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At least 1,225 records · Page 68

Logistics Reduction Technologies for Exploration Missions

Human exploration missions under study are limited by the launch mass capacity of existing and planned launch vehicles. The logistical mass of crew items is typically considered separate from the vehicle structure, habitat outfitting, and life support systems. Although mass is typically the focus of exploration missions, due to its strong impact on launch vehicle and habitable volume for the crew, logistics volume also needs to be considered. NASA's Advanced Exploration Systems (AES) Logistics Reduction and Repurposing (LRR) Project is developing six logistics technologies guided by a systems engineering cradle-to-grave approach to enable after-use crew items to augment vehicle systems. Specifically, AES LRR is investigating the direct reduction of clothing mass, the repurposing of logistical packaging, the use of autonomous logistics management technologies, the processing of spent crew items to benefit radiation shielding and water recovery, and the conversion of trash to propulsion gases. Reduction of mass has a corresponding and significant impact to logistical volume. The reduction of logistical volume can reduce the overall pressurized vehicle mass directly, or indirectly benefit the mission by allowing for an increase in habitable volume during the mission. The systematic implementation of these types of technologies will increase launch mass efficiency by enabling items to be used for secondary purposes and improve the habitability of the vehicle as mission durations increase. Early studies have shown that the use of advanced logistics technologies can save approximately 20 m(sup 3) of volume during transit alone for a six-person Mars conjunction class mission.

Broyan, James L., Jr.↗

Nuclear Energy Return on Energy Investment

This report provides a methodology and requisite data to assess the potential Energy Return on (Energy) Investment (EROI) for nuclear fuel cycle alternatives, and applies that methodology to an example “once-through” fuel cycle using low enrichment uranium (LEU) in conventional light water cooled reactors (LWRs). Within the DOE Office of Nuclear Energy Science and Technology - Fuel Cycle Technologies program, the Fuel Cycle Options Campaign “performs integrating analyses of nuclear energy and fuel cycle systems to inform fuel cycle R&D, programmatic decisions, strategy formulation, and policy development”. Campaign objectives include development of relevant fuel cycle metrics, and development of tools and associated data for analysis of fuel cycle systems. This study represents an extension of a prior evaluation of EROI as a metric for fuel cycle facilities, processes and technologies. That prior study [Simon 2011] addressed the energy return on the addition of fuel recycle to an existing nuclear energy system. Limited to just the addition of fuel recycle, that study did not include all the energy investments required to create, operate and decommission the underlying nuclear fuel cycle, such as uranium mining, fuel fabrication, reactor construction, and used fuel disposition. This extension of the prior work adds these remaining pieces of the fuel cycle to provide a basic evaluation framework and initial data to enable evaluation of EROI for nuclear energy in general. It is intended as a basis for evaluation of alternative fuel cycle options in the future with the addition of pertinent details for other fuel cycle scenarios. In the prior work, a spreadsheet tool was constructed for the specific purpose of this energy input/output analysis of nuclear fuel cycle facilities. This tool allows the user to enter the parameters of the nuclear fuel cycle and assumptions about energy use in reprocessing. In the current analysis, energy consumption for an entire nuclear energy enterprise is considered, including facility construction, materials, facility operation, and decommissioning. The analysis tool has been extended to include the entire fuel cycle for a representative scenario of a once-through LWR nuclear energy system. Energy content data have been developed for an initial representation. In many cases where there is a valid range of plausible energy content, the range is discussed and a representative value selected for demonstration of the evaluation methodology. In this analysis, energy produced is the energy output of power reactors within the fuel cycle. The spreadsheet calculates both Primary EROI and Final EROI for the fuel cycle entered. The EROI is the ratio of the output energy divided by the consumed energy. The intent for this study was to develop the methodology and analysis tool for a complete fuel cycle. It is not the intent of the study to fully explore the wide range of potential energy intensities, or to reconcile the disparate values found in the literature. Representative numbers were used in this demonstration. The methodology and tool do provide a framework for future exploration of the key energy intensity values and for conducting sensitivity studies on specific values, either to assess improved understanding of the values, or to explore the potential for alternative technologies to impact EROI. The Primary and Final Energy EROI values calculated for the representative scenario were ~ 52 and 24, respectively.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Technological advances for studying human behavior

Technological advances for studying human behavior are noted in viewgraph form. It is asserted that performance-aiding systems are proliferating without a fundamental understanding of how they would interact with the humans who must control them. Two views of automation research, the hardware view and the human-centered view, are listed. Other viewgraphs give information on vital elements for human-centered research, a continuum of the research process, available technologies, new technologies for persistent problems, a sample research infrastructure, the need for metrics, and examples of data-link technology.

Roske-Hofstrand, Renate J.↗

ISAAC Advanced Composites Research Testbed

The NASA Langley Research Center is acquiring a state-of-art composites fabrication capability to support the Center's advanced research and technology mission. The system introduced in this paper is named ISAAC (Integrated Structural Assembly of Advanced Composites). The initial operational capability of ISAAC is automated fiber placement, built around a commercial system from Electroimpact, Inc. that consists of a multi-degree of freedom robot platform, a tool changer mechanism, and a purpose-built fiber placement end effector. Examples are presented of the advanced materials, structures, structural concepts, fabrication processes and technology development that may be enabled using the ISAAC system. The fiber placement end effector may be used directly or with appropriate modifications for these studies, or other end effectors with different capabilities may either be bought or developed with NASA's partners in industry and academia.

Wu, K. Chauncey↗

Magneto-Acoustic Mixing Technology: A Novel Method of Processing Metal-Matrix Nanocomposites

In recent decades, nanoparticles have received substantial scientific attention due to their novel behavior and industrial applications, from quantum dots to catalysis.Synthesis of nanoparticles is often challenging, since they exist far from equilibrium with a high surface to volume ratio. This work investigates a novel nanoparticle fabrication methodology: combined reaction and acoustic cavitation abrasion of a solid in contact with a liquid. A mechanism is proposed by which particles are generated more effectively by the combination of reaction and cavitation than by either independently. In the current study, a novel method known as Magneto-Acoustic Mixing Technology (MAMT)[3] is used to produce nanometer to micron sized particles by chemical and acoustic mechanisms between diamond particles and a stainless steel surface in the presence of a metallic liquid, in this application Mg. This method demonstrates a number of advantages, including fabrication of novel chemistries and continuous particle production. This methodology is also easily adaptable to an in-situ nanoparticle generation mechanism for the production of metal matrix nanocomposites (MMnCs). In-situ particle generation methods like MAMT inherently limit particle agglomeration and improve the safety of nanocomposite fabrication by eliminating environmental contamination. In the current study, particle size, volume fraction, and chemistry are investigated, as well as the interaction of sonic power and chemical reaction.

36 MATERIALS SCIENCE↗

ISAAC - A Testbed for Advanced Composites Research

The NASA Langley Research Center is acquiring a state-of-art composites fabrication environment to support the Center's research and technology development mission. This overall system described in this paper is named ISAAC, or Integrated Structural Assembly of Advanced Composites. ISAAC's initial operational capability is a commercial robotic automated fiber placement system from Electroimpact, Inc. that consists of a multi-degree of freedom commercial robot platform, a tool changer mechanism, and a specialized automated fiber placement end effector. Examples are presented of how development of advanced composite materials, structures, fabrication processes and technology are enabled by utilizing the fiber placement end effector directly or with appropriate modifications. Alternatively, end effectors with different capabilities may either be bought or developed with NASA's partners in industry and academia.

Wu, K. Chauncey↗

State recommendations on approaches to LANDSAT

The feasibility of continuing the LANDSAT program is contingent upon the success of the technology transfer process to state and local governments. The focus of these concerns can be generally expressed in terms of these issue areas: (1) user needs, in terms of awareness, technical capabilities, and training; (2) product availability and pricing; and (3) roles and communication links, in terms of federal and state governments, the private sector, and the universities. The perspective of the states on these issues are classified. Where possible, alternative strategies for accomplishing the satellite technology transfer for effective state implementation are suggested. Those suggestions are based on the recommendations offered by the state and local user community.

Bay, S. M.↗

STATUS OF THE DEVELOPMENT OF IN-TANK/AT-TANK SEPARATIONS TECHNOLOGIES FOR FOR HIGH-LEVEL WASTE PROCESSING FOR THE U.S. DEPARTMENT OF ENERGY

Within the U.S. Department of Energy's (DOE) Office of Technology Innovation and Development, the Office of Waste Processing manages a research and development program related to the treatment and disposition of radioactive waste. At the Savannah River (South Carolina) and Hanford (Washington) Sites, approximately 90 million gallons of waste are distributed among 226 storage tanks (grouped or collocated in 'tank farms'). This waste may be considered to contain mixed and stratified high activity and low activity constituent waste liquids, salts and sludges that are collectively managed as high level waste (HLW). A large majority of these wastes and associated facilities are unique to the DOE, meaning many of the programs to treat these materials are 'first-of-a-kind' and unprecedented in scope and complexity. As a result, the technologies required to disposition these wastes must be developed from basic principles, or require significant re-engineering to adapt to DOE's specific applications. Of particular interest recently, the development of In-tank or At-Tank separation processes have the potential to treat waste with high returns on financial investment. The primary objective associated with In-Tank or At-Tank separation processes is to accelerate waste processing. Insertion of the technologies will (1) maximize available tank space to efficiently support permanent waste disposition including vitrification; (2) treat problematic waste prior to transfer to the primary processing facilities at either site (i.e., Hanford's Waste Treatment and Immobilization Plant (WTP) or Savannah River's Salt Waste Processing Facility (SWPF)); and (3) create a parallel treatment process to shorten the overall treatment duration. This paper will review the status of several of the R&D projects being developed by the U.S. DOE including insertion of the ion exchange (IX) technologies, such as Small Column Ion Exchange (SCIX) at Savannah River. This has the potential to align the salt and sludge processing life cycle, thereby reducing the Defense Waste Processing Facility (DWPF) mission by 7 years. Additionally at the Hanford site, problematic waste streams, such as high boehmite and phosphate wastes, could be treated prior to receipt by WTP and thus dramatically improve the capacity of the facility to process HLW. Treatment of boehmite by continuous sludge leaching (CSL) before receipt by WTP will dramatically reduce the process cycle time for the WTP pretreatment facility, while treatment of phosphate will significantly reduce the number of HLW borosilicate glass canisters produced at the WTP. These and other promising technologies will be discussed.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Progress in the Multijunction Solar Cell Mantech Program

In September, 1995, the joint Wright Laboratory/Phillips Laboratory/NASA Lewis Multijunction Solar Cell Manufacturing Technology (ManTech) Program began to improve multijunction cell performance and scale them up to production size and quantity to support Air Force and commercial satellite programs. The first milestone of the program has been reached and the purpose of this paper is to present the results of the program so far. The objectives of the Multijunction Solar Cell ManTech Program are to increase the GaInP2/GaAs/Ge lot average cell efficiency to 24-26%, increase the cell size to > or equal to 16 sq cm while maintaining high efficiency, and limit the per cell costs to < or equal to 1.15X state of the art GaAs/Ge cells. Advanced manufacturing technology and process control techniques such as in-situ process monitoring and real time process feedback are being used to optimize multijunction solar cell growth processes to achieve these goals. This paper will discuss progress made in Phase I of the program and give an overview of Phase II but will focus on side-by-side testing results collected by Phillips Laboratory and NASA Lewis on Phase I deliverable cells from both vendors. Cell performance, pre- and post radiation, and temperature coefficient results on initial production multijunction solar cells will be presented and discussed. The data shows that this technology meets the objectives of the program, and that, in the interim before a new solar simulation standard becomes widely available, the measurement techniques being used by the major space solar cell manufacturers are providing adequate testing results for solar array design.

Keener, David N.↗

Bosch - An alternate CO2 reduction technology

The Bosch process is the most promising CO2 reduction concept for future prolonged space missions. The paper presents the design of a three-person-capacity preprototype B-CRS (Bosch-based CO2 Reduction Subsystem). It is sized to reduce 3.0 kg/d CO2 generated by the crew and to supply the product water to an O2 generation subsystem to obtain O2. The design supports future development of the B-CRS as an alternative CO2 reduction subsystem to the Sabatier-based process presently under test at NASA. The discussion covers the Bosch CO2 reduction concept, process and hardware description, performance parameters, design specifications, subsystem schematic and operation, mechanical subsystem summary, control/monitor instrumentation, and subsystem packaging. A B-CRS with a proven technological base is an attractive CO2 reduction subsystem that eliminates overboard venting.

Heppner, D. B.↗

Production of Energy Efficient Preform Structures (PEEPS)

Due to its low density, good structural characteristics, excellent fabrication properties, and attractive appearance, aluminum metal and its alloys continue to be widely utilized. The transportation industry continues to be the largest consumer of aluminum products, with aerospace as the principal driver for this use. Boeing has long been the largest single company consumer of heat-treated aluminum in the U.S. The extensive use of aluminum to build aircraft and launch vehicles has been sustained, despite the growing reliance on more structurally efficient carbon fiber reinforced composite materials. The trend in the aerospace industry over the past several decades has been to rely extensively on large, complex, thin-walled, monolithic machined structural components, which are fabricated from heavy billets and thick plate using high speed machining. The use of these high buy-to-fly ratio starting product forms, while currently cost effective, is energy inefficient, with a high environmental impact. The widespread implementation of Solid State Joining (SSJ) technologies, to produce lower buy-to-fly ratio starting forms, tailored to each specific application, offers the potential for a more sustainable manufacturing strategy, which would consume less energy, require less material, and reduce material and manufacturing costs. One objective of this project was to project the energy benefits of using SSJ techniques to produce high-performance aluminum structures if implemented in the production of the world fleet of commercial aircraft. A further objective was to produce an energy consumption prediction model, capable of calculating the total energy consumption, solid waste burden, acidification potential, and CO2 burden in producing a starting product form - whether by conventional or SSJ processes - and machining that to a final part configuration. The model needed to be capable of computing and comparing, on an individual part/geometry basis, multiple possible manufacturing pathways, to identify the best balance of energy consumption and environmental impact. This model has been created and populated with energy consumption data for individual SSJ processes and process platforms. Technology feasibility cases studies were executed, to validate the model, and confirm the ability to create lower buy-to-fly ratio performs and machine these to final configuration aircraft components. This model can now be used as a tool to select manufacturing pathways that offer significant energy savings and, when coupled with a cost model, drive implementation of the SSJ processes.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Failure Predictions of Out-of-Autoclave Sandwich Joints with Delaminations under Flexure Loads

An analysis and a test program was conducted to investigate the damage tolerance of composite sandwich joints. The joints contained a single circular delamination between the face-sheet and the doubler. The coupons were fabricated through out-of-autoclave (OOA) processes, a technology NASA is investigating for joining large composite sections. The four-point bend flexure test was used to induce compression loading into the side of the joint where the delamination was placed. The compression side was chosen since it tends to be one of the most critical loads in launch vehicles. Autoclave cure was used to manufacture the composite sandwich sections, while the doubler was co-bonded onto the sandwich face-sheet using an OOA process after sandwich panels were cured. A building block approach was adopted to characterize the mechanical properties of the joint material, including the fracture toughness between the doubler and facesheet. Twelve four-point-bend samples were tested, six in the sandwich core ribbon orientation and six in sandwich core cross-ribbon direction. Analysis predicted failure initiation and propagation at the pre-delaminated location, consistent with experimental observations. A building block approach using fracture analyses methods predicted failure loads in close agreement with tests. This investigation demonstrated a small strength reduction due to a flaw of significant size compared to the width of the sample. Therefore, concerns of bonding an OOA material to an in-autoclave material was mitigated for the geometries, materials, and load configurations considered.

Damage↗

Failure Predictions of Out-of-Autoclave Sandwich Joints with Delaminations Under Flexure Loads

An analysis and a test program was conducted to investigate the damage tolerance of composite sandwich joints. The joints contained a single circular delamination between the face-sheet and the doubler. The coupons were fabricated through out-of-autoclave (OOA) processes, a technology NASA is investigating for joining large composite sections. The four-point bend flexure test was used to induce compression loading into the side of the joint where the delamination was placed. The compression side was chosen since it tends to be one of the most critical loads in launch vehicles. Autoclave cure was used to manufacture the composite sandwich sections, while the doubler was co-bonded onto the sandwich face-sheet using an OOA process after sandwich panels were cured. A building block approach was adopted to characterize the mechanical properties of the joint material, including the fracture toughness between the doubler and face-sheet. Twelve four-point-bend samples were tested, six in the sandwich core ribbon orientation and six in sandwich core cross-ribbon direction. Analysis predicted failure initiation and propagation at the pre-delaminated location, consistent with experimental observations. Fracture analyses methods predicted failure loads in close agreement with tests. This investigation demonstrated a strength reduction of 10 percent due to a flaw of significant size compared to the width of the sample. Therefore, concerns of bonding an OOA material to an in-autoclave material was mitigated for the geometries, materials, and load configurations considered.

Tolerance↗

Failure Predictions of Out-of-Autoclave Sandwich Joints with Delaminations Under Flexure Loads

An analysis and a test program was conducted to investigate the damage tolerance of composite sandwich joints. The joints contained a single circular delamination between the face-sheet and the doubler. The coupons were fabricated through out-of-autoclave (OOA) processes, a technology NASA is investigating for joining large composite sections. The four-point bend flexure test was used to induce compression loading into the side of the joint where the delamination was placed. The compression side was chosen since it tends to be one of the most critical loads in launch vehicles. Autoclave cure was used to manufacture the composite sandwich sections, while the doubler was co-bonded onto the sandwich face-sheet using an OOA process after sandwich panels were cured. A building block approach was adopted to characterize the mechanical properties of the joint material, including the fracture toughness between the doubler and face-sheet. Twelve four-point-bend samples were tested, six in the sandwich core ribbon orientation and six in sandwich core cross-ribbon direction. Analysis predicted failure initiation and propagation at the pre-delaminated location, consistent with experimental observations. A building block approach using fracture analyses methods predicted failure loads in close agreement with tests. This investigation demonstrated a small strength reduction due to a flaw of significant size compared to the width of the sample. Therefore, concerns of bonding an OOA material to an in-autoclave material was mitigated for the geometries, materials, and load configurations considered.

Tolerance↗

Digitalization mapping and assessment process supporting ION strategic transformation activities

The existing fleet of commercial nuclear power plants (NPPs) are an important asset in the nation’s portfolio of electrical generating resources. Their continued safe and reliable operation are critical to providing a large source of carbon-free electricity to power the nation’s economy. The United States Department of Energy’s (DOE) Light Water Reactor Sustainability (LWRS) Program develops the scientific bases, methods, and tools, for the continued safe and economical operation of the nation's commercial NPPs. The Plant Modernization Pathway within LWRS Program focuses on providing guidance to industry on the full-scale implementation of modernization solutions for NPPs that significantly reduce the technical and financial risks associated with modernization. This research is focused on helping the nuclear industry understand how to digitize and digitalize their NPPs so that they can design their modernization solutions to be scalable, sustainable, and integrated both laterally and horizontally within their organization. That is, this research creates a digital transformation in NPPs by reshaping cultural mindsets and by identifying business efficiencies. In partnership with industry, and using four previously established guiding principles for digitalization, this research supported NPP modernization through assessing readiness for digitalization as a means to achieve integrated operations for nuclear. Specifically, this research created an assessment to review an entire organization’s work processes to gather information about the digitalization health of the plant. The assessment tools were administered to plant employees, and the results were used to develop a digitalization plan. The survey assessment identified the optimal candidate processes that would most benefit from a digitalization initiative which were revealed through analytical frameworks. One analysis calculated mean digitalization health indicator scores for all endorsed activities which allowed the researchers to rank and color code the results for easy identification. Individual health indicator scores are also provided, should our industry partner wish to understand these findings according to their own organizational priorities, business considerations and desired end-state. The results were also analyzed from the perspective that organizations are comprised of different types of innovators (e.g., generators, optimizers, conceptualizers, and implementers), which differentially affects the organization’s ability to comprehend and adapt to change (i.e., opportunities to innovate). Understanding the relative composition of innovator types at an NPP allows them to gather insights into the strengths and weaknesses they have in innovating how work is performed. For the utility that partnered with this research team, the results showed that implementers make up the largest portion of respondents and conceptualizers the smallest portion. Knowing the proportion of innovator types gave this organization insights on how they can effectively implement their innovation solutions. Additionally, the results were analyzed from a technical, economic, and risk perspective to identify and quantify work reduction opportunities (WROs). Recognizing that not all cost-saving opportunities are the same, a Technical, Economic and Risk Assessment (TERA) was performed to evaluate WROs to identify areas of greatest potential and lowest risk. The key results from TERA included a digitalization opportunity score for each activity, and a calculation of potential cost savings. These two outputs formed the bases for calculating a priority index and rank for the activities/processes assessed. From the prioritization calculations, TERA can then help the utility 1) decide what digitalization priorities to invest money in implementing and then 2) calculates how much should be invested in the digitalization initiatives selected to achieve cost savings and/or an acceptable return on investment. Last, onsite interviews revealed several inefficiencies in the standard work processes that occur cross-departmentally that are due to the absence of digitized and digitalized processes. Examples of these include time spent scanning paper documents and then uploading the documents electronically, obtaining signatures, and searching for desired information. This represents a digital but not digitalized process. Over 15 opportunities to improve work processes were identified through this multi-method digitalization assessment. The various analytical assessments used (e.g., TERA, digitalization health indicator scores), as well as discussions with the utility partner, corroborated that all the opportunities identified had a strong potential to make work processes more efficient and to improve overall performance of the NPP.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Composite structural materials

Progress is reported in studies of constituent materials composite materials, generic structural elements, processing science technology, and maintaining long-term structural integrity. Topics discussed include: mechanical properties of high performance carbon fibers; fatigue in composite materials; experimental and theoretical studies of moisture and temperature effects on the mechanical properties of graphite-epoxy laminates and neat resins; numerical investigations of the micromechanics of composite fracture; delamination failures of composite laminates; effect of notch size on composite laminates; improved beam theory for anisotropic materials; variation of resin properties through the thickness of cured samples; numerical analysis composite processing; heat treatment of metal matrix composites, and the RP-1 and RP2 gliders of the sailplane project.

Ansell, G. S.↗

Pilger Mill Processing

The Nuclear Technology Research & Development program of the Office of Nuclear Energy has implemented a program to develop an advanced reactor cladding fabrication capability by using the extrusion and pilgering processes. Oxide-dispersion strengthened (ODS) steels are a promising class of advanced materials, but processes need to be developed to produce tubing for these advanced alloys. The Pacific Northwest National Laboratory (PNNL) has converted its rolling mill into a lab-scale pilger mill, which required designing pilger tooling and rolls that contained multiple pilgering grooves and designing a servo-driven feed mechanism. Upon assembling and checking out the system, pilgering runs on stainless steel, MA956, and 14YWT iron (Fe)-based alloys were completed. The feed rates and rotation rates were established, the reduction schedules were determined. This report will provide a description of the lab-scale pilger mill performance and processing results for the stainless steel, MA956, and 14YWT alloys.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A Process for Comparing Dynamics of Distributed Space Systems Simulations

The paper describes a process that was developed for comparing the primary orbital dynamics behavior between space systems distributed simulations. This process is used to characterize and understand the fundamental fidelities and compatibilities of the modeling of orbital dynamics between spacecraft simulations. This is required for high-latency distributed simulations such as NASA s Integrated Mission Simulation and must be understood when reporting results from simulation executions. This paper presents 10 principal comparison tests along with their rationale and examples of the results. The Integrated Mission Simulation (IMSim) (formerly know as the Distributed Space Exploration Simulation (DSES)) is a NASA research and development project focusing on the technologies and processes that are related to the collaborative simulation of complex space systems involved in the exploration of our solar system. Currently, the NASA centers that are actively participating in the IMSim project are the Ames Research Center, the Jet Propulsion Laboratory (JPL), the Johnson Space Center (JSC), the Kennedy Space Center, the Langley Research Center and the Marshall Space Flight Center. In concept, each center participating in IMSim has its own set of simulation models and environment(s). These simulation tools are used to build the various simulation products that are used for scientific investigation, engineering analysis, system design, training, planning, operations and more. Working individually, these production simulations provide important data to various NASA projects.

Cures, Edwin Z.↗