses such as simulation of interactions betweencomponents and evaluating system behavior againstrequirements. Execution of the system model has produced statetimelines, plots of system variables, and simulation traces basedon input scenarios. The executable system model enables therapid and repeatable production of these artifacts.

Reeves, Glenn↗

NASA NTRS2021

IceNode: A Buoyant Vehicle for Acquiring Well-Distributed, Long-Duration Melt Rate Measurements Under Ice Shelves

Antarctic ice shelves buttress the Antarctic Ice Sheet from sliding into the ocean and significantly raising global sea level. However, the accelerating dynamics of ice shelf melt in a warming environment are poorly understood, and the collapse of Antarctic ice shelves remains one of the largest sources of uncertainty in global sea level rise projections. The cavities below Antarctic ice shelves are notoriously difficult to access, making model-based hypotheses about the relationship between ocean warming and greater ice shelf melting difficult to verify because of a lack of in-situ data to constrain model parameters and examine key assumptions. We present early progress on IceNode, a novel vehicle under development at the NASA Jet Propulsion Laboratory designed to acquire well-distributed, concurrent, long-duration melt rate measurements under ice shelves. IceNodes are deployed as an array from a ship at the shelf edge, and use variable buoyancy to ride melt-driven exchange currents far into the cavity. Once underneath their target, they release a ballast weight to become highly positively buoyant and attach to the underside of the ice shelf, where they acquire in-situ measurements of basal melt rate directly at the ice-ocean interface for a year or more. Finally, IceNodes detach from their landing structure and use variable buoyancy to ride melt-driven exchange currents back to open water, where they surface and transmit their mission data home. IceNodes are designed to be relatively low-cost, expendable, and have simple logistics, enabling scientists to deploy scalable arrays that simultaneously measure co-varying ice shelf melt and ocean conditions over large spatial areas, thereby providing an unprecedented view of ice shelf melt rate variability and its drivers.

Zapien, Xavier↗

NASA NTRS2020

Hardware Verification and Validation for a Navigation Sensor Software Model in Support of Flight Vehicle Performance Analysis

… or, “It’s in the details, how to make complicated software perform like complicated hardware.” In attempts to minimize development time and quickly build an operational vehicle, NASA’s Space Launch System (SLS) has had to be intentional about integrated testing. Constraints on budget and schedule have required balance between testing needs and the desire for an integrated flight vehicle as soon as possible. To provide key insights early in design and analysis cycles, a large amount of effort has shifted into maturing and validating models at the component level with integrated testing as a means to validate their integration. In terms of SLS Navigation, this, and the model-based design approach have pushed explicit requirements for sensor models to be validated against flight hardware to high precision. This paper covers the approach taken to verify and validate the models for the two key navigation sensors on the SLS vehicle, the Redundant Inertial Navigation Sensor and the Rate Gyro Assembly. These models are used in performance evaluation, fault detection, and operations development extensively. Using a mix of data from hardware vendor documentation and testing reports, limited in-house testing, and integration activities, these models were able to be validated against flight hardware at multiple levels, from the internal software design to statistical behavior at the raw sensor and integrated box levels. The high level of insight into the hardware elements is instrumental to support flight certification activities and building confidence in SLS Navigation capability. Focused testing enabled additional insight and validation that proved invaluable and the resulting insights were used to focus and mature models. Additionally, of having validated performance-based hardware models enables a wide breadth of activities including detailed fault detection studies and integration into future vehicle frameworks, such as an upper stage and provide a valuable asset to continued SLS analysis and design.

Evan J Anzalone↗

NASA NTRS2020

Hardware Verification and Validation for a Navigation Sensor Software Model in Support of Flight Vehicle Performance Analysis

… or, “It’s in the details, how to make complicated software perform like complicated hardware.” In attempts to minimize development time and quickly build an operational vehicle, NASA’s Space Launch System (SLS) has had to be intentional about integrated testing. Constraints on budget and schedule have required balance between testing needs and the desire for an integrated flight vehicle as soon as possible. To provide key insights early in design and analysis cycles, a large amount of effort has shifted into maturing and validating models at the component level with integrated testing as a means to validate their integration. In terms of SLS Navigation, this, and the model-based design approach have pushed explicit requirements for sensor models to be validated against flight hardware to high precision. This paper covers the approach taken to verify and validate the models for the two key navigation sensors on the SLS vehicle, the Redundant Inertial Navigation Sensor and the Rate Gyro Assembly. These models are used in performance evaluation, fault detection, and operations development extensively. Using a mix of data from hardware vendor documentation and testing reports, limited in-house testing, and integration activities, these models were able to be validated against flight hardware at multiple levels, from the internal software design to statistical behavior at the raw sensor and integrated box levels. The high level of insight into the hardware elements is instrumental to support flight certification activities and building confidence in SLS Navigation capability. Focused testing enabled additional insight and validation that proved invaluable and the resulting insights were used to focus and mature models. Additionally, of having validated performance-based hardware models enables a wide breadth of activities including detailed fault detection studies and integration into future vehicle frameworks, such as an upper stage and provide a valuable asset to continued SLS analysis and design.

Thomas Park↗

NASA NTRSDate not supplied

Initial Development of A Digital Twin Model for an Electrified Aircraft Propulsion Emulation Rig

In support of aviation fuel burn and emission reduction goals, NASA is pursing high-payoff research investments that promise to transform aviation. This includes investments in Electrified Aircraft Propulsion (EAP), which relies on the generation, storage, transmission, and use of electrical power for producing thrust and optimizing propulsion system efficiency. Multiple technology challenges must be addressed to unlock the full potential of EAP. This includes advances in propulsion controls, which will be vital for ensuring coordinated efficient operation of the complex integrated subsystems that comprise EAP architectures. To support EAP controls research, the NASA Glenn Research Center has developed the Hybrid Propulsion Emulation Rig (HyPER). The HyPER laboratory hardware includes shaft-mounted electric machines, power converters, power supplies, power distribution cables, and an energy storage device that can be reconfigured to represent a variety of EAP architectures. It also includes an integrated real-time computer system that hosts developed EAP control software and turbomachinery simulations. This enables the electrical system and rotating shafts of EAP designs to be implemented in actual hardware and integrated with turbomachinery simulations and system-level EAP control logic implemented in software. In this form, the HyPER laboratory provides a partially simulated, partially hardware-in-the-loop test environment enabling the initial development and evaluation of EAP control technology. A prerequisite for the development of EAP control designs is the availability of a system model that accurately reflects the operation of the electrical system hardware. To support this need, a digital twin model of the HyPER electrical system hardware is under development. This model is being coded in the MATLAB Simulink environment and uses the NASA-developed Electrical Modeling and Thermal Analysis Toolbox (EMTAT) to construct a digital twin framework. EMTAT contains generic electrical component building blocks that are simulated at turbomachinery timescales. Associated inputs and outputs allow the blocks to be combined to model complete electrical systems. The EMTAT blocks also contain adjustable internal maps and parameters that can be set to reflect the operation of a specific electrical component. For the HyPER digital twin, the settings of these EMTAT block internal maps and parameters is determined through machine learning approaches applied to characterization run data collected from the laboratory. During characterization runs the laboratory electrical system hardware is subjected to a full range of torque, speed, and power settings. Acquired data is then used to estimate EMTAT block parameters using a variety of machine learning techniques. The resulting digital twin model is found to match the operation of actual HyPER hardware with an accuracy suitable for control development purposes. It also holds promise for other applications including modeling the performance of HyPER laboratory reconfigurations and model-based anomaly detection. Planned follow-on work to automate post-processing of acquired laboratory data to update the HyPER digital twin model will also be presented and discussed.

Electrified Aircraft Propulsion↗

NASA NTRS2023

JWST Observations of the Enigmatic Y Dwarf WISE 1828+2650: I. Limits to a Binary Companion

The Y-dwarf WISE 1828+2650 is one of the coldest known brown dwarfs with an effective temperature of∼300K. Located at a distance of just 10 pc, previous model-based estimates suggest WISE1828+2650 has a mass of∼5–10MJ, making it a valuable laboratory for understanding the formation, evolution, and physical characteristics of gas giant planets. However, previous photometry and spectroscopy have presented a puzzle, with the near impossibility of simultaneously fitting both the short-(0.9–2.0μm)and long-wavelength(3–5μm)data. A potential solution to this problem has been the suggestion that WISE 1828+2650 is a binary system whose composite spectrum might provide a better match to the data. Alternatively, new models being developed to fit JWST/NIRSpec, and MIRI spectroscopy might provide new insights. This article describes JWST/NIRCam observations of WISE 1828+2650 in six filters to address the binarity question and to provide new photometry tobe used in model fitting. We also report adaptive optics imaging with the Keck I0 m telescope. We find no evidence for multiplicity for a companion beyond 0.5 au with either JWST or Keck. Companion articles will present low-and high-resolution spectra of WISE 1828 obtained with both NIRSpec and MIRI.

NIRCam↗

NASA NTRSDate not supplied

Modeling Deformable Linear Objects for Autonomous Robotic Outfitting of Lunar Surface Systems

This paper presents structural models of deformable linear objects (DLOs). DLOs are a subclass of deformable objects that encompasses common outfitting elements such as cables and ropes. Models are validated through hardware experiments, and integration in a robotic autonomy architecture for space environments is discussed. A persistent human presence on the lunar surface is one of the next major milestones in space exploration. This requires the development of robust extraplanetary construction technologies including structures and materials modeling and robotic systems. Previous robotic construction technology development has primarily focused on structural assembly, with significantly less focus on robotically performed outfitting tasks to instantiate subsystems providing power, data, life support, etc. These tasks involve manipulation of highly flexible elements, which are difficult to model, such as cable harnesses, ropes, and hoses. Robotic manipulation of DLOs, especially cable harnesses, is an active area of research as cable harnesses are essential for providing power and data to space assets. DLO models that can be used for robot manipulator trajectory generation are necessary for autonomous operation of lunar infrastructure. There are many proposed methods for modeling DLOs, and they primarily fall into three types: 1) discrete model-based, 2) continuum model-based, and 3) Neural Network-based. These types each have pros and cons, and the tradeoff between model accuracy and computational speed informs which type should be used. An understanding of this trade-off is imperative for real-time control of autonomous systems. High computational requirements reduce the speed of the model, making real-time control difficult, while accuracy is critical to preventing collisions. Discrete models, such as a mass-spring multibody representation, require relatively few calculations, and accuracy is directly tied to the step size of the discretization. Continuum models, such as a B-spline representation or a Cosserat rod model (a mix of continuous and discrete), are more informed of the structural properties of the cable and are much more accurate than a rigid body mass-spring model, but at significant computational cost. A Neural Network approach can provide an online solution with very few computational steps, but properly generating training data can be difficult and validation for an in-space application is not trivial. This paper explores the trade-off between different modeling approaches and compares accuracy and computational speed/complexity of the three types mentioned above. Model accuracy is evaluated using a cable in a static configuration. True cable shape is obtained using a depth camera for RGB images and point-cloud segmentation. The purpose of this experiment is to evaluate the trade-offs of different approaches to the DLO modeling problem. Understanding the tradeoffs between different cable modeling techniques paves the way for developing robotic control and planning architectures necessary for real-time manipulation of DLOs for lunar infrastructure outfitting. Real-time control is required for robotic systems to be able to actively manipulate a cable in a harsh environment where model and sensor errors compound, and environmental conditions can cause significant disturbances. Cable routing must be performed in areas with high density of objects/obstacles: through truss structures, near solar panels or mirror arrays, next to bundles of electrical equipment. Understanding the best way to plan and manipulate a cable without disrupting the environment or damaging the cable is imperative to robotic outfitting operations on the lunar surface.

Amy M Quartaro↗

NASA NTRS2024

2023 Artemis Crew Health and Performance (CHP) System Model Development

While the NASA Human Research Program (HRP) utilizes a Crew Health and Performance (CHP) System to represent all the Agency’s efforts to ensure the health and performance of NASA astronauts, there is no shared mental model of a CHP system at NASA. Some groups may consider a CHP system to be only a medical kit, while others may not be using the concept at all. To facilitate the integration of functions and capabilities to ensure astronaut health and performance during vehicle development, HRP has proposed a CHP Shared Mental Model derived from the NASA Human Health, Medical, and Performance Spaceflight Standards (NASA-STD-3001 Vol.1/Vol.2). [1] Even though many vehicle, ground, and communication systems as well as mission operations are modeled for the Artemis Campaigns, no mission level CHP system model was created to achieve the intent of the HRP CHP Shared Mental Model. The lack of this model renders it difficult to visualize and understand how the many programs work together to provide the necessary cross program functions and capabilities to ensure the health and performance of the crew throughout an Artemis mission. For this purpose, the Exploration Medical Capability (ExMC) element of HRP developed a CHP system model for the Artemis III and IV missions to provide a view of how each program contributes to and interacts with the overall CHP system. To develop the 2023 Artemis CHP system model, ExMC leveraged existing data and models from the Moon to Mars Program Office, the Office of the Chief Health and Medical Officer (OCHMO) and the Orion, Gateway, Extravehicular Activity and Human Surface Mobility (EHP) and Human Landing System (HLS) programs. By using a Model-Based Systems Engineering (MBSE) approach, existing requirements, functions, and concepts of operations were combined to create a single system model focused on representing CHP from the launch to the return to Earth segments of the Artemis III and IV missions. Additionally, by incorporating the HRP Systems Platform for Aggregating and Relating Capabilities, or SPARC tool, the data from the programs was also related back to the 2nd volume of the NASA Human Health, Medical, and Performance Spaceflight Standard (NASA-STD-3001, Vol.2) and the human system risks identified by the Human System Risk Board (HSRB). The first version of the 2023 Artemis CHP system model was baselined in Fall of 2023 after the model was demonstrated to be a potentially useful tool for systems engineers integrating CHP capabilities in vehicle development as well as members of the Health and Medical Technical Authority providing oversight of those programs. The model may also be useful to any stakeholder of astronaut health and performance by providing insights on how an Artemis mission satisfies the NASA Human Health, Medical, and Performance Spaceflight Standards as well as how they mitigate the HSRB Human System Risks. This presentation highlights how the model was developed and the possible benefits of the model. [1] NASA HRP (2022), Crew Health and Performance System Whitepaper

Systems engineering↗

NASA NTRSDate not supplied

Enhancing Air Quality Applications in the Hindu Kush-Himalayan Region Using Satellite, Model, and Machine Learning Techniques

Air pollution in the Hindu Kush Himalayan (HKH) region of South Asia is a severe issue, as increases in emissions over the past two decades have degraded air quality (AQ) across the region, which poses major threats to human health, the ecosystem, climate, and agriculture. A diversity of anthropogenic and natural emission sources including transportation, power plants, industries, open biomass burning of crop residue, forest fires, cooking and heating fires, and dust storms contribute to unhealthy AQ and transboundary pollution issues in the region. Further complicating matters is the importance of meteorology and terrain on AQ, especially in the Kathmandu Valley where extreme haze episodes frequently develop from the atmospherically stable weather conditions during the winter monsoon. This study uses state-of-the-art satellite observations and modeling capabilities in conjunction with machine learning techniques to develop a comprehensive toolkit for enhancing AQ monitoring and forecasting in HKH. The toolkit incorporates new generation satellite observations from the TROPOspheric Monitoring Instrument (TROPOMI), Geostationary Environment Monitoring Spectrometer (GEMS), and Advanced Meteorological Imager (AMI), which provide unprecedented resolution on aerosols and trace gases, including nitrogen dioxide (NO 2 ), formaldehyde (CH2O), sulfur dioxide (SO 2 ), carbon monoxide (CO), and ozone (O 3 ), and aerosol optical depth (AOD). Value-added products [e.g., Particulate matter with diameters less than 2.5 micrometers (PM2.5)] are developed from the suite of satellite observations to further improve AQ monitoring capabilities in the region. The satellite products are also used to assimilate a high-resolution chemical transport model tailored for the HKH region, which is providing daily, 54-hour AQ forecasts with horizontal grid spacings of 12- and 4-km. This presentation will provide an overview of the suite of satellite- and model-based products in the AQ toolkit and application and performance of the toolkit for AQ monitoring and forecasting in HKH.

Air Quality↗

NASA NTRSDate not supplied

Overview of the Subscale RAVEN Flight Controls and Modeling Testbed

The Research Aircraft for eVTOL Enabling TechNologies (RAVEN) Subscale Wind-Tunnel and Flight Test (SWFT) model is a subscale aircraft built for flight dynamics and controls research demonstrated in wind-tunnel and flight-test experiments. The intent of this paper is to provide a summary of past, current, and future efforts being pursued by the RAVEN-SWFT project. Initially, vehicle development guidelines were crafted by a multidisciplinary team to ensure that the RAVEN-SWFT vehicle was well suited for research in multiple areas, including aero-propulsive modeling, flight controls, and autonomy, among others. The vehicle has been used to obtain extensive wind-tunnel data, enabling aero-propulsive model development across the transition flight envelope and validation of computational tools. The vehicle will be used to conduct flight testing in order to evaluate modeling strategies and flight control logic. The RAVEN-SWFT model also serves as a risk reduction activity for a conceptual, full-scale vehicle in the 1000-lb class. The next steps in the project are to successfully demonstrate free flight in hover, transition, forward flight, and the reverse thereof, utilizing custom control laws integrated onto the RAVEN-SWFT avionics hardware. The project intends to publicize all of the geometry, data, and methods in future reports.

eVTOL↗

NASA NTRSDate not supplied

A Novel Additive Manufacturing Process Metric for Predicting Spatter-related Porosity in Laser Powder Bed Fusion

Components fabricated using the powder bed fusion laser beam metallic (PBF) additive manufacturing (AM) process comprise a multitude of sequential weld passes. Porosity defects resulting from weld pass inconsistencies are a concern for PBF materials and have a strong adverse effect on the mechanical properties. In an effort to understand and avoid spatter induced porosity, this work aims to provide a novel computational technique that can be used to quantify and predict the sequence-sensitive impact of spatter upon the PBF process stability and consequential porosity in as-printed material. A novel spatter impact AM model-based process metric (AM-PM) is introduced to model and quantify the impact that spatter has on the PBF process. The occurrence of spatter induced porosity is studied using thermal rise, lack of fusion, and spatter impact AM-PMs synchronized with porosity measured by high-resolution X-ray computed tomography. Six cylindrical specimens were designed to compare the AM-PM correlations with porosity across two different laser powers and three hatch scanning strategies. A point field based computational approach is shown to be effective for testing the influence of the different AM-PMs and interrogating the physical process conditions underlying the porosity formation. Further, characterization using optical metallography and scanning electron microscopy indicated that both keyhole and lack of fusion porosity correlated with the spatter impact AM-PM, which can be exploited to predict and control spatter related porosity by the hatch strategy. Efforts to predict porosity composition within PBF material should incorporate the PBF process disturbances that can result from spatter. The spatter impact AM-PM can be readily incorporated into the development of defect prediction models at the part scale.

Additive Manufacturing↗

NASA NTRSDate not supplied

ARCTRON: A Rapid Experimental Proving Ground for TPS Experiments and Arcjet Technology Development

Innovation in high-enthalpy facilities is fundamentally limited by the cost and risk of experimentation. New concepts for plasma control, diagnostics, facility components, and plasma-material interaction often require repeated iterations that are impractical to perform in production arcjets. As a result, promising ideas may remain unexplored or reach operational facilities only after significant development effort. ARCTRON is being developed as a rapid experimental proving ground where new ideas in plasma science, arcjet engineering, diagnostics, and material response can be conceived, tested, and quantitatively evaluated before transition to large-scale facilities. The platform combines radio-frequency (RF) and DC arc plasma generation, externally applied magnetic fields, configurable gas composition, reduced-pressure operation, laser heating, electrical biasing, and modular diagnostic access. These capabilities permit the plasma source, applied forcing, test article, and measurement configuration to be modified independently, allowing individual physical mechanisms to be isolated more readily than in a traditional test environment. One class of investigations addresses fundamental plasma-surface interaction physics. Conventional material tests often expose a specimen simultaneously to convective heating, reactive species, pressure, shear, radiation, and surface-current effects. The resulting material response may be measured accurately, while the contribution of each mechanism remains difficult to identify. ARCTRON is designed to vary these effects selectively. Plasma chemistry can be changed independently through configurable gas mixtures; magnetic fields and electrical biasing can modify charged-particle transport; laser heating can provide a non-plasma thermal input; and pressure, flow, and discharge mode can be varied over a broad operating space. This enables controlled tests of hypotheses involving surface catalycity, reactive-species transport, plasma-assisted oxidation, electromagnetic effects, shear, and the relative contributions of thermal and chemical loading. A second class of investigations enabled by this approach concerns the engineering of high-enthalpy facilities themselves. Arc-heated facilities are limited by electrode erosion, unstable arc attachment, localized heating, and damage to nozzles and other plasma-facing components. ARCTRON provides a lower-cost environment for testing concepts intended to mitigate these limitations. Candidate investigations include the use of applied magnetic fields to alter current paths and reduce plasma interaction with nozzle walls, ExB forcing to introduce controlled plasma rotation, magnetic or geometric approaches for distributing arc attachment, and alternative electrode or discharge configurations intended to reduce erosion and improve stability. Because the platform is reconfigurable, these concepts can be evaluated through repeated design--build--test cycles before they are considered for implementation in operational facilities. The platform also supports the development and validation of diagnostics that may be difficult to introduce initially into a large arcjet. Current and planned measurements include spatially resolved optical emission spectroscopy, electrostatic probes, fast imaging, pyrometry, calorimetry, laser-induced fluorescence, and absorption spectroscopy. These diagnostics are intended not merely to document a nominal operating condition, but to constrain the local plasma state and its relationship to component or material response. The modular facility geometry allows diagnostic concepts to be tested, calibrated, and compared under repeatable conditions before deployment in more demanding environments. ARCTRON is also supported by an integrated software suite. Automated control and data acquisition allow discharge parameters, gas composition, magnetic fields, diagnostic timing, and test configuration to be recorded as part of each experiment (STARDAC - Software for Testing, Analysis, Research Data, and Control). The Backend for Experiment Analysis, Storage, and Traceability (BEAST) is a database that provides the infrastructure needed to associate heterogeneous measurements with facility configuration, specimen identity, calibration state, geometry, and analysis provenance. This backend is particularly important for exploratory campaigns, in which many related configurations may be tested, and the value of an individual experiment depends on its connection to earlier and subsequent iterations. Complementary analysis capabilities, including computer-vision-based transient response measurements (arcjetCV), three-dimensional surface reconstruction (STARSCAN), and model-based Bayesian inference (SHIELD), and tomography data analysis (TOMATO, PuMA) can be incorporated when required by a specific hypothesis without becoming the focus of every campaign. The central objective of ARCTRON is therefore not to maximize heat flux or reproduce a complete flight environment. Its purpose is to reduce the cost and time required to ask consequential questions about plasma behavior, plasma-facing materials, diagnostics, and arcjet technology. By providing a controlled environment for rapid reconfiguration, mechanism isolation, quantitative measurement, and iterative engineering, ARCTRON can help mature concepts that would otherwise remain too speculative or too risky for evaluation in production facilities. The resulting knowledge can then guide the design of material models, focus test objectives in larger arcjets, reduce facility-development risk, and improve the physical basis of high-enthalpy ground testing. This work will present the ARCTRON architecture, operating modes, diagnostic suite, and digital experimental workflow. Initial experimental results from the first integrated operation of the facility will be presented, including flow characterization, power limitations, and deployment of the initial diagnostic suite. Ongoing development efforts aimed at catalycity characterization, magnetic plasma control, and advanced optical diagnostics will also be discussed, illustrating how the platform supports rapid iteration from concept to experiment.

experimental diagnostics↗

NASA NTRSDate not supplied

ARCTRON: A Rapid Experimental Proving Ground for TPS Experiments and Arcjet Technology Development

Innovation in high-enthalpy facilities is fundamentally limited by the cost and risk of experimentation. New concepts for plasma control, diagnostics, facility components, and plasma-material interaction often require repeated iterations that are impractical to perform in production arcjets. As a result, promising ideas may remain unexplored or reach operational facilities only after significant development effort. ARCTRON is being developed as a rapid experimental proving ground where new ideas in plasma science, arcjet engineering, diagnostics, and material response can be conceived, tested, and quantitatively evaluated before transition to large-scale facilities. The platform combines radio-frequency (RF) and DC arc plasma generation, externally applied magnetic fields, configurable gas composition, reduced-pressure operation, laser heating, electrical biasing, and modular diagnostic access. These capabilities permit the plasma source, applied forcing, test article, and measurement configuration to be modified independently, allowing individual physical mechanisms to be isolated more readily than in a traditional test environment. One class of investigations addresses fundamental plasma-surface interaction physics. Conventional material tests often expose a specimen simultaneously to convective heating, reactive species, pressure, shear, radiation, and surface-current effects. The resulting material response may be measured accurately, while the contribution of each mechanism remains difficult to identify. ARCTRON is designed to vary these effects selectively. Plasma chemistry can be changed independently through configurable gas mixtures; magnetic fields and electrical biasing can modify charged-particle transport; laser heating can provide a non-plasma thermal input; and pressure, flow, and discharge mode can be varied over a broad operating space. This enables controlled tests of hypotheses involving surface catalycity, reactive-species transport, plasma-assisted oxidation, electromagnetic effects, shear, and the relative contributions of thermal and chemical loading. A second class of investigations enabled by this approach concerns the engineering of high-enthalpy facilities themselves. Arc-heated facilities are limited by electrode erosion, unstable arc attachment, localized heating, and damage to nozzles and other plasma-facing components. ARCTRON provides a lower-cost environment for testing concepts intended to mitigate these limitations. Candidate investigations include the use of applied magnetic fields to alter current paths and reduce plasma interaction with nozzle walls, ExB forcing to introduce controlled plasma rotation, magnetic or geometric approaches for distributing arc attachment, and alternative electrode or discharge configurations intended to reduce erosion and improve stability. Because the platform is reconfigurable, these concepts can be evaluated through repeated design--build--test cycles before they are considered for implementation in operational facilities. The platform also supports the development and validation of diagnostics that may be difficult to introduce initially into a large arcjet. Current and planned measurements include spatially resolved optical emission spectroscopy, electrostatic probes, fast imaging, pyrometry, calorimetry, laser-induced fluorescence, and absorption spectroscopy. These diagnostics are intended not merely to document a nominal operating condition, but to constrain the local plasma state and its relationship to component or material response. The modular facility geometry allows diagnostic concepts to be tested, calibrated, and compared under repeatable conditions before deployment in more demanding environments. ARCTRON is also supported by an integrated software suite. Automated control and data acquisition allow discharge parameters, gas composition, magnetic fields, diagnostic timing, and test configuration to be recorded as part of each experiment (STARDAC - Software for Testing, Analysis, Research Data, and Control). The Backend for Experiment Analysis, Storage, and Traceability (BEAST) is a database that provides the infrastructure needed to associate heterogeneous measurements with facility configuration, specimen identity, calibration state, geometry, and analysis provenance. This backend is particularly important for exploratory campaigns, in which many related configurations may be tested, and the value of an individual experiment depends on its connection to earlier and subsequent iterations. Complementary analysis capabilities, including computer-vision-based transient response measurements (arcjetCV), three-dimensional surface reconstruction (STARSCAN), and model-based Bayesian inference (SHIELD), and tomography data analysis (TOMATO, PuMA) can be incorporated when required by a specific hypothesis without becoming the focus of every campaign. The central objective of ARCTRON is therefore not to maximize heat flux or reproduce a complete flight environment. Its purpose is to reduce the cost and time required to ask consequential questions about plasma behavior, plasma-facing materials, diagnostics, and arcjet technology. By providing a controlled environment for rapid reconfiguration, mechanism isolation, quantitative measurement, and iterative engineering, ARCTRON can help mature concepts that would otherwise remain too speculative or too risky for evaluation in production facilities. The resulting knowledge can then guide the design of material models, focus test objectives in larger arcjets, reduce facility-development risk, and improve the physical basis of high-enthalpy ground testing. This work will present the ARCTRON architecture, operating modes, diagnostic suite, and digital experimental workflow. Initial experimental results from the first integrated operation of the facility will be presented, including flow characterization, power limitations, and deployment of the initial diagnostic suite. Ongoing development efforts aimed at catalycity characterization, magnetic plasma control, and advanced optical diagnostics will also be discussed, illustrating how the platform supports rapid iteration from concept to experiment.

experimental diagnostics↗