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NASA NTRS2015

Spin Forming Aluminum Crew Module (CM) Metallic Aft Pressure Vessel Bulkhead (APVBH) - Phase II

The principal focus of this project was to assist the Multi-Purpose Crew Vehicle (MPCV) Program in developing a spin forming fabrication process for manufacture of the Orion crew module (CM) aft pressure vessel bulkhead. The spin forming process will enable a single piece aluminum (Al) alloy 2219 aft bulkhead resulting in the elimination of the current multiple piece welded construction, simplify CM fabrication, and lead to an enhanced design. Phase I (NASA TM-2014-218163 (1)) of this assessment explored spin forming the single-piece CM forward pressure vessel bulkhead. The Orion MPCV Program and Lockheed Martin (LM) recently made two critical decisions relative to the NESC Phase I work scope: (1) LM selected the spin forming process to manufacture a single-piece aft bulkhead for the Orion CM, and (2) the aft bulkhead will be manufactured from Al 2219. Based on the Program's new emphasis related to the spin forming process, the NESC was asked to conduct a Phase II assessment to assist in the LM manufacture of the aft bulkhead and to conduct a feasibility study into spin forming the Orion CM cone. This activity was approved on June 19, 2013. Dr. Robert Piascik, NASA Technical Fellow for Materials at the Langley Research Center (LaRC), was selected to lead this assessment. The project plan was approved by the NASA Engineering and Safety Center (NESC) Review Board (NRB) on July 18, 2013. The primary stakeholders for this assessment were the NASA and LM MPCV Program offices. Additional benefactors are commercial launch providers developing CM concepts.

Hoffman, Eric K.↗

DOE OSTI2018

Regulatory and Licensing Strategy for Microreactor Technology

With electricity demand on the rise, an increase in the use of nuclear energy is needed in order to meet future energy demands. The use of nuclear energy will not only begin to positively address this demand, but will also mitigate the negative impacts of carbon-induced climate change and provide energy security to the United States. An appropriate option to address the increasing energy demand is the use of advanced reactor systems like microreactors. Microreactors, often referred to as special-purpose reactors or vSMRs, are neutronically simple, factory manufacturable, easily transportable, and designed to produce less than 20 MWt (for classification as Hazard Category 2 per 10 CFR 830, DOE STD 1027). These reactors are decentralized energy sources that have the ability to provide sustainable and affordable power to remote communities and to industrial users, while having self-contained geometry that requires very low maintenance care. In order for microreactors to be approved for operation, they must abide by and successfully complete a rigorous regulatory and licensing process monitored by the Nuclear Regulatory Commission (NRC), the Department of Energy (DOE), or the Department of Defense (DoD). Because microreactors are a relatively new and disruptive technology, there is no clear licensing path for them to follow. Current licensing frameworks are tailored specifically to large, traditional light water reactors (LWRs) that have been developed and understood by the nuclear industry for many years. Unlike LWRs, microreactors have major design differences, specifically in the materials, coolant, reflectors and potential technology applications used. They also have higher in-core operating temperatures, which have the potential to push the materials used past their allowable limits. Because they are much smaller, safety margins, the amount of space required for assembly, and the distances required to meet dose-based regulatory criteria can technically be altered to better fit their new size. The following strategies and recommendations are intended to assure that key licensing issues do not influence the path to microreactor development, demonstration, and commercialization: Nuclear Regulatory Commission • The NRC should address the lack of knowledge and support of risk informed decision-making concepts from staff members and continue to advance and communicate risk initiatives using their Risk Informed Steering Committee • More research should be done into whether or not microreactors, which are small Class 103 facilities, can be licensed using Class 104-type guidance (e.g., NUREG 1537) • The NRC should use frequency-consequence curves to incrementally reduce regulatory uncertainty and risk to facilitate future construction and operation of advanced reactor designs Department of Energy • The DOE should continue to implement their multi-step Phenomena Identification and Ranking Table process in order to help detect and recommend the major design and technology work needed for licensing future reactor systems • The DOE should consider a joint licensing approach with the NRC where microreactors first go through the DOE process, then finish with the NRC process, providing an advantage for both applicants and NRC staff Department of Defense • The DoD should invest in personnel with sufficient expertise, incorporate their military reactors into tactical power systems, and self-regulate using Section 91b of the Atomic Energy Act Transportation • Licensees should convert enriched uranium hexafluoride into metal or oxide at an enrichment facility and then transport them to a fabrication facility • To avoid transportation issues altogether, licensees should consider positioning the enrichment and fabrication facilities on the same site • The DOE should provide their support in developing new shipping packages for safe transport, criticality benchmark data needed to license high-assay low-enriched uranium fuel facilities and transport packages, and provide financial and technical help to the Department of Transportation; and, • The NRC should help transportation efforts by finalizing and developing guidance for implementing 10 CFR 73 and 10 CFR 74 specifically for Category 2 Special Nuclear Material.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS1998

New Space Industries for the Next Millennium

New Space Industries For the Next Millennium is a final report of the findings from the New Space Industries Workshop held in Washington, DC, in February 1998. The primary purpose of this workshop was to identify what must be done to develop new markets, and to generate plans, milestones and new organizational relationships designed to facilitate the goal of space development. This document provides a summary report on the results of that workshop and is not intended as a statement of NASA or government policy. Previous studies had shown great potential for the development of new markets in space (e.g., travel and entertainment, space solar power, satellite and space transfer services, research and development in space, space manufacturing, and space resources), and a great need for coordination and formation of infrastructures (e.g., space transportation, space business parks, and space utilities), to facilitate the growth of new space businesses. The New Space Industries Workshop brought together government, academia, and industry participants from several previous studies and other professionals interested in the development of space for commercial purposes. Their participation provided input into the role of government and industry in space development as well as the technology needs that will enable space development. The opening of the frontier of space, not just to government missions but to private individuals and commercial business, is a challenge of overarching importance. It is our hope that the workshop and this final report continue in earnest the process of identifying and overcoming the barriers to large-scale public access and development of space in the early years of the next century.

Smitherman, D. V., Jr.↗

NASA NTRS2016

Modeling and Simulation of Phased Array Antennas to Support Next-Generation Satellite Design

Developing enhanced simulation capabilities has become a significant priority for the Space Communications and Navigation (SCaN) project at NASA as new space communications technologies are proposed to replace aging NASA communications assets, such as the Tracking and Data Relay Satellite System (TDRSS). When developing the architecture for these new space communications assets, it is important to develop updated modeling and simulation methodologies, such that competing architectures can be weighed against one another and the optimal path forward can be determined. There have been many simulation tools developed here at NASA for the simulation of single RF link budgets, or for the modeling and simulation of an entire network of spacecraft and their supporting SCaN network elements. However, the modeling capabilities are never fully complete and as new technologies are proposed, gaps are identified. One such gap is the ability to rapidly develop high fidelity simulation models of electronically steerable phased array systems. As future relay satellite architectures are proposed that include optical communications links, electronically steerable antennas will become more desirable due to the reduction in platform vibration introduced by mechanically steerable devices. In this research, we investigate how modeling of these antennas can be introduced into out overall simulation and modeling structure. The ultimate goal of this research is two-fold. First, to enable NASA engineers to model various proposed simulation architectures and determine which proposed architecture meets the given architectural requirements. Second, given a set of communications link requirements for a proposed satellite architecture, determine the optimal configuration for a phased array antenna. There is a variety of tools available that can be used to model phased array antennas. To meet our stated goals, the first objective of this research is to compare the subset of tools available to us, trading-off modeling fidelity of the tool with simulation performance. When comparing several proposed architectures, higher- fidelity modeling may be desirable, however, when iterating a proposed set of communication link requirements across ranges of phased array configuration parameters, the practicality of performance becomes a significant requirement. In either case, a minimum simulation - fidelity must be met, regardless of performance considerations, which will be discussed in this research. Given a suitable set of phased array modeling tools, this research then focuses on integration with current SCaN modeling and simulation tools. While properly modeling the antenna elements of a system are vital, this is only a small part of the end-to-end communication path between a satellite and the supporting ground station and/or relay satellite assets. To properly model a proposed simulation architecture, this toolset must be integrated with other commercial and government development tools, such that the overall architecture can be examined in terms of communications, reliability, and cost. In this research, integration with previously developed communication tools is investigated.

Phased Array↗

DOE OSTI2017

Best Practice for the Commercial Deployment of Carbon Dioxide Geologic Storage: Adaptive Management Approach

The Plains CO 2 Reduction (PCOR) Partnership is one of seven regional partnerships formed as part of the U.S. Department of Energy’s National Energy Technology Laboratory Regional Carbon Sequestration Partnerships (RCSP) Initiative. The RCSP Initiative is focused on the safe and long-term storage of CO 2 to support the commercial deployment of carbon capture and storage (CCS). To that end, the PCOR Partnership has spent over 10 years developing, testing, and validating the best methods and technologies to conduct the geologic storage of CO 2 (hereafter referred to as CO 2 storage). Through this effort, the PCOR Partnership has formalized an adaptive management approach (AMA) for the commercial development of CO 2 storage projects. The use of this approach, which draws upon the collective experience and lessons learned from the PCOR Partnership, represents best practice for advancing CO 2 storage projects toward commercial deployment. At the heart of the AMA are four technical elements necessary for any successful CO 2 storage project: 1) site characterization; 2) modeling and simulation; 3) risk assessment; and 4) monitoring, verification, and accounting (MVA). Each of these elements plays a key role in gathering and assessing site-specific data that provide a fundamental understanding of the storage complex and its performance. While each of the four technical elements can provide useful data independently, integrating them through the AMA yields a streamlined, fit-for-purpose strategy for the commercial deployment of CO 2 storage. Key to this integration and resulting best practice are feedback loops that allow the results of each element to serve as inputs to the others. Each iteration of the AMA creates an improved understanding of the storage complex and thus more targeted and efficient applications of the technical elements. For the purpose of establishing an adaptive management framework, hard lines have been drawn between the technical elements of the AMA. However, in practice, the rapid and seamless interaction between the elements can blur these lines. For example, to aid in the analysis and interpretation of site characterization data, a static geocellular model is often required. While this model development is part of the technical element, modeling and simulation, it is an integral part of the site characterization effort. Likewise, much of the monitoring data collected as part of the MVA technical element can be used to inform site characterization. This back-and-forth flow of data and use of models between the technical elements continues throughout the project.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1999

An Initial Strategy for Commercial Industry Awareness of the International Space Station

While plans are being developed to utilize the ISS for scientific research, and human and microgravity experiments, it is time to consider the future of the ISS as a world-wide commercial marketplace developed from a government owned, operated and controlled facility. Commercial industry will be able to seize this opportunity to utilize the ISS as a unique manufacturing platform and engineering testbed for advanced technology. NASA has begun the strategic planning of the evolution and commercialization of the ISS. The Pre-Planned Program Improvement (P3I) Working Group at NASA is assessing the future ISS needs and technology plans to enhance ISS performance. Some of these enhancements will allow the accommodation of commercial applications and the Human Exploration and Development of Space mission support. As this information develops, it is essential to disseminate this information to commercial industry, targeting not only the private and public space sector but also the non-aerospace commercial industries. An approach is presented for early distribution of this information via the ISS Evolution Data book that includes ISS baseline system information, baseline utilization and operations plans, advanced technologies, future utilization opportunities, ISS evolution and Design Reference Missions (DRM). This information source and tool can be used as catalyst in the commercial world for the generation of ideas and options to enhance the current capabilities of the ISS.

Jorgensen, Catherine A.↗

DOE OSTI2018

Understanding the U.S. Commercial Building Stock: Building Envelope and HVAC Systems Characteristics Using 2012 CBECS Data Analysis

The U.S. Department of Energy (DOE) and its national labs developed a series of commercial reference building models in 2007. Over the past decade, the Pacific Northwest National Laboratory, in support of DOE’s Building Energy Codes Program, expanded these prototype building models to comply with multiple editions of national model codes and standards, including both ASHRAE Standard 90.1 and International Energy Conservation Code. The prototype building models established a credible foundation to develop new requirements in building codes and standards, track progress of codes and standards, and evaluate the energy saving potential of new technologies or systems in the commercial building sector. The 2003 Commercial Building Energy Consumption Survey (CBECS) was the primary data source used to develop the original models. Given the recent release of 2012 CBECS data, this paper characterizes the most representative design choices for building envelope and HVAC systems in recently-constructed commercial buildings. The results from this analysis provide actionable insight for future commercial building research in reflection of recent construction practices.

energy efficiency, building energy codes, CBECS, b↗

NASA NTRS1981

Energy efficient engine. Volume 1: Component development and integration program

Technology for achieving lower installed fuel consumption and lower operating costs in future commercial turbofan engines are developed, evaluated, and demonstrated. The four program objectives are: (1) propulsion system analysis; (2) component analysis, design, and development; (3) core design, fabrication, and test; and (4) integrated core/low spoon design, fabrication, and test.

Source record↗

DOE OSTI2023

High Sulfur Loading and Capacity Retention in Bilayer Garnet Sulfurized‐Polyacrylonitrile/Lithium‐Metal Batteries with Gel Polymer Electrolytes

The cubic‐garnet (Li 7 La 3 Zr 2 O 12 , LLZO) lithium–sulfur battery shows great promise in the pursuit of achieving high energy densities. The sulfur used in the cathodes is abundant, inexpensive, and possesses high specific capacity. In addition, LLZO displays excellent chemical stability with Li metal; however, the instabilities in the sulfur cathode/LLZO interface can lead to performance degradation that limits the development of these batteries. Therefore, it is critical to resolve these interfacial challenges to achieve stable cycling. Here, an innovative gel polymer buffer layer to stabilize the sulfur cathode/LLZO interface is created. Employing a thin bilayer LLZO (dense/porous) architecture as a solid electrolyte and significantly high sulfur loading of 5.2 mg cm −2 , stable cycling is achieved with a high initial discharge capacity of 1542 mAh g −1 (discharge current density of 0.87 mA cm −2 ) and an average discharge capacity of 1218 mAh g −1 (discharge current density of 1.74 mA cm −2 ) with 80% capacity retention over 265 cycles, at room temperature (22 °C) and without applied pressure. Achieving such stability with high sulfur loading is a major step in the development of potentially commercial garnet lithium–sulfur batteries.

25 ENERGY STORAGE↗

DOE OSTI2025

Automation for Electric Vehicle Battery Pack Disassembly

Battery‐electric vehicles (EVs) are growing exponentially. The demand for these batteries is expected to increase sevenfold by 2035. The EV batteries reach their end of life when the capacity fades to 70%–80% of new, with some being removed from the primary applications with even lower levels of degradation. These batteries can be used in less demanding applications. The disassembly process is currently manual, slow, unsafe, and expensive. Automation is needed to increase the throughput. EV battery packs feature various continually changing designs and form factors, which limit the usefulness of deterministically programmed robotic solutions. The conceptual robotic disassembly of EV batteries has attracted the attention of researchers. However, while many approaches have been proposed, practical implementations are lacking. Here, we review proposed concepts for EV battery disassembly and describe the selected approach, with elements of partial solutions validated in a laboratory setting, including the selection of commercial solutions, the development of custom end effectors, and methodologies for detection, localization, and classification of fasteners. The computer vision tasks employed an overhead 2D camera to detect the type of battery pack and approximate localization of fasteners, and a 3D camera mounted on the robotic arm for precise localization (position and tilt) and classification.

Islam, Abu [Rochester Inst. of Technology, Rochest↗

DOE OSTI2024

Evaluation of SR/ TEVA/ TRU triple stack for separation of activation products

A rapid method to separate Ta, Po, Au, Pt, and W from a sample containing mixed fission and activation products was developed using three commercially available extraction chromatography resins stacked in series. When the separation was tested using all the target activation products, even those with short half-lives were measurable. Finally, combining multiple extraction chromatography resin cartridges in tandem allows for multiple short-lived activation products to be separated from one sample addition without the complication of multiple steps.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

DOE OSTI2019

UV–Vis Photodissociation Action Spectroscopy on Thermo LTQ-XL ETD and Bruker amaZon Ion Trap Mass Spectrometers: a Practical Guide

We report automated procedures for multiple tandem mass spectra acquisition allowing UV–Vis photodissociation action spectroscopy measurements of ions and radicals. The procedures were developed for two commercial ion trap mass spectrometers and applied to collision-induced and electron–transfer dissociation tandem mass spectrometry modes of ion generation. .

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

BISON validation to in situ cladding burst test and high-burnup LOCA experiments

The process for developing and qualifying nuclear fuels for commercial nuclear application requires fundamental material development, characterization, and design; out-of-pile testing on unirradiated materials; integral fuel rod irradiations, testing, and postirradiation examinations; and transient analyses. The historical approach depends on the generation of large empirical datasets and series of integral fuel rod irradiations, and this approach ultimately takes ~20 years—or sometimes longer—to acquire data through extensive sequential testing. Thus, the qualification and eventual deployment of new fuel systems constitute a long process. However, recent technological advancements have provided researchers the opportunity to perform out-of-cell, in situ measurements to assess material performance for the duration of the experiment. One such example of this capability is the use of digital image coordination and thermal imaging to assess Zircaloy cladding performance under a simulated loss-of-coolant accident (LOCA) transient condition. In situ measurements generally provide high-fidelity strain, strain rates, and temperature surface maps. This is critical for the US nuclear industry, which is actively developing a technical basis to support extending the peak rod average burnup from 62 to ~75 GWd/tU and the deployment of accident-tolerant fuel. However, the US Nuclear Regulatory Commission (NRC) outlined in its research information letter several technical issues that the industry must address before extending burnup. One topic of specific interest is understanding the cladding balloon and rupture geometry during the LOCA heat-up phase. By leveraging these advanced in situ capabilities, this work used in situ data generated from a simulated LOCA to better understand high-temperature creep and its effect on Zircaloy balloon and rupture performance. Here, this work used the BISON fuel performance code to assess the high-temperature creep model predictions with in situ data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Microalgae to biofuels through hydrothermal liquefaction: Open-source techno-economic analysis and life cycle assessment

Hydrothermal liquefaction is a promising conversion technology in algae biofuel research due to its ability to agnostically convert proteins, carbohydrates, and lipids to biocrude. The high-temperature conditions that define this conversion process require the material to maintain a subcritical liquid state, which complicates the assessment of accurate thermochemical properties due to the required pressure. To clarify this issue, this work compares the estimated performance of algal hydrothermal liquefaction between different thermodynamic models. A process model was developed in Aspen Plus from a robust assessment of current literature. Techno-economic assessment and life-cycle assessment metrics are derived from this model and used as key performance indicators. The baseline fuel price contribution of hydrothermal liquefaction is $0.45 per liter gasoline equivalent. Independently decreasing the temperature from 350 °C to 260 °C while maintaining yield reduces the conversion cost by 19%, illustrating the importance of understanding the high-temperature thermodynamics of the system. Different thermodynamic property models can vary fuel conversion cost results by $0.07 per liter gasoline equivalent. The baseline global warming potential is +23 g CO 2 eq MJ -1 and the net energy ratio is 0.30. Environmental metrics beyond global warming potential and net energy ratio are also discussed for the first time. Uncertainties in conversion performance are bounded through a scenario analysis that manipulates parameters such as product yield and nutrient recycle to produce a range of economic and environmental metrics. The report is supplemented with an open source model to support future hydrothermal liquefaction assessments and accelerate the development of commercial-scale systems.

09 BIOMASS FUELS↗

DOE OSTI2023

Performance analysis and comparison of data-driven models for predicting indoor temperature in multi-zone commercial buildings

Building thermal models, which characterize the properties of a building’s envelope and thermal mass, are essential for accurate indoor temperature and cooling/heating demand prediction. Because of their flexibility and ease of use, data-driven models are increasingly used. Here, this study compared and analyzed the performance of gray-box (resistance-capacitance) and black-box (recurrent neural network) models for predicting indoor air temperature in a real multi-zone commercial building. The developed resistance-capacitance model served as a benchmark model for which full sets of temporal data and building information were used as inputs. The recurrent neural network models were trained and tested assuming various available types and amounts of temporal data and known building physical information to investigate the effects of data and information availability. Feature importance analysis was conducted to select the key variables for different prediction targets under different scenarios. This research provides guidance in selecting an appropriate building thermal response modeling method based on the measured data availability, building physical information, and application.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Biophysical analysis of the plant-specific GIPC sphingolipids reveals multiple modes of membrane regulation

The plant plasma membrane (PM) is an essential barrier between the cell and the external environment, controlling signal perception and transmission. It consists of an asymmetrical lipid bilayer made up of three different lipid classes: sphingolipids, sterols, and phospholipids. The glycosyl inositol phosphoryl ceramides (GIPCs), representing up to 40% of total sphingolipids, are assumed to be almost exclusively in the outer leaflet of the PM. However, their biological role and properties are poorly defined. In this study, we investigated the role of GIPCs in membrane organization. Because GIPCs are not commercially available, we developed a protocol to extract and isolate GIPC-enriched fractions from eudicots (cauliflower and tobacco) and monocots (leek and rice). Lipidomic analysis confirmed the presence of trihydroxylated long chain bases and 2-hydroxylated very long-chain fatty acids up to 26 carbon atoms. The glycan head groups of the GIPCs from monocots and dicots were analyzed by gas chromatograph-mass spectrometry, revealing different sugar moieties. Multiple biophysics tools, namely Langmuir monolayer, ζ-Potential, light scattering, neutron reflectivity, solid state 2H-NMR, and molecular modeling, were used to investigate the physical properties of the GIPCs, as well as their interaction with free and conjugated phytosterols. We showed that GIPCs increase the thickness and electronegativity of model membranes, interact differentially with the different phytosterols species, and regulate the gel-to-fluid phase transition during temperature variations. These results unveil the multiple roles played by GIPCs in the plant PM.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2022

Melt pool temperature measurement and monitoring during laser powder bed fusion based additive manufacturing via single-camera two-wavelength imaging pyrometry (STWIP)

Melt pool (MP) temperature is one of the determining factors and a key signature for evaluating the properties of printed components in metal additive manufacturing (AM). The state-of-the-art measurement systems are hindered, primarily by the large-scale data acquisition and processing demands. In this work, we introduce a novel coaxial, high-speed, single-camera two-wavelength imaging pyrometer (STWIP) system as opposed to the typical utilization of multiple cameras for measuring MP temperature profiles in laser powder bed fusion (LPBF) processes. Developed on a commercial LPBF machine (EOS M290), the STWIP system demonstrated its ability to quantitatively monitor the MP temperature and its variation for 50 layers at high framerates (>30,000 fps) for a real-world application (standard fatigue specimens) print. High performance computing is employed to analyze the acquired big data (MP images), for determining each MP's average temperature and 2D temperature profile. The MP temperature evolution in the gage section of a fatigue specimen is also examined at a temporal resolution of 1 ms, by evaluating the MP temperatures in the samples' first, middle, and last layers. This report is the first of its kind on monitoring MP temperature distribution and evolution at such a large, detailed scale for longer durations in practical applications.

42 ENGINEERING↗

DOE OSTI2022

Frictional Contacts Between Individual Woody Biomass Particles under Wet and Dry Conditions

Friction between wood particles can be a critical property when designing processing equipment for creating cellulosic biofuels and similar natural products. Also, as wood processing is likely to occur year-round, understanding the friction between wet as well as dry wood particles can help design and model equipment, such as screw feeders. Here, a tribo-rheometry method was developed using a commercial rheometer that measured the torque required to rotate two contacting millimeter-scale wood chip particles. First, a range of normal forces were used to find the limits of the experimental method. Torque values were measured for seven pairs of wood chip particles at 1 N normal force under both dry and wet conditions, at both ambient conditions and in a humidity-controlled chamber. The torque required to rotate the wet particles was consistently higher than that of the dry particles, although differences were not quite statistically significant when measurements were performed at ambient conditions. Using humidity control resulted in torque values for wet particles of 1900 uNm and 900 uNm for dry particles. Finally, the friction coefficient was calculated as 0.23 for wet particles and 0.11 for dry particles when humidity was controlled. These frictions coefficients agreed with values for wood reported in the literature. Overall, controlling humidity is strongly recommended to quantify the range of friction for particles that uptake water, including granular systems from biomass to food to powders.

biomass↗