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NASA NTRSDate not supplied

Autonomous In-space Construction, Maintenance, and Reconfiguration Using Programmable Meta-Material

NASA ARC's Coded Structures Laboratory (CSL) is developing autonomous construction, maintenance, and reconfiguration technologies to meet long-duration and deep space infrastructure needs, in accordance with long-term NASA goals of "in-space reliance" and "mass-less exploration." We seek to achieve these capabilities by utilizing a "programmable meta-material" approach that integrates emerging advances in materials (mechanical meta-materials), manufacturing (cooperative mobile robotics), and autonomy (multi-agent planning algorithms). Through the ARMADAS project, we have shown assembly of high-performance engineered cellular materials using multiple cooperating mobile robotic assemblers. In this paper, we describe how such a programmable meta-material architecture may shift the paradigm of how we design, build, manufacture, and operate future space infrastructure and assets. The core of a programmable meta-material architecture consists of 3 main technology sub-areas: the structure, the assembly agents, and the assembly algorithms. We co-design these systems to ensure an adaptable system that can create and reconfigure structures from a base set of building block components. From this core technology, we can branch out and expand the capability of the system through additional secondary component types and robotic agents to perform activities such as inspections, maintenance, repair, payload installation, or perform power and communications interconnect. As these technologies mature, future designers will be able to utilize the system to rapidly integrate and operate assets in space or on planetary surfaces from a set of well-tested part library, or create their own modules to integrate into the system. A core trait to the development of this system is the automation approach. Because of the modular and functional discrete (pixel-like) nature of the structural system, a diverse set of powerful algorithms for analysis, planning, and simulation can be adapted and leveraged to optimize construction, maintenance, and dynamic reorganization (as hardware with programmable form and function). With an ability to free the design space from launch vehicle constraints and fundamentally shift how a mission is designed and conducted, we discuss the influence of a programmable meta-material architecture on mission design, build, and operations. For the "design phase", we discuss project lifecycle effects, costs, time, and performance. For the "build phase", we discuss reusability, ISRU, manufacturing, material logistics, and scalability. And for "operations", we discuss autonomy, maintenance and upgrades, reliability, and reconfiguration. Autonomy and modularity are the primary enabling traits of this system. Engineering systems that utilize a modular and reconfiguration building block approach such as digital communication and computation systems, currently lead all other areas of technology in size and complexity scalability. NASA is extending the benefits and flexibility of digital systems to hardware systems, to optimize materials lifecycle management and expand our space exploration mission capabilities.

in space assembly↗

NASA NTRSDate not supplied

Lessons Learned From Designing and Building Low Organic Outgassing Cleanrooms for NASA OSIRIS-REx and Hayabusa2 Curation Facility

NASA Johnson Space Center Astromaterials Acquisition and Curation Office completed construction and commissioning of the OSIRIS-REx and Hayabusa2 cleanroom laboratory suites along with new precision cleaning and advanced curation laboratories consisting of ISO Class 5, 6, and 7 cleanrooms. The new curation facilities are designed for initial receiving, basic characterization, curation processing, and preliminary examination of carbonaceous asteroidal material. The facilities are also designed to enable long-term pristine sample storage to preserve the scientific integrity of each sample to enable future research by the international science community. The scientific study of organics is critical for both missions. The OSIRIS-REx mission instituted a stringent contamination control plan for low organics. Given these mission requirements and long-term storage preservation requirements, cleanroom construction materials were carefully selected to not hinder the scientific search for amino acids and the study of organics in the samples. Cleanroom candidate construction materials were researched for the HVAC system, floors, walls, ceiling, and plenum areas. The team chose several candidate materials that were further tested for their specific outgassing characteristics using ASTM E-595 per ASTM E-2312. The information gained provided the foundation for the final design selection of the cleanroom materials. While material selection is important before and during the facility design phase, the construction phase is where these choices are implemented by the prime construction contractor through final product and material submittals. These submittals are the last check point and changes are often submitted due to engineering/construction conflicts, especially when renovating an existing building. Any new material or equipment/product change must be identified and scrutinized for low particulate shedding and outgassing properties. In some cases, quick testing of new material is required, and compromises must be made in real-time. Careful selection and implementation of cleanroom materials significantly reduced organic and inorganic contamination beyond normal cleanroom baselines.

astromaterials curation↗

NASA NTRSDate not supplied

Development and Validation of an Initial Electric Motor Rotor Vibration Model

An overview of the development of a low fidelity prediction tool for electric motor rotor resonant modes and frequencies. These predictions are useful for the prediction of UAM motor noise during the design phase. Finite Element Analysis of motor rotors has led to the development of a parameterized model to predict these modes shapes. This has in turn allowed to a curve-fit based model from parametric sweeps. These curves can predict resonant frequencies and shapes for 1-5kW class motors without running a simulation.

acoustics↗

NASA NTRSDate not supplied

Lessons Learned From Designing and Building Low Organic Outgassing Cleanrooms for NASA OSIRIS-REx and Hayabusa2 Curation Facility

astromaterials curation↗

NASA NTRSDate not supplied

Design and Technology Maturation of the Stratospheric Projectile Experiment of Entry Dynamics

The supersonic and transonic dynamic stability of blunt-body reentry vehicles currently poses large risks in all of NASA’s ongoing entry missions (MSR SRL, MSR EES, and Dragonfly). These projects have allocated millions of dollars to testing and modeling efforts to buy down risk by using the current state-of-the-art (SoA) facilities at NASA’s disposal. While these facilities have heritage in supplying dynamics data to reentry missions, their availability is severely limited – particularly with the high number of concur-rent projects requesting simultaneous testing– and are costly when considering the science density per dollar. None of the current SoA facility methodologies allow the test model to have the dynamics fully develop through a flight relevant free-stream profile and as such require extrapolations with resultant high uncertainties in order to relate the test dynamics to flight expectations. SPEED is a NASA Ames Center Innovation Fund (CIF) project that is developing a highly tailorable and cost-effective test methodology to better assess the dynamic stability of blunt-body reentry vehicles via a stratospheric balloon flight. This is accomplished by dropping a suite of instrumented capsules from a stratospheric balloon to gain a statistically relevant dataset of scaled reentry vehicles in mission relevant free-flight conditions. This presentation will walk through how the test methodology is being implemented specifically for the Mars Sample Return (MSR) Earth Entry System (EES) geometry in an awarded Flight Opportunities Program (FOP) test flight in early CY24. SPEED Application to MSR: SPEED consists of three main mechanical systems: the Drop Platform, the Projectile, and the test Capsule. SPEED is being developed as a set of guidelines and recommendations for how to test with the proposed Concept of Operations (Conops) since the specific design parameters will vary depending on the specific project’s reference trajectory and entry vehicle design. As such, this presentation will walk through the development time-line as shown in Fig. 2. This is meant to serve as a blueprint for further missions as desired. Mechanical and Avionics Design. The SPEED test platform designed for the MSR-EES capsule geometry with nominal entry parameters has the ability to carry 10 Capsules to altitude instrumented with: 1. 3-Axis Accelerometer 2. IMU 3. Gyroscope 4. Magnetometer 5. Pressure Transducer cruciform 6. Uplook and Horizon Cameras To package the avionics/instrumentation suite, the capsule is approximately 1’ in diameter with the Outer Mold Line (OML) centroid-scaled from the full EES design. The internal volume is gutted and custom-shaped to fit the desired instrumentation suite, as well as to allow for the positioning of ballast mass such that the Center of Gravity is analogous to the flight vehicle. All structural components in the Capsule and Projectile are 3D printed, which significantly reduces the cost of each flight unit to around $1500 including all instrumentation, avionics, and structural components. Flight Conops. The test Capsule is accelerated to the desired altitude and Mach number while stowed in the Projectile, a missile-like vehicle consisting of steel ballast in the nose, a low-drag OML, and an Ejection Mechanism to reliably release the Capsule into the free-flow supersonic conditions. For the MSR-EES design, the capsule employs ~3kg of ballast mass at the nose to accelerate the 1.25kg test Capsule to ~Mach 1.7 at 23km altitude. This requires an initial release altitude of 40km, the quoted limit of a 80kg payload by the FOP-contracted balloon provider. Once the Ejection Mechanism avionics detect the proper conditions, the spring-loaded Ejection Mechanism will release and – guided by the sabot – expose the test Capsule to the desired test conditions for ~5 seconds of free-flight in the supersonic/transonic regimes. Dynamics in the subsonic regime will also be captured with the instrumentation suite with post-flight recovery operations aimed at recovering the high-G-load capable SD cards after the planned hard impact landings. Testing and Development: In the few months the SPEED project has worked the development of MSR-EES flight test, the team has performed lab and drone based testing which this presentation will overview. After the first design phase, the team fabricated Engineering Demonstration Units (EDUs) of all subsystems to perform validation testing shown in Fig. 5. After validation was completed on the subsystem level, a drone-drop test was performed at the recreational flight ceiling of 400ft altitude to assess the SPEED systems in a flight environment. Parameters such as in-flight stability, hard impact landing performance, and avionics performance were quantified and qualified. The FY23 CIF will culminate in a helicopter drop test aboard an Air National Guard Blackhawk. This will prepare the team for the CY24 FOP stratospheric balloon flight that should provide the final verification to begin offering the test platform for mission support. Focus of Presentation: This presentation will outline the technology maturation path of the SPEED implementation to the MSR-EES capsule baseline as well as the details regarding the mechanical system, avionics and instrumentation, and flight operations. Note that a complementary presentation is being submitted for a methodology overview of the SPEED test platform, introducing the testing technique and benefits as well as the full application space of the technology.

pitch damping coefficient↗

NASA NTRS2023

The Impact of Soft Magnetic Materials in Electrified Aircraft Applications

Electrical systems with high power and high power density are integral to many aerospace and energy applications. These systems, enabled by power electronics with wide bandgap semiconductor devices, require management of both efficiency/thermal aspects and electromagnetic interference that are problems specific to high power and high frequency applications, respectively. In addition to advanced active components, these applications also require passive components (inductors, capacitors, conductors) capable of operation under challenging conditions. This work surveys the state of the art of magnetic components and soft magnetic materials used as inductive cores. The wide variety of motor and converter topologies translates to a variety of requirements in the magnetics including mechanical properties, permeabilities, and frequency response. The scaling impact of material properties will be surveyed with respect to component performance and sizing, using both data from experiment and the published literature. Variations on simulations, both in lumped circuits and finite element models, will also be discussed as these are important aspects of the design phase of modern power electronics.

Alex Leary↗

NASA NTRSDate not supplied

Scoping, Tailoring, and Abstraction Refinement in Hazard Assessment Processes

Hazard assessment is an engineering activity that produces insight into which states of thing being engineered might be hazardous. In aviation contexts, it is often performed for certification credit at both the aircraft and system levels during the early design phase of the system’s lifecycle. However, novel aircraft paradigms such as urban air mobility (UAM)operations might either violate assumptions on which traditional aviation hazard assessment is based or simply possess attributes that would make other approaches more effective. In this paper, we define the key concepts under pinning hazard assessment and identify the limitations and assumptions inherent in hazard analysis. We analyze popular techniques to show how they embody these key concepts. We identify ways in which hazard assessment may be scoped and tailored to an application. And, using worked examples, we discuss how, where, and why such tailoring might be needed, especially in novel contexts.

aviation safety↗

NASA NTRSDate not supplied

Planetary Protection at Marshall Space Flight Center

Planetary Protection (PP) at NASA aims to 1) protect solar system bodies from contamination by Earth life and 2) protect Earth from possible life forms that may be returned from other solar system bodies. It is particularly relevant for missions focused on life detection. PP specialists at MSFC act as subject matter experts to interpret PP requirements and communicate with other NASA centers and/or vendors to ensure compliance. This includes insight and oversight to help projects consider and plan PP implementation during design phases. It also includes physical implementation during build, assembly, and test operations, (i.e. microbial sampling of environments and spacecraft) to help maintain cleanliness. MSFC has also expanded to include PP research which included standing up a fully functional BSL2 microbiology laboratory.

Planetary Protection↗

NASA NTRSDate not supplied

Scoping, Tailoring, and Abstraction Refinement in the Hazard Assessment Process

Hazard assessment is an engineering activity that produces insight into which states of thing being engineered might be hazardous. In aviation contexts, it is often performed for certification credit at both the aircraft and system levels during the early design phase of the system’s lifecycle. However, novel aircraft paradigms such as urban air mobility (UAM) operations might either violate assumptions on which traditional aviation hazard assessment is based or simply possess attributes that would make other approaches more effective. In this paper, we define the key concepts underpinning hazard assessment and identify the limitations and assumptions inherent in hazard analysis. We analyze popular techniques to show how they embody these key concepts. We identify ways in which hazard assessment may be scoped and tailored to an application. And, using worked examples, we discuss how, where, and why such tailoring might be needed, especially in novel contexts.

Aviation Safety↗

DOE OSTI2014

Ames Lab 101: 3D Metals Printer

To meet one of the biggest energy challenges of the 21st century - finding alternatives to rare-earth elements and other critical materials - scientists will need new and advanced tools. The Critical Materials Institute at the U.S. Department of Energy's Ames Laboratory has a new one: a 3D printer for metals research. 3D printing technology, which has captured the imagination of both industry and consumers, enables ideas to move quickly from the initial design phase to final form using materials including polymers, ceramics, paper and even food. But the Critical Materials Institute (CMI) will apply the advantages of the 3D printing process in a unique way: for materials discovery.

36 MATERIALS SCIENCE↗

DOE OSTI2014

DISCRETE ELEMENT MODELING OF BLADE–STRIKE FREQUENCY AND SURVIVAL OF FISH PASSING THROUGH HYDROKINETIC TURBINES

Evaluating the consequences from blade-strike of fish on marine hydrokinetic (MHK) turbine blades is essential for incorporating environmental objectives into the integral optimization of machine performance. For instance, experience with conventional hydroelectric turbines has shown that innovative shaping of the blade and other machine components can lead to improved designs that generate more power without increased impacts to fish and other aquatic life. In this work, we used unsteady computational fluid dynamics (CFD) simulations of turbine flow and discrete element modeling (DEM) of particle motion to estimate the frequency and severity of collisions between a horizontal axis MHK tidal energy device and drifting aquatic organisms or debris. Two metrics are determined with the method: the strike frequency and survival rate estimate. To illustrate the procedure step-by-step, an exemplary case of a simple runner model was run and compared against a probabilistic model widely used for strike frequency evaluation. The results for the exemplary case showed a strong correlation between the two approaches. In the application case of the MHK turbine flow, turbulent flow was modeled using detached eddy simulation (DES) in conjunction with a full moving rotor at full scale. The CFD simulated power and thrust were satisfactorily comparable to experimental results conducted in a water tunnel on a reduced scaled (1:8.7) version of the turbine design. A cloud of DEM particles was injected into the domain to simulate fish or debris that were entrained into the turbine flow. The strike frequency was the ratio of the count of colliding particles to the crossing sample size. The fish length and approaching velocity were test conditions in the simulations of the MHK turbine. Comparisons showed that DEM-based frequencies tend to be greater than previous results from Lagrangian particles and probabilistic models, mostly because the DEM scheme accounts for both the geometric aspects of the passage event ---which the probabilistic method does--- as well as the fluid-particle interactions ---which the Lagrangian particle method does. The DEM-based survival rates were comparable to laboratory results for small fish but not for mid-size fish because of the considerably different turbine diameters. The modeling framework can be used for applications that aim at evaluating the biological performance of MHK turbine units during the design phase and to provide information to regulatory agencies needed for the environmental permitting process.

blade strike↗

DOE OSTI2014

Mechanical Properties of Ingot Nb Cavities

This contribution presents the results of measurements of the resonant frequency and of strain along the contour of a single-cell cavity made of ingot Nb subjected to increasing uniform differential pressure, up to 6 atm. The data were used to infer mechanical properties of this material after cavity fabrication, by comparison with the results from simulation calculations done with ANSYS. The objective is to provide useful information about the mechanical properties of ingot Nb cavities which can be used in the design phase of SRF cavities intended to be built with this material.

Ciovati, Gianluigi↗

DOE OSTI2013

A Review of NDE Methods for Detecting and Monitoring of Atmospheric SCC in Dry Cask Storage Canisters for Used Nuclear Fuel

Dry cask storage systems (DCSSs) for used nuclear fuel (UNF) were originally envisioned for storage periods of short duration (~ a few decades). However, uncertainty challenges the opening of a permanent repository for UNF implying that UNF will need to remain in dry storage for much longer durations than originally envisioned (possibly for centuries). Thus, aging degradation of DCSSs becomes an issue that may not have been sufficiently considered in the design phase and that can challenge the efficacy of very long-term storage of UNF. A particular aging degradation concern is atmospheric stress corrosion cracking (SCC) of DCSSs located in marine environments. In this report, several nondestructive (NDE) methods are evaluated with respect to their potential for effective monitoring of atmospheric SCC in welded canisters of DCSSs. Several of the methods are selected for evaluation based on their usage for in-service inspection applications in the nuclear power industry. The technologies considered include bulk ultrasonic techniques, acoustic emission, visual techniques, eddy current, and guided ultrasonic waves.

Atmospheric Stress Corrosion Cracking↗

DOE OSTI2015

Model-driven Privacy Assessment in the Smart Grid

In a smart grid, data and information are transported, transmitted, stored, and processed with various stakeholders having to cooperate effectively. Furthermore, personal data is the key to many smart grid applications and therefore privacy impacts have to be taken into account. For an effective smart grid, well integrated solutions are crucial and for achieving a high degree of customer acceptance, privacy should already be considered at design time of the system. To assist system engineers in early design phase, frameworks for the automated privacy evaluation of use cases are important. For evaluation, use cases for services and software architectures need to be formally captured in a standardized and commonly understood manner. In order to ensure this common understanding for all kinds of stakeholders, reference models have recently been developed. In this paper we present a model-driven approach for the automated assessment of such services and software architectures in the smart grid that builds on the standardized reference models. The focus of qualitative and quantitative evaluation is on privacy. For evaluation, the framework draws on use cases from the University of Southern California microgrid.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2018

Kemper County IGCC Final Public Design Report

The Kemper County IGCC plant is a lignite-fueled 2-on-1 Integrated Gasification Combined-Cycle (IGCC) facility incorporating the air-blown Transport Integrated Gasification (TRIG™) technology jointly developed by Southern Company; KBR; and the United States Department of Energy (DOE) at the Power Systems Development Facility (PSDF) in Wilsonville, Alabama. The plant is owned by Mississippi Power Company (MPC) and has a calculated nameplate capacity of 830 MW with a peak net output of 582 MW. As a result of advanced emissions-control equipment, the facility is designed to produce marketable products of ammonia (NH3), sulfuric acid (H 2 SO 4 ), and carbon dioxide (CO 2 ). The plant is designed to capture 65 percent of the carbon entering to sell for enhanced oil recovery (EOR), which makes the Kemper County plant’s carbon emissions comparable to those of a natural-gas-fired combined cycle power plant. This report describes the basic design and function of the plant as determined at the end of the Detailed Design phase of the project. The technical sections of the report were completed in October 2013, and the cost information was incorporated into Section 6.0 in March 2018.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2018

Topical Report: Kemper County IGCC Final Public Design Report

The Kemper County IGCC plant is a lignite-fueled 2-on-1 Integrated Gasification Combined-Cycle (IGCC) facility incorporating the air-blown Transport Integrated Gasification (TRIG™) technology jointly developed by Southern Company; KBR; and the United States Department of Energy (DOE) at the Power Systems Development Facility (PSDF) in Wilsonville, Alabama. The plant is owned by Mississippi Power Company (MPC) and has a calculated nameplate capacity of 830 MW with a peak net output of 582 MW. As a result of advanced emissions-control equipment, the facility is designed to produce marketable products of ammonia (NH 3 ), sulfuric acid (H 2 SO 4 ), and carbon dioxide (CO 2 ). The plant is designed to capture 65 percent of the carbon entering to sell for enhanced oil recovery (EOR), which makes the Kemper County plant’s carbon emissions comparable to those of a natural-gas-fired combined cycle power plant. This report describes the basic design and function of the plant as determined at the end of the Detailed Design phase of the project. The technical sections of the report were completed in October 2013, and the cost information was incorporated into Section 6.0 in March 2018.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2019

Optimization of Workload Distribution of Data Centers Based on a Self-Learning In Situ Adaptive Tabulation Model

Data center cooling typically involves non-uniform airflow and temperature distributions, which are affected by the IT workload distribution. It is helpful to simulate the airflow and temperature to optimize the workload distribution. Traditional computational fluid dynamics (CFD) simulation is usually time-consuming while conventional reduced order models (ROMs), though computationally fast, may generate inaccurate results even after being fully trained. In Situ Adaptive Tabulation (ISAT), contracting to conventional ROM, can make prediction with error lower than a user-specified tolerance. To demonstrate using of ISAT for optimal workload distribution in data center, this paper presents a preliminary study of an ISAT-based genetic algorithm optimization platform. The ISAT is trained offline by using the results from CFD simulations using a hypothetical simple data center. The optimal workload distribution determined by the platform leads to approximately 6.8% of energy savings when compared to the benchmark with a uniform workload distribution. We note that the time cost for the entire optimization process, including the training of ISAT is about 4 hours, which is acceptable in the design phase.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

CTES Pilot Plant Detailed Design Report

Energy storage is becoming an increasingly important component on modern power grids to ensure sufficient balancing capability for intermittent renewable power generations is available to maintain system reliability. Although energy storage has traditionally been provided by pumped storage hydroelectric systems, it is not possible to install these at every location and they can be expensive to construct. Lithium Ion batteries are increasingly being used to carry out energy storage grid services, however these can be expensive when specified over a few hours of capacity. An alternative way to store substantial energy is to use thermal energy storage (TES). This has been deployed on concentrated solar units using molten nitrate salts as a storage media. Again, the cost of the material can be prohibitive, thus lower cost alternative materials are being actively sought, such as sand, rocks and concrete. This project investigates the potential for Concrete Thermal Energy Storage (CTES) when used to directly store thermal energy from a thermal plant source. This report represents the Detailed Design phase deliverables comprising of the process, mechanical, electrical, piping along with control and instrumentation documents. Civil and structural deliverables are included on a preliminary basis due to outstanding site investigation activities. CTES block transportation testing results and the pilot plant testing plan is also included in this report.

25 ENERGY STORAGE↗