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DOE OSTI2023

Comparison of Zirconium Redistribution in BISON EBR-II Models Using FIPD and IMIS Databases with Experimental Post Irradiation Examination

Metallic fuels have seen increased interest for future sodium fast reactors due to their material properties: high thermal conductivities and advantageous neutronic properties allow for greater fission densities. One drawback to typical metallic fuels is zirconium redistribution, which impacts this advantageous material and its neutronic properties. Unfortunately, the processes behind zirconium migration behavior are understood using first principles, so before these fuels are implemented in future fast reactors, characterization and fuel qualification regimes must be completed. These activities can be supported through the use of robust modeling using the most accurate empirical models currently available to fuel researchers around the world. The tool that allows researchers to model this complex coupled thermo-mechanical behavior and nuclear properties is BISON. Additionally, BISON model parameters need to be compared against PIE measurements. The current work utilizes two fuel pins from EBR-II experiment X441 to optimize various model parameters, including porosity correction factor, thermal conductivity, phase transition temperature, and diffusion coefficient multipliers, before implementing the final model for seven fuel pins with differing characteristics. To properly evaluate the BISON simulations, the results are compared to PIE metallography data for each fuel pin, to ensure the zirconium redistribution is properly reflected in the simulation results. Six out of seven analyzed fuel pins demonstrate good agreement between the metallography images and BISON results, showing alignment of the Zr-rich, Zr-depleted, and moderately Zr-enriched zones at various axial heights along the fuel pins. Further work is needed to refine the model parameters for general pin use.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2018

Evaluation of Commercial-Off-The-Shelf (COTS) Electronics for Extreme Cold Environments

Deep space and Icy Moon missions (Titan, Enceladus, Ceres, Europa, & Ganymede) will need qualified extreme environment capable components for electronic systems located in extremities of their rovers and spacecraft. Commercial off the shelf (COTS) components would be advantageous to use for some aspects of such projects, given that they are easier to procure and offer a broad range of functionalities. Furthermore, theoretical and experimental data suggest that many COTS parts are capable of operation, and not just storage, at temperatures well beyond the manufacturer specified temperature limits. To help address the challenges presented at near cryogenic temperatures, a COTS selection knowledge base is being developed to estimate the performance of COTS components within cold environments. The knowledge base captures queries from a range of information sources such as cold functionality test results for part types and families, theoretical and experimental literature reviews and key findings are summarized here. In addition, a selection of components are planned to be examined for their performance to near cryogenic temperatures to generate a methodology for identification and verification of the COTS candidates. As the qualification of COTS parts for extreme environments can be very costly, this knowledge base can serve to reduce qualification time and cost by pre-selecting and limiting candidates.

Mojarradi, Mohammad↗

NASA NTRS2015

AST Launch Vehicle Acoustics

The liftoff phase induces acoustic loading over a broad frequency range for a launch vehicle. These external acoustic environments are then used in the prediction of internal vibration responses of the vehicle and components which result in the qualification levels. Thus, predicting these liftoff acoustic (LOA) environments is critical to the design requirements of any launch vehicle. If there is a significant amount of uncertainty in the predictions or if acoustic mitigation options must be implemented, a subscale acoustic test is a feasible pre-launch test option to verify the LOA environments. The NASA Space Launch System (SLS) program initiated the Scale Model Acoustic Test (SMAT) to verify the predicted SLS LOA environments and to determine the acoustic reduction with an above deck water sound suppression system. The SMAT was conducted at Marshall Space Flight Center and the test article included a 5% scale SLS vehicle model, tower and Mobile Launcher. Acoustic and pressure data were measured by approximately 250 instruments. The SMAT liftoff acoustic results are presented, findings are discussed and a comparison is shown to the Ares I Scale Model Acoustic Test (ASMAT) results.

Houston, Janice↗

NASA NTRS2020

Electric Six Degree of Freedom Installation Timelapse (Six Degree of Freedom Dynamic Test System)

The Six-degree-of-freedom Dynamic Test System (SDTS) is a short-range real-time motion based testing platform. Its primary use at NASA/JSC has been for development and qualification testing of docking systems, robotic assisted berthing mechanisms, and dynamic attachment systems. The SDTS is a closed-loop force feedback system that can simulate on-orbit contact dynamics between two vehicles utilizing the actual mechanical interfaces for testing. The facility is controlled by interconnected computers running real-time simulation software that takes measured contact forces, integrates the equations of motion in real time, and provide those states back into the motion table. This infrastructure can also be used for non-mating applications such as relative position sensor testing/evaluations. The SDTS facility provides a superstructure for mounting test articles, multiple test sensors, an intercom network for voice communications, and a synchronized timing system for data acquisition that includes HD video. This time-lapse video shows the buildup and testing of a modern electric actuation system created by Mikrolar, Inc. at the Johnson Space Center. This motion base will replace the current hydraulic actuator system, which is been in use since the 1970s, for all-future NASA testing. Once the system goes through customization to provide JSC’s unique closed-loop environment, the facility will help certify docking system and attach mechanisms on the ground before we send the first woman and the next man to the lunar surface

hexapod↗

NASA NTRS1970

Backscatter Ultraviolet (BUV) Instrument

This final project report covers the design, development, construction, testing and qualification of the NIMBUS D BUV (Backscatter Ultraviolet) instrument. The instrument was designed and constructed in accordance with GSFC specification S-623-P-l and amendments. The design phase consisted of activity in three areas of technology: (1) Optical, (2) Mechanical, and (3) Electrical. Beckman Instruments, Inc. performed the tasks concerned with optical and mechanical design while Analog Technology Corporation was the electronics subcontractor. Initial studies resulted in the development of a breadboard model of the BUV instrument. Following extensive testing, additional mathematical analyses, and required modifications, preliminary and critical design reviews were performed. The results of these activities were the construction of an engineering model, used for extensive testing and demonstration of the final design features. Final design data resulted in the construction of two flight-rated instruments, serial numbers P103 and Fl04. On April 8, 1970, the P103 instrument was successfully launched into orbit on NIMBUS D and is presently fully operational.

Source record↗

DOE OSTI2025

Characterization of Pinhole Collimators for High-Resolution Gamma Imaging of Irradiated Fuel

Post-irradiation examination (PIE) of nuclear fuels requires imaging tools capable of resolving isotopic and spatial features with high throughput. This project contributes to a proof-of-concept effort aimed at advancing gamma emission tomography (GET) by evaluating novel fine-aperture pinhole collimators. Two Rose’s metal collimators, 100 µm (20° acceptance angle) and 350 µm (30° acceptance angle), were prototyped and characterized for their effectiveness in transporting gamma rays through the pinhole aperture. To support data collection, a Python-based data acquisition system was developed to coordinate a rotation stage, linear stage, and CZT detector, reducing latency in high-rate gamma event logging to one second per acquisition. Queue-based file writing enabled seamless real-time data capture for count rates up to 35,000 counts per second (cps). List-mode parsing algorithms were implemented to differentiate single and simultaneous gamma interactions for future tomographic reconstruction. Detector response was evaluated in both spectroscopy and list mode acquisition methods across varying source distances to confirm absolute and collimator efficiencies. Preliminary efficiency figures suggest effective collimation of gamma-rays with energies below 700 keV, with ~4% residual intensity through the aperture for Cs-137. The impact of collimator geometry on image quality is currently being evaluated. This groundwork supports the ongoing development of a sub mm resolution cone-beam CT system for imaging fuel phantoms, an essential step toward improving GET efficiency and accelerating nuclear fuel qualification efforts.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗

DOE OSTI2021

Structural Health Monitoring: Using an Autoencoder to Identify Damage in a Bolted Joint [Capstone Project]

Los Alamos National Laboratory (LANL) is an important fixture in the United States Department of Energy’s (DOE) National Nuclear Security Agency (NNSA) complex. LANL is one of the largest national laboratories in the country, and the laboratory’s primary mission is to support the nation’s nuclear stockpile. The lab functions as a design agencies for the NNSA and performs extensive testing on weapons as part of that mission. The shock and vibration test team at LANL utilizes electrodynamic shaker systems for important qualification testing in support of the laboratory’s mission. Modern engineering relies heavily on bolted joints to connect two objects. During these shaker tests, engineers depend on bolted joints to secure the test article to a fixture and the fixture to the table. The test article may be hazardous and contain high explosives which could create a safety issue if a bolted joint failed. A loss of preload in a bolt will affect the way energy is input to the system and may introduce nonlinearities as the joint opens and closes. The loss of preload can create challenges controlling the test and make acquired signals useless. Being able to monitor preload within bolted joints during testing can improve the quality of the data and keep workers safe.

42 ENGINEERING↗

NASA NTRSDate not supplied

Obtaining cryogenic molecular transport data for analysis

The James Webb Space Telescope (JWST) has a primary mirror, made of 18 segments, and a secondary mirror (SM) that are used to direct the light of desired targets. While on orbit, the secondary mirror assembly (SMA) was stowed for approximately 10 days and was subject to molecular contamination outgassing from the cavity of the secondary mirror support structure (SMSS) in-board hinge (IBH) which contains cables, motors, resolvers, and coatings. The main concern during this period before SMA deployment is the accumulation of ice due to the lack of a heater on the SMA. The temperature differentials between the IBH surfaces and SMA could cause redistribution of contaminants. To address this concern, single layer insulation (SLI) was used to create adequate venting and path redirection of outgassing from the IBH. Two separate thermal vacuum tests were performed to quantify this contamination: one Z307 ASTM E 1559 materials test of the radiator paint used on the motor of the IBH and a separate test on a primary mirror backplane assembly (PMBA) qualification engineering test unit (ETU) of the IBH. These tests approximately followed the predicted SMA pre-deployment thermal environment. To quantify source rates in case of a leak, the motor and resolver sides were separated and quartz crystal microbalances (QCM) were used to measure the deposition of water. The SLI redesign and implementation and outgassing measurements to understand leak effects from the IBH were essential to mitigate the deposition of contamination on the SMA.

James Webb Space Telescope, contamination, cleanro↗

NASA NTRSDate not supplied

Obtaining Cryogenic Molecular Transport Data for Analysis

James Webb Space Telescope↗

DOE OSTI2021

An Accelerated Creep Testing (ACT) Program for Advanced Creep Resistant Alloys for High Temperature Fossil Energy (FE) Applications (Final Report)

The research objective of this study is to develop an accelerated creep testing (ACT) program for advanced creep resistant alloys for high temperature FE applications. This research produced a new ACT for metallic materials based on Time-Temperature-Stress Superposition (TTSSP). In TTSSP, there exists a fundamental relationship between creep resistance, time, temperature, and stress that can be manipulated to reduce test durations. In our study, the stepped isostress method was employed where step increases of load during creep testing accelerated the time-to-rupture. Well-posed constitutive models including sin-hyperbolic and Wilshire-Cano-Stewart where calibrated using the SSM data and employed to predict the conventional creep response of the material. In our best experiments, <100-hour tests on lnconel 718 at 750 deg C produced over a 64x acceleration of data when compared to conventional data from Japan's National Institute of Materials Science. The ACTs enable the rapid screening of candidate materials, where a small test matrix of short duration tests can be employed to determine the creep resistance (minimum-creep-strain-rate, stress-rupture, and creep deformation) of a material across decades.

20 FOSSIL-FUELED POWER PLANTS↗

NASA NTRS2014

Investigation of HZETRN 2010 as a Tool for Single Event Effect Qualification of Avionics Systems

NASA's future missions are focused on long-duration deep space missions for human exploration which offers no options for a quick emergency return to Earth. The combination of long mission duration with no quick emergency return option leads to unprecedented spacecraft system safety and reliability requirements. It is important that spacecraft avionics systems for human deep space missions are not susceptible to Single Event Effect (SEE) failures caused by space radiation (primarily the continuous galactic cosmic ray background and the occasional solar particle event) interactions with electronic components and systems. SEE effects are typically managed during the design, development, and test (DD&T) phase of spacecraft development by using heritage hardware (if possible) and through extensive component level testing, followed by system level failure analysis tasks that are both time consuming and costly. The ultimate product of the SEE DD&T program is a prediction of spacecraft avionics reliability in the flight environment produced using various nuclear reaction and transport codes in combination with the component and subsystem level radiation test data. Previous work by Koontz, et al.1 utilized FLUKA, a Monte Carlo nuclear reaction and transport code, to calculate SEE and single event upset (SEU) rates. This code was then validated against in-flight data for a variety of spacecraft and space flight environments. However, FLUKA has a long run-time (on the order of days). CREME962, an easy to use deterministic code offering short run times, was also compared with FLUKA predictions and in-flight data. CREME96, though fast and easy to use, has not been updated in several years and underestimates secondary particle shower effects in spacecraft structural shielding mass. Thus, this paper will investigate the use of HZETRN 20103, a fast and easy to use deterministic transport code, similar to CREME96, that was developed at NASA Langley Research Center primarily for flight crew ionizing radiation dose assessments. HZETRN 2010 includes updates to address secondary particle shower effects more accurately, and might be used as another tool to verify spacecraft avionics system reliability in space flight SEE environments.

Rojdev, Kristina↗

NASA NTRS2018

Stirling Convertor Controller Development at NASA Glenn Research Center

Over the past decade, NASA Glenn Research Center (GRC) has been supporting the development of Radioisotope Power Systems (RPS). NASA desires higher conversion efficiency RPS options that are reliable and robust with long life design. Dynamic conversion, such as Stirling and Brayton, offer the potential for higher conversion efficiencies but have yet to be demonstrated in a flight application. The RPS program sent out a solicitation to investigate options for dynamic conversion technologies. As a result of this solicitation, four dynamic power convertor (DPC) technologies were selected for design and fabrication of a prototype dynamic convertor. One lesson learned from the Advanced Stirling Radioisotope Generator (ASRG) project is that controller development should start early in the development of a dynamic convertor. As a result of this, NASA GRC has been utilizing hardware from past Stirling convertor projects including that of the ASRG to support controller development for the DPC's. NASA GRC has developed a strong knowledge base on both analog and digital Stirling dynamic power convertor controllers and will continue to expand and apply that knowledge to the four DPC's. Over the past 15 years, controllers were developed in-house at GRC, at Lockheed Martin Coherent Technologies (LMCT) and by the Johns Hopkins University/Applied Physics Laboratory (JHU/APL). Various generations of the controllers, have been developed as lessons were learned through various component and system level tests. Some of the tests performed were fault tolerance, qualification vibration level, electromagnetic interference, Radioisotope Power System Systems Integration (RSIL) tests, and extended operation. The fault tolerance test characterized the controller's ability to handle various fault conditions, including high or low bus power consumptions, total open load or short circuit, and replacing a failed controller card while the backup maintains control of the ASC. The vibration test confirms the controller's ability to control an ASC during launch. The EMI test characterized the AC and DC magnetic and electric fields emitted by the single ASC and if the controller has an impact on the radiated EMI. RSIL testing provided insight into the electrical interactions between the representative RPS, its associated control schemes, and realistic electric system loads. The extended operation test allows data to be collected over a period of thousands of hours to obtain long term performance data of the system. This paper describes the history of controller development at NASA GRC, tests performed on these controllers, and lessons learned.

Dugala, Gina M.↗

DOE OSTI2026

Online and Offline Analytical Techniques to Quantify Chloride Salts

This report serves as the deliverable for Milestone- M3FT-26AN080502017: Summary of Accomplishments for Online and Offline Analytical Qualification of Chloride Fuel Salts. The qualification of chloride fuel salts is a critical challenge for the development and deployment of molten salt reactors (MSRs), requiring precise control and verification of chemical and isotopic composition to ensure predictable neutronics, manageable radiological behavior, and safe plant operation. Currently, there is no universally accepted standard for fuel salt qualification, particularly for chloride-based systems, which underscores the need for robust, science-based analytical methodologies. This report presents a comprehensive evaluation of both online and offline techniques for quantifying chloride fuel salts, including multielectrode array voltammetry, differential thermal analysis (DTA) probes, inert gas fusion (IGF) analyzers, and gamma spectrometry using the Mirion NAIS-2x2 NaI(Tl) detector. The integration of these methods enables real-time monitoring of actinide concentrations, redox state, and thermophysical properties, as well as high-precision measurement of impurities and isotopic composition. The acquisition of advanced instruments such as the Bruker Leonardo G6 for IGF and the Mirion NaI detector enhances analytical capabilities, supporting the establishment of operational envelopes and impurity thresholds. These approaches provide essential data for neutronic impact evaluation, feedstock documentation, and compliance with nuclear safety standards. The methodologies developed and validated in this report lay the groundwork for future standardized protocols, bridging the gap between laboratory research and commercial reactor operation, and advancing the safe and efficient deployment of chloride-fueled MSRs.

Polke, Amber↗

NASA NTRS2009

Feasibility of Mixed Equipage Operations in the Same Airspace

This study used a human-in-the-loop simulation to examine the feasibility of mixed equipage operations in an automated separation assurance environment under higher traffic densities. The study involved two aircraft equipage alternatives with and without data link and four traffic conditions. In all traffic conditions the unequipped traffic count was increased linearly throughout the scenario from approximately 5 to 20 aircraft. Condition One consisted solely of this unequipped traffic, while the remaining three conditions also included a constant number of equipped aircraft operating within the same airspace: 15 equipped aircraft in condition two, 30 in condition three, and 45 in condition four. If traffic load became excessive during any run, participants were instructed to refuse sector entry to inbound unequipped aircraft until sector load became manageable. Results showed a progressively higher number of unequipped aircraft turned away under the second, third, and fourth scenario conditions. Controller workload also increased progressively. Participants rated the mixed operations concept as acceptable, with some qualifications about procedures and information displays. These results showed that mixed operations might be feasible in the same airspace, if unequipped aircraft count is held to a workable level. This level will decrease with increasing complexity. The results imply that integrated airspace configuration is feasible to a limit. The results also indicate that the conflict detection and resolution automation, equipage, and traffic density are important factors that will need to be considered for airspace configuration.

Kopardekar, Parimal↗

NASA NTRS2009

Feasibility of Mixed Equipage Operations in the Same Airspace

This study used a human-in-the-loop simulation to examine the feasibility of mixed equipage operations in an automated separation assurance environment under higher traffic densities. The study involved two aircraft equipage alternatives - with and without data link- and four traffic conditions. In all traffic conditions the unequipped traffic count was increased linearly throughout the scenario from approximately 5 to 20 aircraft. Condition One consisted solely of this unequipped traffic, while the remaining three conditions also included a constant number of equipped aircraft operating within the same airspace: 15 equipped aircraft in condition two, 30 in condition three, and 45 in condition four. If traffic load became excessive during any run, participants were instructed to refuse sector entry to inbound unequipped aircraft until sector load became manageable. Results showed a progressively higher number of unequipped aircraft turned away under the second, third, and fourth scenario conditions. Controller workload also increased progressively. Participants rated the mixed operations concept as acceptable, with some qualifications about procedures and information displays. These results showed that mixed operations might be feasible in the same airspace, if unequipped aircraft count is held to a workable level. This level will decrease with increasing complexity. The results imply that integrated airspace configuration is feasible to a limit. The results also indicate that the conflict detection and resolution automation, equipage, and traffic density are important factors that will need to be considered for airspace configuration.

Kopardekar, Parimal↗

NASA NTRSDate not supplied

The Additive Manufacturing Moment Measure - A Parallel Computation Technique for Determining Build Variance in the Laser Powder Bed Fusion Process

Additive manufacturing (AM) has unique process attributes that facilitate the creation of optimized, complex, and unique parts for aerospace applications. However, the multi-scale and complicated building process for AM parts can cause unexpected build conditions that result in microstructural variability within the deposited material. The need for richer datasets and computational modeling capabilities to improve AM process reliability is a consequence of this microstructural variability. A computational approach, referred to as the Additive Manufacturing Moment Measure (AM3), addresses this need by leveraging the way AM processes fuse material in precise, incremental steps. During the layering sequence, each previous step contributes to the condition of the current step at the center of the heat source. The precise steps can be selected to systematically create a time-space point field with co-located machine input and in-situ sensor data. The sequential nature of the AM process, coupled with nearest neighbor calculations, allows for a fully parallel computation for part-scale build profile analysis. The AM3 concept introduced here enables part-scale assessment directly from build files and in-situ process monitoring sensors alike. The AM moment measures were calculated for build point fields and compared with co-located in-situ and ex-situ nondestructive evaluation and optical microscopy observations. These comparisons permit a better understanding of how the sequential process actions can affect the quality of a laser powder bed fusion (LPBF) build. Details of the AM3technique will be discussed and compared to measured LPBF part characteristics. The AM3 results indicate a strong potential to advance the qualification process for aerospace applications.

Additive Manufacturing↗

NASA NTRS1994

A programmable heater control circuit for spacecraft

Spacecraft thermal control is accomplished for many components through use of multilayer insulation systems, electrical heaters, and radiator systems. The heaters are commanded to maintain component temperatures within design specifications. The programmable heater control circuit (PHCC) was designed to obtain an effective and efficient means of spacecraft thermal control. The hybrid circuit provides use of control instrumentation as temperature data, available to the spacecraft central data system, reprogramming capability of the local microprocessor during the spacecraft's mission, and the elimination of significant spacecraft wiring. The hybrid integrated circuit has a temperature sensing and conditioning circuit, a microprocessor, and a heater power and control circuit. The device is miniature and housed in a volume which allows physical integration with the component to be controlled. Applications might include alternate battery-powered logic-circuit configurations. A prototype unit with appropriate physical and functional interfaces was procured for testing. The physical functionality and the feasibility of fabrication of the hybrid integrated circuit were successfully verified. The remaining work to develop a flight-qualified device includes fabrication and testing of a Mil-certified part. An option for completing the PHCC flight qualification testing is to enter into a joint venture with industry.

Nguyen, D. D.↗

NASA NTRS2012

Quantum-Well Infrared Photodetector (QWIP) Focal Plane Assembly

A paper describes the Thermal Infrared Sensor (TIRS), a QWIP-based instrument intended to supplement the Operational Land Imager (OLI) for the Landsat Data Continuity Mission (LDCM). The TIRS instrument is a far-infrared imager operating in the pushbroom mode with two IR channels: 10.8 and 12 microns. The focal plane will contain three 640x512 QWIP arrays mounted on a silicon substrate. The silicon substrate is a custom-fabricated carrier board with a single layer of aluminum interconnects. The general fabrication process starts with a 4-in. (approx.10-cm) diameter silicon wafer. The wafer is oxidized, a single substrate contact is etched, and aluminum is deposited, patterned, and alloyed. This technology development is aimed at incorporating three large-format infrared detecting arrays based on GaAs QWIP technology onto a common focal plane with precision alignment of all three arrays. This focal plane must survive the rigors of flight qualification and operate at a temperature of 43 K (-230 C) for five years while orbiting the Earth. The challenges presented include ensuring thermal compatibility among all the components, designing and building a compact, somewhat modular system and ensuring alignment to very tight levels. The multi-array focal plane integrated onto a single silicon substrate is a new application of both QWIP array development and silicon wafer scale integration. The Invar-based assembly has been tested to ensure thermal reliability.

Jhabvala, Murzy↗