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Probabilistic Design and Analysis Framework

PRODAF is a software package designed to aid analysts and designers in conducting probabilistic analysis of components and systems. PRODAF can integrate multiple analysis programs to ease the tedious process of conducting a complex analysis process that requires the use of multiple software packages. The work uses a commercial finite element analysis (FEA) program with modules from NESSUS to conduct a probabilistic analysis of a hypothetical turbine blade, disk, and shaft model. PRODAF applies the response surface method, at the component level, and extrapolates the component-level responses to the system level. Hypothetical components of a gas turbine engine are first deterministically modeled using FEA. Variations in selected geometrical dimensions and loading conditions are analyzed to determine the effects of the stress state within each component. Geometric variations include the cord length and height for the blade, inner radius, outer radius, and thickness, which are varied for the disk. Probabilistic analysis is carried out using developing software packages like System Uncertainty Analysis (SUA) and PRODAF. PRODAF was used with a commercial deterministic FEA program in conjunction with modules from the probabilistic analysis program, NESTEM, to perturb loads and geometries to provide a reliability and sensitivity analysis. PRODAF simplified the handling of data among the various programs involved, and will work with many commercial and opensource deterministic programs, probabilistic programs, or modules.

Strack, William C.↗

A Quasi-Steady Flexible Launch Vehicle Stability Analysis Using Steady CFD with Unsteady Aerodynamic Enhancement

Launch vehicles frequently experience a reduced stability margin through the transonic Mach number range. This reduced stability margin is caused by an undamping of the aerodynamics in one of the lower frequency flexible or rigid body modes. Analysis of the behavior of a flexible vehicle is routinely performed with quasi-steady aerodynamic lineloads derived from steady rigid computational fluid dynamics (CFD). However, a quasi-steady aeroelastic stability analysis can be unconservative at the critical Mach numbers where experiment or unsteady computational aeroelastic (CAE) analysis show a reduced or even negative aerodynamic damping. This paper will present a method of enhancing the quasi-steady aeroelastic stability analysis of a launch vehicle with unsteady aerodynamics. The enhanced formulation uses unsteady CFD to compute the response of selected lower frequency modes. The response is contained in a time history of the vehicle lineloads. A proper orthogonal decomposition of the unsteady aerodynamic lineload response is used to reduce the scale of data volume and system identification is used to derive the aerodynamic stiffness, damping and mass matrices. The results of the enhanced quasi-static aeroelastic stability analysis are compared with the damping and frequency computed from unsteady CAE analysis and from a quasi-steady analysis. The results show that incorporating unsteady aerodynamics in this way brings the enhanced quasi-steady aeroelastic stability analysis into close agreement with the unsteady CAE analysis.

Bartels, Robert E.↗

A UML Profile for State Analysis

State Analysis is a systems engineering methodology for the specification and design of control systems, developed at the Jet Propulsion Laboratory. The methodology emphasizes an analysis of the system under control in terms of States and their properties and behaviors and their effects on each other, a clear separation of the control system from the controlled system, cognizance in the control system of the controlled system's State, goal-based control built on constraining the controlled system's States, and disciplined techniques for State discovery and characterization. State Analysis (SA) introduces two key diagram types: State Effects and Goal Network diagrams. The team at JPL developed a tool for performing State Analysis. The tool includes a drawing capability, backed by a database that supports the diagram types and the organization of the elements of the SA models. But the tool does not support the usual activities of software engineering and design - a disadvantage, since systems to which State Analysis can be applied tend to be very software-intensive. This motivated the work described in this paper: the development of a preliminary Unified Modeling Language (UML) profile for State Analysis. Having this profile would enable systems engineers to specify a system using the methods and graphical language of State Analysis, which is easily linked with a larger system model in SysML (Systems Modeling Language), while also giving software engineers engaged in implementing the specified control system immediate access to and use of the SA model, in the same language, UML, used for other software design. That is, a State Analysis profile would serve as a shared modeling bridge between system and software models for the behavior aspects of the system. This paper begins with an overview of State Analysis and its underpinnings, followed by an overview of the mapping of SA constructs to the UML metamodel. It then delves into the details of these mappings and the constraints associated with them. Finally, we give an example of the use of the profile for expressing an example SA model.

Murray, Alex↗

Description, Usage, and Validation of the MVL-15 Modified Vortex Lattice Analysis Capability

MVL-15 is the most recent version of the Modified Vortex-Lattice (MVL) code developed within the Aerodynamics Systems Analysis Branch (ASAB) at NASA LaRC. The term "modified" refers to the primary modification of the core vortex-lattice methodology: inclusion of viscous aerodynamics tables that are linked to the linear solution via iterative processes. The inclusion of the viscous aerodynamics inherently converts the MVL-15 from a purely analytic linearized method to a semi-empirical blend which retains the rapid execution speed of the linearized method while empirically characterizing the section aerodynamics at all spanwise lattice points. The modification provides a means to assess non-linear effects on lift that occur at angles of attack near stall, and provides a means to determine the drag associated with the application of design strategies for lift augmentation such as the use of flaps or blowing. The MVL-15 code is applicable to the analyses of aircraft aerodynamics during cruise, but it is most advantageously applied to the analysis of aircraft operating in various high-lift configurations. The MVL methodology has been previously conceived and implemented; the initial concept version was delivered to the ASAB in 2001 (van Dam, C.), subsequently revised (Gelhausen, P. and Ozoroski, T. 2002 / AVID Inc., Gelhausen, P., and Roberts, M. 2004), and then overhauled (Ozoroski, T., Hahn, A. 2008). The latest version, MVL-15 has been refined to provide analysis transparency and enhanced to meet the analysis requirements of the Environmentally Responsible Aviation (ERA) Project. Each revision has been implemented with reasonable success. Separate applications of the methodology are in use, including a similar in-house capability, developed by Olson, E. that is tailored for structural and acoustics analyses. A central premise of the methodology is that viscous aerodynamic data can be associated with analytic inviscid aerodynamic results at each spanwise wing section, thereby providing a pathway to map viscous data to the inviscid results. However, a number of factors can sidetrack the analysis consistency during various stages of this process. For example, it should be expected that the final airplane lift curve and drag polar results depend strongly on the geometry and aerodynamics of the airfoil section; however, flap deflections and flap chord extensions change the local reference geometry of the input airfoil, the airplane wing, the tabulated non-dimensional viscous aerodynamics, and the spanwise links between the linear and the viscous aerodynamics. These changes also affect the bound circulation and therefore, calculation and integration of the induced angle of attack and induced drag. MVL-15 is configured to ensure these types of challenges are properly addressed. This report is a comprehensive manual describing the theory, use, and validation of the MVL-15 analysis tool. Section 3 summarizes theoretical, procedural, and characteristic features of MVL-15, and includes a list of the files required to setup, execute, and summarize an analysis. Section 4, Section 5, Section 6, and Section 7 combine to comprise the User's Guide portions of this report. The MVL-15 input and output files are described in Section 4 and Section 5, respectively; the descriptions are supplemented with example files and information about the file formats, parameter definitions, and typical parameter values. Section 6 describes the Wing Geometry Setup Utility and the 2d-Variants Utility files that simplify and assist setting up a consistent set of MVL-15 geometry and aerodynamics input parameters and input files. Section 7 describes the use of the 3d-Results Presentation Utility file that can be used to automatically create summary tables and charts from the MVL-15 output files. Section 8 documents the Validation Results of an extensive and varied validation test matrix, including results of an airplane analysis representative of the ERA Program. A start-to-finish example of the airplane analysis procedure is described in Section 7.

Ozoroski, Thomas A.↗

Achieving Improved Reliability with Failure Analysis

Reliability is the ability of a product to properly function, within specified performance limits, for a specified period of time, under the life cycle application conditions. Failure analysis is a vital tool in the effort to ensure reliability of electronic products and systems throughout their product lifecycle. Today, organizations involved in activities within the electronics supply chain are facing new challenges, not just from complex assembly styles, harsher lifecycle environments, and sophisticated supply chains, but also from customers who are demanding a quicker turn-around. Unfortunately, root cause failure analysis is often performed incompletely, leading to a poor understanding of failure mechanisms and causes and, customer dissatisfaction due to recurring failures. The PDC starts with an introduction to reliability concepts, physics of failure and an overview of failure mechanisms that affect PCBs, PCBAs and components. The PDC then dives into root cause hypothesizing techniques (Pareto, FMEA, fishbone, FTA), non-destructive and destructive analysis and, materials characterization will be discussed. Numerous failure analysis case studies will be used to illustrate the techniques and analysis principles to arrive at the root cause(s) of field failures on printed circuit boards, active components, and assemblies. What Will You Learn: Topics include: Overview of Reliability Concepts Failure mechanisms of electronic products Root cause analysis Failure analysis techniques -Non-destructive techniques (optical, CSAM etc.) -Destructive analysis (DPA, Decap, FIB etc.) -Materials characterization (XRF, EDS, TMA/DSC etc.) Who Will Benefit: Reliability engineers, failure analysis engineers, engineering managers, design engineers, component engineers, quality assurance functions and, personnel involved with reliability activities within their company.

non-destructive techniques↗

An Energy-Based Low-Order Approach for Mission Analysis of Air Vehicles in LEAPS

Mission analysis methods that allow rapid analysis of conceptual aircraft provide great benefits to designers because a large number of feasibility and optimization studies can be performed quickly. This paper presents a novel low-order mission analysis approach that will be included in a new aircraft analysis tool called the Layered and Extensible Aircraft Performance System, also known as LEAPS. This approach is based on the mission analysis method used in the Flight Optimization System, also known as FLOPS. FLOPS has been developed at NASA Langley Research Center for over 30 years, and it is mainly used to analyze conventional aircraft (e.g., gas turbine-powered aircraft). One of the main features of FLOPS is its ability to perform rapid mission analysis. This quick analysis turnaround makes FLOPS a suitable tool to perform a large number of trade studies and optimizations. For this reason, the main concepts applied in FLOPS will be used and expanded in LEAPS to allow the analysis of unconventional aircraft that use novel propulsion systems. This expanded approach includes the capability to handle electric propulsion systems as well as multiple propulsor classes at the same time. A novel hybrid-electric aircraft configuration is used to investigate the potential benefits of the proposed mission analysis approach. The results show that the design space increases which can potentially lead to better designs.

Capristan, Francisco M.↗

Initial analysis of “stone” size Ryugu samples: current status

As a part of the initial analysis of the Ryugu samples, we perform a variety of analyses of millimeter-sized "stones". Our goals are to elucidate the entire formation process of C-type asteroid Ryugu from the viewpoint of petrology and mineralogy ande obtain necessary information by sample analysis, and then simulate the formation of Ryugu based on the evidencef obtained rom sample analysis. Eighteen stones (8 from Room A and 10 from Room C) were received from the ISAS curation facility on June 1, 2021, and brought into a fully nitrogen-displaced glove box at Tohoku University. At the same time, we also received the powder samples from Room A and Room C. To completely block the atmosphere from leaking into the container, all samples were put in the sample transport containers prepared by ISAS, transferred from the main chamber to the glovebox at ISAS, and then all containers were completely sealed in plastic bags with moisture and oxygen absorbers. No moisture or oxygen was detected when the bags were opened in the glove box at Tohoku University, so it was confirmed that there was no exposure to the atmosphere during transport. To date, a number of analyses have been carried out successfully and almost on schedule. The analysis started with the measurement of reflectance spectra, which are sensitive to atmospheric oxidation, hydroxylation, and adsorbed water. The visible, near-infrared, and mid-infrared reflectance spectra were measured while the samples were kept airtight. The spectra of powder samples and stone samples (as aggregates and as single stone) were successfully obtained. A major feature of the stone team's analysis is the use of synchrotron radiation facilities around the world. Since this analysis is non-destructive, stone samples whose reflectance spectra were measured were sent to KEK, SPring-8, ESRF (France), SOLEIL (France), DESY (Germany), and APS (USA). Using these synchrotron radiation facilities, high spatial resolution and sensitivity XRD, STXM, XANES, CT [1], IR-CT, FT-IR [2, 3], XRF, and Mössbauer analyses were performed. Most of the analyses were carried out under air-tight conditions on the stone samples and the particulates separated from the stone samples. These analyses allowed us to determine the three-dimensional distribution of minerals and elements, redox state, density and porosity of the stone samples. Furthermore, as a characteristic analysis of the stone team, light elemental analysis using negative Muon was performed at the MLF facility of J-PARC with an exceptionally long allocation of machine time. This is the only non-destructive method to measure the concentration of light elements in the whole (not the surface) of stone samples. Because the characteristic X-rays produced by muon irradiation are much higher in energy than the fluorescent X-rays produced by X-ray irradiation, there is little effect of self-absorption by the sample, and therefore, the concentration of light elements such as carbon, oxygen, and Na in the entire "stone" sample can be determined. Some stone samples are currently being measured for heat and strength physical properties in order to understand the physical properties of asteroid Ryugu. The data obtained from these measurements are useful for interpreting the remote-sensing data data taken from the surface layer of the asteroid Ryugu [4-7]. It is also important for understanding the behavior of the Ryugu material during impact events. The surfaces of many stone samples were observed by electron microscopy and other techniques, especially on natural “flat” surfaces formed on 5 stomes. As a result, characteristric mineral aggregates formed by the reactions with water and characteiristic impact features were observed on some of the samples. Based on the observations of surfaces and the synchrotron measurements of the whole stones, important objects such as characteristic structures and specific crystal aggregates for understanding the formation history of the asteroid were identified, and these parts were separated from the stone samples using an Xe beam (pFIB) and analyzed by various methods including transmission electron microscopy and synchrotron radiation analysis. Many stone samples, from which important objects have been separated, are embedded in epoxy resin and cut to produce many polished sections. Electron microscopy and spectroscopic measurements of the polished surfaces are being carried out to reveal the detailed mineralogical properties and elemental distribution inside the stone samples. In the fall, machine time for synchrotron radiation will begin, and we plan to analyze single crystals and characteristic objects separated from the stone samples.

Tomoki Nakamura↗

Orion Artemis I As Flown MMOD Analysis

Introduction The Lockheed Martin Orion spacecraft conducted the Artemis I flight around the Moon from November 16 through December 11, 2022. After the flight, an engineer from the NASA Johnson Space Center (JSC) Hypervelocity Impact Technology (HVIT) Group performed a Micrometeoroid and Orbital Debris MMOD analysis using the Bumper 3 risk assessment tool to predict the number of small impacts that would likely have occurred during the mission. Separately, a team from the same group inspected the Orion capsule for hypervelocity impact damage features. The results of the inspection were compared to those of the analysis to aid in improving the analysis, including the environment models. Scope of Work The spacecraft geometry model was created by Lockheed Martin during construction of the Artemis I Orion vehicle based on Computer Aided Design (CAD) models of the vehicle. New hypervelocity impact testing was performed to verify Ballistic Limit Equations (BLEs) used in the analysis to link impactor size and damage to the Thermal Protection System (TPS). The exact trajectory flown was recorded during the flight, including vehicle attitude. This data was used in conjunction with the ORDEM 3.2 and MEM 3 environment modeling tools to create models of particle flux impacting the spacecraft throughout the mission. Meteoroid shower forecast information was also included to account for additional particle flux associated with meteoroid showers. Inspection of the Orion capsule included the Backshell thermal tiles and the tape covering it, windows, fabric thermal materials, and small areas of other materials. Potential MMOD damage found was characterized using various techniques, including optical microscopy, computed tomography scanning, and X-ray spectroscopy. Findings The number of craters found in the Backshell tile, and their size distribution, matches well with the Bumper analysis prediction. Tape, window, and other material impacts recorded similarly align to Bumper analysis predictions. Conclusions and Recommendations This comparison of analysis with inspection of the hardware provides valuable insight into the MMOD environment and how accurately analysis tools assess the impact risk to spacecraft. As this was the first large, non-ablative returned surface from a lunar mission, this analysis extends the MMOD community’s insight beyond low Earth orbit into cis-lunar space.

MMOD↗

Orion Artemis I As Flown MMOD Analysis

Introduction The Lockheed Martin Orion spacecraft conducted the Artemis I flight around the Moon from November 16 through December 11, 2022. After the flight, an engineer from the NASA Johnson Space Center (JSC) Hypervelocity Impact Technology (HVIT) Group performed a Micrometeoroid and Orbital Debris MMOD analysis using the Bumper 3 risk assessment tool to predict the number of small impacts that would likely have occurred during the mission. Separately, a team from the same group inspected the Orion capsule for hypervelocity impact damage features. The results of the inspection were compared to those of the analysis to aid in improving the analysis, including the environment models. Scope of Work The spacecraft geometry model was created by Lockheed Martin during construction of the Artemis I Orion vehicle based on Computer Aided Design (CAD) models of the vehicle. New hypervelocity impact testing was performed to verify Ballistic Limit Equations (BLEs) used in the analysis to link impactor size and damage to the Thermal Protection System (TPS). The exact trajectory flown was recorded during the flight, including vehicle attitude. This data was used in conjunction with the ORDEM 3.2 and MEM 3 environment modeling tools to create models of particle flux impacting the spacecraft throughout the mission. Meteoroid shower forecast information was also included to account for additional particle flux associated with meteoroid showers. Inspection of the Orion capsule included the Backshell thermal tiles and the tape covering it, windows, fabric thermal materials, and small areas of other materials. Potential MMOD damage found was characterized using various techniques, including optical microscopy, computed tomography scanning, and X-ray spectroscopy. Findings The number of craters found in the Backshell tile, and their size distribution, matches well with the Bumper analysis prediction. Tape, window, and other material impacts recorded similarly align to Bumper analysis predictions. Conclusions and Recommendations This comparison of analysis with inspection of the hardware provides valuable insight into the MMOD environment and how accurately analysis tools assess the impact risk to spacecraft. As this was the first large, non-ablative returned surface from a lunar mission, this analysis extends the MMOD community’s insight beyond low Earth orbit into cis-lunar space.

MMOD↗

Quantitative Risk Analysis of High Safety Significant Safety-related Digital Instrumentation and Control Systems in Nuclear Power Plants using IRADIC Technology

This report documents the activities performed by Idaho National Laboratory (INL) during fiscal year (FY) 2021 for the U.S. Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program, Risk Informed Systems Analysis (RISA) Pathway, digital instrumentation and control (DI&C) Risk Assessment project. In FY-2019, the RISA Pathway initiated a project to develop a risk assessment strategy for delivering a strong technical basis to support effective, licensable, and secure DI&C technologies for digital upgrades/designs. An integrated risk assessment technology for the DI&C systems (IRADIC technology) was proposed for this strategy, which aims to (1) provide a best-estimate risk-informed capability to quantitatively and accurately estimate the safety margin obtained from plant modernization, especially for the High Safety Significant Safety-related (HSSSR) DI&C systems, (2) develop an advanced risk assessment technology to support transition from analog to DI&C technologies for nuclear industry, (3) assure the long-term safety and reliability of vital HSSSR DI&C systems, (4) reduce uncertainty in costs and support integration of DI&C systems in the plant. To achieve these technical goals and deal with the expensive licensing justifications from regulatory insights, the IRADIC technology is instructive for nuclear vendors and utilities to effectively lower the costs associated with digital compliance and speed industry advances by: (1) defining an integrated risk-informed analysis process for DI&C upgrade, including hazard analysis, reliability analysis, and consequence analysis, (2) applying systematic and risk-informed tools to address common cause failures (CCFs) and quantify responding failure probabilities for DI&C technologies, particularly software CCFs, (3) evaluating the impact of digital failures at the individual level, system level, and plant level, (4) providing insights and suggestions on designs to manage the risks; thus, to support the development, licensing, and deployment of advanced DI&C technologies on nuclear power plant (NPPs). In this report, an approach for performing software CCF analysis, given limited data, is developed and demonstrated using a case study of a highly redundant digital reactor trip system. Consequence analysis is also performed based on different accident scenarios. Results indicate that plant modernization including the improvement of HSSSR DI&C systems will make great benefits to plant safety by providing more safety margins to accident management. In addition, a novel approach is proposed in this report for the quantification of software hazards when sufficient operational and testing data available. The method incorporates software development quality as well as strong analysis techniques to identify and link software defects to potential failure modes. The approach includes both semantic and test-based analysis to detect failures that can exist in different stages of the software development life cycle. This method is applied to an advanced human system interface relevant to reactor trip safety developed from the APR 1400 design.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Test and Analysis of the 8-foot Diameter Cylindrical Sandwich Composite Test Article CTA8.2B: As part of the NASA Engineering and Safety Center Shell Buckling Knockdown Factor Project

The buckling response of thin-walled cylindrical structures have long been shown to be sensitive to various imperfections. That is, imperfections related to load introduction, boundary conditions, material property variation, and geometric deviations can all contribute to experimentally obtained buckling loads being lower than the buckling loads predicted for perfect representations of the same thin-walled cylindrical structure. To account for the influence of geometry-based imperfections of a thin-walled cylindrical structure on buckling response, a design factor (also known as a buckling knockdown factor) is used during the design phase. Guidelines for buckling knockdown factors are readily available in NASA SP-8007, Buckling of Thin Walled Circular Cylinders, which was updated in 2020. Prior to this recent update, NASA SP-8007 had not been updated since 1969, and since that time, computational analysis, experimental testing, and manufacturing methods have significantly improved. The NASA Engineering and Safety Center (NESC) Shell Buckling Knockdown Factor Project (SBKF, NESC Assessment 07-010-E) had the goal of developing buckling design recommendations for select classes of metallic and composite launch-vehicle structures [3]. Specifically, the test and analysis results from the fourth SBKF composite test article SBKF-P3-CYL-CTA8.2B, which is referred to as CTA8.2B, are described in this paper. This test was the fourth in a series of four tests on sandwich composite cylinders that will be used to experimentally validate analysis methods, which in turn can be used to develop new analysis-based shell buckling design guidelines for typical sandwich composite launch vehicle cylindrical structures. Publications describing previous test validation with analysis are available in Refs. CTA8.2B was designed to occupy one corner of the design space with approximately equal bending stiffnesses in the axial and transverse directions and have a larger ratio of radius to effective shell thickness. Each test article had a unique design and was designed to occupy a specific region of the design space. CTA8.2B was an 8-foot diameter honeycomb-core sandwich cylinder that was fabricated and tested at the NASA Marshall Space Flight Center (MSFC). The primary objectives of this test were to interrogate the structural capability of a composite test article, and to verify the test article design and analysis approach for cylinders subjected to axial compression and combined axial and bending loads. First, descriptions of the test article design and test are given in Section 2.0, and modeling and analysis methods used in support of the test article design and testing activities are described briefly in Section 3.0. Then, select test results are presented and compared to predicted results in Section 4.0, and concluding remarks are presented in Section 5.0. Finally, drawings of CTA8.2B and references used to support the test and analysis are provided in the Appendix.

Nonlinear analysis↗

Comparison of Multi-Scale Nonlinear and Conventional Linear Methods for Stress Analysis of Nb 3 Sn Superconducting Magnets

Here this is an extension of the work on a multi-scale nonlinear procedure that demonstrated how to conduct nonlinear stress analysis of Nb 3 Sn superconducting accelerator magnets. The nonlinear procedure uses measured stress-strain curves of annealed copper, Nb 3 Sn strands and coil samples as inputs, which reduces the number of assumptions made for material properties—key uncertainties of any engineering analysis. The results from nonlinear analysis, semi-nonlinear analysis, and linear analysis of the same QFFB2 Nb 3 Sn quadrupole magnet under the same temperature and loads, were compared and discussed. The comparison illustrates that nonlinear stress analysis is significantly more accurate than other methods. As the superconducting coil block is a complex, composite material, it would be inadequate to assume the whole coil block to be linear, either isotropic or orthotropic. It is imperative to conduct nonlinear analysis by simulating the superconducting coil to the level of detail of the individual cables and individual strands. The nonlinear stress analysis procedure can be used to simulate not only Nb 3 Sn magnets, but also NbTi and HTS magnets.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Critical Evaluation of a Novel Analysis Technique for Assessment of Printed Circuit Heat Exchangers in High-Temperature Nuclear Service

Application of printed circuit heat exchangers (PCHEs) to very high-temperature reactors (VHTRs) requires mechanical performance assessment methodologies. The PCHE morphology consists of thousands of millimeter-scale channels, for enhanced thermal efficiency, enclosed in a meter-scale PCHE core. PCHE geometry under thermomechanical creep-fatigue transients results in multi-axial interactions between its different segments, such as channeled core, walls, and headers. These global-level interactions influence the local channel-level responses. Hence, developing a PCHE performance assessment methodology, following the ASME Code, Section III, Division 5 provisions, is a critical gap to be filled. There is no analysis or design methodology available in ASME Code to assess a PCHE for its global and local level performances under high temperature and pressure loadings. This paper critically evaluates a recently proposed two-step analysis technique to estimate global interactions and local channel-level responses of PCHEs. In this novel analysis technique, the channeled PCHE core is replaced with orthotropic solid blocks of representative stiffness properties for the global thermomechanical analysis. Here, subsequent channel scale submodel analysis with detailed channel geometry, loading, and elastic-perfectly plastic (EPP) material model estimates the local responses for PCHE performance assessment. This paper critically evaluates this novel technique for its effectiveness in PCHE performance assessment. Finite element (FE) models imitating various analysis issues are developed, and FE analysis results are scrutinized. An important outcome of this study is the validation of the novel two-step PCHE analysis technique for application to the performance assessment of PCHEs in VHTRs.

42 ENGINEERING↗

Enhancing Risk Analysis of Accidental Release Using CFD Modeling and Machine Learning

This project report presents the results from the AU31 project that is entitled “Enhancing Risk Analysis of Accidental Release Using CFD Modeling and Machine Learning” performed between FY2021 and FY2022. The technical objective of this project is to enhance risk analysis of accidental release of radioactive materials and provide novel risk forecasting and capabilities for assessing unplanned hazardous chemical releases for the U.S. Department of Energy (DOE). The approach includes a cross-platform finite element analysis of airborne chemical release, machine learning (ML) for simulation and forecasting, and a big data approach to data management, transformation and analysis capable of handling petabyte-scale unstructured and structured data. The outcome of these findings were assembled and accessible as a final output via an intuitive web hosted geospatial-based user interface for demonstration and general dissemination. These new results also provide a mechanism of combining this knowledge in a risk analysis framework tool. The geospatial analysis and output can utilize 5 years of qualified meteorological data to illustrate projected plume footprints that are generated from computational aspects of this study. Specifically, we show the development of a geospatial risk analysis capabilities to respond to and plan for accidental release of radioactive materials and to provide a risk forecasting tool for assessing hazardous chemical releases for the DOE. The focus of this effort is germane to common practices in risk analysis; and it is highly relevant to the timely and transparent release of information related to materials at risk including hazardous materials and chemical vapors and rapid assessment of the potential impacts on the workforce at active sites across the DOE complex.

42 ENGINEERING↗

A Universal Tare Load Prediction Algorithm for Strain-Gage Balance Calibration Data Analysis

An algorithm is discussed that may be used to estimate tare loads of wind tunnel strain-gage balance calibration data. The algorithm was originally developed by R. Galway of IAR/NRC Canada and has been described in the literature for the iterative analysis technique. Basic ideas of Galway's algorithm, however, are universally applicable and work for both the iterative and the non-iterative analysis technique. A recent modification of Galway's algorithm is presented that improves the convergence behavior of the tare load prediction process if it is used in combination with the non-iterative analysis technique. The modified algorithm allows an analyst to use an alternate method for the calculation of intermediate non-linear tare load estimates whenever Galway's original approach does not lead to a convergence of the tare load iterations. It is also shown in detail how Galway's algorithm may be applied to the non-iterative analysis technique. Hand load data from the calibration of a six-component force balance is used to illustrate the application of the original and modified tare load prediction method. During the analysis of the data both the iterative and the non-iterative analysis technique were applied. Overall, predicted tare loads for combinations of the two tare load prediction methods and the two balance data analysis techniques showed excellent agreement as long as the tare load iterations converged. The modified algorithm, however, appears to have an advantage over the original algorithm when absolute voltage measurements of gage outputs are processed using the non-iterative analysis technique. In these situations only the modified algorithm converged because it uses an exact solution of the intermediate non-linear tare load estimate for the tare load iteration.

balance calibration analysis↗

Comparison of Electrical Output Format Options for the Analysis of Strain-Gage Balance Calibration Data

Fundamental characteristics of three gage output formats are discussed that may be used to both interpret and analyze wind tunnel strain-gage balance data. The first output format uses raw outputs, i.e., absolute voltage measurements, for the analysis. This choice requires an intercept term in the regression model of the outputs if the Iterative Method is chosen for the load prediction. Raw outputs can be used for the analysis of all known output characteristics as long as the Iterative Method is applied. However, raw outputs cannot be used to analyze data of a balance with bi-directional outputs if the Non-Iterative Method is chosen for the analysis. The second output format, i.e., difference type 1, uses the difference between raw outputs and the natural zeros of the balance gages for the analysis. In this case, the use of the intercept term becomes optional. Analysis results for difference type 1 will exactly match analysis results obtained by using raw outputs as long as identical math models are used for the regression analysis. In addition, difference type 1 may be used to analyze data of a balance with bi directional outputs if an analyst prefers to process data using the Non-Iterative Method. The third output format, i.e., difference type 2, uses the difference between raw outputs and the outputs of the zero load point of a load series for the data analysis. The application of this format is only recommended if the maximum magnitude of all tare loads of a given balance calibration data set is less than two percent of capacity. Data from the calibration of a force balance is used to illustrate the application of the three gage output formats.

Wind Tunnel Strain-Gage Balance↗

Development Strategies for Uncertainty Quantification to Enable Aircraft Certification by Analysis

Aircraft Certification by Analysis (CbA) is a broad term that describes the process by which engineering analysis tools are used to supplement flight testing to demonstrate compliance with regulatory requirements. For each requirement that is to be met through this process, the analysis tools must be sufficiently accurate to ensure that an equivalent level of safety is obtained as if the aircraft to be certified had been flight tested for the requirement. In recent decades, the ability of analysis tools to accurately predict aircraft performance has improved dramatically, leading to increasing interest and limited early adoption of Certification by Analysis across the aerospace industry. However, rigorously demonstrating the credibility of analysis tools remains a challenge for many types of certification requirements, yet is necessary for widespread adoption of CbA approaches in the future. The field of uncertainty quantification is well-suited to address this problem, but will require substantial advances in order to achieve the ambitious industry goals for Certification by Analysis. The objective of this position paper is to highlight gaps in the current technical and programmatic state of uncertainty quantification. Four main categories – Mindset & Awareness, Tools & Capabilities, Data and Benchmarks for V&V, and Applied Research & Established Processes – will be introduced. Each of these categories contains several shortcomings and impediments which, if overcome, will enable more widespread possibilities for Certification by Analysis in the 2040-2050 timeframe.

Uncertainty Quantification↗

Risk Analysis of Various Design Architectures for High Safety-significant Safety-related Digital Instrumentation and Control Systems of Nuclear Power Plants during Accident Scenarios

This report documents the plus-up activities performed by Idaho National Laboratory (INL) during Fiscal Year (FY) 2022 for the U.S. Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program, Risk Informed Systems Analysis (RISA) Pathway, digital instrumentation and control (DI&C) risk assessment project. In FY 2019, the RISA Pathway initiated a project to develop a risk assessment strategy for delivering a strong technical basis to support effective, licensable, and secure DI&C technologies for digital upgrades/designs. An integrated risk assessment technology for the DI&C systems was proposed for this strategy, which aims to (1) provide a best-estimate, risk-informed capability to quantitatively and accurately estimate the safety margin obtained from plant modernization, especially for the high safety-significant safety-related (HSSSR) DI&C systems, (2) support and supplement existing advanced risk-informed DI&C design guides by providing quantitative risk information and evidence, (3) offer a capability of design architecture evaluation of various DI&C systems to support system design decisions and diversity and redundancy applications, (4) assure the long-term safety and reliability of HSSSR DI&C systems, and (5) reduce uncertainty in costs and support integration of DI&C systems in the plant. To achieve these technical goals and deal with the expensive licensing justifications from regulatory insights, the LWRS-developed framework instructs nuclear vendors and utilities on how to effectively lower the costs associated with digital compliance and speed industry advances by: (1) defining an integrated risk-informed analysis process for DI&C upgrade, including hazard analysis, reliability analysis, and consequence analysis, (2) applying systematic and risk-informed tools to address common cause failures (CCFs) and quantify corresponding failure probabilities for DI&C technologies, particularly software CCFs, (3) evaluating the impact of digital failures at the component level, system level, and plant level, and (4) providing insights and suggestions on designs to manage the risks, thus to support the development, licensing, and deployment of advanced DI&C technologies on nuclear power plant (NPPs). Adding diversity within system or components is the main means to eliminate and mitigate CCFs, but diversity also increases plant complexity and errors and may not address all sources of systematic failures. How to optimize the diversity and redundancy applications for the safety-critical DI&C systems remains a challenge. To deal with the technical issues in addressing potential software CCFs in HSSSR DI&C systems of NPPs and supporting relevant design optimization, the framework provides: ? An integrated best-estimate, risk-informed capability to address new technical digital issues quantitatively, accurately, and efficiently in plan modernization progress, such as software CCFs in HSSSR DI&C systems of NPPs ? A common and a modularized platform for DI&C designers, software developers, cybersecurity analysts, and plant engineers to efficiently predict and prevent risk in the early design stage of DI&C systems ? Technical bases and risk-informed insights to assist U.S. Nuclear Regulatory Commission (NRC) and industry to address and fulfill the risk-informed alternatives for evaluation of CCFs in HSSSR DI&C systems of NPPs ? An integrated risk-informed tool that offers a capability of design architecture evaluation of various DI&C systems to support system design decisions in diversity and redundancy applications. The plus-up research and development efforts of this project in FY 2022 are focused on methodology improvement of software CCF modeling and estimation, prevention analysis, importance analysis and risk analysis of various design architectures of HSSSR DI&C systems. This work greatly enhances the capability of the LWRS-developed framework for the risk assessment and design optimization of safety-critical DI&C systems. It should be noted that all the analyses are performed for the demonstration of the LWRS-developed framework, not for the evaluation of relevant systems. Results are obtained based on very limited design information and testing data.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗