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NASA NTRS1993

A fracture criterion for widespread cracking in thin-sheet aluminum alloys

An elastic-plastic finite-element analysis was used with a critical crack-tip-opening angle (CTOA) fracture criterion to model stable crack growth in thin-sheet 2024-T3 aluminum alloy panels with single and multiple-site damage (MSD) cracks. Comparisons were made between critical angles determined from the analyses and those measured with photographic methods. Calculated load against crack extension and load against crack-tip displacement on single crack specimens agreed well with test data even for large-scale plastic deformations. The analyses were also able to predict the stable tearing behavior of large lead cracks in the presence of stably tearing MSD cracks. Small MSD cracks significantly reduced the residual strength for large lead cracks.

Newman, J. C., Jr.↗

NASA NTRS2008

Thermal Vacuum Testing of a Multi-Evaporator Miniature Loop Heat Pipe

Under NASA's New Millennium Program Space Technology 8 Project, four experiments are being developed for future small system applications requiring low mass, low power, and compactness. GSFC is responsible for developing the Thermal Loop experiment, which is an advanced thermal control system consisting of a miniature loop heat pipe (MLHP) with multiple evaporators and condensers. The objective is to validate the operation of an MLHP, including reliable start-ups, steady operation, heat load sharing, and tight temperature control over the range of 273K to 308K. An MLHP Breadboard has been built and tested for 1200 hours under the laboratory environment and 500 hours in a thermal vacuum chamber. Results of the TV tests are presented here.

Ku, Jentung↗

NASA NTRS2011

VEGGIE Pillow Testing: Microbial Analysis of Cut-and-Come-Again Species Testing

With NASA focused on researching and developing technology for deep space missions, the need for a reliable supplementary food source must also be considered. For the ISS, resupplying the food source is more practical and cost effect since the facility is in low Earth orbit. However, as NASA attempts to push the frontier in space, the costs and distance for resupply will surely increase. Plants would contribute to the proportion of food and reduce the dependency on food from Earth. In addition, plants would provide oxygen production, carbon dioxide removal, and psychological benefits. As a result, a vegetable production system, VEGGIE, was developed for NASA to produce salad crops with minimal resources and study the beneficial effects. The VEGGIE pillow is a single use bag for growing crops that is used with the VEGGIE hardware. The VEGGIE pillow was tested with four different species of plants with the cut-and-come-again harvest method to determine the greatest yield. Instead of harvesting the entire plant, the harvest consisted of cutting leaves to allow the plant to regrow leaves. The harvest methods included cutting the plants weekly, bi-weekly, and monthly. A fifth plant species, radishes, was also harvested and replanted. Microbial load analysis and an ANOVA significance test were utilized. The data suggest that the two Brassica plants have the greatest yields; however, the microbial load is also greatest for the two plants per gram of fresh weight. Furthermore, the results support the reuse of pillows for multiple harvests as shown by the replanted radishes.

Nguyen, Bao-Thang↗

NASA NTRS2016

Investigating the Simulink Auto-Coding Process

Model based program design is the most clear and direct way to develop algorithms and programs for interfacing with hardware. While coding "by hand" results in a more tailored product, the ever-growing size and complexity of modern-day applications can cause the project work load to quickly become unreasonable for one programmer. This has generally been addressed by splitting the product into separate modules to allow multiple developers to work in parallel on the same project, however this introduces new potentials for errors in the process. The fluidity, reliability and robustness of the code relies on the abilities of the programmers to communicate their methods to one another; furthermore, multiple programmers invites multiple potentially differing coding styles into the same product, which can cause a loss of readability or even module incompatibility. Fortunately, Mathworks has implemented an auto-coding feature that allows programmers to design their algorithms through the use of models and diagrams in the graphical programming environment Simulink, allowing the designer to visually determine what the hardware is to do. From here, the auto-coding feature handles converting the project into another programming language. This type of approach allows the designer to clearly see how the software will be directing the hardware without the need to try and interpret large amounts of code. In addition, it speeds up the programming process, minimizing the amount of man-hours spent on a single project, thus reducing the chance of human error as well as project turnover time. One such project that has benefited from the auto-coding procedure is Ramses, a portion of the GNC flight software on-board Orion that has been implemented primarily in Simulink. Currently, however, auto-coding Ramses into C++ requires 5 hours of code generation time. This causes issues if the tool ever needs to be debugged, as this code generation will need to occur with each edit to any part of the program; additionally, this is lost time that could be spent testing and analyzing the code. This is one of the more prominent issues with the auto-coding process, and while much information is available with regard to optimizing Simulink designs to produce efficient and reliable C++ code, not much research has been made public on how to reduce the code generation time. It is of interest to develop some insight as to what causes code generation times to be so significant, and determine if there are architecture guidelines or a desirable auto-coding configuration set to assist in streamlining this step of the design process for particular applications. To address the issue at hand, the Simulink coder was studied at a foundational level. For each different component type made available by the software, the features, auto-code generation time, and the format of the generated code were analyzed and documented. Tools were developed and documented to expedite these studies, particularly in the area of automating sequential builds to ensure accurate data was obtained. Next, the Ramses model was examined in an attempt to determine the composition and the types of technologies used in the model. This enabled the development of a model that uses similar technologies, but takes a fraction of the time to auto-code to reduce the turnaround time for experimentation. Lastly, the model was used to run a wide array of experiments and collect data to obtain knowledge about where to search for bottlenecks in the Ramses model. The resulting contributions of the overall effort consist of an experimental model for further investigation into the subject, as well as several automation tools to assist in analyzing the model, and a reference document offering insight to the auto-coding process, including documentation of the tools used in the model analysis, data illustrating some potential problem areas in the auto-coding process, and recommendations on areas or practices in the current Ramses model that should be further investigated. Several skills were required to be built up over the course of the internship project. First and foremost, my Simulink skills have improved drastically, as much of my experience had been modeling electronic circuits as opposed to software models. Furthermore, I am now comfortable working with the Simulink Auto-coder, a tool I had never used until this summer; this tool also tested my critical thinking and C++ knowledge as I had to interpret the C++ code it was generating and attempt to understand how the Simulink model affected the generated code. I had come into the internship with a solid understanding of Matlab code, but had done very little in using it to automate tasks, particularly Simulink tasks; along the same lines, I had rarely used shell script to automate and interface with programs, which I gained a fair amount of experience with this summer, including how to use regular expression. Lastly, soft-skills are an area everyone can continuously improve on; having never worked with NASA engineers, which to me seem to be a completely different breed than what I am used to (commercial electronic engineers), I learned to utilize the wealth of knowledge present at JSC. I wish I had come into the internship knowing exactly how helpful everyone in my branch would be, as I would have picked up on this sooner. I hope that having gained such a strong foundation in Simulink over this summer will open the opportunity to return to work on this project, or potentially other opportunities within the division. The idea of leaving a project I devoted ten weeks to is a hard one to cope with, so having the chance to pick up where I left off sounds appealing; alternatively, I am interested to see if there are any opening in the future that would allow me to work on a project that is more in-line with my research in estimation algorithms. Regardless, this summer has been a milestone in my professional career, and I hope this has started a long-term relationship between JSC and myself. I really enjoy the thought of building on my experience here over future summers while I work to complete my PhD at Missouri University of Science and Technology.

Gualdoni, Matthew J.↗

NASA NTRS2017

Thermal Vacuum Testing of ICPTA RCS at Plum Brook B-2

Vacuum and thermal vacuum testing of the Integrated Cryogenic Propulsion Test Article (ICPTA) was performed at the Plum Brook B-2 facility as a part of a system checkout and facility characterization effort. Multiple test objectives included: integrated Reaction Control System (RCS) characterization, cold helium pressurization system characterization, modal propellant gaging experiment (Orion), CFM propellant loading experiments, main engine characterization. The ICPTA is a test bed for LOX/LCH4 technologies built in 2016 using new components and hardware from the former Morpheus vehicle and other projects.

Atwell, M. J.↗

NASA NTRSDate not supplied

Verb Sense Disambiguation for Densifying Knowledge Graphs in Earth Science

We begin with an ambitious goal: to create a knowledge graph that spans the entire discipline of Earth science. In order to achieve this, we need to apply Natural Language Processing (NLP) techniques on Earth science journal articles to extract their semantic components for the graph. When sentences from Earth science journal articles are broken down into their semantic components and loaded onto a graph, the relationships among these semantic components are represented by the verbs in the sentences. However, since there are multiple verbs in English that can be used to denote the same meaning, the knowledge graph can become sparse and so can the results when we query the graph. In order to ensure quality results, it would be desirable to consolidate similar verbs into a single "class". So, this is the problem at hand: how do we make sure that multiple verbs that mean the same thing are represented as a single class of verb in the knowledge graph? Or in other words, how do we distinguish which meaning a particular verb takes given a particular sentence? In this poster, we demonstrate a potential technique to solve this problem.

Ashish Acharya↗

DOE OSTI2018

Hardware-in-the-Loop (HIL) Simulations for Smart Grid Impact Studies: Preprint

Hardware-in-the-loop (HIL) simulation is increasingly employed in power engineering as more inverter-based generation and smart appliances are connected to the electric grid. HIL techniques allow for co-simulation of analytical models with actual devices whose complex behavior is computationally inefficient or difficult to capture. It also allows for testing of the behavior of these devices under adverse conditions that only occur rarely in the field, but that are important to evaluate. An overview of how HIL simulation has been used to date is provided. This paper further proposes that HIL simulation should play an important role in evaluating new control strategies, especially at the distribution level, that are being proposed to allow for continued affordable and reliable operation of the electric grid with the introduction of these new technologies. It presents a new capability that was developed to enable evaluation of interactions between residential loads and the smart grid: smart home hardware-in-the-loop. The paper includes results from an HIL simulation that incorporates multiple technologies and controls.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2019

Framework for Evaluating Grid Readiness for Integrating Electric Vehicles and Utility Scale Storage in India

Electric vehicles (EVs) and distributed solar are poised to grow substantially in India in the coming years following ambitious Government of India targets. The localized impact of these changes, both in terms of infrastructure investments and demand patterns, are not well understood, nor are tools for this type of analysis readily available. This paper describes the development of a framework that can analyze network readiness in terms of feeder impacts for distributed energy resources (DERs) including growing EV penetration, and the potential solutions introduced by utility-scale battery energy storage systems (BESSs). The building blocks of the feeder analysis require multiple data sets to be compiled into a usable network model. The work is driven by feeder head and distribution transformer (DT) loading data along with all the technical specifications and schematics of distribution feeders. These measured data sets are conditioned to remove any afflictions, and the cleaned load profiles are used to perform multi-year quasi-static time-series power flow analyses on detailed three-phase feeder models. EVs translated to grid-tied loads are represented with aggregated EV demand profile estimates based on possible charging scenarios in residential sector, and in workplace and/or public charging stations. Finally, BESSs are evaluated for their cost-effectiveness in the framework through an initial screening that includes the benefits of grid service applications to mitigate present and future overloading scenarios. The outcomes from this framework are expected to help utilities gauge the readiness of their distribution grid for integrating an increasing number of EVs as well as load growth during a projected multi-year time horizon, where BESSs can contribute in making the grid more reliable.

electric vehicles↗

DOE OSTI2020

High-frequency direct current bulk capacitors with interleaved busbar packages

Presented are electrical capacitors with interleaved busbar architectures, methods for making/operating such capacitors, and electric-drive vehicles equipped with such capacitors. A bulk capacitor includes multiple capacitor devices disposed within an outer housing and operable to modify electric current transmitted between a power source and an electrical load. An interleaved busbar package is interposed between the capacitor devices and outer housing. The interleaved busbar package includes a first busbar plate that electrically connects to first terminals of the capacitor devices and defines a busbar pocket. A second busbar plate is seated within the busbar pocket and electrically connects to second terminals of the capacitor devices. The second busbar plate includes a capacitor basin that seats therein the capacitor devices. An isolator sheet is interleaved between and electrically insulates the first and second busbar plates. The capacitor devices and interleaved busbar package may be partially submerged in an epoxy endfill composition.

42 ENGINEERING↗

DOE OSTI2020

Highly Reliable Multi-Port Smart Inverter Modules for PV-Based Energy Systems

Generally, large electrolytic capacitors (E-caps) are required to decouple the double-line frequency power fluctuation inherent in all single-phase dc-ac or ac-dc converters. These E-caps pose the weak link in the photovoltaic (PV) inverter because they have poor reliability as a result of short life expectancy and higher equivalent series resistance (ESR) which leads to lower system efficiency. In this paper, multiport smart dual-inverter modules are proposed for residential PV inverter systems with balanced outputs to eliminate the requirement of large decoupling capacitors, thus leading to more reliable and highly efficient inverter modules. The balanced dual outputs are controlled in phase quadrature such that the double frequency current is completely eliminated. One phase supports the standalone residential loads, and the other phase interfaces with the grid, which is synchronized to the utility grid. Also, the proposed modular configuration is scalable to accommodate higher power rating by stacking and paralleling multiple modules. Simulation results for the dual-inverter modules rated for 1 kW each are presented to validate the proposed concept. Experimental results from a controller hardware-in-the-loop (CHIL) platform also verify its feasibility.

14 SOLAR ENERGY↗

NASA NTRS1999

Control Design Strategies to Enhance Long-Term Aircraft Structural Integrity

Over the operational lifetime of both military and civil aircraft, structural components are exposed to hundreds of thousands of low-stress repetitive load cycles and less frequent but higher-stress transient loads originating from maneuvering flight and atmospheric gusts. Micro-material imperfections in the structure, such as cracks and debonded laminates, expand and grow in this environment, reducing the structural integrity and shortening the life of the airframe. Extreme costs associated with refurbishment of critical load-bearing structural components in a large fleet, or altogether reinventoring the fleet with newer models, indicate alternative solutions for life extension of the airframe structure are highly desirable. Increased levels of operational safety and reliability are also important factors influencing the desirability of such solutions. One area having significant potential for impacting crack growth/fatigue damage reduction and structural life extension is flight control. To modify the airframe response dynamics arising from command inputs and gust disturbances, feedback loops are routinely applied to vehicles. A dexterous flight control system architecture senses key vehicle motions and generates critical forces/moments at multiple points distributed throughout the airframe to elicit the desired motion characteristics. In principle, these same control loops can be utilized to influence the level of exposure to harmful loads during flight on structural components. Project objectives are to investigate and/or assess the leverage control has on reducing fatigue damage and enhancing long-term structural integrity, without degrading attitude control and trajectory guidance performance levels. In particular, efforts have focused on the effects inner loop control parameters and architectures have on fatigue damage rate. To complete this research, an actively controlled flexible aircraft model and a new state space modeling procedure for crack growth have been utilized. Analysis of the analytical state space model for crack growth revealed the critical mathematical factors, and hence the physical mechanism they represent, that influenced high rates of airframe crack growth. The crack model was then exercised with simple load inputs to uncover and expose key crack growth behavior. To characterize crack growth behavior, both "short-term" laboratory specimen test type inputs and "long-term" operational flight type inputs were considered. Harmonic loading with a single overload revealed typical exponential crack growth behavior until the overload application, after which time the crack growth was retarded for a period of time depending on the overload strength. An optimum overload strength was identified which leads to maximum retardation of crack growth. Harmonic loading with a repeated overload of varying strength and frequency again revealed an optimum overload trait for maximizing growth retardation. The optimum overload strength ratio lies near the range of 2 to 3 with dependency on frequency. Experimental data was found to correlate well with the analytical predictions.

Newman, Brett A.↗

DOE OSTI2014

Dose Rate Analysis of As-Loaded Spent Nuclear Fuel Casks - Paper 97

Used Nuclear Fuel Storage, Transportation and Disposal Analysis Resource and Data System (UNF-ST[and]DARDS) is a comprehensive data and calculation capability for UNF safety assessments currently being developed at Oak Ridge National Laboratory through a collaborative effort of multiple national laboratories and industry participants. The purpose of UNF-ST[and]DARDS is to provide a unified domestic UNF system of data and analysis capabilities in support of U.S. Department of Energy waste management and fuel cycle-related objectives. UNF-ST[and]DARDS is designed to provide safety assessments for UNF storage, transportation, and disposal systems based on actual characteristics of the as-loaded UNF (e.g., fuel assembly burnup, enrichment, decay time, cladding integrity, etc.). The cask-specific safety evaluations allow quantification of realistic safety margins and conditions and provide the technical basis for addressing concerns related to potential fuel failure (e.g., for high-burnup fuel). This paper describes the UNF-ST[and]DARDS methodology for calculating radiation dose rates for U.S. Nuclear Regulatory Commission (NRC) licensed casks based on actual UNF canister contents. Realistic dose rate values based on actual canister contents may be used in place of bounding dose rate values to support development of repackaging operations procedures, evaluation of radiation-related transportation risks, and communication with stakeholders. UNF-ST[and]DARDS capabilities have been recently expanded to include automated radiation source term calculations and dose rate analyses of as-loaded transportation casks. This unique capability determines realistic dose rate values based on actual canister UNF contents that may be used in radiation dose assessments to demonstrate safe transportation of commercial UNF. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Mechanical Loads on Spent Nuclear Fuel in the General 30 cm Package Drop Scenario

The U.S. Department of Energy Office of Nuclear Energy (DOE-NE) Spent Fuel and Waste Science & Technology (SFWST) research program is guided by the high-level goal of closing prioritized knowledge gaps related to spent nuclear fuel (SNF) storage and transportation, which are summarized by Saltzstein et al. (2020). One of the high-priority knowledge gaps is the identification and quantification of mechanical loads that are expected to affect SNF during normal conditions of transportation and storage to inform the range of physical SNF test programs. This report uses modeling and analysis methods to estimate the mechanical loads on spent nuclear fuel (SNF) in the general 30 cm package drop scenario. The drop scenario assumes impact limiters are in place in the transportation configuration and the impact surface is perfectly rigid. The goal of this analysis is to consider the universe of potential mechanical loading conditions that can happen to SNF and present the results in a manner that is useful for materials testing, decision making, and regulatory rule making purposes. This study uses validated finite element models and methods to perform a broad parametric study of key variables that can affect the mechanical loads on SNF during a hypothetical package free drop scenario. Physical drop test data from a cask and fuel assembly drop test campaign is the basis for model validation. Additionally, the results of the parametric study are used to inform a damage model, which uses multiple nonlinear regression to estimate the relationships between input variables and output response. The parametric finite element analyses consider thousands of input variable combinations, while the damage model estimates millions of combinations. The breadth of this study provides confidence that the potential range of mechanical loads that SNF might experience during the general 30 cm package drop scenario are characterized well enough to consider this knowledge gap closed. While this report documents the overall peak values calculated in this study, the 95 th percentile values, the histograms, and the observed trends are equally important. This study covered a large range of SNF temperatures, room temperature to 300°C, and burnups, 10 GWd/MTU to 62 GWd/MTU. Each temperature and burnup combination has a different cladding yield strain, so it is more meaningful to summarize the calculated cladding strain response as its factor of safety, which is defined relative to the yield strain. The factor of safety is calculated as the yield strain divided by the peak cladding strain. A factor of safety greater than unity indicates that the cladding remains below yield, whereas a value less than unity is indicative of plastic deformation. In all cases of this study a safety factor over 1.0 was calculated, although in the most limiting case at 300°C the safety factor was only 1.01, which suggests that yielding could occur when additional loads like rod internal pressure are included. When the temperature is restricted to 200°C the limiting safety factor increases to 1.28, which has significant margin to accommodate internal pressure and potential local cladding defects that could cause a local stress concentration. An important trend in the calculated fuel rod mechanical loads is that the 2 nd highest loaded fuel rod in an assembly tends to be significantly lower than the highest loaded rod. The implication is that even if one rod in an assembly experiences a failure the loads would have to be significantly higher to cause two or more rods to fail.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

Finite Element Structural Analysis Evaluating New Retrieval Strategies in the Hanford Waste Tanks 1 - 19125

Several waste retrieval methods being considered for the Hanford underground single- and double-shell nuclear waste storage tanks would require changes to the equipment loads above the tanks or structural modifications to the tanks themselves. Detailed structural analysis has been used in the planning phase to ensure that the reinforced concrete tanks continue to meet structural design codes in the modified configuration of these waste retrieval options. The feasibility of installing new single and multiple large risers penetrating the tank dome was evaluated using this approach. This paper summarizes the structural analysis methods and design codes used to evaluate the introduction of new unreinforced penetrations in a single-shell tank dome. The anticipated equipment loads during current and future waste retrieval operations are evaluated to ensure the continued structural integrity of the tank under thermal, dead weight, and seismic loads. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2013

A Multi-scale Approach to Statistical and Model-based Structural Health Monitoring with Application to Embedded Sensing for Wind Energy [Dissertation]

This dissertation presents a systems-level approach to multi-scale structural health monitoring (SHM) with specific focus on wind turbine rotor blades, combining innovative sensing platforms for incipient damage detection with state estimation for structural performance assessment. The practical implementation of this approach rests in three areas: hardware development and deployment for embedded data acquisition; demonstration of incipient damage detection using embedded systems for active-sensing SHM, including an in depth assessment of sensor diagnostics; and development of a nonlinear observer for state and loads estimation applied to a geometrically nonlinear beam model. Structural Health Monitoring is generally defined as the development of an in-situ damage assessment capability, and when combined predictive loading and failure models, enables risk-informed models for decision-making. These decision models require contributions from a wide variety of technology areas. Sensing systems (in many cases, capable of providing multiple data types) must be developed specifically to provide the data necessary for structural damage detection and performance assessment. A means of sensor diagnostics is necessary to provide confidence in the recorded data. Statistical modeling and classification feed the development of optimal detectors necessary to ascertain the presence, location, and severity of damage. Methods of state estimation are needed to map kinematic measurements to physical performance metrics. A probabilistic representation of future loads applied to a structural model enables an assessment of the structure’s future performance. Finally, a cost model is combined with a probabilistic risk assessment, given the detectors’ output and the structure’s estimated future performance, to render the risk-minimizing decision. This dissertation presents key contributions among the underpinnings of this ultimate decision model: (1) embedded sensor development and deployment; (2) sensor diagnostics for active-sensing methods; (3) an assessment of incipient damage detection performance for large-scale composite structures; and (4) the development and application of a state observer, demonstrated in the specific case of a geometrically nonlinear beam model.

17 WIND ENERGY↗

NASA NTRS2007

An Investigation of High-Cycle Fatigue Models for Metallic Structures Exhibiting Snap-Through Response

A study is undertaken to develop a methodology for determining the suitability of various high-cycle fatigue models for metallic structures subjected to combined thermal-acoustic loadings. Two features of this problem differentiate it from the fatigue of structures subject to acoustic loading alone. Potentially large mean stresses associated with the thermally pre- and post-buckled states require models capable of handling those conditions. Snap-through motion between multiple post-buckled equilibrium positions introduces very high alternating stress. The thermal-acoustic time history response of a clamped aluminum beam structure with geometric and material nonlinearities is determined via numerical simulation. A cumulative damage model is employed using a rainflow cycle counting scheme and fatigue estimates are made for 2024-T3 aluminum using various non-zero mean fatigue models, including Walker, Morrow, Morrow with true fracture strength, and MMPDS. A baseline zero-mean model is additionally considered. It is shown that for this material, the Walker model produces the most conservative fatigue estimates when the stress response has a tensile mean introduced by geometric nonlinearity, but remains in the linear elastic range. However, when the loading level is sufficiently high to produce plasticity, the response becomes more fully reversed and the baseline, Morrow, and Morrow with true fracture strength models produce the most conservative fatigue estimates.

Przekop, Adam↗

NASA NTRSDate not supplied

Development of Aerodynamic Loads Databases for the Space Launch System Booster Separation Event

Booster separation is a mission-critical event within the orbital ascent of the Space Launch System (SLS). The complexity of the engine plume-affected, multibody, supersonic aerodynamics is compounded by the large span of the likely trajectory space. Characterization of the multiple input, multiple output system requires a combination of wind tunnel testing and computational simulation, but additional data processing is also required before the sparse, high-fidelity data can be fused into a continuous database with acceptable uncertainty quantification. This paper outlines the state of this approach as it has been applied to the most recent SLS booster separation aerodynamic loads database: that of the Artemis II launch vehicle.

Michael W Lee↗

NASA NTRSDate not supplied

Development of Aerodynamic Loads Databases for the Space Launch System Booster Separation Event

Michael Lee↗