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Columbia Accident Investigation Board Report: Volume One

The Columbia Accident Investigation Board's independent investigation into the February 1, 2003, loss of the Space Shuttle Columbia and its seven-member crew lasted nearly seven months. A staff of more than 120, along with some 400 NASA engineers, supported the Board's 13 members. Investigators examined more than 30,000 documents, conducted more than 200 formal interviews, heard testimony from dozens of expert witnesses, and reviewed more than 3,000 inputs from the general public. In addition, more than 25,000 searchers combed vast stretches of the Western United States to retrieve the spacecraft's debris. In the process, Columbia's tragedy was compounded when two debris searchers with the U.S. Forest Service perished in a helicopter accident. This report discusses the attributes of an organization that could more safely and reliably operate the inherently risky Space Shuttle, but does not provide a detailed organizational prescription. Among those attributes are: a robust and independent program technical authority that has complete control over specifications and requirements, and waivers to them; an independent safety assurance organization with line authority over all levels of safety oversight; and an organizational culture that reflects the best characteristics of a learning organization. This report concludes with recommendations, some of which are specifically identified and prefaced as "before return to flight." These recommendations are largely related to the physical cause of the accident, and include preventing the loss of foam, improved imaging of the Space Shuttle stack from liftoff through separation of the External Tank, and on-orbit inspection and repair of the Thermal Protection System. The remaining recommendations, for the most part, stem from the Board's findings on organizational cause factors. While they are not "before return to flight" recommendations, they can be viewed as "continuing to fly" recommendations, as they capture the Board's thinking on what changes are necessary to operate the Shuttle and future spacecraft safely in the mid- to long-term.

CAIB

Flammability Testing Configuration and Approach of Barrier Material Assemblies Designed for Space Flight Applications

The NASA Engineering and Safety Center (NESC) partnered with Materials and Processes and Flammability subject matter experts from the Johnson Space Center, White Sands Test Facility, and the Marshall Space Flight Center to design and develop a test for evaluating the effectiveness of material assemblies to serve as a barrier between a potential cabin ignition source based on typical flammable materials in the habitable volume of spacecraft.

Morgan Abney

Probing the atomic dynamics of ultrafast melting with femtosecond electron diffraction

Melting is an every-day phase transition that is determined by thermodynamic parameters like temperature and pressure. In contrast, ultra-fast melting is governed by the microscopic response to a rapid energy input and, thus, can reveal the strength and dynamics of atomic bonds as well as the energy flow rate to the lattice. Accurately describing these processes remains challenging and requires detailed insights into transient states encountered. Here, we present data from femtosecond electron diffraction measurements that capture the structural evolution of copper during the ultrafast solid-to-liquid phase transformations. At absorbed energy densities 2-4 times the melting threshold, melting begins at the surface slightly below the nominal melting point followed by rapid homogeneous melting throughout the volume. Molecular dynamics simulations reproduce these observations and reveal a weak electron-lattice energy transfer rate for the given experimental conditions. Both simulations and experiments show no indications of rapid lattice collapse when its temperature surpasses proposed limits of superheating, providing evidence that the inherent dynamics limits the speed of disordering in ultrafast melting of metals.

FOS: Physical sciences

Battery study for the Mars Environmental Survey (MESUR) Pathfinder

Viewgraphs on the battery study for the Mars Environmental Survey (MESUR) Pathfinder are presented. Topics covered include: MESUR pathfinder introduction; power subsystem concept; battery technology selection; mission battery performance; cell/battery baseline design; charge methodology; and proposed testing.

Dawson, Stephen F.

Tracing U.S. fuel life-cycle greenhouse gas emissions in a multi-sector dynamics model using LC-GCAM

Model-based analysis of fuel pathways is essential for informing energy and environmental policy. Two major model types are typically used: multi-sector dynamics models, which capture the broader energy-economy, such as GCAM (Global Change Analysis Model), and life cycle assessment models, such as GREET (Greenhouse Gases, Regulated Emissions, and Energy Use in Transportation). Each has distinct strengths and limitations, and recent studies increasingly adopt hybrid approaches to harness the advantages of both. However, such integration is often time-consuming and complicated by inconsistencies in system boundaries and technology definitions. We present LC-GCAM, a new tool that enables estimation of life-cycle greenhouse gas emissions and primary energy use for any fuel pathway represented in GCAM. We apply LC-GCAM to 300 scenarios designed to explore key uncertainties affecting the life-cycle performance of future fuel options in the U.S. freight sector. To evaluate LC-GCAM, we compare its results with those from GREET for nine fuel types in a 2030 reference scenario. When input assumptions are modestly aligned, LC-GCAM and GREET estimates typically agree within 10% (absolute sum-based mean absolute percentage error). LC-GCAM offers a flexible and efficient approach to generating life-cycle metrics within an integrated modeling framework, supporting robust policy analysis across a wide range of interacting energy system uncertainties.

Wolfram, Paul

Chemical recycling of mixed textile waste

Globally, less than 0.5% of postconsumer textile waste is recycled, with the majority incinerated or ending up in landfills. Most postconsumer textiles are mixed fibers, complicating mechanical recycling due to material blends and contaminants. Here, we demonstrate the chemical conversion of postconsumer mixed textile waste using microwave-assisted glycolysis over a ZnO catalyst followed by solvent dissolution. This approach electrifies the process heat while allowing rapid depolymerization of polyester and spandex to their monomers in 15 minutes. A simple solvent dissolution enables the separation of cotton and nylon. We assess the quality of all components through extensive material characterization, discuss their potential for sustainable recycling, and provide a techno-economic analysis of the economic feasibility of the process.

Science & Technology - Other Topics

The 1999 NASA Aerospace Battery Workshop

This document contains the proceedings of the 32nd annual NASA Aerospace Battery Workshop, hosted by the Marshall Space Flight Center on November 16-18, 1999. The workshop was attended by scientists and engineers from various agencies of the US Government, aerospace contractors, and battery manufacturers, as well as international participation in like kind from a number of countries around the world. The subjects covered included nickel-hydrogen, nickel-cadmium, lithium-ion, and silver-zinc technologies.

Brewer, J. C.

Artemis I Space Launch System Base Heat Shield Thermal Protection System Performance

The Space Launch System (SLS) Core Stage base heat shield experienced the highest external heating environments on the entire launch vehicle during Artemis I ascent flight. This result was consistent with design predictions. The base heat shield experiences P50 cork combustion dynamics at low altitudes, plume-induced recirculation at moderate altitudes and then in-space base flow physics out to Main Engine Cut-Off (MECO). The base heat shield thermal protection system (TPS) is composed of a P50 cork ablator which is bonded to a substrate. The heat shield protects the gimbal actuation system, RS-25 turbomachinery systems and other aft section sensitive components during ascent. This paper estimates the base heat shield TPS performance from Artemis I using flight data from the NASA Langley Research Center’s Scientifically Calibrated In-Flight Imagery (SCIFLI) Airborne Multispectral Imager (SAMI), development flight instrumentation (DFI) and other TPS recession flight measurements. Predictions from computational and ground test-derived engineering ablation models and observations are also applied. Since no base heat shield substrate thermocouple data were obtained for Artemis I, an estimate of the TPS performance data is derived here. This data assesses thermal margin of the SLS Core Stage base heat shield and best informs the Artemis II Crewed mission to the moon.

aerothermodynamics

Treatment of Lagoon Dairy Manure Wastewater via Iron Electrocoagulation, Microfiltration, and Adsorption

Dairy manure wastewater generated by flushing barn cow waste contains nutrients, pathogens, and organic and inorganic contaminants. This study utilized a process consisting of iron electrocoagulation (Fe-EC), microfiltration (MF), and activated carbon (AC) adsorption to treat farm wastewater and explore the reclamation of clean water for irrigation and livestock consumption. Significant removal (>99.9%) of chemical oxygen demand (COD), total organic carbon (TOC), phosphorus (P), turbidity, and microorganisms, as well as ions including magnesium, calcium, sulfur, and silica was achieved by the combined EC-MF-AC process. Specifically, a charge loading of ∼37,500 C/L in a continuous-flow EC configuration, followed by MF, achieved more than 95% removal of TOC and COD. Characterization of produced flocs and foam via scanning-electron microscopy with energy-dispersal spectroscopy and Fourier transform infrared spectroscopy confirmed the removal of ions, including calcium, sulfur, and silica. A key finding was the electrocatalytic conversion of nitrogen species to ammonia gas through the intermediate reduction of nitrate/nitrite, which led to ∼60% total nitrogen (TN) removal. AC treatment further improved TN removal to ∼70%. The Fe-EC process also eradicated >99.9% of bacteria. Preliminary process cost assessment, based on recycled materials for EC electrodes, showed significant cost savings (∼2 times) compared to commercial electrodes.

Dutta, Swapnamoy [ORNL]

SOLPS-ITER modeling of a dedicated divertor for negative triangularity operation on DIII-D

The design of a new dedicated divertor for negative triangularity (NT) operation on DIII-D with neutral baffles and pumping is informed by SOLPS-ITER transport modeling. This dedicated NT divertor is the latest step in a progression of NT shapes with various divertor characteristics explored on DIII-D, including NT shapes at reduced triangularity and a campaign with stronger shaping that included new armored components on the outboard side. SOLPS simulations played a key role in these divertor designs. Interpretive simulations, using cross-field diffusivities constrained by experimental data in the NT Shelf shape were used to inform the design of the 2023 armor campaign components. A similar procedure used armor campaign data to predict conditions for the dedicated NT divertor. The predictive simulations were used to assess the divertor fluxes, detachment threshold, pumped flux, and neutral leakage. For the dedicated NT divertor, SOLPS simulations and two-point-modeling were used to show the relative impact of magnetic topology (mainly longer connection length) and divertor closure on the divertor conditions relative to the armor campaign. It is predicted that the dedicated NT divertor reaches detachment (measured by target ion flux rollover) at a lower upstream density (≈(1.75−−2.4)×1⁢019m−3) as compared to the armor campaign shape. For the preliminary design geometry, divertor closure reduces the neutral leakage by ≈10%. Parametric optimization indicating further ≈20%–60% improvement in the leakage flux and recycled flux crossing the pump entrance is possible for relatively minor changes to the divertor and baffle layout.

Lore, Jeremy [ORNL] (ORCID:000000029192465X)

Oversizing and Part-Load Problems

Oversizing, the common engineering practice of specifying devices with capacity exceeding the actual load requirement, is a widespread practice across virtually all building technologies end-use categories, including HVAC, electrical systems, lighting, appliances, and plug loads. This practice, driven by factors like design uncertainty, institutional pressures, and risk aversion, results in wasted capital investment, control difficulties, and excessive energy consumption due to inefficient part-load operation. Part-load operation, where devices run below maximum capacity, is the dominant operating mode in most energy systems and presents a complex design challenge. Solutions to match output to load fall into three broad categories: constraining the output, adjusting the device’s internal behavior, and linking output to energy storage or other waste-heat reuse applications. The energy implications of part-load are critical, as efficiency often drops sharply as load decreases across a wide diversity of devices. To quantify the extent of this problem, we derive a dimensionless Part-Load Metric (PLM) based on device efficiency and its frequency distribution of operating hours at various output levels. The PLM quantifies the deviation of a device's actual efficiency from its maximum design efficiency. This metric also serves as a measure of "capital inefficiency," enabling engineers to compare the impact of different part-load solutions and providing a unified framework for evaluating performance across various devices and systems.

Meier, Alan

Remote sensing of hurricane waves

A program was undertaken to obtain data on wind generated ocean waves in hurricanes by remote sensing techniques. The sensor, a synthetic aperture radar, has collected the first data ever on the directional wave climate throughout a hurricane. This information was found to have inconsistencies with present hurricane wave generation models.

David B King

The 2000 NASA Aerospace Battery Workshop

This document contains the proceedings of the 33nd annual NASA Aerospace Battery Workshop, hosted by the Marshall Space Flight Center on November 14-16, 2000. The workshop was attended by scientists and engineers from various agencies of the U.S. Government, aerospace contractors, and battery manufacturers, as well as international participation in like kind from a number of countries around the world. The subjects covered included nickel-hydrogen, lithium-ion, lithium-sulfur, and silver-zinc technologies.

Brewer, J. C.