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NASA NTRS2017

An Advanced Trajectory-Based Operations Prototype Tool and Focus Group Evaluation

Trajectory-based operations (TBO) is a key concept in the Next Generation Air Transportation System transformation of the National Airspace System (NAS) that will increase the predictability and stability of traffic flows, support a common operational picture through the use of digital data sharing, facilitate more effective collaborative decision making between airspace users and air navigation service providers, and enable increased levels of integrated automation across the NAS. The National Aeronautics and Space Administration (NASA) has been developing trajectory-based systems to improve the efficiency of the NAS during specific phases of flight and is now also exploring Advanced 4-Dimensional Trajectory (4DT) operational concepts that will integrate these technologies and incorporate new technology where needed to create both automation and procedures to support gate-to-gate TBO. A TBO Prototype simulation toolkit has been developed that demonstrates initial functionality that may reside in an Advanced 4DT TBO concept. Pilot and controller subject matter experts (SMEs) were brought to the Air Traffic Operations Laboratory at NASA Langley Research Center for discussions on an Advanced 4DT operational concept and were provided an interactive demonstration of the TBO Prototype using four example scenarios. The SMEs provided feedback on potential operational, technological, and procedural opportunities and concerns. After viewing the interactive demonstration scenarios, the SMEs felt the operational capabilities demonstrated would be useful for performing TBO while maintaining situation awareness and low mental workload. The TBO concept demonstrated produced defined routings around weather which resulted in a more organized, consistent flow of traffic where it was clear to both the controller and pilot what route the aircraft was to follow. In general, the controller SMEs felt that traffic flow management should be responsible for generating and negotiating the operational constraints demonstrated, in cooperation with the Air Traffic Control System Command Center, while air traffic control should be responsible for the implementation of those constraints. The SMEs also indicated that digital data communications would be very beneficial for TBO operations and would result in less workload due to reduced communications, would eliminate issues due to language barriers and frequency problems, and would make receiving, loading, accepting, and executing clearances easier, less ambiguous, and more expeditious. This paper describes an Advanced 4DT operational concept, the TBO Prototype, the demonstration scenarios and methods used, and the feedback obtained from the pilot and controller SMEs in this focus group evaluation.

Guerreiro, Nelson M.↗
NASA NTRSDate not supplied

A Prototype Early Planetary Organic Processor Assembly (OPA) Based on Dual-Stage Anaerobic Membrane Bioreactor (AnMBR) for Fecal and Food Waste Treatment and Resource Recovery

Long-duration, deep-space exploration and habitation missions demand robust and reliable technologies to ensure crew health, safety, and mission success. Local food production will be essential for crew nutrition and morale. However, at $10,000/lb, the payload costs and mass/volume limitations to transport and provide the necessary resources, including fertilizer, for an anticipated 30-month mission become challenging over time. For mission success and sustainability, the Environmental Control and Life Support System (ECLSS) of the near future will need to recover resources from all “waste” sources and be near-closed loop. Organic wastes (e.g., fecal and food) offer a renewable source of C, N, P, water and other trace elements necessary to sustain crop production. However, these high solidwastes are often difficult to treatdue to factors includingheterogeneity, complexity, high organic strength, and the presence of pathogens. To date, there is no flight-ready technology capable of treating mixed organic wastes, creating a technology gap for future space missions. To address this need, a prototype Organic Processor Assembly (OPA) was developed through collaboration between the University of South Florida (USF) and NASA’s Kennedy Space Center (KSC). The OPA is based on the anaerobic membrane bioreactor (AnMBR), a hybrid technology coupling high-rate anaerobic digestion with membrane filtration. The system is designed for an early planetary base (EPB) scenario to aid in closing the resource recovery loop and decreaseresupply dependence. This presentation discusses initial research pertaining to: 1) design challenges in maximizing hydraulic/organic throughputandReliability, Availability, Maintainability, and Safety(RAMS)while minimizingmass and volume; 2) create capabilities for treating simulated high solids waste under steady and non-steady state conditions; and 3) measuresolids performance parameter(s). Future research and development pertaining to further optimization on system operation, performance, and expanded treatment capabilities arepresented.

Bioreactor↗
DOE OSTI2024

Department of Energy/IDEA: More best-practices research

This article continues the overview of the U.S. Department of Energy and IDEA collaboration by highlighting additional case studies that demonstrate innovative engineering approaches in district energy systems. It focuses on how campuses are improving efficiency, integrating advanced technologies, and reducing energy use and emissions through data-driven strategies. The University of Cincinnati is featured for its highly efficient chilled water system, using advanced algorithms and upgraded “smart chillers” to optimize performance, reduce energy consumption, and lower costs. Wake Forest University emphasizes a data-informed modernization process, using system optimization and targeted building improvements to significantly boost efficiency and reduce overall energy use. Arizona Western College showcases creative solutions to extreme cooling demands, including system redesign, smart controls, and thermal storage to improve reliability and cut peak energy costs. Overall, the article demonstrates that combining innovative engineering, real-time data analysis, and system optimization can significantly enhance performance, reduce emissions, and deliver cost savings in district energy systems.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗
DOE OSTI2025

DESI 2024 VII: cosmological constraints from the full-shape modeling of clustering measurements

We present cosmological results from the measurement of clustering of galaxy, quasar and Lyman-α forest tracers from the first year of observations with the Dark Energy Spectroscopic Instrument (DESI Data Release 1). We adopt the full-shape (FS) modeling of the power spectrum, including the effects of redshift-space distortions, in an analysis which has been thoroughly validated in a series of supporting papers as summarised in [1]. We combine the full-shape information with DESI's DR1 constraints from the baryon acoustic oscillations (BAO) of these tracers. In the flat ΛCDM cosmological model, DESI (FS+BAO), combined with a baryon density prior from Big Bang Nucleosynthesis and a weak prior on the scalar spectral index, determines matter density to Ω m = 0.2962 ± 0.0095, and the amplitude of mass fluctuations to σ 8 = 0.842 ± 0.034. The addition of the cosmic microwave background (CMB) data tightens these constraints to Ω m = 0.3056 ± 0.0049 and σ 8 = 0.8121 ± 0.0053, while further addition of the joint clustering and lensing analysis from the Dark Energy Survey Year-3 (DESY3) data further improves these measurements, and leads to a 0.4% determination of the Hubble constant, H 0 = (68.40 ± 0.27) km s -1 Mpc -1 . In models with a time-varying dark energy equation of state parametrised by w 0 and w a , combinations of DESI (FS+BAO) with CMB and type Ia supernovae continue to show the preference, previously found in the DESI DR1 BAO analysis, for w 0 > -1 and w a < 0 with similar levels of significance. DESI data, in combination with the CMB, improve the upper limits on the sum of the neutrino masses relative to the case when only the DR1 BAO was available, giving ∑m ν < 0.071 eV at 95% confidence. We finally constrain deviations from general relativity represented by two modified gravity parameters. DESI (FS+BAO) data alone measure the parameter that controls the clustering of massive particles, μ 0 = 0.11 +0.45 -0.54 , in agreement with the zero value predicted by general relativity. The combination of DESI with the CMB and the clustering and lensing analysis from DESY3 constrains both modified-gravity parameters, giving μ 0 = 0.04 ± 0.22 and Σ 0 = 0.044 ± 0.047, again in agreement with general relativity.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2024

Maps of plant functional type (PFT), PFT fractional cover, and uncertainty derived from AVIRIS-NG data, 2019, Seward Peninsula

Remote sensing maps of plant functional type (PFT), PFT fractional cover (fCover), and fCover uncertainty maps derived from NASA’s Airborne Visible / Infrared Imaging Spectrometer – Next Generation (AVIRIS-NG). The AVIRIS-NG imaging spectroscopy data (380 ~ 2510 nm) was collected as a part of the collaboration between NASA’s Arctic-Boreal Vulnerability Experiment (ABoVE; Miller et al., 2019) and DOE’s Next Generation Ecosystem Experiment in the Arctic (NGEE-Arctic). This package includes maps for flights over Teller, Kougarok, and Council watersheds created using eight AVIRIS-NG imagery collected in July, 2019. The map data and metadata are provided as image (ENVI, *.png) and text (*.txt, *hdr) formats. Additional supporting map quicklooks are provided as GIS *.kml files. Detailed description of the methods for each map are provided in Yang et al., (2023). These datasets are provided in support of Yang et al., (In revision) “Topography and Functional Traits Control the Distribution of Key Shrub Plant Functional Types in Low-Arctic Tundra”.The Next-Generation Ecosystem Experiments: Arctic (NGEE Arctic), was a research effort to reduce uncertainty in Earth System Models by developing a predictive understanding of carbon-rich Arctic ecosystems and feedbacks to climate. NGEE Arctic was supported by the Department of Energy's Office of Biological and Environmental Research.The NGEE Arctic project had two field research sites: 1) located within the Arctic polygonal tundra coastal region on the Barrow Environmental Observatory (BEO) and the North Slope near Utqiagvik (Barrow), Alaska and 2) multiple areas on the discontinuous permafrost region of the Seward Peninsula north of Nome, Alaska.Through observations, experiments, and synthesis with existing datasets, NGEE Arctic provided an enhanced knowledge base for multi-scale modeling and contributed to improved process representation at global pan-Arctic scales within the Department of Energy's Earth system Model (the Energy Exascale Earth System Model, or E3SM), and specifically within the E3SM Land Model component (ELM).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Accelerator Physics at NSLS-II: Research Accomplishments in 2024

NSLS-II accelerator physicists advanced the operational performance and scientific capabilities of NSLS-II, providing regular lattice characterization and correction, injec tion optimization, vertical emittance control, and beam dynamics reports with corre lation analysis. We further developed advanced lattice characterization techniques and studies on impedance, beam-induced heating, and higher-harmonic RF cavity effects to support NSLS-II and its high-brightness upgrade. The assessment of free-electron laser options for the NSLS-II upgrade has been completed. We carried out comprehensive studies focused on complex bend magnets and novel efficient injection schemes for next-generation low-emittance synchrotrons. We contributed to the Electron-Ion Collider project, including Electron Storage Ring lattice design, beam diagnostics, and injector studies. The physicists participated in international collaborations, including the development of Python-based Middle Layer software, and participated in key accel erator physics workshops and scientific meetings. The main research accomplishments achieved in 2024 are summarized in this report.

43 PARTICLE ACCELERATORS↗
DOE OSTI2019

Collaborative Project: An Integrated Parameterization of Boundary Layer and Convective Mixing: The Eddy-Diffusivity/Mass-Flux (EDMF) Approach

The key goal of this project was to reduce cloud modeling deficiencies and biases by developing and implementing a new unified boundary layer and convection parameterization based on the multi-plume Eddy-Diffusivity/Mass-Flux (EDMF) approach. This is a turbulence and convection parameterization that can be considered fully unified, in the sense that it is able to represent convective processes from boundary layer convection to deep moist convection with one single parameterization. This project will ultimately lead to more accurate climate predictions, which have a significant societal impact. In general, turbulence and convection in the atmosphere are at the core of key climate prediction problems. For example: i) to reduce uncertainties in climate projections, it is essential to improve predictions of cloud feedbacks (how clouds respond to, and influence, climate change), which are controlled by the interactions between a turbulent flow with water phase transitions and radiation; (ii) to improve extreme weather prediction under climate change, it is essential to improve our understanding of how moist convection responds to a warmer world. A fully unified boundary layer and convection parameterization, such as EDMF, will help better represent and predict boundary layer, cloud and convection processes in the atmosphere during present and future climate. The following are the specific tasks that were completed and addressed the project’s objectives: i) Implementation and evaluation of the multi-plume EDMF parameterization into the Single Column Model (SCM) version of CESM; ii) Development of a fully unified multi-plume (shallow to deep convection) EDMF parameterization – that is also scale-aware; iii) Implementation and evaluation of the moist multi-plume EDMF scheme in the global version of WRF; iv) Extension and evaluation of the LES model to deep moist convection regimes; v) Implementation of EDMF in the SCM version of the LBL dynamical core.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Micro-Environmental Control System (Final Report)

This project developed an innovative micro-environmental control system (µX) that enables office buildings to reduce energy used for heating and cooling by 15% or more. The µX is a compact, quiet, and ergonomic device that is designed to be installed under an office workstation; it is designed to maintain occupant comfort when room thermostat setpoints are incremented by 4°F or more (warmer in the summer and cooler in the winter) to save energy. When ambient room temperatures are outside of the usual comfort range, the µX maintains occupant comfort by delivering personalized cooling or heating locally to each office worker. The µX provides personalized cooling using a micro vapor compression system that includes a new high-performance micro-scroll compressor and a novel thermal storage unit. The vapor compression system operates at night to freeze a phase-change material (PCM). During the workday, the cooling stored in the PCM is released as a cool breeze of air to make occupants more comfortable. The micro-scroll compressor was developed specifically for this application; it is smaller than any of its type, minimizing the amount of power needed. In heating mode, the µX maintains occupant comfort using a foot heating mat with an infrared reflective box. The µX R&D project was conducted by Syracuse University in collaboration with United Technologies Research Center, Air Innovations, Bush Technical, and Cornell University. Over the course of the initial three-year project, the team developed and evaluated four versions of the unit, advancing the concept to Technology Readiness Level 6. The capabilities of individual proof-of-concept prototypes were verified in tests that were conducted with: 1) units in psychrometric chambers, 2) an instrumented manikin in a laboratory, and 3) human subjects in laboratories that simulate office environments. The tests verified that the µX prototypes met or exceeded all performance targets required to enable office buildings to reduce energy used for heating and cooling by 15% or more by maintaining occupant comfort when thermostat setpoints are incremented by 4°F or more.

25 ENERGY STORAGE↗
DOE OSTI2024

Mixed-phase Convective Clouds in the Polar Marine Boundary Layer

This proposal, a collaboration between two universities, firstly aims to describe the high-latitude CAO cloud regime using the array of instruments at the NSA (Barrow, Alaska) and at two mobile ARM sites (MARCUS 2017-18, and COMBLE 2020). These ARM data, and the multi-sensor variables we propose to derive, allow detailed descriptions of mesoscale organization of precipitation, thermodynamic profiles, vertical velocity, cloud depth, and cloud and precipitation properties. These observations are key for our second goal, which is to use output from validated cloud- and eddy-resolving simulations to gain insights into the linkages between microphysical processes, the MBL vertical structure, and the MBL dynamics that control cloud macrostructure.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Lightweight Metal Stamping Optimization Enabled by Artificial Intelligence

Successfully manufacturing an automotive body structure made via the sheet metal stamping process depends upon simultaneous consideration of component design, tooling design, stamping process control, and material properties. In many cases, introducing lightweight sheet materials (e.g., aluminum alloys, magnesium alloys, advanced high strength steels) holds the potential to significantly reduce vehicle weight, but challenges the stamping process by introducing materials with inherently less ductility. Successful and repeatable applications require co-developing the stamping process controls with the varying material properties, including formability. During the stamping process, as soon as the forming limit of the sheet is exceeded, the material shows localized necking which quickly leads to splits. Controlling process variability to avoid these material splits will enable deployment of less formable, lighter, and stronger materials for stamped automotive components. A typical optimization procedure for manufacturing requires an iterative process involving parameter setting, execution of computational simulations, and modifying the parameters. The entire process demands substantial computational time, making it impractical for real-time feedback towards rapid corrective actions required for in-line control for running production processes. To overcome this challenge, artificial intelligence (AI) can be leveraged to determine optimal manufacturing parameters within a single manufacturing cycle time. This research proposes an in-line optimization framework incorporating a trained AI model to predict kidney-shaped die forming. Preliminary results indicate that the AI framework can accurately predict draw-in values based on a given parameter set, a process referred to as forward prediction. Furthermore, the AI framework can also predict the optimal parameter set that leads to the desired draw-in values, referred to as inverse optimization (or backward prediction). This research has been performed in collaborations with USCAR (US Council for Automotive Research) and AutoForm. The members of USCAR are Ford, GM, and Stellantis.

36 MATERIALS SCIENCE↗
NASA NTRS1993

Overview of research in progress at the Center of Excellence

The Center of Excellence (COE) was created nine years ago to facilitate active collaboration between the scientists at Ames Research Center and the Stanford Psychology Department. Significant interchange of ideas and personnel continues between Stanford and participating groups at NASA-Ames; the COE serves its function well. This progress report is organized into sections divided by project. Each section contains a list of investigators, a background statement, progress report, and a proposal for work during the coming year. The projects are: Algorithms for development and calibration of visual systems, Visually optimized image compression, Evaluation of advanced piloting displays, Spectral representations of color, Perception of motion in man and machine, Automation and decision making, and Motion information used for navigation and control.

Wandell, Brian A.↗
NASA NTRS2002

MISSE PEACE Polymers: An International Space Station Environmental Exposure Experiment Being Conducted

As part of the Materials International Space Station Experiment (MISSE), 41 different polymers are being exposed for approximately 1 1/2 years to the low-Earth-orbit (LEO) environment on the exterior of the International Space Station. MISSE is a materials flight experiment sponsored by the Air Force Research Lab/Materials Lab and NASA, and is the first external experiment on the space station. A similar set of 41 polymers will be flown as part of the Polymer Erosion and Contamination Experiment (PEACE) a shuttle flight experiment that is being developed at the NASA Glenn Research Center collaboratively with the Hathaway Brown School for girls. Therefore, these 41 polymers are collectively called the MISSE PEACE Polymers. The purpose of the MISSE PEACE Polymers experiment is to determine how durable polymers are in the LEO space environment where spacecraft, such as the space station, orbit. Polymers are commonly used as spacecraft materials because of their desirable properties such as good flexibility, low density, and certain electrical properties or optical properties (such as a low solar absorptance and high thermal emittance). Two examples of the use of polymers on the exterior of spacecraft exposed to the space environment include metalized Teflon FEP (fluorinated ethylene propylene, DuPont) thermal control materials on the Hubble Space Telescope, and polyimide Kapton (DuPont) solar array blankets.

deGroh, Kim K.↗
NASA NTRS2013

NASA Activity Update for the 2013 Unmanned Vehicle Systems International (UVSI) Yearbook

This year s report offers a high level perspective on some of the UAS related activities in which NASA is involved, both internal and external to the agency. Internally, NASA issued UAS operational policy on certification of NASA UAS and aircrew. A team of NASA UAS experts and operators analyzed all current procedures and best practices to design the policy. An update to the agencies Aircraft Operations Management Manual incorporated a new chapter to address UAS planning, preflight operations, flight operations, flight crew requirements, airworthiness and flight safety reviews. NASA UAS are classified into three categories based on weight and airspeed. Aircrews, including observers, are classified by how they interface with the UAS, and the policy defines qualifications, training, and currency. The NASA flight readiness approval process identifies risks and mitigations in order to reduce the likelihood and/or consequence of the risk to an acceptable level. The UAS operations process incorporates all aspects of airworthiness, flight standards and range safety exactly the same processes used for NASA manned aircraft operations. NASA has two internal organizations that routinely operate UAS. The Science Mission Directorate utilizes UAS as part of its Airborne Science Program and is the most frequent operator of NASA UAS in both national and international airspace. The Aeronautics Research Mission Directorate conducts UAS flight operations in addition to conducting research important to the UAS community. This past year the Science Mission Directorate supported the Hurricane and Severe Storm Sentimental (HS3) Mission with two NASA Global Hawk platforms. HS3 is a five-year mission specifically targeted to investigate the processes that underlie hurricane formation. During the 2012 portion of this mission the Global Hawk overflew hurricanes Leslie and Nadine in the Atlantic Ocean completing 6 flights and accumulating more than 148 flight hours. Another multi-year mission was initiated last year when the Sensor Integrated Environmental Remote Research Aircraft (SIERRA) UAS began surveying faults in California s Surprise Valley. A team of scientists and engineers from the United States Geological Survey (USGS), NASA Ames Research Center, Central Washington University, and Carnegie Mellon University will measure magnetic fields using ground surveys and the SIERRA to map the geophysics below the surface of Surprise Valley. The data collected will be used to generate 3D maps of the geophysical data of the area. The Aeronautics Mission Directorate continues its collaboration with Boeing to conduct UAS flight operations of the X-48C, a modified version of the X-48B originally built by Cranfield Aerospace, United Kingdom. The Aeronautics Mission Directorate utilizes vehicles of this size for a wide variety of research studies. Most of these operations are conducted within restricted airspace. The Aeronautics Research Mission Directorate also sponsors the UAS in the National Airspace System (NAS) Project, which is working in close cooperation with the Federal Aviation Administration (FAA) to address critical challenges associated with routine UAS operations in civil airspace. The project is focused on separation assurance and collision avoidance systems and algorithms, command and control for non-military operations including spectrum allocation requirements, human system interaction issues, and safety and certification topics.

Bauer, Jeffrey E.↗
NASA NTRS2010

Request-Driven Schedule Automation for the Deep Space Network

The DSN Scheduling Engine (DSE) has been developed to increase the level of automated scheduling support available to users of NASA s Deep Space Network (DSN). We have adopted a request-driven approach to DSN scheduling, in contrast to the activity-oriented approach used up to now. Scheduling requests allow users to declaratively specify patterns and conditions on their DSN service allocations, including timing, resource requirements, gaps, overlaps, time linkages among services, repetition, priorities, and a wide range of additional factors and preferences. The DSE incorporates a model of the key constraints and preferences of the DSN scheduling domain, along with algorithms to expand scheduling requests into valid resource allocations, to resolve schedule conflicts, and to repair unsatisfied requests. We use time-bounded systematic search with constraint relaxation to return nearby solutions if exact ones cannot be found, where the relaxation options and order are under user control. To explore the usability aspects of our approach we have developed a graphical user interface incorporating some crucial features to make it easier to work with complex scheduling requests. Among these are: progressive revelation of relevant detail, immediate propagation and visual feedback from a user s decisions, and a meeting calendar metaphor for repeated patterns of requests. Even as a prototype, the DSE has been deployed and adopted as the initial step in building the operational DSN schedule, thus representing an important initial validation of our overall approach. The DSE is a core element of the DSN Service Scheduling Software (S(sup 3)), a web-based collaborative scheduling system now under development for deployment to all DSN users.

Johnston, Mark D.↗
NASA NTRS2020

Model Validation for Bigelow Expandable Activity Module (BEAM) with Stowage

The Bigelow Expandable Activity Module (BEAM) was a collaboration between NASA and Bigelow Aerospace to develop an expandable habitat technology that could be used for future space exploration missions such as the Artemis program. On April 26, 2016, the BEAM was launched and berthed to the International Space Station (ISS) on the aft port of Node 3. After the originally planned two-year mission life, BEAM was approved for use as a stowage module for a 109-cargotransfer bag equivalent (CTBE) to alleviate stowage limitations onboard the ISS. The present work builds on the previous 2017 model validation to flight data that demonstrated that BEAM could generally accommodate cargo stowage without adversely affecting BEAM thermal control, primarily for condensation management. Once the stowage was configured in early 2019, model validation efforts resumed. The thermal model revisions included the CTBE stowage and updated CFD-derived heat transfer coefficients for various intra-module ventilation (IMV) flow rates. The coefficients were provided by the Crew and Thermal Systems Division (EC) at NASA JSC and Jacobs Technology. The model is now revalidated and able to predict minimum temperatures with good agreement to flight temperatures (within 1 °C) for both historic and recurring minimum values. Additionally, the model is partially validated for reduced flow rates. With this model, the team was able to provide new flight rule recommendations for condensation and IMV operations management.

Sydney Taylor↗
DOE OSTI2022

Need for research and training reactors for advanced reactor designs

Full text of publication follows. Research and training reactors have served a valuable role in helping train workforce for currently operating fleet of light water reactors. These research and training reactors have been used in reactor laboratory classes to familiarize the students with such vital concepts as approach to criticality, reactor period, neutron moderation, reactivity, flux distribution and leakage, etc. As the industry moves toward advanced non-light-water reactor designs, it is critical that research and training reactors be developed and deployed at university campuses to help train the new generation of nuclear and non-nuclear engineers who are likely to design, build, and operate these advanced reactors. Among the designs currently being pursued for nuclear power generation include molten salt, sodium cooled, and gas cooled designs, with options for various fuel forms. Thus, industry and DOE in collaboration with academic institutions should devise plans on how to familiarize the next generation of nuclear workforce with hands-on experience necessary for such designs. These research and training reactors will play a vital role in familiarizing the future workforce with hands-on experience with concepts associated with fast spectrum reactors, gas cooled reactors, and other features not associated with light water reactors. In addition to classical nuclear engineering concepts, these advanced research and training reactors can also be used for hands-on training as well as for research on features being considered in the design of GEN-IV reactors: cyber security for digital control room operations, hybrid energy system, hydrogen generation, district heating, autonomous control... (author)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Mitigate Stress Corrosion Cracking (SCC) in High-strength Al Castings (CRADA 508)

Development of high strength, corrosion resistant, aluminum alloys is important to a number of industries, including automotive, aerospace, power, etc. Understanding how processing methods such as casting, chemistry, additives and recycle content affect an alloy’s microstructure and performance in real world environments is crucial to their implementation. One major concern is how the repeated exposure to saline solutions can be detrimental to the structural integrity of aluminum alloy components. This study was undertaken as a collaboration between Eck Industries and PNNL to investigate the stress corrosion cracking (SCC) and corrosion behavior of aluminum alloys. This work examines the SCC response of three different materials set. First is cast A206 Al alloy produced by three different casting techniques (i.e., permanent mold, and sand casting with and without chill) and with or without nano forming additives as potential grain refiners. The second materials set comprises Al alloy tubes extruded by PNNL’s ShAPE process and produced using raw material with three different ratios of twitch and pre-consumer Al 6061 scrap. Finally, the third materials set comprises two Al-Si-Mg-Fe alloys with controlled Si% and Fe% to mimic recycle grade Al alloys. The corrosion behavior of these materials was characterized using SCC testing and scanning electrochemical cell microscopy (SECCM) technique; mechanical behavior was characterized using tensile testing, and microstructure was characterized using optical and electron microscopy techniques. Of the A206 Al alloys, the samples with nano forming additives performed poorly compared to those without. The best SCC performance (i.e. least degradation in mechanical properties) was demonstrated by A206 alloy sand cast with chill while the permanent mold sample showed the worst SCC performance. The SECCM was performed on A206 alloy sand cast with chill to understand the effect of microstructure and determine the location-dependent corrosion properties on grain boundaries (GB) and inside grains (IG) on the sample. The corrosion potential and current measured on GB and IG at various points on the sample established that the GB locations are more cathodic and corrosive than the IG locations. Further work needs to be conducted to investigate the mechanisms behind the observed dependence of SCC on casting technique and nano forming additives. Among the ShAPE extruded tubes, SECCM data suggests the decreasing order of tendency to corrode as follows: 100% twitch > 75% twitch > 50% twitch. Finally, both variants of the Al-Si-Mg-Fe alloys showed a large volume fraction of Fe- and Si-containing intermetallics and additional work is needed to discern differences in their respective corrosion responses. In summary, correlating local electrochemical behavior (e.g. via SECCM) with micro/nanostructure, in conjunction with bulk mechanical behavior, can help identify the right fabrication method and alloy chemistry to minimize SCC issues in Al alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Research, Development and Demonstration of Advanced Vehicle Technologies in Clean Motor Fuels (CRADA Final Report)

NREL/DOE has been funding research, development, and demonstration (RD&D) projects to facilitate the deployment of alternative fuels into the marketplace in order to achieve three objectives: 1) enhance the reduction of mobile source emissions in California and the U.S.; 2) increase U.S. competitiveness and economic prosperity; and 3) preserve the environment through the reduction of emissions and toxins from the motor vehicle population. The Lewis-Presley Air Quality Management Act requires the South Coast Air Quality Management District to establish a program to encourage participation in projects to increase the utilization of clean-burning fuels. The parties seek to collaborate on a joint RD&D project to perform a field test on a small vehicle fleet operating on Fischer-Tropsch synthetic diesel fuel. Recently the 106th U.S. Congress designated "gas-to-liquid" (GTL) transportation fuels that are produced from domestic products as alternative fuels under the Energy Policy Act of 1992 (EPACT). Niche markets could develop quickly for these fuel products, perhaps especially for the use of Fischer-Tropsch synthetic fuels in centrally fueled vehicle fleets in California. NREL and its project partners from the U.S. Department of Energy and West Virginia University have recently conducted what we believe to be the first-ever controlled tests of Fischer-Tropsch synthetic fuels in heavy vehicles. These tests have shown that Fischer-Tropsch fuels can be substituted in unmodified trucks and buses without any detectable loss in drivability and performance. Compared to a California diesel fuel baseline, neat Shell Fischer-Tropsch fuel emitted about 12% lower NOx and 24% lower particulate matter over a five-mile driving route while maintaining the same fuel economy on an energy equivalent basis. Whereas these exhaust emissions reductions from these previous studies have been impressive, far greater exhaust emissions reductions can be achieved if the vehicles are retrofitted with emissions control technologies that are enabled by Fischer-Tropsch fuels. For this program, a test fleet would be selected and retrofitted with continuously regenerating traps (CRT’s) or diesel particulate filters (DPF's). The University of West Virginia, under a separate subcontract to SCAQMD will have the responsibility to test and measure the emissions from the test fleet of vehicles.

33 ADVANCED PROPULSION SYSTEMS↗