SEARCH · Search NASA

Results for “Process Control”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,099 records · Page 61

All sources NASA NTRS DOE OSTI

NASA NTRS1993

Investigate zero-stress replicated optics

The contracted activities for the procurement of 'Investigate Zero-Stress Replicated Optics' to support the AXAF-S x-ray spectrometer mirrors has been completed. To date four large Wolter I grazing incidence x-ray optical shells have been electroformed from nickel. The mirrors were fabricated utilizing each of two nickel alloy plated aluminum substrates twice. A wide variety of testing has been completed by NASA MSFC and UAH. This testing includes heat treatment control tests, subscale plating and fixture testing, alloy control of the electroless nickel, adhesion and release testing of the gold to electroless nickel, electroforming instrumentation and software and fabrication of subscale models. The full scale shells are one millimeter thick nickel electrodeposited over a thin gold layer which in turn has the optical surface on the inside. The optical surface is the replicate of the surface prepared on the substrate. Appendix I briefly outlines the fabrication process. Major objectives which were shared by UAH and MSFC include the design of facilities, equipment and tooling and procurement of materials and equipment. Process development followed with the fabrication of small scale pilot units. Procurement commenced immediately and equipment and materials were ordered to implement the fabrication of first surface full scale substrates (mandrels) and the second surface electroformed optical components. All principal objectives have been achieved. Inspection of the mirrors in visible and x-ray modes validates that the required performance and the quality can be achieved by an electroforming replication process. A very distinct progressive improvement has been achieved with each of the four mirrors produced. The final mirror exceeded the original goals and set an improved standard for flight hardware. The future goal of a 30 arc second resolution at 8 KEV x-ray appears to be achievable by this process when proper cleanliness and process control is utilized.

Engelhaupt, Darell↗

DOE OSTI2018

Integrating quantitative defense-in-depth metrics into new reactor designs

Risk-informed, performance-based (RIPB) methods have progressed to the point where high-level guidance can be used to augment traditional, deterministic, nuclear safety design practices in areas important to nuclear reactor safety. This paper describes an approach for augmenting the traditional defense-in-depth (DID) qualitative approach with quantitative risk information from a plant-specific probabilistic risk assessment (PRA) in a way that is structured, can be applied on a consistent basis, and allows for clear acceptance criteria. Adding performance-based targets that should be achieved is expected to result in safer and more economical plant designs. Evaluations of DID can be conducted throughout the design process as well as in support of design certification and operating license applications to identify where defense protections could be enhanced or relaxed. Consistent with the United States Nuclear Regulatory Commission's policy statement encouraging greater use of PRA to improve safety decision making and regulatory efficiency, this scenario-based DID method can be used to evaluate changes and overall plant design as part of the normal design control process. Although the RIPB method presented in this paper was developed for application to advanced passive light water reactor designs, the metrics could be tailored to other reactor designs. This risk-informed approach to DID helps to ensure that public and worker risk insights are integrated into the design process holistically.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2017

Chemical evolution of groundwater in the Wilcox aquifer of the northern Gulf Coastal Plain, USA

The Wilcox aquifer is a major groundwater resource in the northern Gulf Coastal Plain (lower Mississippi Valley) of the USA, yet the processes controlling water chemistry in this clastic aquifer have received relatively little attention. The current study combines analyses of solutes and stable isotopes in groundwater, petrography of core samples, and geochemical modeling to identify plausible reactions along a regional flow path ∼300 km long. The hydrochemical facies evolves from Ca-HCO{sub 3} upgradient to Na-HCO{sub 3} downgradient, with a sequential zonation of terminal electron-accepting processes from Fe(III) reduction through SO{sub 4}{sup 2−} reduction to methanogenesis. In particular, decreasing SO{sub 4}{sup 2−} and increasing δ{sup 34}S of SO{sub 4}{sup 2−} along the flow path, as well as observations of authigenic pyrite in core samples, provide evidence of SO{sub 4}{sup 2−} reduction. Values of δ{sup 13}C in groundwater suggest that dissolved inorganic carbon is contributed both by oxidation of sedimentary organic matter and calcite dissolution. Inverse modeling identified multiple plausible sets of reactions between sampled wells, which typically involved cation exchange, pyrite precipitation, CH{sub 2}O oxidation, and dissolution of amorphous Fe(OH){sub 3}, calcite, or siderite. These reactions are consistent with processes identified in previous studies of Atlantic Coastal Plain aquifers. Contrasts in groundwater chemistry between the Wilcox and the underlying McNairy and overlying Claiborne aquifers indicate that confining units are relatively effective in limiting cross-formational flow, but localized cross-formational mixing could occur via fault zones. Consequently, increased pumping in the vicinity of fault zones could facilitate upward movement of saline water into the Wilcox.

58 GEOSCIENCES↗

NASA NTRS2011

Cryogenic Behavior of the High Temperature Crystal Oscillator PX-570

Microprocessors, data-acquisition systems, and electronic controllers usually require timing signals for proper and accurate operation. These signals are, in most cases, provided by circuits that utilize crystal oscillators due to availability, cost, ease of operation, and accuracy. Stability of these oscillators, i.e. crystal characteristics, is usually governed, amongst other things, by the ambient temperature. Operation of these devices under extreme temperatures requires, therefore, the implementation of some temperature-compensation mechanism either through the manufacturing process of the oscillator part or in the design of the circuit to maintain stability as well as accuracy. NASA future missions into deep space and planetary exploration necessitate operation of electronic instruments and systems in environments where extreme temperatures along with wide-range thermal swings are countered. Most of the commercial devices are very limited in terms of their specified operational temperature while very few custom-made and military-grade parts have the ability to operate in a slightly wider range of temperature. Thus, it is becomes mandatory to design and develop circuits that are capable of operation efficiently and reliably under the space harsh conditions. This report presents the results obtained on the evaluation of a new (COTS) commercial-off-the-shelf crystal oscillator under extreme temperatures. The device selected for evaluation comprised of a 10 MHz, PX-570-series crystal oscillator. This type of device was recently introduced by Vectron International and is designed as high temperature oscillator [1]. These parts are fabricated using proprietary manufacturing processes designed specifically for high temperature and harsh environment applications [1]. The oscillators have a wide continuous operating temperature range; making them ideal for use in military and aerospace industry, industrial process control, geophysical fields, avionics, and engine control. They exhibit low jitter and phase noise, consume little power, and are suited for high shock and vibration applications. The unique package design of these crystal oscillators offers a small ceramic package footprint, as well as providing both through-hole mounting and surface mount options.

Patterson, Richard↗

NASA NTRS2012

Characterization of the Vectron PX-570 Crystal Oscillator for Use in Harsh Environments

Computing hardware, data-acquisition systems, communications systems, and many electronic control systems require well-controlled timing signals for proper and accurate operation. These signals are, in most cases, provided by circuits that employ crystal oscillators due to availability, cost, ease of operation, and accuracy. In some cases, the electronic systems are expected to survive and operate under harsh conditions that include exposure to extreme temperatures. These applications exist in terrestrial systems as well as in aerospace products. Well-logging, geothermal systems, and industrial process control are examples of ground-based applications, while distributed jet engine control in aircraft, space-based observatories (such as the James Webb Space Telescope), satellites, and lunar and planetary landers are typical environments where electronics are exposed to harsh operating conditions. To ensure these devices produce reliable results, the digital heartbeat from the oscillator must deliver a stable signal that is not affected by external temperature or other conditions. One such solution is a recently introduced commercial-off-the-shelf (COTS) oscillator, the PX-570 series from Vectron International. The oscillator was designed for high-temperature applications and as proof, the crystal oscillator was subjected to a wide suite of tests to determine its ruggedness for operation in harsh environments. The tests performed by Vectron included electrical characterization under wide range of temperature, accelerated life test/aging, shock and vibration, internal moisture analysis, ESD threshold, and latch-up testing. The parametric evaluation was performed on the oscillator's frequency, output signal rise and fall times, duty cycle, and supply current over the temperature range of -125 C to +230 C. The evaluations also determined the effects of thermal cycling and the oscillator's re-start capability at extreme hot and cold temperatures. These thermal cycling and restart tests were performed at the NASA Glenn Research Center. Overall, the crystal oscillator performed well and demonstrated very good frequency stability. This paper will discuss the test procedures and present details of the performance results.

Li, Jacob↗

DOE OSTI2019

Mechanistic origins of stochastic rupture in metals

The classic models for ductile fracture of metals were based on experimental observations dating back to the 1950’s. Using advanced microscopy techniques and modeling algorithms that have been developed over the past several decades, it is possible now to examine the micro- and nano-scale mechanisms of ductile rupture in more detail. This new information enables a revised understanding of the ductile rupture process under quasi-static room temperature conditions in ductile pure metals and alloys containing hard particles. While ductile rupture has traditionally been viewed through the lens of nucleation-growth-and-coalescence, a new taxonomy is proposed involving the competition or cooperation of up to seven distinct rupture mechanisms. Generally, void nucleation via vacancy condensation is not rate limiting, but is extensive within localized shear bands of intense deformation. Instead, the controlling process appears to be the development of intense local dislocation activity which enables void growth via dislocation absorption.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Ply Strength Prediction of Unidirectional Continuous Carbon Fiber Composites

As inhomogeneous orthotropic materials, composite mechanical properties can be difficult to predict. Even with tight fabrication process controls, there is always some microstructural variation that will affect these properties. As a highly defect-dependent phenomena, mechanical strength is even more subject to variation, especially considering that composites exhibit multiple potential failure modes. The most direct way to determine composite material strength is via experimental testing, maintaining loading and specimen morphology as close as possible to the in situ states. When multiple materials and designs are being considered, this process is often prohibitively costly and slow. However, some approximations and rules of thumb can consistently guide the design process and consideration of alternatives.

36 MATERIALS SCIENCE↗

NASA NTRS2002

Packaging Technology for SiC High Temperature Circuits Operable up to 500 Degrees Centigrade

New high temperature low power 8-pin packages have been fabricated using commercial fabrication service. These packages are made of aluminum nitride and 96 percent alumina with Au metallization. The new design of these packages provides the chips inside with EM shielding. Wirebond geometry control has been achieved for precise mechanical tests. Au wirebond samples with 45 degree heel-angle have been tested using wireloop test module. The geometry control improves the consistency of measurement of the wireloop breaking point.Also reported on is a parametric study of the thermomechanical reliability of a Au thick-film based SiC die-attach assembly using nonlinear finite element analysis (FEA) was conducted to optimize the die-attach thermo-mechanical performance for operation at temperatures from room temperature to 500 degrees Centigrade. This parametric study centered on material selection, structure design and process control.

Chen, Lian-Yu↗

DOE OSTI2015

Fermilab Muon Campus g-2 Cryogenic Distribution Remote Control System

The Muon Campus (MC) is able to measure Muon g-2 with high precision and comparing its value to the theoretical prediction. The MC has four 300 KW screw compressors and four liquid helium refrigerators. The centerpiece of the Muon g-2 experiment at Fermilab is a large, 50-foot-diameter superconducting muon storage ring. This one-of-a-kind ring, made of steel, aluminum and superconducting wire, was built for the previous g-2 experiment at Brookhaven. Due to each subsystem has to be far away from each other and be placed in the distant location, therefore, Siemens Process Control System PCS7-400, Automation Direct DL205 & DL05 PLC, Synoptic and Fermilab ACNET HMI are the ideal choices as the MC g-2 cryogenic distribution real-time and on-Line remote control system. This paper presents a method which has been successfully used by many Fermilab distribution cryogenic real-time and On-Line remote control systems.

43 PARTICLE ACCELERATORS↗

DOE OSTI2021

Etching with electron beam-generated plasmas: Selectivity versus ion energy in silicon-based films

In the ideal case, plasma-enhanced atomic layer etching enables the ability to not only remove one monolayer of material but also leave adjacent layers undamaged. This dual mandate requires fine control over the flux of species to ensure efficacy, while maintaining an often arduously low ion energy. Electron beam-generated plasmas are well-suited for etching at low ion energies as they are generally characterized by highly charged particle densities (10 10 –10 11 cm –3 ) and low electron temperatures (<1.0 eV), which provide the ability to deliver a large flux of ions whose energies are <5 eV. Raising the ion energy with substrate biasing thus enables process control over an energy range that extends down to values commensurate with the bond strength of most material systems. In this work, we discuss silicon nitride etching using pulsed, electron beam-generated plasmas produced in argon-SF6 backgrounds. We pay particular attention to the etch rates and selectivity versus oxidized silicon nitride and polycrystalline silicon as a function of ion energy from a few eV up to 50 eV. Here, we find the blanket etch rate of Si 3 N 4 to be in the range of 1 A/s, with selectivities (versus SiO 2 and poly-Si) greater than 10:1 when ion energies are below 30 eV.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2015

New Particle Formation Study Final Campaign Report

The scientific foci of the New Particle Formation Study were the formation and evolution of atmospheric aerosols and the impacts of newly formed particles on cloud processes. Specifically, we planned to: (1) to identify the species and mechanisms responsible for the initial steps of new particle formation, i.e., the formation of thermodynamically stable clusters; (2) investigate the role of acid-base chemistry in new particle growth through measurements of ammonia and amines as well as organic and inorganic acids in both atmospheric nanoparticles and the gas phase; (3) investigate the contribution of other surface area or volume-controlled processes to nanoparticle formation and growth; (4) create a comprehensive dataset related to new particle formation and growth that can be used as input for our own thermodynamic models as well as the modeling efforts by our Department of Energy (DOE) Aerosol Life Cycle working group collaborators; (5) characterize the increase of the number and activity of cloud condensation nuclei (CCN) due to particle formation and growth; (6) determine the regional extent of new particle formation to address the role that atmospheric transport plays in determining the impacts, if any, of new particle formation on cloud number and properties.

Smith, JN↗

DOE OSTI2021

An upgraded cryogenic test stand for HL-LHC cryo-assemblies

The Fermilab horizontal test stand previously used for testing the LHC inner triplet quadrupoles has been upgraded to test cryo-assemblies for the high-luminosity LHC upgrade (HL-LHC). The test requirements of these new cryo-assemblies required additional capabilities of the test stand cryogenic system, including controlled cool-down and warm-up, helium recovery after a quench, and operation at higher pressures. Most of these upgrades were completed to support a zero-magnet test in late 2020, with the remainder of the upgrades completed to support the first pre-series cryo-assembly test in early 2022. An overview of the design and initial operating experience of the upgraded test stand cryogenic system and associated process controls system are presented in this paper.

Rabehl, Roger J.↗

DOE OSTI2011

Rapid hydrogen gas generation using reactive thermal decomposition of uranium hydride.

Oxygen gas injection has been studied as one method for rapidly generating hydrogen gas from a uranium hydride storage system. Small scale reactors, 2.9 g UH{sub 3}, were used to study the process experimentally. Complimentary numerical simulations were used to better characterize and understand the strongly coupled chemical and thermal transport processes controlling hydrogen gas liberation. The results indicate that UH{sub 3} and O{sub 2} are sufficiently reactive to enable a well designed system to release gram quantities of hydrogen in {approx} 2 seconds over a broad temperature range. The major system-design challenge appears to be heat management. In addition to the oxidation tests, H/D isotope exchange experiments were performed. The rate limiting step in the overall gas-to-particle exchange process was found to be hydrogen diffusion in the {approx}0.5 {mu}m hydride particles. The experiments generated a set of high quality experimental data; from which effective intra-particle diffusion coefficients can be inferred.

08 HYDROGEN↗

DOE OSTI2015

Comparison of HLW Glass Melting Rate Between Frit and Glass Forming Chemicals Using X-Ray Computed Tomography

Efforts are being made to increase the loading of Hanford tank wastes in glass while meeting melter lifetime expectancies, as well as requirements for processing, regulatory compliance, and product quality. To achieve these goals, the Department of Energy – Office of River Protection (DOE-ORP) has requested that the Savannah River National Laboratory (SRNL) support the advancement of glass formulations and process control strategies in various key technical areas, which include melting rate studies. Numerous parameters influence cold cap melting and it is important to identify laboratory test methods to discern changes in melting rate. One of the primary screening tools being used at SRNL for melting rate comparisons is the dry-fed melt rate furnace (MRF). The MRF has been very effective in ranking relative melting rates of candidate frits for the Defense Waste Processing Facility (DWPF) on the laboratory-scale, which has successfully translated to facility operations.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

Instrumentation Framework for Molten Salt Reactors

This report provides an overview of the specialized instrumentation necessary to operate and maintain liquid-fueled molten salt reactors (MSRs). The report does not include non-specialized industrial process control instrumentation, fissile material tracking instrumentation, or digital control/communication technologies. The report focuses on identifying MSR measurement technology gaps, and recommending research, development, and demonstration (RD&D) activities to close the identified gaps. To a large extent modern MSRs can rely on the instrumentation demonstrated during prior MSR development efforts. No fundamental technology gaps have been identified that would prevent operating or maintaining MSRs. However, improved instrumentation technology combined with the integration of modern process modeling and simulation could significantly improve the reliability and decrease the operating costs of future plants. The largest potential impact of new instrumentation technologies is in the integration of maintenance automation into reactor operations. Flow measurement has the largest technology hurdles remaining for to enable deployment of robust systems. Also, the technology for reliable, on-line fuel salt sample acquisition remains at relatively low technology readiness.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2017

CMM Data Analysis Tool

Due to the increase in the use of Coordinate Measuring Machines (CMMs) to measure fine details and complex geometries in manufacturing, many programs have been made to compile and analyze the data. These programs typically require extensive setup to determine the expected results in order to not only track the pass/fail of a dimension, but also to use statistical process control (SPC). These extra steps and setup times have been addressed through the CMM Data Analysis Tool, which only requires the output of the CMM to provide both pass/fail analysis on all parts run to the same inspection program as well as provide graphs which help visualize where the part measures within the allowed tolerances. This provides feedback not only to the customer for approval of a part during development, but also to machining process engineers to identify when any dimension is drifting towards an out of tolerance condition during production. This program can handle hundreds of parts with complex dimensions and will provide an analysis within minutes.

Source record↗

NASA NTRS2005

Spatial Scaling of Snow Observations and Microwave Emission Modeling During CLPX and Appropriate Satellite Sensor Resolution

Accurate estimates of snow water equivalent and other properties play an important role in weather, natural hazard, and hydrological forecasting and climate modeling over a range of scales in space and time. Remote sensing-derived estimates have traditionally been of the "snapshot" type, but techniques involving models with assimilation are also being explored. In both cases, forward emission models are useful to understand the observed passive microwave signatures and developing retrieval algorithms. However, mismatches between passive microwave sensor resolutions and the scales of processes controlling subpixel heterogeneity can affect the accuracy of the estimates. Improving the spatial resolution of new passive microwave satellite sensors is a major desire in order to (literally) resolve such subpixel heterogeneity, but limited spacecraft and mission resources impose severe constraints and tradeoffs. In order to maximize science return while mitigating risk for a satellite concept, it is essential to understand the scaling behavior of snow in terms of what the sensor sees (brightness temperature) as well as in terms of the actual variability of snow. NASA's Cold Land Processes Experiment-1 (CLPX-1: Colorado, 2002 and 2003) was designed to provide data to measure these scaling behaviors for varying snow conditions in areas with forested, alpine, and meadow/pasture land cover. We will use observations from CLPX-1 ground, airborne, and satellite passive microwave sensors to examine and evaluate the scaling behavior of observed and modeled brightness temperatures and observed and retrieved snow parameters across scales from meters to 10's of kilometers. The conclusions will provide direct examples of the appropriate spatial sampling scales of new sensors for snow remote sensing. The analyses will also illustrate the effects and spatial scales of the underlying phenomena (e.g., land cover) that control subpixel heterogeneity.

Kim, Edward J.↗

DOE OSTI2012

Nuclear waste vitrification efficiency: cold cap reactions

The cost and schedule of nuclear waste treatment and immobilization are greatly affected by the rate of glass production. Various factors influence the performance of a waste-glass melter. One of the most significant, and also one of the least understood, is the process of batch melting. Studies are being conducted to gain fundamental understanding of the batch reactions, particularly those that influence the rate of melting, and models are being developed to link batch makeup and melter operation to the melting rate. Batch melting takes place within the cold cap, i.e., a batch layer floating on the surface of molten glass. The conversion of batch to glass consists of various chemical reactions, phase transitions, and diffusion-controlled processes. These include water evaporation (slurry feed contains as high as 60% water), gas evolution, the melting of salts, the formation of borate melt, reactions of borate melt with molten salts and with amorphous oxides (Fe2O3 and Al2O3), the formation of intermediate crystalline phases, the formation of a continuous glass-forming melt, the growth and collapse of primary foam, and the dissolution of residual solids. To this list we also need to add the formation of secondary foam that originates from molten glass but accumulates on the bottom of the cold cap. This study presents relevant data obtained for a high-level-waste melter feed and introduces a one-dimensional (1D) mathematical model of the cold cap as a step toward an advanced three-dimensional (3D) version for a complete model of the waste glass melter. The 1D model describes the batch-to-glass conversion within the cold cap as it progresses in a vertical direction. With constitutive equations and key parameters based on measured data, and simplified boundary conditions on the cold-cap interfaces with the glass melt and the plenum space of the melter, the model provides sensitivity analysis of the response of the cold cap to the batch makeup and melter conditions. The model demonstrates that batch foaming has a decisive influence on the rate of melting. Understanding the dynamics of the foam layer at the bottom of the cold cap and the heat transfer through it appears crucial for a reliable prediction of the rate of melting as a function of the melter-feed makeup and melter operation parameters. Although the study is focused on a batch for waste vitrification, the authors expect that the outcome will also be relevant for commercial glass melting.

Hrma, Pavel R↗