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NASA NTRSDate not supplied

Modeling Reliability Growth

Reliability growth has been modelled as an exponential decline in the cumulative failure rate that continues indefinitely as long as testing continues. Contrary to this, most reliability growth data show a brief high initial failure rate due to infant mortality followed by a long period of constant low failure rate. A two part failure rate model with an initial exponential decline followed by a constant failure rate usually fits the data and provides a more realistic description of reliability growth. The reliability growth process consists of testing, experiencing failures, finding the failure causes, and redesigning the system to remove them. The cost of reliability growth increases with the number of inherent failure modes and the time needed for them to occur and be removed. The failure modes with the lower failure rates will tend to occur later, as their Mean Time Before Failure (MTBF) is the inverse of the failure rate. Reliability growth testing has diminishing returns, since it takes longer to find and remove the less probable failures.This paper first discusses the reliability bathtub curve and then explains that reliability growth is produced by testing, identifying failure causes, and designing to remove them. A simple model of reliability growth is introduced, with a brief group of early failures followed by a constant failure rate. The cumulative failure rate n(t)/t can decline as rapidly as1/t or t-1butdeclines more slowly if additiona lfailures occur. The 56-failure Crow data seti s used to demonstrate the two-phase model of reliability growth followed by a constant failure rate. 13 additional data sets are modeled, with 9 of the 14 data sets showing reliability growth approximately as n(t)/t =1/t or t-1and substantial final failure rates. The model fits most of the data sets, but 4of the 14 show no reliability growth. The reliability growth period typically includes six failures and extends one-quarter or half the total test time. As reliability growth testing continues, the cumulative failure rate should be tracked to estimate the reliability growth exponent and the final failure rate.

reliability growth modeling↗
DOE OSTI2018

Practical factors of envelope model setup and their effects on the performance of model predictive control for building heating, ventilating, and air conditioning systems

Model predictive control (MPC) for buildings is attracting significant attention in research and industry due to its potential to address a number of challenges facing the building industry, including energy cost reduction, grid integration, and occupant connectivity. However, the strategy has not yet been implemented at any scale, largely due to the significant effort required to configure and calibrate the model used in the MPC controller. While many studies have focused on methods to expedite model configuration and improve model accuracy, few have studied the impact a wide range of factors have on the accuracy of the resulting model. In addition, few have continued on to analyze these factors’ impact on MPC controller performance in terms of final operating costs. Therefore, this study first identifies the practical factors affecting model setup, specifically focusing on the thermal envelope. The seven that are identified are building design, model structure, model order, data set, data quality, identification algorithm and initial guesses, and software tool-chain. Then, through a large number of trials, it analyzes each factor's influence on model accuracy, focusing on grey-box models for a single zone building envelope. Finally, this study implements a subset of the models identified with these factor variations in heating, ventilating, and air conditioning MPC controllers, and tests them in simulation of a representative case that aims to optimally cool a single-zone building with time-varying electricity prices. It is found that a difference of up to 20%25 in cooling cost for the cases studied can occur between the best performing model and the worst performing model. The primary factors attributing to this were model structure and initial parameter guesses during parameter estimation of the model.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Effects of digital fringe projection operational parameters on detecting powder bed defects in additive manufacturing

Additive manufacturing is a technology transforming traditional production timelines. Specifically, metal additive manufacturing (MAM) has been increasingly adopted by a variety of industries, not only to prototype, but also to fulfill full production scale applications with much lower lead times. Like any maturing manufacturing technology, developments in verifying and validating processes are necessary to support continuous growth. Due to the complex nature of MAM, part quality and repeatability remain integral challenges that inhibit further adoption of MAM for critical component production. In this study, we present data taken from a developing in-process monitoring system designed to measure and detect powder bed defects (PBDs) in powder bed fusion MAM systems using surface height maps created with structured light illumination. We showcase the feasibility of the monitoring technique for in-process implementation by detecting streak PBDs with varying severities (height, width) created in a lab environment. We present results of powder bed measurements for varying experimental parameters of the structured light system such as illumination angle, illumination pattern, and number of illuminations. We also present an expression used to determine experimental height noise based on input parameters for PBD detection based on the instrument transfer function of the structured light monitoring system for arbitrary pixel intensity noise contributions. In conclusion, with the results of PBD detection across multiple experimental measurement parameters, we provide a best practices approach to in-process implementation of the monitoring system in powder bed fusion manufacturing.

36 MATERIALS SCIENCE↗
NASA NTRS1999

Neuroprotective "agents" in surgery. Secret "agent" man, or common "agent" machine?

The search for clinically-effective neuroprotective agents has received enormous support in recent years--an estimated $200 million by pharmaceutical companies on clinical trials for traumatic brain injury alone. At the same time, the pathophysiology of brain injury has proved increasingly complex, rendering the likelihood of a single agent "magic bullet" even more remote. On the other hand, great progress continues with technology that makes surgery less invasive and less risky. One example is the application of endovascular techniques to treat coronary artery stenosis, where both the invasiveness of sternotomy and the significant neurological complication rate (due to microemboli showering the cerebral vasculature) can be eliminated. In this paper we review aspects of intraoperative neuroprotection both present and future. Explanations for the slow progress on pharmacologic neuroprotection during surgery are presented. Examples of technical advances that have had great impact on neuroprotection during surgery are given both from coronary artery stenosis surgery and from surgery for Parkinson's disease. To date, the progress in neuroprotection resulting from such technical advances is an order of magnitude greater than that resulting from pharmacologic agents used during surgery. The progress over the last 20 years in guidance during surgery (CT and MRI image-guidance) and in surgical access (endoscopic and endovascular techniques) will soon be complemented by advances in our ability to evaluate biological tissue intraoperatively in real-time. As an example of such technology, the NASA Smart Probe project is considered. In the long run (i.e., in 10 years or more), pharmacologic "agents" aimed at the complex pathophysiology of nervous system injury in man will be the key to true intraoperative neuroprotection. In the near term, however, it is more likely that mundane "agents" based on computers, microsensors, and microeffectors will be the major impetus to improved intraoperative neuroprotection.

Review Literature↗
DOE OSTI2022

Soil phosphorus drawdown by perennial bioenergy cropping systems in the Midwestern US

Abstract Without fertilization, harvest of perennial bioenergy cropping systems diminishes soil nutrient stocks, yet the time course of nutrient drawdown has not often been investigated. We analyzed phosphorus (P) inputs (fertilization and atmospheric deposition) and outputs (harvest and leaching losses) over 7 years in three representative biomass crops—switchgrass ( Panicum virgatum L.), miscanthus ( Miscanthus × giganteus ) and hybrid poplar trees ( Populus nigra × P. maximowiczii )—as well as in no‐till corn (maize; Zea mays L.) for comparison, all planted on former cropland in SW Michigan, USA. Only corn received P fertilizer. Corn (grain and stover), switchgrass, and miscanthus were harvested annually, while poplar was harvested after 6 years. Soil test P (STP; Bray‐1 method) was measured in the upper 25 cm of soil annually. Harvest P removal was calculated from tissue P concentration and harvest yield (or annual woody biomass accrual in poplar). Leaching was estimated as total dissolved P concentration in soil solutions sampled beneath the rooting depth (1.25 m), combined with hydrological modeling. Fertilization and harvest were by far the dominant P budget terms for corn, and harvest P removal dominated the P budgets in switchgrass, miscanthus, and poplar, while atmospheric deposition and leaching losses were comparatively insignificant. Because of significant P removal by harvest, the P balances of switchgrass, miscanthus, and poplar were negative and corresponded with decreasing STP, whereas P fertilization compensated for the harvest P removal in corn, resulting in a positive P balance. Results indicate that perennial crop harvest without P fertilization removed legacy P from soils, and continued harvest will soon draw P down to limiting levels, even in soils once heavily P‐fertilized. Widespread cultivation of bioenergy crops may, therefore, alter P balances in agricultural landscapes, eventually requiring P fertilization, which could be supplied by P recovery from harvested biomass.

09 BIOMASS FUELS↗
NASA NTRSDate not supplied

A Proposed Clock Synchronization Method for the Solar System Internet

Networked communications in space are necessary to achieve scalability in terms of the number of communicating nodes but also in terms of the overall system complexity. A key component to such a system is the ability to synchronize clocks, which is the focus of this paper. The so-called Solar System Internet (SSI) will be built upon Delay Tolerant Networking (DTN), which, in analogy to the Internet Protocol (IP), can be considered a suite of protocols necessary for networking in the space domain. Therefore, our goal is to extend this suite to include a DTN clock synchronization capability, analogous to the Network Time Protocol (NTP) used in the Internet. A motivating example of a network in space is NASA’s LunaNet, a vision for a multi-hop multi-path network extending to the moon wherein not all nodes will have direct connections to an authoritative reference clock. In this paper, we propose a general clock synchronization methodology and algorithm that could be used for LunaNet as well as more elaborate time-varying networks. In recent years, DTN has benefited from modeling efforts founded on the mathematical tool of sheaves. Here we continue this work to provide an approach to clock synchronization. Due to the time-varying nature of space networks, absolute consensus is not possible. However, the sheaf Laplacian provides a practical, distributed approach to approximating consensus by allowing data to diffuse through the network. In particular, the sheaf Laplacian is readily computable, lending our approach to implementation. Our approach is well suited to handle the difficulties of space networks. For instance, differences in clock accuracy mean certain nodes are more authoritative than others; we can account for these differences through hierarchies in the network, generalizing the strata in NTP. Furthermore, just as error estimation is an integral part of NTP, we are able to give concrete error bounds for our approach. Indeed, different applications (e.g., communications schedules, pointing, navigation, distributed science) will have different requirements, hence it is necessary to maintain clocks within a given tolerance. We outline some of the necessary steps to turn our approach into a practical network protocol that could be used in DTN, and we conclude the paper with suggestions for future research.

Michael Moy↗
NASA NTRS2012

Lidar Remote Sensing of Forests: New Instruments and Modeling Capabilities

Lidar instruments provide scientists with the unique opportunity to characterize the 3D structure of forest ecosystems. This information allows us to estimate properties such as wood volume, biomass density, stocking density, canopy cover, and leaf area. Structural information also can be used as drivers for photosynthesis and ecosystem demography models to predict forest growth and carbon sequestration. All lidars use time-in-flight measurements to compute accurate ranging measurements; however, there is a wide range of instruments and data types that are currently available, and instrument technology continues to advance at a rapid pace. This seminar will present new technologies that are in use and under development at NASA for airborne and space-based missions. Opportunities for instrument and data fusion will also be discussed, as Dr. Cook is the PI for G-LiHT, Goddard's LiDAR, Hyperspectral, and Thermal airborne imager. Lastly, this talk will introduce radiative transfer models that can simulate interactions between laser light and forest canopies. Developing modeling capabilities is important for providing continuity between observations made with different lidars, and to assist the design of new instruments. Dr. Bruce Cook is a research scientist in NASA's Biospheric Sciences Laboratory at Goddard Space Flight Center, and has more than 25 years of experience conducting research on ecosystem processes, soil biogeochemistry, and exchange of carbon, water vapor and energy between the terrestrial biosphere and atmosphere. His research interests include the combined use of lidar, hyperspectral, and thermal data for characterizing ecosystem form and function. He is Deputy Project Scientist for the Landsat Data Continuity Mission (LDCM); Project Manager for NASA s Carbon Monitoring System (CMS) pilot project for local-scale forest biomass; and PI of Goddard's LiDAR, Hyperspectral, and Thermal (G-LiHT) airborne imager.

Cook, Bruce D.↗
DOE OSTI2026

High-Resolution South American Wind Resource Data Downscaled with Generative Machine Learning Conditioned on Near-Surface Observations

High-resolution historical wind data was developed for the entirety of South America using the innovative Super-Resolution for Renewable Resource Data (sup3r) machine learning framework. The publicly available Sup3rWind South America dataset represents a significant advancement in wind resource data generation, leveraging generative machine learning conditioned on near-surface observations from the Meteorological Assimilation Data Ingest System (MADIS) to efficiently and accurately downscale coarse reanalysis data from the European Centre for Medium-Range Weather Forecasts (ERA5). This approach produces fine-scale, spatially and temporally coherent wind and meteorological fields hundreds of times more computationally efficient than traditional numerical weather modeling methods, enabling access to high-fidelity wind information across both continental and offshore regions. Sup3rWind South America builds on the earlier Sup3rWind Ukraine dataset through improvements in model architecture and outputs conditioned on near-surface observation inputs. As with the Ukraine data release, this dataset includes wind speed, wind direction, temperature, relative humidity, and pressure at a horizontal resolution of ~2 km, representing a 15x spatial enhancement relative to the 31 km ERA5 grid. Wind speed and direction are provided at 5-minute resolution, a 12x temporal refinement compared to the hourly ERA5 data, while temperature, relative humidity, and pressure remain at hourly resolution. The data covers all years from 2005 to 2024. Before downscaling, ERA5 inputs were bias-corrected using long-term monthly means and a limited number of quality-controlled observations to align large-scale statistics with regional conditions. The resulting dataset is the first publicly available high-resolution timeseries wind record that provides full spatial coverage of South America. Model validation demonstrates strong agreement with observations across several statistical metrics, consistent with other state-of-the-art high-resolution wind resource datasets. The potential applications of Sup3rWind South America span renewable energy resource assessment, energy system modeling, and grid resilience analysis. The 20-year record and high spatial and temporal resolution support accurate estimation of long-term energy yield and the economic feasibility of potential wind development sites. Continuous coverage across both continental and offshore regions enables comprehensive site prospecting within exclusive economic zones. The 2 km, 5-minute resolution data provide the spatial and temporal variability required for power system simulation, operational planning, and regional risk assessments.

17 WIND ENERGY↗
DOE OSTI2022

ARPA-E PNDIODES "PN Junctions by Ion Implantation" Project (Final Report)

Electricity accounts for nearly 40% of the energy generated in the United States, of which 65% is lost to electrical system inefficiency before reaching end-use sectors. Power electronics will play a growing role in this distribution and end-use, with up to 80% of electricity estimated to pass through power electronics from generation to consumption by 2030. This gives technical improvements in power electronics enormous potential to drive efficiency gains throughout the U.S. economy. Current Si-based power architectures including MOSFETs and IGBTs are limited by high losses, low switching frequency, and poor high-temperature performance. Given the material properties of GaN, devices can exhibit a given turn-on resistance and breakdown voltage with a minute fraction of the area of a Si device—all with higher switching speeds. While n-type doping of III-nitrides has reached a high level of maturity and integration into commercialized products, p-type doping presents distinct challenges that requires continued research. The success of the next generation of GaN-based power devices depends in large part on the ability to form selective-area p-type regions, which can be accomplished by ion implantation of the prevailing acceptor dopant, Mg. This approach is relatively inexpensive and is a fab-ready processing step for creation of current-generation power electronic devices including BJTs, IGBTs, and diode rectifiers. However, ion implantation induces lattice damage and creates point defects within the material, which negatively impacts dopant activation annealing. These forms of damage may be removed by high-temperature annealing, however short annealing time and higher pressures are required to prevent decomposition of the material. We approach this challenge through an innovative combination of approaches toward obtaining high-conductivity p-type GaN. By the novel employment of a gyrotron, a microwave source that can be shaped into a highly localized beam to dissipate very high power in a semiconductor target, a wafer of GaN can be annealed in short (<2 s) ‘pulses’ at temperatures of 1450 °C (2640 °F) to achieve p-type activation without appreciable surface degradation. The p-type activation of Mg-implanted GaN can be further aided by co-implantation with N, believed to enhance the removal of point defects that compensate the acceptors dopant. Elevation to such high temperatures for even a short time induces degradation of GaN-to overcome, we have implemented additional measures to retain high-quality crystalline GaN while removing implant damage and activating Mg dopant. A bilayer cap of AlN is deposited by a combination of chemical and physical vapor deposition to protect the GaN surface. To prevent decomposition of GaN loss of N during annealing, a custom vessel—to contain pressurized N while allowing injection of microwave energy—is employed. By detailed study of the interaction of various measures that are implemented to protect the sample surface (GaN), activate the implanted dopants, and mitigate damage of the lattice heating damage during annealing, we are able to achieve p-type GaN and observe recovery of the crystal and removal of substantial density of defects created during the implantation process.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

C2QA - Bosonic Qiskit

The practical benefits of hybrid quantum information processing hardware that contains continuous-variable objects (bosonic modes such as mechanical or electromagnetic oscillators) in addition to traditional (discrete-variable) qubits have recently been demonstrated by experiments with bosonic codes that reach the break-even point for quantum error correction [1]–[5] and by efficient Gaussian boson sampling simulation of the Franck-Condon spectra of triatomic molecules [6] that is well beyond the capabilities of current qubit-only hardware. The goal of this Co-design Center for Quantum Advantage (C2QA) project is to develop an instruction set architecture (ISA) for hybrid qubit/bosonic mode systems that contains an inventory of the fundamental operations and measurements that are possible in such hardware. The corresponding abstract machine model (AMM) would also contain a description of the appropriate error models associated with the gates, measurements and time evolution of the hardware. This information has been implemented as an extension of IBM Qiskit. IBM Qiskit is an open-source software development toolkit (SDK) for simulating the quantum state of a quantum circuit and for running the same circuits on prototype hardware within the IBM Quantum Experience. We introduce the Bosonic Qiskit software to enable the simulation of hybrid qubit/bosonic systems using the existing Qiskit software development kit [7]. This implementation can be used for simulating new hybrid systems, verifying proposed physical systems, and modeling systems larger than can currently be constructed. We also cover tutorials and example use cases included within the software to study JaynesCummings models, bosonic Hubbard models, plotting Wigner functions and animations, and calculating maximum likelihood estimations using Wigner functions.

quantum, boson, Qiskit↗
NASA NTRS1991

A strongly goal-directed close-range vision system for spacecraft docking

In this presentation, we will propose a strongly goal-oriented stereo vision system to establish proper docking approach motions for automated rendezvous and capture (AR&C). From an input sequence of stereo video image pairs, the system produces a current best estimate of: contact position; contact vector; contact velocity; and contact orientation. The processing demands imposed by this particular problem and its environment dictate a special case solution; such a system should necessarily be, in some sense, minimalist. By this we mean the system should construct a scene description just sufficiently rich to solve the problem at hand and should do no more processing than is absolutely necessary. In addition, the imaging resolution should be just sufficient. Extracting additional information and constructing higher level scene representations wastes energy and computational resources and injects an unnecessary degree of complexity, increasing the likelihood of malfunction. We therefore take a departure from most prior stereopsis work, including our own, and propose a system based on associative memory. The purpose of the memory is to immediately associate a set of motor commands with a set of input visual patterns in the two cameras. That is, rather than explicitly computing point correspondences and object positions in world coordinates and trying to reason forward from this information to a plan of action, we are trying to capture the essence of reflex behavior through the action of associative memory. The explicit construction of point correspondences and 3D scene descriptions, followed by online velocity and point of impact calculations, is prohibitively expensive from a computational point of view for the problem at hand. Learned patterns on the four image planes, left and right at two discrete but closely spaced instants in time, will be bused directly to infer the spacecraft reaction. This will be a continuing online process as the docking collar approaches.

Boyer, Kim L.↗
NASA NTRSDate not supplied

Communication Demand in the National Airspace - A Federated Learning Approach

Within the national airspace system (NAS), efficient use of spectrum remains a challenge; as UAS and UAM missions evolve, the amount of mission-critical aircraft communications are expected to significantly grow. To accommodate the increased demand, NASA Glenn Research Center is investigating artificial intelligence approaches that could dynamically allocate spectrum; however, these solutions are driven by communication and aviation data items, many of which are not directly available. One such cornerstone data item is communication demand, parameterizing the needs within a sector in terms that may directly inform spectrum allocation, such as channel access duration, bandwidth, and modulation type. This paper considers the complexity of predicting communication demand as a function of NAS behaviors. Unlike prior prediction work in communications, this research must consider how the NAS may be impacted by external factors - such as convective weather and closures - rather than estimating demand from time-series forecasting alone. Much of this research considers a federated learning design to predict communication events in terms of the type of event occurring (sector coordination, conflict resolution, etc.). To do so, an investigation of products from Sherlock Data Warehouse is conducted, identifying the trends, sufficiency, and correlations of each product to identified events. Additionally, a preliminary discussion for inferring associations between these event types and their communication parameters (duration, bandwidth, modulation) is presented. By utilizing federated learning, imbalances in the types of events and data present throughout the NAS can inform local models without impairing global training. Furthermore, the two-stage approach proposed allows for robust and speculative communication modelling, as communication techniques continue to evolve. As a result, this model enables a generalized approach to understanding NAS communications which is able to inform long-term changes to aviation spectrum management.

Nathan Schimpf↗
NASA NTRSDate not supplied

A Federated Learning Approach to Predicting Communication Demand in the National Airspace

Within the national airspace system (NAS), efficient use of spectrum remains a challenge; as UAS and UAM missions evolve, the amount of mission-critical aircraft communications are expected to significantly grow. To accommodate the increased demand, NASA Glenn Research Center is investigating artificial intelligence approaches that could dynamically allocate spectrum; however, these solutions are driven by communication and aviation data items, many of which are not directly available. One such cornerstone data item is communication demand, parameterizing the needs within a sector in terms that may directly inform spectrum allocation, such as channel access duration, bandwidth, and modulation type. This paper considers the complexity of predicting communication demand as a function of NAS behaviors. Unlike prior prediction work in communications, this research must consider how the NAS may be impacted by external factors - such as convective weather and closures - rather than estimating demand from time-series forecasting alone. Much of this research considers a federated learning design to predict communication events in terms of the type of event occurring (sector coordination, conflict resolution, etc). To do so, an investigation of products from Sherlock Data Warehouse is conducted, identifying the trends, sufficiency, and correlations of each product to identified events. Additionally, a preliminary discussion for inferring associations between these event types and their communication parameters (duration, bandwidth, modulation) is presented. By utilizing federated learning, imbalances in the types of events and data present throughout the NAS can inform local models without impairing global training. Furthermore, the two-stage approach proposed allows for robust and speculative communication modelling, as communication techniques continue to evolve. As a result, this model enables a generalized approach to understanding NAS communications which is able to inform long-term changes to aviation spectrum management.

Nathan Schimpf↗
DOE OSTI2025

Modular Processing of Flare Gas for Carbon Nanoproducts

This project demonstrated the technical viability and economic promise of a modular system for converting flared natural gas into valuable carbon nanoproducts (CNPs) through catalytic chemical vapor deposition (CVD). All major project milestones were successfully completed, including reactor design and commissioning, catalyst development, process optimization, technoeconomic analysis, and application testing in concrete systems. The overarching goal was to create a scalable, field-deployable process that valorizes stranded methane by producing high-value carbon materials for use in cementitious composites. At the lab scale, the team designed and built a fluidized bed reactor optimized for use with silica fume-supported nickel catalysts synthesized via atomic layer deposition (ALD). A statistically designed sintering study enabled precise tuning of nickel nanoparticle size, identifying the influence of oxygen partial pressure, time, and temperature on catalyst morphology and performance. These insights allowed the team to target catalyst conditions that maximize carbon nanofilament growth. Subsequent CVD experiments achieved up to 31.8 wt% carbon deposition under optimized conditions, with TEM confirming the presence of nanofilament structures and sustained hydrogen evolution during reaction. Reactor upgrades and empirical fluidization studies supported the development of reliable, repeatable experimental protocols. The modular pilot-scale skid reactor was fully constructed, instrumented, and commissioned. Capable of operating at 675–800°C and pressures up to 290 psig, the system was designed for continuous operation at a carbon production rate of 1 kg/hr. Initial demonstration runs confirmed solids handling, thermal control, and system leak-tightness, although a critical reactor component (the downfeed tube) was inadvertently omitted during final assembly. This omission limited gas–solid contact and prevented meaningful carbon deposition during pilot-scale CVD runs. Nonetheless, the system operated safely under design conditions, and the root cause of performance limitations was clearly identified. Complementary work on UHPC formulations demonstrated that small additions of carbon nanoproducts, including those derived from flare gas, can significantly enhance mechanical performance while preserving workability. A comprehensive study of CNF dispersion techniques and mix design optimization led to a clear protocol for integrating these nanomaterials into concrete. Incorporation of CNPs improved flexural toughness and reduced porosity, supporting their use in high-performance infrastructure applications. A technoeconomic analysis (TEA) confirmed that this process can produce CNP-loaded catalyst material at a levelized cost below $\$$7/kg across a range of catalyst loadings and reaction yields. With estimated market values for the carbon composite product ranging from $\$$14 to over $\$$60/kg, and the ability to blend CNPs into concrete at sub-percent levels with less than 10% added cost, the system presents a compelling economic case. While additional engineering work is needed to optimize fluidization and heat transfer at scale, this project establishes a strong foundation for commercial development. The process is not only technically sound but also economically promising, representing a viable pathway for flare gas mitigation through modular carbon nanomaterial production.

03 NATURAL GAS↗
NASA NTRS2014

Service Life Extension of the Propulsion System of Long-Term Manned Orbital Stations

One of the critical non-replaceable systems of a long-term manned orbital station is the propulsion system. Since the propulsion system operates beginning with the launch of station elements into orbit, its service life determines the service life of the station overall. Weighing almost a million pounds, the International Space Station (ISS) is about four times as large as the Russian space station Mir and about five times as large as the U.S. Skylab. Constructed over a span of more than a decade with the help of over 100 space flights, elements and modules of the ISS provide more research space than any spacecraft ever built. Originally envisaged for a service life of fifteen years, this Earth orbiting laboratory has been in orbit since 1998. Some elements that have been launched later in the assembly sequence were not yet built when the first elements were placed in orbit. Hence, some of the early modules that were launched at the inception of the program were already nearing the end of their design life when the ISS was finally ready and operational. To maximize the return on global investments on ISS, it is essential for the valuable research on ISS to continue as long as the station can be sustained safely in orbit. This paper describes the work performed to extend the service life of the ISS propulsion system. A system comprises of many components with varying failure rates. Reliability of a system is the probability that it will perform its intended function under encountered operating conditions, for a specified period of time. As we are interested in finding out how reliable a system would be in the future, reliability expressed as a function of time provides valuable insight. In a hypothetical bathtub shaped failure rate curve, the failure rate, defined as the number of failures per unit time that a currently healthy component will suffer in a given future time interval, decreases during infant-mortality period, stays nearly constant during the service life and increases at the end when the design service life ends and wear-out phase begins. However, the component failure rates do not remain constant over the entire cycle life. The failure rate depends on various factors such as design complexity, current age of the component, operating conditions, severity of environmental stress factors, etc. Development, qualification and acceptance test processes provide rigorous screening of components to weed out imperfections that might otherwise cause infant mortality failures. If sufficient samples are tested to failure, the failure time versus failure quantity can be analyzed statistically to develop a failure probability distribution function (PDF), a statistical model of the probability of failure versus time. Driven by cost and schedule constraints however, spacecraft components are generally not tested in large numbers. Uncertainties in failure rate and remaining life estimates increase when fewer units are tested. To account for this, spacecraft operators prefer to limit useful operations to a period shorter than the maximum demonstrated service life of the weakest component. Running each component to its failure to determine the maximum possible service life of a system can become overly expensive and impractical. Spacecraft operators therefore, specify the required service life and an acceptable factor of safety (FOS). The designers use these requirements to limit the life test duration. Midway through the design life, when benefits justify additional investments, supplementary life test may be performed to demonstrate the capability to safely extend the service life of the system. An innovative approach is required to evaluate the entire system, without having to go through an elaborate test program of propulsion system elements. Evaluating every component through a brute force test program would be a cost prohibitive and time consuming endeavor. ISS propulsion system components were designed and built decades ago. There are no representative ground test articles for some of the components. A 'test everything' approach would require manufacturing new test articles. The paper outlines some of the techniques used for selective testing, by way of cherry picking candidate components based on failure mode effects analysis, system level impacts, hazard analysis, etc. The type of testing required for extending the service life depends on the design and criticality of the component, failure modes and failure mechanisms, life cycle margin provided by the original certification, operational and environmental stresses encountered, etc. When specific failure mechanism being considered and the underlying relationship of that mode to the stresses provided in the test can be correlated by supporting analysis, time and effort required for conducting life extension testing can be significantly reduced. Exposure to corrosive propellants over long periods of time, for instance, lead to specific failure mechanisms in several components used in the propulsion system. Using Arrhenius model, which is tied to chemically dependent failure mechanisms such as corrosion or chemical reactions, it is possible to subject carefully selected test articles to accelerated life test. Arrhenius model reflects the proportional relationship between time to failure of a component and the exponential of the inverse of absolute temperature acting on the component. The acceleration factor is used to perform tests at higher stresses that allow direct correlation between the times to failure at a high test temperature to the temperatures to be expected in actual use. As long as the temperatures are such that new failure mechanisms are not introduced, this becomes a very useful method for testing to failure a relatively small sample of items for a much shorter amount of time. In this article, based on the example of the propulsion system of the first ISS module Zarya, theoretical approaches and practical activities of extending the service life of the propulsion system are reviewed with the goal of determining the maximum duration of its safe operation.

Kamath, Ulhas↗
DOE OSTI2019

WBS 4.1.2.31 Bioproduct Transition System Dynamics

Bioproducts are chemicals derived from a biomass feedstock; they can be produced on their own or as co-products of a biorefinery that also produces biofuels. Bioproducts have historically been difficult to scale up and bring to market, despite a broad understanding developed within BETO of the various conversion processes that can be used to produce bioproducts. Expanding the bioproducts industry by bringing more bioproducts to market would have a variety of positive impacts. Growth in the bioproducts industry would support the biofuels industry by enabling biorefinery co-products that yield additional revenue streams, allowing biofuel selling prices to be reduced and expanding the biofuels market. A larger bioproducts industry also has the potential to reduce carbon and other emissions associated with the U.S. chemical sector and contribute to increased price stability in some areas of the chemical market by shifting portions of the chemical sector away from reliance on fossil feedstocks. The key barrier to realizing these positive impacts is a lack of knowledge around the factors that prevent or enable bioproducts to reach the commercial market. To date, there has been essentially no research done on how successful bioproducts (commercially produced bioproducts that have captured market share) become successful, why failed bioproducts fail, and what the similarities and differences are between successful and failed bioproducts. The current project addresses this knowledge gap with a decision support tool that can be used by investors, technology developers and government agencies to bring more bioproducts to market, thereby simultaneously growing the bioproducts and biofuels industries. Development of the decision support tool was based on research on the technology development process and success rates in analogous industries, data gathered during previous BETO-funded projects, and a series of interviews with subject-matter experts within BETO, the bioproducts industry, and the investment community. This information formed a knowledge base around how bioproducts are developed from applied research to commercial scale was assembled, which was used to build the Bioproduct Transition Dynamics (BTD) model, a system dynamics (SD) model that tracks bioproduct development projects from applied research through the 'valley of death' of piloting and demoing to commercial scale production. The end-of-project goal is to release the BTD, along with supporting documentation, as a transparent open-source model that will inform decisions around bioproduct development and investments and enable more bioproducts to reach the market. The BTD takes as inputs techno-economic data on specific bioproducts, behavioral parameters for developers and investors, expectations around government support, and exogenous market factors. Model outputs include bioproduct technological progress over time, a cash flow statement for the development project, and market share estimates. Following initial model development, a sensitivity analysis was performed on a subset of model inputs to determine, first, if the BTD could be used to answer analysis questions of interest to BETO, and second, which of the inputs considered were most influential on bioproduct success. Results indicate that the BTD can be used to identify scenarios that enable bioproduct development, and that 'soft' or semi-quantitative factors play a large role in determining if a bioproduct will reach the market. A workshop was also held for subject-matter experts and prospective BTD users in July 2018. The workshop covered BTD model logic, input data and assumptions as well as the sensitivity analysis results and a discussion of potential use cases. Workshop feedback was used to identify additional model development tasks and was incorporated into a draft technical report completed in September 2018. BTD model development, validation and application will continue through 2019.

09 BIOMASS FUELS↗
DOE OSTI2024

Prognostic model and failure mechanisms of steam generators in Sodium-Cooled fast reactors

This paper presents a prognostic model for sodium-cooled fast reactor (SFR) steam generators (SGs). Here, the purpose of the model is to estimate the remaining useful life of SFR SGs and thus to support the decision-making of autonomous control. SFR SGs are of great interest for plant integrity due to their harsh operation environment. They operate at higher temperatures and higher coolant-to-steam pressure differences than those of current light water reactors (LWR). The severity of the SFR SG failure consequences, which include water-sodium contact, is another reason. Understanding its failure mechanisms is important for the development of its prognostic model. Based on our literature review and physics-based analysis, we concluded that creep would be a dominant degradation mode of SFR SGs due to SFR’s high-temperature and high-pressure environment. Thus, creep is the focus of the prognostic model. Various other failure modes were also investigated in this study. The mechanical fatigue due to flow-induced vibration is usually observed in early developmental phases and would not be an important issue during normal operation. The thermal fatigue due to thermal stripping is occasionally observed in other components in SFRs but does not affect SG integrity. Pure water stress corrosive crack, fretting, and so on are commonly observed in LWR SGs but are significantly less important in SFR SGs because of the high temperatures, high pressure differences, and chemical properties of liquid sodium. Based on these investigations, a prognostic model focusing on creep failures was developed. It estimates the failure probability profile by sampling the Larson-Miller parameter (LMP) and temperature and associated uncertainties through Monte Carlo methods. Two case studies were presented. The first one demonstrated the model’s capability to calculate the failure probability for a new specimen within a given time. If the tube is working under temperatures of 500C ± 3 and pressures of 15.2 MPa, which leads to LMP of 20,100 ± 50, the failure probabilities within 50, 70, and 90 years are approximately 0.1 %, 3.2 %, and 17.5 %. The second demonstrated how adjusting the workload can help to protect the integrity of the component. For an old tube reaching 99 % of its lifespan, continuing to run at temperatures of 500C ± 3 and LMP of 20,100 ± 50 leads to a failure probability of about 29.0 % within a year. If the temperature is reduced by 5C, the failure probability can be reduced to 2.5 %, and, if the pressure is also reduced such that the LMP is increased by 100, the failure probability can further be reduced to 0.12 %.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Tensor network study of the m = 1/2 magnetization plateau in the Shastry-Sutherland model at finite temperature

The two-dimensional infinite projected entangled pair state tensor network is evolved in imaginary time with the full update (FU) algorithm to simulate the Shastry-Sutherland model in a magnetic field at finite temperature directly in the thermodynamic limit. We focus on the phase transition into the m = 1/2 magnetization plateau, which was observed in experiments on SrCu 2 (BO 3 ) 2 . For the largest simulated bond dimension, the early evolution in the high-temperature regime is simulated with the simple update (SU) scheme and then, as the correlation length increases, continued with the FU scheme towards the critical regime. We apply a small symmetry-breaking bias field and then extrapolate towards zero bias using a simple scaling theory in the bias field. The combined SU + FU scheme provides an accurate estimate of the critical temperature, even though the results could not be fully converged in the bond dimension in the vicinity of the transition. Here, the critical temperature estimate is improved with a generalized scaling theory that combines two divergent length scales: One due to the bias, and the other due to the finite bond dimension. The obtained results are consistent with the transition being in the universality class of the two-dimensional classical Ising model. The estimated critical temperature is 3.5(2) K, which is well above the temperature 2.1 K used in the experiments.

2-dimensional systems↗