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DOE OSTI2026

Automation of Nanoparticle Synthesis Processes in a Plasma Environment Using LabVIEW

This work presents an automated control system for the synthesis of nanomaterials by plasma-enhanced chemical vapor deposition (PECVD), implemented using the LabVIEW software environment. The main objective of the study is to develop an integrated hardware-software platform that enables sequential control of the key stages of the PECVD process, including vacuum chamber preparation, pressure monitoring, working gas supply, plasma ignition, power matching, cyclic nanomaterial growth, and optical monitoring of nanoparticles in the plasma environment. The use of LabVIEW made it possible to integrate actuator control, experimental parameter acquisition, and realtime process visualization within a single automated system. The automated cycle begins with evacuation of the reaction chamber to a predefined base pressure. Transition to the next stage is permitted only after the specified pressure threshold has been reached, ensuring reproducible initial conditions for each experiment. The program then controls the supply of the working gas through mass flow controllers (MFCs). In this work, two gas-flow control modes were considered: analog control using a 0-5 V voltage signal and digital communication via RS-232 interface. It was shown that the analog approach requires accurate scaling of the control voltage, since applying 5 V corresponds to full-scale opening of the controller and results in the maximum gas flow. In contrast, the RS232 interface enables the gas flow rate to be specified directly in sccm, improving the accuracy, flexibility, and convenience of gas-environment control. After pressure stabilization, LabVIEW initiates RF plasma ignition and executes the RF matching algorithm aimed at minimizing reflected power and improving the stability of the plasma process. A separate software module implements the cyclic nanomaterial growth mode, in which the plasma-on time, plasma duration, and total number of synthesis cycles are predefined. This approach makes it possible to control material accumulation on the substrate and to correlate the process parameters with the morphological characteristics of the resulting nanostructures. The final module of the system is designed for optical monitoring of the nanoparticle cloud density in dusty plasma. For this purpose, the change in the intensity of laser radiation passing through the plasma region is recorded using a photodetector and a Keithley 2401 measuring unit connected to LabVIEW via RS-232 interface. The difference between the initial and modified optical signal intensity is used as a diagnostic parameter characterizing the formation and temporal evolution of nanoparticles. The developed system demonstrates that LabVIEW can be effectively applied not only for the automation of individual instruments, but also for the implementation of a complete digital control cycle for PECVD-based nanomaterial synthesis.

PECVD↗

NASA NTRS1975

Design, fabrication, and test of a graphite/epoxy metering truss

A graphite/epoxy metering truss as applied to the large space telescope was investigated. A full-scale truss was designed, fabricated and tested. Tests included static limit loadings, a modal survey and thermal-vacuum distortion evaluation. The most critical requirement was the demonstration of the dimensional stability provided by the graphite/epoxy truss concept. Crucial to the attainment of this objective was the ability to make very sophisticated thermal growth measurements which was provided by a seven beam laser interferometer. The design of the basic truss elements were tuned to provide the high degree of dimensional stability and stiffness required by the truss. The struts and spider assembly were fabricated with Fiberite's AS/934 and HMS/934 broadgoods. The rings utilized T300 graphite fabricate with the same materials. The predicted performance of the truss was developed using the NASTRAN program. These results showed conformance with the critical stiffness and thermal distortion requirements and correlated well with the test results.

Oken, S.↗

NASA NTRS1988

A comparison of theory and experiment for coupled rotor body stability of a bearingless rotor model in hover and forward flight

Seven cases were selected for correlation from a 1/5.86 Froude-scale experiment that examined several rotor designs which were being considered for full-scale flight testing as part of the Bearingless Main Rotor (BMR) program. The model rotor hub used in these tests consisted of back-to-back C-beams as flexbeam elements with a torque tube for pitch control. The first four cases selected from the experiment were hover tests which examined the effects on rotor stability of variations in hub-to-flexbeam coning, hub-to-flexbeam pitch, flexbeam-to-blade coning, and flexbeam-to-blade pitch. The final three cases were selected from the forward flight tests of optimum rotor configuration as defined during the hover test. The selected cases examined the effects of variations in forward speed, rotor speed, and shaft angle. Analytical results from Bell Helicopter Textron, Boeing Vertol, Sikorsky Aircraft, and the U.S. Army Aeromechanics Laboratory were compared with the data and the correlations ranged from poor-to-fair to fair-to-good.

Mirick, Paul H.↗

DOE OSTI2025

Morphotype-resolved characterization of microalgal communities in a nutrient recovery process with ARTiMiS flow imaging microscopy

Microalgae-driven nutrient recovery represents a promising technology for phosphorus removal from wastewater while simultaneously generating biomass that can be valorized to offset treatment costs. As full-scale processes come online, system parameters including biomass composition must be carefully monitored to optimize performance and prevent culture crashes. In this study, flow imaging microscopy (FIM) was leveraged to characterize microalgal community composition in near real-time at a full-scale municipal wastewater treatment plant (WWTP) in Wisconsin, USA, and population and morphotype dynamics were examined to identify relationships between water chemistry, biomass composition, and system performance. Two FIM technologies, FlowCam and ARTiMiS, were evaluated as monitoring tools. ARTiMiS provided a more accurate estimate of total system biomass, and estimates derived from particle area as a proxy for biovolume yielded better approximations than particle counts. Deep learning classification models trained on annotated image libraries demonstrated equivalent performance between FlowCam and ARTiMiS, and convolutional neural network (CNN) classifiers proved significantly more accurate when compared to feature table-based dense neural network (DNN) models. Across a two-year study period, Scenedesmus spp. appeared most important for phosphorus removal, and were negatively impacted by elevated temperatures and increase in nitrite/nitrate concentrations. Chlorella and Monoraphidium also played an important role in phosphorus removal. For both Scenedesmus and Chlorella, smaller morphological types were more often associated with better system performance, whereas larger morphotypes likely associated with stress response(s) correlated with poor phosphorus recovery rates. Furthermore, these results demonstrate the potential of FIM as a critical technology for high-resolution characterization of industrial microalgal processes.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2025

Advanced Computational Modeling of High-Level Waste Vitrification at the Hanford Site

The U.S. Department of Energy (DOE) has selected vitrification for stabilizing legacy tank waste at the Hanford site, where radioactive waste from plutonium production was historically stored in underground tanks. This waste will be separated into low-activity waste (LAW) and high-level waste (HLW) fractions and processed at the Waste Treatment and Immobilization Plant (WTP). At WTP, glass melters are used for the vitrification of radioactive tank waste, transforming it into a stable borosilicate glass form for safe long-term storage. The melter vessel is constructed from highly durable and heat-resistant materials, where the vitrification process occurs. The main regions that are modeled are the melt pool, plenum, cold cap, riser/discharge chamber, and surrounding structure with insulation layers. Forced convection induced by air bubblers at the base of the melter ensure uniform temperature distribution and provide heat to the cold cap layer. The cold cap is a region of reacting batch feed that floats on top of the molten glass and is where the batch-to-glass reactions occur. Joule heating provided by electrodes mounted along the vertical walls of the melter and immersed directly in the glass, generates the necessary heat for the net endothermic conversion processes that occur in the cold cap. The high temperatures, radioactivity, and opaque nature of the glass prevent direct observation inside the melters. Therefore, computational models are essential for providing insight into factors that affect melter throughput. Thermocouples in the plenum provide operators with plenum temperature measurements. Operational adjustments include bubbling rate, voltage supplied to the electrodes, feed adjustments, and glass removal rate. Different computational fluid dynamics (CFD) models have been developed, each serving a specific purpose. There are CFD models of different scale melters, as well as models that capture the two-phase flow interfaces of rising bubbles in the molten glass or models with a simplified molten glass region so that the surrounding structure and plenum can be feasibly incorporated. Pilot-scale melter models have been developed to serve as validation of the methods employed in the simulation of the full-scale WTP melters. Models incorporating resolved bubbling are used to develop momentum source terms to implement into a single phase, multi-region, steady-state flow model that is being validated by measured process parameters such as glass production rate, voltage, input power, plenum temperatures, etc. The resolved bubbling model uses the multiphase volume of fluid approach to model the system with a high-resolution interface capturing scheme to maintain sharp interfaces between the molten glass and the air phase. The suite of CFD models is continually being improved to incorporate more realistic physics and achieve faster turnaround time. For example, an incremental controller is implemented to automatically adjust electrode voltage within the simulation to a molten glass set point temperature of 1150°C. Newer models feature improved meshes to ensure conformal meshes between regions and eliminate unnecessary mesh refinement in areas that are not of interest (such as boundary layers in offgas ports). Instead of explicitly modeling the structural, refractory, and insulation layers of the melter, a thermal resistance approach is used with published correlations used for boundary conditions. The development of robust and efficient CFD models will be instrumental in enabling the WTP to successfully fulfill its mission of safely stabilizing legacy nuclear waste.

12 - MGMT OF RADIOACTIVE AND NON-RADIOACTIVE WASTE↗

NASA NTRS1973

Shockwave-boundary layer interference heating analysis.

Interference heating correlations have been developed based on existing wind tunnel test data taken with simple configurations such as wedge/flat plate and compression corner models. For turbulent flow, peak interference heating was first correlated with shock strength (pressure ratio across shock wave) and then as a function of Reynolds number. The peak interference Stanton number was found to exhibit the same Reynolds number and Prandtl number characteristics as the Stanton number variation for undisturbed flow over a flat plate. Similar correlations were developed for laminar flow. Results indicated that for laminar flow at higher Reynolds number, the impinging shockwave may act as a boundary layer trip and cause boundary layer transition resulting in high interference heating. The correlations derived in this study can be used to scale wind tunnel model test data to a full-scale space vehicle at supersonic or hypersonic flight conditions.

Hung, F. T.↗

NASA NTRS1974

Investigation of noise from full-scale high bypass engine and blown flap system

A summary is presented of an acoustic test program for investigating engine noise suppression and jet/flap interaction noise associated with an EBF STOL powered lift system. A highly suppressed TF-34 engine and EBF wing were used in the investigation. The engine was suppressed 21 PndB to a level of 94 PndB. An UTW powered lift system was tested with conventional, mixer, and decayer-type nozzles. The configuration with velocity decayer nozzle and acoustically treated shroud had the lowest noise (98 PndB). An OTW configuration with non-decayer nozzle was about 10 db quieter than the corresponding UTW system. UTW and OTW noise data are compared with scale model correlations.

Jones, W. L.↗

NASA NTRS1974

Geometry considerations for jet noise shielding with CTOL engine-over-the-wing concept

Jet noise shielding benefits for CTOL engine-over-the-wing installations were obtained with various model-scale circular nozzles and wing chord geometries. Chord-to-nozzle diameter ratios were varied from 3 to 20, while ratios of nozzle height above the wing to the diameter were varied from near zero to 3. Spectral noise data were obtained with jet velocities from 640 to 1110 ft/sec. Characteristics of low frequency noise sources are discussed. Jet-noise shielding is correlated in terms of acoustic and geometric parameters. Implications of extending the model-scale data to full-scale are discussed.

Vonglahn, U.↗

NASA NTRS1974

Geometry considerations for jet noise shielding with CTOL engine-over-the-wing concept

Von Glahn, U.↗

NASA NTRS1974

Investigation of noise from full-scale high bypass engine and blown flap system

A summary is presented of an acoustic test program for investigating engine noise suppression and jet/flap interaction noise associated with an externally blown flap (EBF) STOL powered lift system. A highly suppressed TF-34 engine and EBF wing were used in the investigation. The engine was suppressed 21 PndB to a level of 94 PndB. An under the wing (UTW) powered lift system was tested with conventional, mixer, and decayer-type nozzles. The configuration with velocity decayer nozzle and acoustically treated shroud had the lowest noise (98 PndB). An over the wing (OTW) configuration with nondecayer nozzle was about 10 dB quieter than the corresponding UTW system. UTW and OTW noise data are compared with scale model correlations.

Jones, W. L.↗

NASA NTRS1982

Effects of wing-leading-edge modifications on a full-scale, low-wing general aviation airplane: Wind-tunnel investigation of high-angle-of-attack aerodynamic characteristics

Wing-leading-edge modifications included leading-edge droop and slat configurations having full-span, partial-span, or segmented arrangements. Other devices included wing-chord extensions, fences, and leading-edge stall strips. Good correlation was apparent between the results of wind-tunnel data and the results of flight tests, on the basis of autorotational stability criterion, for a wide range of wing-leading-edge modifications.

Newsom, W. A., Jr.↗

NASA NTRS1982

The need for an optical transition detection system in the NTF

Methods for transition detection were studied. The very high test and model costs necessitate testing of any new configuration over a range of Reynolds numbers for correlation with data obtained in conventional tunnels. The Reynolds number variations will be carried out at constant dynamic pressure, i.e., constant aeroelastic condition, by varying test temperature. Boundary layer transition cannot be expected to occur at the full scale location at significantly less than full-scale Reynolds numbers, and transition patterns will change with varying Reynolds number. Knowledge of the location of transition on model surfaces is essential for correct interpretation of drag data. The importance of transition, the limitations of artificial transition fixing, and their relation to the NTF are reviewed. The calculated minimum roughness height to instantaneously trip transition on a model transport wing over a range of Reynolds numbers of interest is shown in the NTF.

Fancher, M. F.↗

NASA NTRS1987

Comparing Test Data on Scale-Model Helicopter Rotors

Hovering data correlate well, but forward-flight data do not. Report compares acoustics and performance of small-scale helicopter rotor with those of full-scale rotor in both hovering and forward flight.

Kitaplioglu, Cahit↗

NASA NTRS1988

Use of Dynamically Scaled Models for Studies of the High-Angle-of-Attack Behavior of Airplanes

Dynamically scaled, free-flying models are used by the National Aeronautics and Space Administration (NASA) to study the stalling and spinning characteristics of civil and military airplane configurations. Such tests have been conducted for many different designs, and it has been possible to correlate the results predicted by the model tests with flight test results obtained in the investigations. The present paper describes four of the dynamic model testing techniques used at the NASA Langley Research Center, including the scaling laws used in the construction of models and in the interpretation of results. Predictions of stall/spin behavior based on model results have generally been very accurate, and the model tests are regarded as an invaluable precursor to full-scale flight tests. However, aerodynamic scale effects between some models and full-scale airplanes due to differences in test values of Reynolds number have resulted in erroneous predictions for a few configurations. A discussion of these effects is provided, together with the approach used to modify the model so that its behavior more closely matches that of the airplane. Finally, two typical applications of the techniques to the X-29A research airplane and several general aviation research airplanes are presented to illustrate the type of information provided by the tests.

Joseph R Chambers↗

NASA NTRS1988

Use of dynamically scaled models for studies of the high-angle-of-attack behavior of airplanes

Joseph R Chambers↗

NASA NTRS1990

Predictions of F-111 TACT aircraft buffet response

A summary is presented for the prediction method development and correlations of predicted response with flight test measurements. The prediction method was based on refinements to the method described by Cunningham. One improvement made use of direct time integration of the correlated fluctuating pressure data to obtain buffet excitation for the various modes of interest. Another improvement incorporated a hybrid technique for scaling measured wind tunnel damping data to full-scale for the modes of interest. A third improvement made use of the diagonalized form of the fully coupled equations of motion. Finally, a mechanism was described for explaining an apparent coupling between the aircraft wing torsion modes and shock induced trailing edge separation that led to very high wing motion on the aircraft that was not observed on the wind tunnel model.

Cunningham, Atlee M., Jr.↗

NASA NTRS1992

Aerodynamic roughness measured in the field and simulated in a wind tunnel

This study evaluates how well values of aerodynamic surface roughness, z sub 0, measured over scale models in wind tunnels correlate with values of z sub 0 measured at full scale in the field. A field experiment was conducted in which values of z sub 0 and u* (wind friction speed) were measured over three arrays of non-erodible roughness elements on a dry lake bed. Wind profiles were measured by ten anemometers on a 15 m mast under thermally neutral atmospheric conditions. Values of z sub 0 increased from .00014 m (dry lake bed only) to .026 m with increasing roughness element density. The three roughness element arrays were simulated at 1/10 and 1/20 scale in an open-circuit atmospheric boundary-layer wind tunnel. Velocities were measured with a boundary-layer pitot-tube rake from the same relative position within the scale model arrays as the anemometers were relative to the field arrays. Each array at each scale was sampled three times at five freestream velocities. Average values of z sub 0 for each model array at each scale were compared with full-scale values of z sub 0 obtained in the field. The field vs. wind tunnel correspondence of z sub 0 is found to be z sub 0 field = 0.2661 x (z sub(0 model) x scale(exp -1))exp .8159.

Sullivan, Robert↗

NASA NTRS1947

Correlation of the Trim Limits of Stability Obtained for a PB2Y-3 Flying Boat and a 1/8-Size Powered Dynamic Model

Tests of a PB2Y-3 flying boat were made at the U.S> Naval Air Station, Patuxent River, Md., to determine its hydrodynamic trim limits of stability. Corresponding tests were also made of a 1/8-size powered dynamic model of the same flying boat in Langley tank no. 1. During the tank tests, the full-size testing procedure was reproduced as closely as possible in order to obtain data for a direct correlation of the results. As a nominal gross load of 66,000 pounds, the lower trim limits of the full-size and model were in good agreement above a speed of 80 feet per second. As the speed decreased below 80 feet per second, the difference between the model trim limits and full-scale trim limits gradually became larger. The upper trim limit of the model with flaps deflected 0 deg was higher than that of the full-size, but the difference was small over the speed range compared. At flap deflections greater than 0 deg, it was not possible to trim either the model of the airplane to the upper limit with the center of gravity at 28 percent of the mean aerodynamic chord. The decrease in the lower trim limits with increase in flap deflection showed good agreement for the airplane and model. The lower trim limits obtained at different gross loads for the full-size airplane were reduced to approximately a single curve by plotting trim against the square root of C(sub delta (sub o)) divided by C(sub V).

Garrison, Charlie C.↗