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High Energy Hydroforming Friction Stir Welded 2050 Al-Li Blanks for Aerospace Domes and Cones

Friction stir welded (FSW) aluminum blanks offer larger preform sizes than available from the mill in single width plates. Large blanks made from aerospace-grade aluminum alloys are essential for making large domes and cones for launch vehicles and crew vehicles. Previous research efforts have demonstrated >5m FSW blanks can be formed into large domes or cones using spin forming, but the subsequent solution heat treatment consistently led to abnormal grain growth (AGG). The AGG phenomenon occurs because the FSW blanks must be spin formed in the -O annealed temper to withstand the high strain process without cracking. Subsequently, the solution heat treatment process leads to the onset of AGG, whereby a small number of grains grow much larger than the surrounding matrix. Ultimately, the large grains and bimodal grain-size distribution leads to unacceptable ductility in the short-transverse direction of the part. Alternatively, explosive hydroforming is a nascent process that can be applied to large and thick aerospace-grade aluminum alloy blanks in the -T3 temper and only require a post-forming artificial aging process to a -T8. Avoiding the solution heat treatment (SHT) process mitigates AGG, and also eliminates the need for very rare drop-furnace quench baths that can accommodate a part size larger than 5m in diameter. This presentation summarizes a Lockheed Martin-led effort that demonstrated explosive hydroforming of a 1.9m diameter, 39mm thick 2050 aluminum lithium FSW blank. Details will be provided on the process flow, mechanical properties, and metallographic analyses. This work was performed in partnership with NASA Langley Research Center (LaRC) under a NASA Announcement of Collaboration Opportunities program.

Friction stir welded blank↗

DOE OSTI2024

Novel Instrumentation for Advanced Quantum Chromodynamics Studies with Flavor Sensitivity

The true nature of ordinary matter has always fascinated humankind, whose imagination has been pointed to the right direction since the 5th century BC with the first known atomic theory by Leucippus and Democritus. They described the matter as formed by small, invisible, indivisible, and eternal particles: the atoms. A long investigation followed them, including contributions from several of history?s greatest philosophers and scientists. The progress led to the understanding that atoms have an internal structure consisting of a central nucleus composed of protons and neutrons, surrounded by a cloud of electrons. About 50 years ago, scientists discovered that nucleons also have an internal structure. Through the Deep Inelastic Scattering (DIS) experiments, on which a lepton is scattered off a nucleon, it was possible to access the distribution of partons inside the nucleon along the longitudinal direction defined by the hard-scale probe. It was a crucial step in developing Quantum Chromodynamics (QCD), currently the best theory describing the subatomic matter. Ultimately, DIS was recognized as a limited tool to investigate the nucleon structure because it is mainly sensitive to observables at the probe?s energy scale. In recent decades, theoretical developments have allowed defining soft-scale observables by measuring more complex processes. Reactions such as Semi-Inclusive Deep Inelastic Scattering (SIDIS) with single or di-hadron production, can provide information about the momentum of parton inside the nucleon. In particular, polarized SIDIS allows access to the Transverse-Momentum-Dependent (TMD) parton distributions describing the correlations of the quark and gluon degrees of freedom in transverse momentum and spin. This study can provide three-dimensional imaging of nucleon structure and inner dynamics, as long as the hadronic component in the final state can be measured. Identifying the species of the produced particles provides information on the quark flavor and assumes a crucial role in this context. The thesis describes the work carried out by the author in preparing novel instrumentation for particle identification in the final state of DIS experiments, to support modern analysis of the parton dynamics within the basic confined object (nucleon) with flavor sensitivity. The work has been focused on the CLAS12 spectrometer in operation at Jefferson Laboratory (JLab), Newport News, VA, USA, and the ePIC experiment in preparation for the future Electron-Ion Collider (EIC) at Brookhaven National Laboratory (BNL), Long Island, NY, USA. CLAS12 is a fixed-target experiment using a 12 GeV beam of polarized electrons scattering off polarized nuclear targets. In 2018 and 2022, two Ring Imaging Cherenkov (RICH) detector modules were installed to improve the ?±/K± separation in the high-momentum region (3÷8 GeV/c) of the experiment. The author contributed to the assembly, installation, and com- missioning of the second RICH module, to the efficiency studies of the first module, and to the first SIDIS analysis with high-momentum kaons identified by the RICH. These studies led to the observation of the first spin asymmetry with high-momentum kaons from the CLAS12 experiment, and an initial assessment of the systematic error associated with the hadron identification. ePIC will be the first experiment at the future EIC, the new collider designed to expand the frontiers of QCD. The author was involved in the development of the dual-radiator Ring Imaging Cherenkov (dRICH). This detector will interpolate the measurements of the Cherenkov angles of photons produced by relativistic particles crossing two different radiators to identify charged hadrons. The author contributed to the studies conducted with the dRICH prototype, developing the reconstruction and analysis software and simulations, characterizing the aerogel radiator samples, and being responsible for the tracking system used during the beam tests. The performance obtained by the prototype has been progressively improved and the results are now comparable with the expectation derived from the simulation and satisfy the requirements of the experiment. In Chapter 1, the SIDIS theory is briefly introduced, outlying the connection with the experimental measurement. Chapter 2 includes the description of the CLAS12 RICH, its assembly and installation, and the efficiency study. In Chapter 3, the analysis of the Beam-Spin Asymmetry associated with SIDIS kaons is described. Chapter 4 describes the contribution to the dRICH for EIC, starting from a description of the ePIC experiment and focusing on the studies performed for the dRICH prototype. The conclusions of this work are summarized at the end.

Vallarino, Simone↗

DOE OSTI2024

The United States' (DOE) Action Plan for Power Sector Decarbonization

A collaborative report from the Clean Energy Ministerial (CEM) on Lessons Learned for Rapid Decarbonization of Power Sectors was delivered to energy ministers and presented at the 13th CEM (CEM13) in the United States in September 2022. In light of these lessons learned and discussed at CEM13, several jurisdictions signaled intent to develop Action Plans for power sector decarbonization. The first cohort of Action Plans was released at CEM14 in India in July 2023. The U.S. Department of Energy (DOE) is pleased to release this Action Plan as a contribution to the second cohort of Action Plans released at CEM15 in Brazil in October 2024. The Action Plans, supported by the 21st Century Power Partnership, and other CEM workstreams via direct technical assistance and capacity building, are intended to focus on select implementation actions, given each country's existing power sector goals and activities, and are an opportunity for countries to display leadership in power sector decarbonization. The Action Plans are organized in a framework for Planning, Building and Operating, as well as Stakeholder Engagement where appropriate based on country priorities. These Action Plans are voluntary, developed by each country individually, not comprehensive of all activities within the jurisdiction, and are living documents that are subject to change. This Action Plan, developed by DOE, is focused on federal actions for power sector decarbonization primarily led by DOE. There are many other actions being led by other U.S. government agencies, or at the state and local level, that are not featured in this Action Plan.

21st Century Power Partnership↗

DOE OSTI2024

Technology Development of a High-Capacity High-Assay Low Enriched Uranium Transportation Concept

This paper discusses the technology development (TD) efforts that led to the development of a High-Capacity High-Assay Low Enriched Uranium Transportation (HALEU) transportation concept. In 2018, the Department of Energy (DOE) Office of Nuclear Technology and Research Development tasked Idaho National Laboratory (INL) to investigate strategies to transport large quantities of HALEU. To complete this task, INL collaborated with Pacific Northwest National Laboratory and Oak Ridge National Laboratory. The project was completed in 2020, and one of the project outcomes was a transportation concept that consisting of five individual Type B packages transported on a single legal-weight truck (LWT). The total payload capacity of this concept is 1,881 kg (4,149 lb) of HALEU in the form of uranium dioxide (UO2) powder. The concept utilizes an existing Type B packaging design carrying a novel fuel basket design with an incorporated flux trap. The basket can be loaded with 18 individual fuel canisters. The research collaboration investigated the U.S. certification potential of this concept. This part of the project included evaluations of criticality safety, radiological safety, thermal safety, structural integrity, and confinement under hypothetical accident scenarios of transport. The results of these evaluations demonstrated a promising potential for U.S. certification of this concept. Eventually, the described efforts led to the pursuance and issuance of a U.S. patent, thus, protecting the associated intellectual property (IP). Current short-term goals include making this IP available to private industry partners for licensing, directly supporting DOE’s objectives of accelerating commercialization of national laboratory-generated IP. If additional funding becomes available, long-term research goals could include exploring the feasibility of transporting other uranium chemical forms (e.g., UF4) with this concept, or refining operational procedures to load or unload the packagings.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Unfolding Structure Formation in the Dark Universe via Weak Gravitational Lensing: from Pixels to Cosmology in the Dark Energy Survey and Roman Space Telescope

Weak gravitational lensing (deflection of light from distant galaxies due to the gravitational potential of intervening mass) is one of the most exciting probes in cosmology as it is sensitive both to the growth of the large-scale structure and the expansion history of the Universe. We can measure the coherent distortion of galaxy shapes (which we call cosmic shear) and infer the matter distribution. With next-generation imaging surveys such as the Vera C. Rubin Observatory Legacy Survey of Space and Time (Rubin LSST) and the Nancy G. Roman Space Telescope (Roman), there is immense new promise in understanding the fundamental nature of dark matter and dark energy. With datasets from current experiments like the Dark Energy Survey (DES), we see apparent cosmological tensions between experiments that may either be real and indicate new physics or new systematics we do not yet understand. LSST and Roman will increase the number of galaxies we have observed by an order of magnitude, leading to improved constraints on our cosmological model by up to 300%. These experiments will have the potential to prove if these cosmological tensions are real. However, our control of systematic uncertainties must also improve by similar levels to achieve the promise of what these missions can deliver. To achieve these scientific outcomes, the challenges of determining galaxy shapes and redshifts and modeling the impact of astrophysical effects must be solved. My PhD has focused on enabling weak lensing science in DES and Roman. I co-led the shear analysis teams in DES to produce the largest weak lensing galaxy sample, as well as the final DES cosmological analysis of cosmic shear. For Roman, I have led two papers characterizing and mitigating shear-related systematics with image simulations.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2025

ViBRANT Applied as a Closed Loop Flux and Thermal Surrogate

Surrogate testing platforms provide a means to develop a target aspect of a larger system. Some systems target single aspects while others are more wholistic. ViBRANT (Visual Benign Reactor as Analog for Nuclear Testing) aims to be a wholistic system by representing the primary reactor behaviors through an accessible LED driven reactor core, photodiodes, thermocouples, and high-performance software interfaces being developed to the standards required for actual microreactor deployment such as MARVEL. With the ability to drive control drums enabled with full reactor capability (e.g. speed/angle/torque capability/limits for operation and clutch/spring scram capability), drive ViBRANT’s high fidelity 36 pin hexagon core to represent phenomena via LEDs, and capture the analog response of distributed photodiodes/thermocouples, this paper will show the system’s ability to operate in a closed-loop fashion and do well at matching reactor power/temperature distribution in an accessible reactor surrogate environment.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Next Generation Refrigerants for Domestic Heat Pump Water Heaters

To select next generation refrigerants and phase out R-134a, we conducted extensive drop-in tests of multiple new refrigerants. For laboratory investigations, we performed drop-in UEF (uniform energy factor) and FHR (first hour rating) tests on two heat pump water heaters (HPWHs), one uses a 220V compressor and 40-gallon water tank, and the other uses a 120V compressor and 50-gallon tank. The alternative refrigerants/blends include R-1234yf, R-1234ze, R-515B, R-513A, and R-516A, among which R-513A is A1, non-flammable and the others are in A2L category. All the alternative refrigerants required similar optimum system charges as the baseline R-134a. They resulted in similar or better UEFs than R-134a. R-516A led to best UEFs in both the HPWHs. The resultant discharge temperatures of the new refrigerants/blends are lower than R-134a, indicating good lubricant compatibility. The 120V HPWH delivered > 60 gallons first-hour rating using R-134a. The alternatives led to reduced FHRs due to their smaller volumetric vaporization capacities using the same compressor. Except R-515B, the other refrigerants/blends delivered FHRs > 60 gallons. R-516A produced better UEFs and FHRs in both the units than the other replacements. If considering flammability, R-513A would be the best option, which has similar UEF and FHR as R-134a.

Shen, Bo [ORNL] (ORCID:0000000336600393)↗

DOE OSTI2024

DERiving Community Economic Development through Distributed Solar

This report explores how distributed solar stakeholders can plan and align economic development with existing community priorities while advancing new solar projects. Because the amount of local community influence drives community economic development, we note the need for investment in community ownership models, which are scarce today. This report seeks to outline the current barriers to community-led economic development through distributed solar, best practices for implementation, and recommendations for sector stakeholders.

14 SOLAR ENERGY↗

DOE OSTI2024

DERiving Community Economic Development through Distributed Solar

14 SOLAR ENERGY↗

DOE OSTI2026

Brewer Recreational Facility Energy Modernization Project (Final Technical Report)

The project replaced a thirty-four-year-old metal halide lighting system on the City's primary athletic field with new energy efficient LED lighting, significantly reducing operating and maintenance cost while providing a safer environment, additional recreational opportunities, improved energy efficiency, and reduced light spillover.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2016

Plant Habitat (PH)

The International Space Station (ISS) will soon have a platform for conducting fundamental research of Large Plants. Plant Habitat (PH) is designed to be a fully controllable environment for high-quality plant physiological research. PH will control light quality, level, and timing, temperature, CO2, relative humidity, and irrigation, while scrubbing ethylene. Additional capabilities include leaf temperature and root zone moisture and oxygen sensing. The light cap will have red (630 nm), blue (450 nm), green (525 nm), far red (730 nm) and broad spectrum white LEDs. There will be several internal cameras (visible and IR) to monitor and record plant growth and operations.

Advanced Plant Habitat↗

NASA NTRS2017

Space Plants for Astronaut Consumption

Growing plants in space will be an essential part of sustaining astronauts during long-range missions. During the summer of 2017, three female NASA interns, have been engaged in research relevant to food production in space, and will present their projects to an all female program known as Girls in STEM camp. Ayla Grandpre, a senior from Rocky Mountain College, has performed data mining and analysis of crop growth results gathered through Fairchild Botanical Gardens program, Growing Beyond Earth. Ninety plants were downselected to three for testing in controlled environment chambers at KSC. Ayla has also managed an experiment testing a modified hydroponics known as PONDS, to grow mizuna mustard greens and red robin cherry tomatoes. Emma Boehm, a senior from the University of Minnesota, has investigated methods to sterilize seeds and analyzed the most common microbial communities on seed surfaces. She has tested a bleach fuming method and an ethanol treatment. Emma has also tested Tokyo bekana Chinese cabbage seeds from four commercial seed vendors to identity differences in germination and growth variability. Lastly, Payton Barnwell, a junior from Florida Polytechnic University has shown that light recipes provided by LEDs can alter the growth and nutrition of 'Outredgeous' lettuce, Chinese cabbage, and Mizuna. The results of her light quality experiments will provide light recipe recommendations for space crops that grown in the Advanced Plant Habitat currently aboard the International Space Station.

VEGGIE↗

NASA NTRS2018

Preparation for Pick-and-Eat Food Production on the International Space Station: Flight Definition for the VEG-04 and VEG-05 Missions

Growth of fresh, nutritious, palatable produce for crew consumption during spaceflight may provide health-promoting, bioavailable nutrients and enhance the dietary experience as we move toward longer-duration missions. Tending plants also may serve as a countermeasure for crew psychological stresses associated with long duration spaceflight. However, requirements to support consistent growth of a variety of high quality, nutritious crops under spaceflight environmental conditions is unknown. This study is exploring the potential to grow plants for food production on the International Space Station (ISS) using the Veggie vegetable production system. Ground testing is underway to compare the impacts of several fertilizer and lighting treatments on growth, quality, and nutritional composition of the leafy green crop mizuna, and the dwarf tomato crop Red Robin when subjected to Veggie ISS environmental conditions. Early testing focused on the leafy crop Tokyo Bekana Chinese cabbage, but ground tests indicated that this plant suffered from stress responses when grown under LEDs and the chronically elevated CO2 levels found on the ISS. Mizuna, a related leafy variety that grows well in the presence of high CO2, and has excellent organoleptic characteristics, was selected as an alternate crop. Tomato crops have been grown using two fertilizer formulations and two pollination techniques, and growth tests using different red:blue lighting environments are underway. Chemical analysis is also being conducted and these data, when coupled with the growth results, will be used to down-select to the two best lighting treatments and best fertilizer treatment for future testing of each crop on the ISS. Additionally, seed-source testing has become important, with mizuna seeds from two different vendors growing very differently. A seed source has been selected, and seed-surface-sanitizing methods have been confirmed for mizuna, but these remain under development for tomato. A crop-handling protocol is also being evaluated to support food safety. All harvests reserve a subset of samples for microbial analysis to determine baseline microbial levels and help establish critical control points for food safety. Testing was initially conducted in hardware analogs of the standard Veggie plant pillows. However, a new Veggie watering system, the Passive Orbital Nutrient Delivery System or PONDS, has been designed and is being prepared for future flight experiments. With the selection of this growth system, ground tests have shifted to analog PONDS systems. Crop tests on ISS, designated VEG-04 for mizuna and VEG-05 for tomato, are planned in 2018 to evaluate any additional impacts of spaceflight on the light and fertilizer conditions down-selected from ground tests. A set of Veggie-specific questions has been developed to characterize the psychological impacts of plant growth and plant-care activities during spaceflight. Organoleptic questionnaires have been developed to assess produce attributes in microgravity taste sessions. These tests for plants growing in the Veggie hardware on ISS will help to mitigate the risk of an inadequate food supply for long duration missions by developing methods and determining hardware requirements to integrate fresh vegetables as a dietary supplement. This research was co-funded by the Human Research Program and Space Biology (MTL1075) in the ILSRA 2015 NRA call.

Veggie↗

NASA NTRS2018

Preparation for Pick-and-Eat Food Production on the International Space Station: Flight Definition for the VEG-04 and VEG-05 Missions

Growth of fresh, nutritious, palatable produce for crew consumption during spaceflight may provide health-promoting, bioavailable nutrients and enhance the dietary experience as we move toward longer-duration missions. Tending plants also may serve as a countermeasure for crew psychological stresses associated with long duration spaceflight. However, requirements to support consistent growth of a variety of high quality, nutritious crops under spaceflight environmental conditions is unknown. This study is exploring the potential to grow plants for food production on the International Space Station (ISS) using the Veggie vegetable production system. Ground testing is underway to compare the impacts of several fertilizer and lighting treatments on growth, quality, and nutritional composition of the leafy green crop mizuna, and the dwarf tomato crop "Red Robin" when subjected to Veggie ISS environmental conditions. Early testing focused on the leafy crop "Tokyo Bekana" Chinese cabbage, but ground tests indicated that this plant suffered from stress responses when grown under LEDs and the chronically elevated CO2 levels found on the ISS. Mizuna, a related leafy variety that grows well in the presence of high CO2, and has excellent organoleptic characteristics, was selected as an alternate crop. Tomato crops have been grown using two fertilizer formulations and two pollination techniques, and growth tests using different red:blue lighting environments are underway. Chemical analysis is also being conducted and these data, when coupled with the growth results, will be used to down-select to the two best lighting treatments and best fertilizer treatment for future testing of each crop on the ISS. Additionally, seed-source testing has become important, with mizuna seeds from two different vendors growing very differently. A seed source has been selected, and seed-surface-sanitizing methods have been confirmed for mizuna, but these remain under development for tomato. A crop-handling protocol is also being evaluated to support food safety. All harvests reserve a subset of samples for microbial analysis to determine baseline microbial levels and help establish critical control points for food safety. Testing was initially conducted in hardware analogs of the standard Veggie plant pillows. However, a new Veggie watering system, the Passive Orbital Nutrient Delivery System or PONDS, has been designed and is being prepared for future flight experiments. With the selection of this growth system, ground tests have shifted to analog PONDS systems. Crop tests on ISS, designated VEG-04 for mizuna and VEG-05 for tomato, are planned in 2018 to evaluate any additional impacts of spaceflight on the light and fertilizer conditions down-selected from ground tests. A set of Veggie-specific questions has been developed to characterize the psychological impacts of plant growth and plant-care activities during spaceflight. Organoleptic questionnaires have been developed to assess produce attributes in microgravity taste sessions. These tests for plants growing in the Veggie hardware on ISS will help to mitigate the risk of an inadequate food supply for long duration missions by developing methods and determining hardware requirements to integrate fresh vegetables as a dietary supplement. This research was co-funded by the Human Research Program and Space Biology (MTL#1075) in the ILSRA 2015 NRA call.

LED light↗

NASA NTRS2015

State-of-the-Art Instrumentation Package to Support Model Organism Research in Space

Hardware was developed for the Ames student Fruit-Fly Experiment (AFEx) to support fly growth and analysis during spaceflight. The hardware consists of a 1.5U vented aluminum box that houses an acrylic habitat, video camera, LED lighting, and environmental sensors. Power is provided via two USB connectors, one of which also supports data downlink. While the hardware was designed for use with fruit flies, it will house plants on an upcoming mission and could be adapted for use with other systems.

Fruit-Fly Experiment↗

NASA NTRS2023

NASA GRC Solar Cell Characterization Facilities

NASA GRC maintains various equipment to calibrate and characterize photovoltaic devices to Air Mass Zero standards and different space-simulated environments. These characterization capabilities are critical to developing and advancing photovoltaic devices, allowing advancements in various NASA-related projects (Artemis, Lunar Gateway, Human Landing System, etc.). Our facilities include an X-25 Triple source Solar Simulator, G2V Sunbrick, Angstrom Designs pLEDss (Programmable LED Solar Simulator), Thermal Balance facility, ER-2 High Altitude aircraft calibration.

Photovoltaic↗

NASA NTRS2023

Managing the Lucy Mission

Lucy is NASA’s 13th Discovery-class mission. It will be the first mission to encounter seven Trojan asteroids in a series of five flybys. Lucy is led by Dr. Hal Levison of the Southwest Research Institute. As the Principal Investigator, Dr. Levison is accountable to NASA for the success of the investigation, with full responsibility for its scientific integrity and execution within committed cost and schedule. Day to day management of the Lucy project is delegated to Goddard Space Flight Center. During Lucy’s development, the project experienced a once-in-a-lifetime pandemic that threatened the team’s ability to meet the planetary launch window. Despite this challenge, Lucy launched on time and under budget. This chapter discusses key factors that enabled project success.

Project Management↗

NASA NTRS2024

Lessons Learned in Designing A Proposed Ultraviolet Sterilization System for Space

This paper presents a number of lessons learned while designing a proposed sterilization system for Mars Sample Return. This sterilization system is needed to inactivate any potentially hazardous Mars material on the exterior surface of the vessel containing sealed sample tubes filled with Mars rock cores, regolith and atmosphere. These returned samples would provide information on the geologic history of Mars, the evolution of its climate and the potential for ancient life. Mars Sample Return is categorized at Planetary Protection Category V Restricted Earth Return, so it is required to protect the Earth–Moon system from the biological impact of returning samples from Mars to Earth. This article reviews lessons learned in the development of a particular engineering implementation to support the protection of the Earth–Moon biosphere: the use of in situ ultraviolet LED illumination. The details of the biological efficacy of this approach or the policy-related impacts are outside of the scope of this manuscript. The lessons learned presented here include establishing design requirements for the system, the selection of a light source, optical design options, contamination control and approaches to thermal and power management.

Planetary Protection↗