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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Mechanical Testing of Additively Manufactured Materials

This report summarizes research activities conducted at Argonne National Laboratory in support of the development, qualification and certification of additively manufactured (AM) metallic components to allow for innovative reactor design and licensing. In this program, AM 316L stainless steel (SS) was evaluated in both light water reactor (LWR) environments as well as at higher temperatures expected in advanced reactors.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Dose-Response Data Considerations for the NASA Quesst Community Test Campaign

Key outcomes for NASA's Quesst mission are noise dose and perceptual response data to inform regulators on their decisions regarding noise certification standards for the future of overland commercial supersonic flight. Dose-response curves are commonly utilized in community noise studies to describe the annoyance of a community to a particular noise source. The X-59 aircraft utilizes shaped-boom technology to demonstrate low noise supersonic flight. For X-59 community studies, the sound level from X-59 overflights constitutes the dose, while the response is an annoyance rating selected from a verbal scale, e.g., “slightly annoyed” and “very annoyed.” Dose-response data will be collected from individual flyovers (single event dose) and an overall response to the accumulation of single events at the end of the day (cumulative dose). There are quantifiable sources of error in the noise dose due to uncertainty in microphone measurements of the sonic thumps and uncertainty in predicted noise levels at survey participant locations. Assessing and accounting for error in the noise dose is essential to obtain an accurate dose-response model. There is also a potential for error in the perceptual response. This error is due to the ability of participants to provide their response in a timely manner and participant fatigue after responding to up to one hundred surveys over the course of a month. This talk outlines various challenges in estimating noise dose and perceptual response and the methods considered in preparation for X-59 community tests.

dose-response↗
NASA NTRS2015

Analysis and Testing of a Composite Fuselage Shield for Open Rotor Engine Blade-Out Protection

The Federal Aviation Administration is working with the European Aviation Safety Agency to determine the certification base for proposed new engines that would not have a containment structure on large commercial aircraft. Equivalent safety to the current fleet is desired by the regulators, which means that loss of a single fan blade will not cause hazard to the Aircraft. The NASA Glenn Research Center and The Naval Air Warfare Center (NAWC), China Lake, collaborated with the FAA Aircraft Catastrophic Failure Prevention Program to design and test lightweight composite shields for protection of the aircraft passengers and critical systems from a released blade that could impact the fuselage. In the test, two composite blades were pyrotechnically released from a running engine, each impacting a composite shield with a different thickness. The thinner shield was penetrated by the blade and the thicker shield prevented penetration. This was consistent with pre-test predictions. This paper documents the live fire test from the full scale rig at NAWC China Lake and describes the damage to the shields as well as instrumentation results.

safety↗
NASA NTRS2016

Analysis and Testing of a Composite Fuselage Shield for Open Rotor Engine Blade-Out Protection

The Federal Aviation Administration is working with the European Aviation Safety Agency to determine the certification base for proposed new engines that would not have a containment structure on large commercial aircraft. Equivalent safety to the current fleet is desired by the regulators, which means that loss of a single fan blade will not cause hazard to the Aircraft. The NASA Glenn Research Center and The Naval Air Warfare Center (NAWC), China Lake, collaborated with the FAA Aircraft Catastrophic Failure Prevention Program to design and test lightweight composite shields for protection of the aircraft passengers and critical systems from a released blade that could impact the fuselage. LS-DYNA® was used to predict the thickness of the composite shield required to prevent blade penetration. In the test, two composite blades were pyrotechnically released from a running engine, each impacting a composite shield with a different thickness. The thinner shield was penetrated by the blade and the thicker shield prevented penetration. This was consistent with pre-test LS-DYNA predictions. This paper documents the analysis conducted to predict the required thickness of a composite shield, the live fire test from the full scale rig at NAWC China Lake and describes the damage to the shields as well as instrumentation results.

Composite↗
NASA NTRS2016

Status of NASA's Space Launch System

NASA's Space Launch System (SLS) continued to make significant progress in 2015 and 2016, completing hardware and testing that brings NASA closer to a new era of deep space exploration. Programmatically, SLS completed Critical Design Review (CDR) in 2015. A team of independent reviewers concluded that the vehicle design is technically and programmatically ready to move to Design Certification Review (DCR) and launch readiness in 2018. Just five years after program start, every major element has amassed development and flight hardware and completed key tests that will lead to an accelerated pace of manufacturing and testing in 2016 and 2017. Key to SLS' rapid progress has been the use of existing technologies adapted to the new launch vehicle. The existing fleet of RS-25 engines is undergoing adaptation tests to prove it can meet SLS requirements and environments with minimal change. The four-segment shuttle-era booster has been modified and updated with a fifth propellant segment, new insulation, and new avionics. The Interim Cryogenic Upper Stage is a modified version of an existing upper stage. The first Block I SLS configuration will launch a minimum of 70 metric tons (t) of payload to low Earth orbit (LEO). The vehicle architecture has a clear evolutionary path to more than 100t and, ultimately, to 130t. Among the program's major 2015-2016 accomplishments were two booster qualification hotfire tests, a series of RS-25 adaptation hotfire tests, manufacturing of most of the major components for both core stage test articles and first flight tank, delivery of the Pegasus core stage barge, and the upper stage simulator. Renovations to the B-2 test stand for stage green run testing was completed at NASA Stennis Space Center. This year will see the completion of welding for all qualification and flight EM-1 core stage components and testing of flight avionics, completion of core stage structural test stands, casting of the EM-1 solid rocket motors, additional testing of RS-25 engines and flight engine controllers This paper will discuss these and other technical and programmatic successes and challenges over the past year and provide a preview of work ahead before the first flight of this new capability.

Honeycutt, John↗
NASA NTRSDate not supplied

Certification Concepts for AI/ML Systems

This presentation goes over some of the tools developed at NASA Ames in the Robust Software Engineering group for the assurance and certification of autonomous systems. The research themes presented include improving safety and risk assessment as early as possible in the lifecycle, elicitation and formalization of requirements to facilitate traceability throughout the lifecycle, especially when formal methods are used, algorithms, tools and techniques for the V&V of ML-enabled systems, advanced testing, use of runtime monitoring to ease use of untrusted components, and contribution to draft regulatory standards and assistance in producing and presenting certification evidences.

Autonomy↗
DOE OSTI2025

Computational Optimization of 133m Xe Production via Neutron Irradiation in a TRIGA Reactor

Here, the Comprehensive Nuclear-Test-Ban Treaty bans all nuclear tests worldwide. As part of treaty compliance, the concentration of radioactive nuclides in the atmosphere is monitored to detect nuclear weapons tests. Radioactive noble gas fission products, specifically radioxenon, can vent into the atmosphere after a nuclear weapons test, even if the test is well contained underground or underwater. Radioxenon thus serves as a signal for nuclear weapons tests. All atmospheric monitoring systems require samples of radioxenon isotopes for detector calibration, quality control, and certification. Here, we present a novel, improved method for creating samples of 133m Xe via neutron irradiation of 132 Xe in the Washington State University TRIGA reactor. 132 Xe neutron absorption results in either 133 Xe or 133m Xe—thermal neutron absorption results in 133m Xe 12% of the time, while fast neutron absorption (above ~1 MeV) results in 133m Xe ~50% of the time. To optimize the production of 133m Xe via neutron absorption in 132 Xe in the thermal TRIGA reactor, spectral tuning using an irradiation chamber is required to maximize the fraction of fast neutrons being absorbed and minimize the number of thermal neutrons interacting with the 132 Xe. We used MCNP to tally 132 Xe absorptions with the isotopic tally function, flux tallies and neutron attenuation to estimate the number of neutrons reaching the 132 Xe through the irradiation chamber, and the adjoint importance function to improve the source strength estimate. Additionally, we performed a heat transfer analysis for safety considerations. It was determined that the use of a 96% enriched 10 B boron carbide chamber, placed next to the fuel elements in reactor position D8, increases the 133m Xe/ 133 Xe activity ratio from a baseline value of 0.3 to 1.0, a 233% increase. Additionally, it was determined that the alpha heating produced in the boron does not become an unmanageable problem in the Washington State University reactor.

37 - INORGANIC, ORGANIC, PHYSICAL AND ANALYTICAL C↗
NASA NTRS1983

Full-scale testing, production and cost analysis data for the advanced composite stabilizer for Boeing 737 aircraft. Volume 1: Technical summary

The full scale ground test, ground vibration test, and flight tests conducted to demonstrate a composite structure stabilizer for the Boeing 737 aircraft and obtain FAA certification are described. Detail tools, assembly tools, and overall production are discussed. Cost analyses aspects covered include production costs, composite material usage factors, and cost comparisons.

Aniversario, R. B.↗
NASA NTRS1993

Material Testing Device

Small Business Innovation Research (SBIR) contracts led to two commercial instruments and a new subsidiary for Physical Sciences, Inc. (PSI). The FAST system, originally developed for testing the effect of space environment on materials, is now sold commercially for use in aging certification of materials intended for orbital operation. The Optical Temperature Monitor was designed for precise measurement of high temperatures on certain materials to be manufactured in space. The original research was extended to the development of a commercial instrument that measures and controls fuel gas temperatures in industrial boilers. PSI created PSI Environmental Instruments to market the system. The company also offers an Aerospace Measurement Service that has evolved from other SBIR contracts.

Source record↗
NASA NTRS2008

Integrated System Test Approaches for the NASA Ares I Crew Launch Vehicle

NASA is maturing test and evaluation plans leading to flight readiness of the Ares I crew launch vehicle. Key development, qualification, and verification tests are planned . Upper stage engine sea-level and altitude testing. First stage development and qualification motors. Upper stage structural and thermal development and qualification test articles. Main Propulsion Test Article (MPTA). Upper stage green run testing. Integrated Vehicle Ground Vibration Testing (IVGVT). Aerodynamic characterization testing. Test and evaluation supports initial validation flights (Ares I-Y and Orion 1) and design certification.

Cockrell, Charles↗
NASA NTRS2012

Certification of COTS Software in NASA Human Rated Flight Systems

Adoption of commercial off-the-shelf (COTS) products in safety critical systems has been seen as a promising acquisition strategy to improve mission affordability and, yet, has come with significant barriers and challenges. Attempts to integrate COTS software components into NASA human rated flight systems have been, for the most part, complicated by verification and validation (V&V) requirements necessary for flight certification per NASA s own standards. For software that is from COTS sources, and, in general from 3rd party sources, either commercial, government, modified or open source, the expectation is that it meets the same certification criteria as those used for in-house and that it does so as if it were built in-house. The latter is a critical and hidden issue. This paper examines the longstanding barriers and challenges in the use of 3rd party software in safety critical systems and cover recent efforts to use COTS software in NASA s Multi-Purpose Crew Vehicle (MPCV) project. It identifies some core artifacts that without them, the use of COTS and 3rd party software is, for all practical purposes, a nonstarter for affordable and timely insertion into flight critical systems. The paper covers the first use in a flight critical system by NASA of COTS software that has prior FAA certification heritage, which was shown to meet the RTCA-DO-178B standard, and how this certification may, in some cases, be leveraged to allow the use of analysis in lieu of testing. Finally, the paper proposes the establishment of an open source forum for development of safety critical 3rd party software.

Goforth, Andre↗
NASA NTRS2001

Mars Sample Handling Protocol Workshop Series: Workshop 2

Numerous NASA reports and studies have identified Planetary Protection (PP) as an important part of any Mars sample return mission. The mission architecture, hardware, on-board experiments, and related activities must be designed in ways that prevent both forward- and back-contamination and also ensure maximal return of scientific information. A key element of any PP effort for sample return missions is the development of guidelines for containment and analysis of returned sample(s). As part of that effort, NASA and the Space Studies Board (SSB) of the National Research Council (NRC) have each assembled experts from a wide range of scientific fields to identify and discuss issues pertinent to sample return. In 1997, the SSB released its report on recommendations for handling and testing of returned Mars samples. In particular, the NRC recommended that: a) samples returned from Mars by spacecraft should be contained and treated as potentially hazardous until proven otherwise, and b) rigorous physical, chemical, and biological analyses [should] confirm that there is no indication of the presence of any exogenous biological entity. Also in 1997, a Mars Sample Quarantine Protocol workshop was convened at NASA Ames Research Center to deal with three specific aspects of the initial handling of a returned Mars sample: 1) biocontainment, to prevent 'uncontrolled release' of sample material into the terrestrial environment; 2) life detection, to examine the sample for evidence of organisms; and 3) biohazard testing, to determine if the sample poses any threat to terrestrial life forms and the Earth's biosphere. In 1999, a study by NASA's Mars Sample Handling and Requirements Panel (MSHARP) addressed three other specific areas in anticipation of returning samples from Mars: 1) sample collection and transport back to Earth; 2) certification of the samples as non-hazardous; and 3) sample receiving, curation, and distribution. To further refine the requirements for sample hazard testing and the criteria for subsequent release of sample materials from quarantine, the NASA Planetary Protection Officer convened an additional series of workshops beginning in March 2000. The overall objective of these workshops was to develop comprehensive protocols to assess whether the returned materials contain any biological hazards, and to safeguard the purity of the samples from possible terrestrial contamination. This document is the report of the second Workshop in the Series. The information herein will ultimately be integrated into a final document reporting the proceedings of the entire Workshop Series along with additional information and recommendations.

Rummel, John D.↗
DOE OSTI2019

Operational Planning Strategy for a Sequim Bay Underwater UXO Test Site (SBU2)

The Department of Defense (DoD) has identified more than 400 underwater sites that are potentially contaminated with munitions. Most areas are in shallow water (0-35 m) where the munitions pose a threat to human health and the environment. The Strategic Environmental Research and Development Program (SERDP) and Environmental Security Technology Certification Program (ESTCP) held a workshop in 2018 to establish the requirements, framework, protocols, responsibilities, and time lines for development of a series of underwater UXO Standardized Demonstration sites (“test beds”) for the purpose of testing the efficacy of sensors, equipment, and technologies to detect UXO. The workshop recommended a phased approach to building test beds to capitalize on: 1) incorporation of lessons learned from existing DoD funded projects, 2) leveraging existing underwater test bed environments funded by other programs, and 3) supporting recursive learning from early phases of the test bed development (i.e. efficiently optimizing through a scaling-up approach). This strategy document provides the framework to establish a working operational plan for the Sequim Bay Underwater UXO (SBU2) Test Bed (Phase II). Details of the plan are dependent on earlier phases of the effort as shown in Figure 1. Results from Phase I are being evaluated, and when complete, will inform the next iteration of this plan. As such, it should be considered a living document that will be informed by the lessons learned and updated as new information becomes known and requirements are refined. This approach will allow SBU2 to evolve to meet the needs of the remediation community.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
NASA NTRS2018

Summary of Ice Shape Geometric Fidelity Studies on an Iced Swept Wing

Understanding the aerodynamic impact of swept-wing ice accretions is a crucial component of the design of modern aircraft. Computer-simulation tools are commonly used to approximate ice shapes, so the necessary level of detail or fidelity of those simulated ice shapes must be understood relative to high-fidelity representations of the ice. Previous tests were performed in the NASA Icing Research Tunnel to acquire high-fidelity ice shapes. Some of those ice shapes are based on aircraft certification requirements. From this database, full-span artificial ice shapes were designed and manufactured for both an 8.9%-scale and 13.3%-scale semispan wing model of the CRM65 which has been established as the full-scale baseline for this swept-wing project. These models were tested in the Walter H. Beech wind tunnel at Wichita State University and at the ONERA (Office national d'etudes et de recherches aerospatiales) F1 facility, respectively. The data collected in the Wichita State University wind tunnel provided a low-Reynolds number baseline study while the pressurized F1 facility produced data over a wide range of Reynolds and Mach numbers with the highest Reynolds number studied being approximately Re = 11.9 by 10 (sup 6). Three different fidelity representations were created based on three different icing conditions. Lower-fidelity ice shapes were created by lofting a smooth ice shape between cross-section cuts of the high-fidelity ice shape. Grit roughness was attached to this smooth ice shape as another fidelity variant. The data indicates that the geometric fidelity of the ice shapes resulted in significant differences in lift and drag. These results were similar at both facilities over the wide range of test conditions utilized.

Aerodynamics↗
NASA NTRS2007

Strain Measurement Using FBG on COPV in Stress Rupture Test

White Sands Test Facility (WSTF) was requested to perform ambient temperature hydrostatic pressurization testing of a Space Transportation System (STS) 40-in. Kevlar Composite Overwrapped Pressure Vessel (COPV). The 40-in. vessel was of the same design and approximate age as the STS Main Propulsion System (MPS) and Orbiter Maneuvering System (OMS) vessels. The NASA Engineering Safety Center (NESC) assembled a team of experts and conducted an assessment that involved a review of national Kevlar COPY data. During the review, the STS COPVs were found to be beyond their original certification of ten years. The team observed that the likelihood of STS COPV Stress rupture, a catastrophic burst before leak failure mode, was greater than previously believed. Consequently, a detailed assessment of remaining stress rupture life became necessary. Prior to STS-114, a certification deviation was written for two flights of OV-103 (Discovery) and OV-104 (Atlantis) per rationale that was based on an extensive review of the Lawrence Livermore National Laboratories, COPV data, and revisions to the STS COPV stress levels. In order to obtain flight rationale to extend the certification deviation through the end of the Program, the Orbiter Project Office has directed an interagency COPV team to conduct further testing and analysis to investigate conservatism in the stress rupture model and evaluate material age degradation. Additional analysis of stress rupture life requires understanding the fiber stresses including stress that occurs due to thru-wall composite compression in COPV components. Data must be obtained at both zero gauge pressure (pre-stress) and at the component operating pressure so that this phenomenon can be properly evaluated. The zero gauge pressure stresses are predominantly a result of the autofrettage process used during vessel manufacture. Determining these pre-stresses and the constitutive behavior of the overwrap at pressure will provide necessary information to better predict the remaining life of the STS COPVs. The primary test objective is obtaining data to verify the hypothesis of a radially oriented thru-thickness stress-riser in the COPV composite whose magnitude is a function of the applied pressure and the load history. The anticipated load dependent response follows from the constitutive behavior of the composite overwrap so data to quantify its nonlinear and time dependent response will be sought. The objective of the Fiber Braggs Gratings (FBGs) were to advance the state-of-the-art by developing techniques using FBG sensors that are capable of assessing stress-rupture degradation in Kevlar COPVs in a health monitoring mode (1). Moreover, they sought to answer questions of how embedded sensors affect overall integrity of the structure. And lastly, they sought to provide an important link in the overall stress rupture study that will help close the loop on the COPV fabrication process. NDE inspection methods will be used from start to finish and FBG will be an integral link within the overall chain.

Banks, Curtis↗
NASA NTRSDate not supplied

In-Space and Lunar Surface Attachment Systems – Seals

While the IDSS standard is specified to enable androgynous docking resulting in a seal-on-seal (SoS) mated configuration, current docking systems and their seals were not certified to do so. This IRAD project goal is to characterize SoS performance including leak rates, compression loads, and adhesion loads under aligned and misaligned conditions at subscale as an initial step toward androgynous docking certification.

Seals↗
DOE OSTI2024

Impacts of floating-point non-associativity on reproducibility for HPC and deep learning applications

Run to run variability in parallel programs caused by floating-point non-associativity has been known to significantly affect reproducibility in iterative algorithms, due to accumulating errors. Non-reproducibility can critically affect the efficiency and effectiveness of correctness testing for stochastic programs. Recently, the sensitivity of deep learning training and inference pipelines to floating-point non-associativity has been found to sometimes be extreme. It can prevent certification for commercial applications, accurate assessment of robustness and sensitivity, and bug detection. New approaches in scientific computing applications have coupled deep learning models with high-performance computing, leading to an aggravation of debugging and testing challenges. Here we perform an investigation of the statistical properties of floating-point non-associativity within modern parallel programming models, and analyze performance and productivity impacts of replacing atomic operations with deterministic alternatives on GPUs. We examine the recently-added deterministic options in PyTorch within the context of GPU deployment for deep learning, uncovering and quantifying the impacts of input parameters triggering run to run variability and reporting on the reliability and completeness of the documentation. Finally, we evaluate the strategy of exploiting automatic determinism that could be provided by deterministic hardware, using the Groq LPUTM accelerator for inference portions of the deep learning pipeline. We demonstrate the benefits that a hardware-based strategy can provide within reproducibility and correctness efforts.

Shanmugavelu, Sanjif↗
NASA NTRS2016

Status of NASA's Space Launch System

NASA's Space Launch System (SLS) continued to make significant progress in 2015, completing hardware and testing that brings NASA closer to a new era of deep space exploration. The most significant program milestone of the year was completion of Critical Design Review (CDR). A team of independent reviewers concluded that the vehicle design is technically and programmatically ready to move to Design Certification Review (DCR) and launch readiness in 2018. Just four years after program start, every major element has amassed development and flight hardware and completed key tests that will set the stage for a growing schedule of manufacturing and testing in 2016. Key to SLS' rapid progress has been the use of existing technologies adapted to the new launch vehicle. The space shuttle-heritage RS-25 engine is undergoing adaptation tests to prove it can meet SLS requirements and environments with minimal change. The four-segment shuttle-era booster has been modified and updated with an additional propellant segment, new insulation, and new avionics. The Interim Cryogenic Upper Stage is a modified version of an existing upper stage. The first Block I SLS configuration will launch a minimum of 70 metric tons of payload to low Earth orbit (LEO). The vehicle architecture has a clear evolutionary path to more than 100 metric tons and, ultimately, to 130 metric tons. Among the program's major accomplishments in 2015 were the first booster qualification hotfire test, a series of seven RS-25 adaptation hotfire tests, manufacturing of most of the major components for both core stage test articles and first flight tank, delivery of the Pegasus core stage barge, and the upper stage simulator. Renovations to the B-2 test stand for stage green run testing was completed at NASA Stennis Space Center. This year will see the second booster qualification motor hotfire, flight and additional development RS-25 engine tests, and completion of core stage test articles and test stands and several flight article sections. This paper will discuss these and other technical and programmatic successes and challenges over the past year and provide a preview of work ahead before the first flight of this new capability.

Honeycutt, John↗