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

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Timely deposition of macromolecular structures is necessary for peer review

Deposition of crystallographic structures should be concurrent with or prior to manuscript submission for peer review, enabling validation and increasing reliability of the PDB. Most of the macromolecular structures in the Protein Data Bank (PDB), which are used daily by thousands of educators and scientists alike, are determined by X-ray crystallography. It was examined whether the crystallographic models and data were deposited to the PDB at the same time as the publications that describe them were submitted for peer review. This condition is necessary to ensure pre-publication validation and the quality of the PDB public archive. It was found that a significant proportion of PDB entries were submitted to the PDB after peer review of the corresponding publication started, and many were only submitted after peer review had ended. It is argued that clear description of journal policies and effective policing is important for pre-publication validation, which is key in ensuring the quality of the PDB and of peer-reviewed literature.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Design update of the ITER upper wide angle viewing system

One of the diagnostic systems being provided by the US is the Upper Wide Angle Viewing System (UWAVS) which provides real-time, simultaneous visible and infrared (IR) images of the ITER divertor regions via optical systems located in five upper ports. UWAVS is designed in three main sections: in-vessel, interspace and port cell assemblies. Each assembly utilizes multiple steering and relay mirrors to direct the in-vessel light out of the tokamak to the port cell camera sensors. The primary design challenge of the in-vessel assembly is maximizing performance of the overall system while surviving the severe electromagnetic and nuclear ITER environment. A first mirror material study was conducted and determined that single crystal molybdenum was the best choice for the first two mirrors in the optical train. A fail open, bellows actuated shutter with cross pivot flexure design was determined to be the most reliable mechanism to protect the first mirror. A geometrically representative glow discharge mirror cleaning system is being created and will be tested to maximize cleaning effectiveness while minimizing optical degradation of the molybdenum mirrors adjacent to the plasma. The shutter and first mirror assemblies were packaged and designed for replacement via remote handling methods to minimize radiation waste and cost associated with eventual component replacement. The preliminary optical and structural design provides a robust and reliable system while maximizing the field of view. The R&D efforts, the technical challenges and issues, and the design and analysis results are introduced.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Determination of transient atomic structure of laser-excited materials from time-resolved diffraction data

The time evolution of the Bragg peaks of photo-excited gold nanofilms is measured using transmission ultrafast electron diffraction (UED) with 3.0 MeV electron pulses and the corresponding structure evolution is calculated using two-temperature molecular dynamics (2T-MD). The good agreement obtained between the measured and calculated Bragg peaks, over the full experimental timescale, enables the lattice temperature effects and the structural changes to be disentangled for the first time. The agreement demonstrates that 2T-MD is a reliable method for solving the inverse problem of structure determination of laser irradiated metals in UED measurements.

36 MATERIALS SCIENCE↗

Direct periodic patterning of GaN-based light-emitting diodes by three-beam interference laser ablation

We report on the direct patterning of two-dimensional periodic structures in GaN-based light-emitting diodes (LEDs) through laser interference ablation for the fast and reliable fabrication of periodic micro- and nano-structures aimed at enhancing light output. Holes arranged in a two-dimensional hexagonal lattice array having an opening size of 500 nm, depth of 50 nm, and a periodicity of 1 μm were directly formed by three-beam laser interference without photolithography or electron-beam lithography processes. The laser-patterned LEDs exhibit an enhancement in light output power of 20% compared to conventional LEDs having a flat top surface without degradation of electrical and optical properties of the top p-GaN layer and the active region, respectively.

36 MATERIALS SCIENCE↗

Machining of Thin-Walled Structures From Stiffness-Driven Additively Manufactured Preform Geometry

Additive manufacturing provides the means to build component preforms with reduced excess material to create functional parts. In the case of aero-structural and aero-engine components, additive manufacturing technologies offer the possibility to substantially reduce the volume of material to be removed by machining operations. To achieve this objective, the preform must be built with the minimum material necessary to contain the final geometry and simultaneously provide enough stiffness to withstand the magnitude of the machining forces. This work describes a computationally efficient method to calculate the geometry required from the preform to reliably manufacture typical thin-walled structures via finish machining processes. This is achieved by defining the preform with near constant static stiffness across the width of the preform, in combination with a prescribed magnitude of stiffness at the top edge of the preform. The prescribed static stiffness is the function of the machining force magnitude, a direct consequence of the preselected cutting conditions. In conclusion, this article illustrates the application of the method to a straight single boundary thin-walled structure as an introduction case and for ease of description.

Additive manufacturing↗

Remote Optical Recession Measurement of Orion Thermal Protection System

For the Orion Multi-Purpose Crew Vehicle (MPCV) project, NASA is minimizing the use of onboard diagnostics, especially external sensors that penetrate the structure. Nonetheless, there is a desire to measure the Thermal Protection System (TPS) recession during reentry. One noninvasive technique currently under investigation is the insertion of indicator metals into the heatshield at varied depths and spatial locations. A remote (airborne) spectrometer detects the emissions from the ionized metal to reveal the time (thus depth) of the metal release. Innovative processing enables the emission features from trace amounts of the selected metals to be reliably detected against the complex and structured spectral background of the shock layer and ablated TPS material. The con-cept has been proven viable through ground testing at NASA HyMETS and AHF arc jet facilities using the Orion TPS material (Avcoat). This presentation highlights the parametric testing that was conducted to select the optimal indicator metals and to assess the accuracy of remote recession measurements using this technique. The CONOPS for integrating the technique into the Orion flight tests is also presented. This includes the onboard indicator metal "seeded plugs" and the offboard airborne sensor platform that would be deployed.

Scriven, Gordon↗

Lidar Altimeter Measurements of Canopy Structure: Methods and Validation for Closed Canopy, Broadleaf Forests

Lidar altimeter observations of vegetated landscapes provide a time-resolved measure of laser pulse backscatter energy from canopy surfaces and the underlying ground. Airborne lidar altimeter data was acquired using the Scanning Lidar Imager of Canopies by Echo Recovery (SLICER) for a successional sequence of four, closed-canopy, deciduous forest stands in eastern Maryland. The four stands were selected so as to include a range of canopy structures of importance to forest ecosystem function, including variation in the height and roughness of the outer-most canopy surface and the vertical organization of canopy stories and gaps. The character of the SLICER backscatter signal is described and a method is developed that accounts for occlusion of the laser energy by canopy surfaces, transforming the backscatter signal to a canopy height profile (CHP) that quantitatively represents the relative vertical distribution of canopy surface area. The transformation applies an increased weighting to the backscatter amplitude as a function of closure through the canopy and assumes a horizontally random distribution of the canopy components. SLICER CHPs, averaged over areas of overlap where lidar ground tracks intersect, are shown to be highly reproducible. CHP transects across the four stands reveal spatial variations in vegetation, at the scale of the individual 10 m diameter laser footprints, within and between stands. Averaged SLICER CHPs are compared to analogous height profile results derived from ground-based sightings to plant intercepts measured on plots within the four stands. Tbe plots were located on the segments of the lidar ground tracks from which averaged SLICER CHPs were derived, and the ground observations were acquired within two weeks of the SLICER data acquisition to minimize temporal change. The differences in canopy structure between the four stands is similarly described by the SLICER and ground-based CHP results, however a Chi-square test of similarity documents differences that are statistically significant. The differences are discussed in terms of measurement properties that define the smoothness of the resulting CHPs and Lidar Altimeter Measurements of Canopy Structure - Harding et al. canopy properties that may vertically bias the CHP representations of canopy structure. The statistical differences are most likely due to the more noisy character of the ground-based CHPs, especially high in the canopy where ground-based sightings are rare resulting in an underestimate of canopy surface area and height, and to departures from the assumption of horizontal randomness which bias the CHPs toward the observer (upward for SLICER and downward for ground-based CHPs). The results demonstrate that the SLICER observations reliably provide a measure of canopy structure that reveals ecologically interesting structural variations such as those characterizing a successional sequence of closed-canopy, broadleaf forest stands.

Harding, D. J.↗

Structure classification and melting temperature prediction in octet AB solids via machine learning

Machine learning methods are being increasingly used in condensed matter physics and materials science to classify crystals structures and predict material properties. However, the reliability of these methods for a given problem, especially when large data sets are unavailable, has not been well studied. By addressing the tasks of classifying crystal structure and predicting melting temperatures of the octet subset of AB solids, we performed such a study and found potential problems with using machine learning methods on relatively small data sets. At the same time, however, we can reaffirm the potential power of such methods for these tasks. In particular, we uncovered an important new material feature, the excess Born effective charge, that significantly increased the accuracy of the predictions for the classification problem we defined. This discovery leads us to propose a new scale for the degree of ionicity and covalency in these solids. More specifically, we partitioned the crystal structures of a set of 75 octet solids into those that are ionic and covalent bonded and thus performed a binary classification task. We found that using the standard indices (r σ ,r π ), suggested by St. John and Bloch several decades ago, enabled an average success in classification of 92%. Using just r σ and the excess Born effective charge ΔZ A of the A atom enabled an average success of 97%, but we also found relatively large variations about these averages that were dependent on how certain machine learning methods were used and for which a standard deviation was not a proper measure of the degree of confidence we can place in either average. Instead, we calculated and report with 95 % confidence that the traditional classification pair predicts an accuracy in the interval [ 89%, 95%] and the accuracy of the new pair lies in the interval [96 %, 99%]. For melting temperature predictions, the size of our data set was 46. We estimate the root-mean-squared error of our resulting model to be 11% of the mean melting temperature of the data, but we note that if the accuracy of this predicted error is itself measured, our estimated fitting error itself has a root-mean-square error of 50%. In short, what we illustrate is that classification and regression predictions can vary significantly, depending on the details of how machine learning methods are applied to small data sets. This variation makes it important, if not essential, to average the predictions and compute confidence intervals about these averages to report results meaningfully. However, when properly used, these statistical methods can advance our understanding and improve predictions of material properties even for small data sets.

36 MATERIALS SCIENCE↗

Experimental Assessment of Elastic Modulus vs. Relative Density for Stretch- and Bend-Dominated Lattices

This project was designed to study the possibility of using structural properties of lattices to replicate the material properties of certain hard to manufacture designs and use topology optimization to determine the lattice type and density required to mimic these properties. The integration of additively manufactured lattice structures with topology optimization highlights the need for well characterized mechanical properties and uncertainty analyses to insure these optimized structures respond as predicted. Stereolithographically printed octet and rhombic dodecahedron lattices were manufactured at 10%, 25% and 65% density by volume. As a separate task, yet integrated into this work, finite element analysis (FEA) was used to predict the printed lattice’s mechanical properties, which were then compared to our experimental results. After comparing FEA and experimentallymeasured elastic moduli, it was determined that the FEA provides highly reliable predictions for the modulus of these printed lattice structures. These lattices also exhibited greater tensile stiffness than that of the solid material demonstrating the flexibility that lattices provide to designing parts with designer structural properties. The accurate printing and reliable modeling of these lattices will enable topology optimization of complex parts from well-characterized rhombic dodecahedron and octet lattice structures of varying densities.

36 MATERIALS SCIENCE↗

The embedded operating system project

The design and construction of embedded operating systems for real-time advanced aerospace applications was investigated. The applications require reliable operating system support that must accommodate computer networks. Problems that arise in the construction of such operating systems, reconfiguration, consistency and recovery in a distributed system, and the issues of real-time processing are reported. A thesis that provides theoretical foundations for the use of atomic actions to support fault tolerance and data consistency in real-time object-based system is included. The following items are addressed: (1) atomic actions and fault-tolerance issues; (2) operating system structure; (3) program development; (4) a reliable compiler for path Pascal; and (5) mediators, a mechanism for scheduling distributed system processes.

Campbell, R. H.↗

Probabilistic structural analysis for nuclear thermal propulsion

Viewgraphs of probabilistic structural analysis for nuclear thermal propulsion are presented. The objective of the study was to develop a methodology to certify Space Nuclear Propulsion System (SNPS) Nozzle with assured reliability. Topics covered include: advantage of probabilistic structural analysis; space nuclear propulsion system nozzle uncertainties in the random variables; SNPS nozzle natural frequency; and sensitivity of primitive variable uncertainties SNPS nozzle natural frequency and shell stress.

Shah, Ashwin↗

Autonomous Assembly of Modular Structures in Space and on Extraterrestrial Locations

The fulfillment of the new US. National Vision for Space Exploration requires many new enabling technologies to accomplish the goal of utilizing space for commercial activities and for returning humans to the moon and extraterrestrial environments. Traditionally, flight structures are manufactured as complete systems and require humans to complete the integration and assembly in orbit. These structures are bulky and require the use of heavy launch vehicles to send the units to the desired location, e.g. International Space Station (ISS). This method requires a high degree of safety, numerous space walks and significant cost for the humans to perform the assembly in orbit. For example, for assembly and maintenance of the ISS, 52 Extravehicular Activities (EVA's) have been performed so far with a total EVA time of approximately 322 hours. Sixteen (16) shuttle flights haw been to the ISS to perform these activities with an approximate cost of $450M per mission. For future space missions, costs have to be reduced to reasonably achieve the exploration goals. One concept that has been proposed is the autonomous assembly of space structures. This concept is an affordable, reliable solution to in-space and extraterrestrial assembly operations. Assembly is autonomously performed when two components containing onboard electronics join after recognizing that the joint is appropriate and in the precise position and orientation required for assembly. The mechanism only activates when the specifications are correct and m a nominal range. After assembly, local sensors and electronics monitor the integrity of the joint for feedback to a master controller. To achieve this concept will require a shift in the methods for designing space structures. In addition, innovative techniques will be required to perform the assembly autonomously. Monitoring of the assembled joint will be necessary for safety and structural integrity. If a very large structure is to be assembled in orbit, then the number of integrity sensors will be significant. Thus simple, low cost sensors are integral to the success of this concept. This paper will address these issues and will propose a novel concept for assembling space structures autonomously. The paper will present Several autonomous assembly methods. Core technologies required to achieve in space assembly will be discussed and novel techniques for communicating, sensing, docking and assembly will be detailed. These core technologies are critical to the goal of utilizing space in a cost efficient and safe manner. Finally, these technologies can also be applied to other systems both on earth and extraterrestrial environments.

Alhorn, Dean C.↗

Estimates Of The Orbiter RSI Thermal Protection System Thermal Reliability

In support of the Space Shuttle Orbiter post-flight inspection, structure temperatures are recorded at selected positions on the windward, leeward, starboard and port surfaces. Statistical analysis of this flight data and a non-dimensional load interference (NDLI) method are used to estimate the thermal reliability at positions were reusable surface insulation (RSI) is installed. In this analysis, structure temperatures that exceed the design limit define the critical failure mode. At thirty-three positions the RSI thermal reliability is greater than 0.999999 for the missions studied. This is not the overall system level reliability of the thermal protection system installed on an Orbiter. The results from two Orbiters, OV-102 and OV-105, are in good agreement. The original RSI designs on the OV-102 Orbital Maneuvering System pods, which had low reliability, were significantly improved on OV-105. The NDLI method was also used to estimate thermal reliability from an assessment of TPS uncertainties that was completed shortly before the first Orbiter flight. Results fiom the flight data analysis and the pre-flight assessment agree at several positions near each other. The NDLI method is also effective for optimizing RSI designs to provide uniform thermal reliability on the acreage surface of reusable launch vehicles.

Kolodziej, P.↗

Effect of Manufacturing-Induced Defects on Reliability of Composite Wind Turbine Blades

In support of DOE's efforts on developing affordable, reliable domestic wind power, this ARRA project brought together a strong, complementary team from academia (University of Massachusetts Lowell), two DOE laboratories (NREL and Sandia), and a major wind turbine blade manufacturer (TPI) to address one of the key issues affecting wind power cost and reliability manufacturing-induced defects in the blades. The complexity of this problem required the assembled team's expertise in materials specifically textile and composite structures finite element modeling, composites manufacturing, mechanical characterization, structural dynamics, nondestructive inspection (NDI) and structural health monitoring (SHM), sensors, and wind turbine blade testing. This final report summarizes the results of this project.

17 WIND ENERGY↗

Nonlinear Ultrasonic Diagnosis and Prognosis of ASR Damage in Dry Cask Storage

Alkali-silica reaction (ASR) is a deleterious chemical process that may occur in cement-based materials such as mortars and concretes, where the hydroxyl ions in the highly alkaline pore solution attack the siloxane groups in the siliceous minerals in the aggregates. The reaction produces a cross-linked alkali-silica gel. The ASR gel swells in the presence of water. Expansion of the gel results in cracking when the swelling-induced stress exceeds the fracture toughness of the concrete. As the ASR continues, cracks may grow and eventually coalesce, which results in reduced service life and a decrease safety of concrete structures. Since concrete is widely used as a critical structural component in dry cask storage of used nuclear fuels, ASR damage poses a significant threat to the sustainability of long term dry cask storage systems. Therefore, techniques for effectively detecting, managing and mitigating ASR damage are needed. Currently, there are no nondestructive methods to accurately detect ASR damage in existing concrete structures. The only current way of accurately assessing ASR damage is to drill a core from an existing structure, and conduct microscopy on this drilled cylindrical core. Clearly, such a practice is not applicable to dry cask storage systems. To meet these needs, this research is aimed at developing (1) a suite of nonlinear ultrasonic quantitative nondestructive evaluation (QNDE) techniques to characterize ASR damage, and (2) a physics-based model for ASR damage evolution using the QNDE data. Outcomes of this research will provide a nondestructive diagnostic tool to evaluate the extent of the ASR damage, and a prognostic tool to estimate the future reliability and safety of the concrete structures in dry cask storage systems

42 ENGINEERING↗

Space Flight Cable Model Development

This work concentrates the modeling efforts presented in last year's VSGC conference paper, "Model Development for Cable-Harnessed Beams." The focus is narrowed to modeling of space-flight cables only, as a reliable damped cable model is not yet readily available and is necessary to continue modeling cable-harnessed space structures. New experimental data is presented, eliminating the low-frequency noise that plagued the first year's efforts. The distributed transfer function method is applied to a single section of space flight cable for Euler-Bernoulli and shear beams. The work presented here will be developed into a damped cable model that can be incorporated into an interconnected beam-cable system. The overall goal of this work is to accurately predict natural frequencies and modal damping ratios for cabled space structures.

testing↗

Test-Based Calibration of Safety Factors for Capacity Models

In this paper, a simple procedure to calibrate the safety factor of capacity models is presented. The calibration can be carried out based on any available database of experimental tests, even of limited size. The procedure aims to assess the model capability of predicting the test results and to calibrate the safety factor so that the capacity equation meets the target reliability level required by the code or sought by the calibrator. After predicting each test of the database with the capacity equation under consideration, the test-prediction pairs are checked for the property of linearity, and the relative error for the properties of homoscedasticity and normality. Once these properties are fulfilled—which may require a nonlinear transformation of the test values and/or the predictions—the closed-form equation proposed in this paper is employed to compute a target design value. The model safety factor is finally obtained by comparing such target design value with the design value obtained from the code. The paper also proposes two approximate analytical equations to compute the tolerance factor, used to attain any given fractile, as a function of the (even small) number of tests, with any assigned confidence level. A fundamental outcome of the procedure is that it yields an objective indicator of the model accuracy, measured by the standard deviation of its error, which may be regarded as a parameter useful for selecting the most reliable model among different competing ones. In the long run, the application of the proposed procedure will allow achieving a uniform reliability level throughout all capacity models used in codes and guidelines. A further advantage is that the partial safety factors so derived can be straightforwardly updated when more experiments become available. Finally, as an example, the proposed procedure is herein applied to the ACI 318 shear design capacity equation for concrete members unreinforced in shear.

42 ENGINEERING↗