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Planetary lander guidance using binary phase-only filters

We demonstrate the use of binary phase-only filters (BPOFs) in a closed loop guidance system for a laboratory lander mockup. Images of a 3-D terrain board taken by the lander's video camera are preprocessed to produce 128 x 128 binary intensity contour maps of the simulated planetary surface. A BPOF is made from a section of the current preprocessed image centered on the exact desired landing site. After the lander has descended to a lower altitude, the BPOF is correlated with a new image. The position of the correlation peak is used in making the next filter and to guide the lander so as to recenter the landing site in the camera's view. We present results of the accuracy with which a site may be tracked from orbit to landing, and the maximum scale, translation, and rotation which can be tolerated between subsequent images. The tolerable scale distortion is quite critical, as it determines the maximum filter update time available at a given descent rate. Application of the results to NASA's proposed Mars Rover Sample Return (MRSR) and Mars Environmental Survey (MESUR) missions is discussed. In both cases, electronic implementations of the algorithm may be sufficient to provide the required guidance system performance.

Reid, Max B.↗

Manual for a workstation-based generic flight simulation program (LaRCsim), version 1.4

LaRCsim is a set of ANSI C routines that implement a full set of equations of motion for a rigid-body aircraft in atmospheric and low-earth orbital flight, suitable for pilot-in-the-loop simulations on a workstation-class computer. All six rigid-body degrees of freedom are modeled. The modules provided include calculations of the typical aircraft rigid-body simulation variables, earth geodesy, gravity and atmospheric models, and support several data recording options. Features/limitations of the current version include English units of measure, a 1962 atmosphere model in cubic spline function lookup form, ranging from sea level to 75,000 feet, rotating oblate spheroidal earth model, with aircraft C.G. coordinates in both geocentric and geodetic axes. Angular integrations are done using quaternion state variables Vehicle X-Z symmetry is assumed.

Jackson, E. Bruce↗

A Plasmoid Thruster for Space Propulsion

There are a number of possible advantages to using accelerated plasmoids for in-space propulsion. A plasmoid is a compact plasma structure with an integral magnetic field. They have been studied extensively in controlled fusion research and are classified according to the relative strength of the poloidal and toroidal magnetic field (BP and Bt, respectively). An Object with B P t >> 1 is classified as a Field Reverse Configuration (FRC); if B, = Bt, it is called a Spheromak. The plasmoid thruster operates by producing FRC-like plasmoids, and subsequently ejecting them from the device at high velocity. The plasmoid is formed inside of a single turn conical theta-pinch coil. As this process is inductive, there are no electrodes. Similar experiments have yielded plasmoid velocities of at least 50 km/s (l), and calculations indicate that velocities in excess of 100 km/s should be possible. This concept should be capable of producing Isp s in the range of 5,000 - 10,000 s with thrust densities of order 10(exp 5) N/sq m. The current experiment is designed to produce jet powers in the range of 5-10 kW, although the concept should be scalable to several MW s. The plasmoids mass and velocity will be measured with a variety of diagnostics, including internal and external B-dot probes, flux loops, Langmuir probes, high-speed cameras, and a laser interferometer. Also of key importance will be measurements of the efficiency and mass utilization. Simulations of the plasmoid thruster using MOQUI, a time dependent MHD code, will be carried out concurrently with experimental testing.

Koelfgen, Syri J.↗

A Plasmoid Thruster for Space Propulsion

There are a number of possible advantages to using accelerated plasmoids for in-space propulsion. A plasmoid is a compact plasma structure with an integral magnetic field. They have been studied extensively in controlled fusion research and are classified according to the relative strength of the poloidal and toroidal magnetic field (B(sub p), and B(sub t), respectively). An object with B(sub p), / B(sub t) much greater than 1 is classified as a Field Reversed Configuration (FRC); if B(sub p) approximately equal to B(sub t), it is called a Spheromak. The plasmoid thruster operates by producing FRC-like plasmoids and subsequently ejecting them from the device at a high velocity. The plasmoid is formed inside of a single-turn conical theta-pinch coil. As this process is inductive, there are no electrodes. Similar experiments have yielded plasmoid velocities of at least 50 km/s, and calculations indicate that velocities in excess of 100 km/s should be possible. This concept should be capable of producing Isp's in the range of 5,000 - 15,000 s with thrust densities on the order of 10(exp 5) N per square meters. The current experiment is designed to produce jet powers in the range of 5 - 10 kW, although the concept should be scalable to several MW's. The plasmoid mass and velocity will be measured with a variety of diagnostics, including internal and external B-dot probes, flux loops, Langmuir probes, high-speed cameras and a laser interferometer. Also of key importance will be measurements of the efficiency and mass utilization. Simulations of the plasmoid thruster using MOQUI, a time-dependent MHD code, will be carried out concurrently with experimental testing.

Koelfgen, Syri J.↗

A Summary of Closed Brayton Cycle Development Activities at NASA

NASA has been involved in the development of Closed Brayton Cycle (CBC) power conversion technology since the 1960's. CBC systems can be coupled to reactor, isotope, or solar heat sources and offer the potential for high efficiency, long life, and scalability to high power. In the 1960's and 1970's, NASA and industry developed the 10 kW Brayton Rotating Unit (BRU) and the 2 kW mini-BRU demonstrating technical feasibility and performance, In the 1980's, a 25 kW CBC Solar Dynamic (SD) power system option was developed for Space Station Freedom and the technology was demonstrated in the 1990's as part of the 2 kW SO Ground Test Demonstration (GTD). Since the early 2000's, NASA has been pursuing CBC technology for space reactor applications. Before it was cancelled, the Jupiter Icy Moons Orbiter (HMO) mission was considering a 100 kWclass CBC system coupled to a gas-cooled fission reactor. Currently, CBC technology is being explored for Fission Surface Power (FSP) systems to provide base power on the moon and Mars. These recent activities have resulted in several CBC-related technology development projects including a 50 kW Alternator Test Unit, a 20 kW Dual Brayton Test Loop, a 2 kW Direct Drive Gas Brayton Test Loop, and a 12 kW FSP Power Conversion Unit design.

Mason, Lee S.↗

NY TBO Research: Integrated Demand Management (IDM): IDM Concept, Tools, and Training Package

A series of human-in-the-loop simulation sessions were conducted in the Airspace Operations Laboratory (AOL) to evaluate a new traffic management concept called Integrated Demand Management (IDM). The simulation explored how to address chronic equity, throughput and delay issues associated with New Yorks high-volume airports by operationally integrating three current and NextGen capabilities the Collaborative Trajectory Options Program (CTOP), Time-Based Flow Management (TBFM) and Required Time of Arrival (RTA) in order to better manage traffic demand within the National Air Traffic System. A package of presentation slides was developed to describe the concept, tools, and training materials used in the simulation sessions. The package will be used to outbrief our stakeholders by both presenting orally and disseminating of the materials via email.

trajectory-based operations↗

Molten Salt Tritium Transport Experiment: A Versatile Fluoride Salt Loop for Validation of Tritium Transport Phenomena

Tritium is generated in Molten Salt Reactors (MSRs) from neutron capture by lithium and other constituents of the molten salt FLiBe. Tritium is a unique radionuclide as it readily permeates through hot structural materials. Thus, any material in contact with tritium laden molten salt is a potential pathway for release. Understanding tritium transport and devising adequate control strategies is necessary for the safe operation of MSRs. The Molten Salt Tritium Transport Experiment (MSTTE) is a forced-convection fluoride salt loop with the capability to inject hydrogen isotopes into flowing molten salt and to measure transport phenomena such as permeation through metals and evolution from free-surfaces. MSTTE is designed to be versatile to test potential control technology in future campaigns. This report focuses on the current design and analysis of MSTTE. Custom designed and fabricated experiment components such as the hydrogen injection system, permeation test section, diagnostics, and gas distribution system are discussed in detail. System-level tritium transport modeling using the System Analysis Module investigates experiment parameters such as hydrogen source terms, salt flow rate, and salt temperature. Computational fluid dynamics of the salt flow in the permeation test section informs design choices to establish fully developed flow in the measured permeation zone.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Update on Development of SiC Multi-Chip Power Modules

Progress has been made in a continuing effort to develop multi-chip power modules (SiC MCPMs). This effort at an earlier stage was reported in 'SiC Multi-Chip Power Modules as Power-System Building Blocks' (LEW-18008-1), NASA Tech Briefs, Vol. 31, No. 2 (February 2007), page 28. The following recapitulation of information from the cited prior article is prerequisite to a meaningful summary of the progress made since then: 1) SiC MCPMs are, more specifically, electronic power-supply modules containing multiple silicon carbide power integrated-circuit chips and silicon-on-insulator (SOI) control integrated-circuit chips. SiC MCPMs are being developed as building blocks of advanced expandable, reconfigurable, fault-tolerant power-supply systems. Exploiting the ability of SiC semiconductor devices to operate at temperatures, breakdown voltages, and current densities significantly greater than those of conventional Si devices, the designs of SiC MCPMs and of systems comprising multiple SiC MCPMs are expected to afford a greater degree of miniaturization through stacking of modules with reduced requirements for heat sinking; 2) The stacked SiC MCPMs in a given system can be electrically connected in series, parallel, or a series/parallel combination to increase the overall power-handling capability of the system. In addition to power connections, the modules have communication connections. The SOI controllers in the modules communicate with each other as nodes of a decentralized control network, in which no single controller exerts overall command of the system. Control functions effected via the network include synchronization of switching of power devices and rapid reconfiguration of power connections to enable the power system to continue to supply power to a load in the event of failure of one of the modules; and, 3) In addition to serving as building blocks of reliable power-supply systems, SiC MCPMs could be augmented with external control circuitry to make them perform additional power-handling functions as needed for specific applications. Because identical SiC MCPM building blocks could be utilized in such a variety of ways, the cost and difficulty of designing new, highly reliable power systems would be reduced considerably. This concludes the information from the cited prior article. The main activity since the previously reported stage of development was the design, fabrication, and testing a 120- VDC-to-28-VDC modular power-converter system composed of eight SiC MCPMs in a 4 (parallel)-by-2 (series) matrix configuration, with normally-off controllable power switches. The SiC MCPM power modules include closed-loop control subsystems and are capable of operating at high power density or high temperature. The system was tested under various configurations, load conditions, load-transient conditions, and failure-recovery conditions. Planned future work includes refinement of the demonstrated modular system concept and development of a new converter hardware topology that would enable sharing of currents without the need for communication among modules. Toward these ends, it is also planned to develop a new converter control algorithm that would provide for improved sharing of current and power under all conditions, and to implement advanced packaging concepts that would enable operation at higher power density.

Lostetter, Alexander↗

Thermophysical Property Measurement and Materials Research in the NASA/MSFC Electrostatic Levitator

Containerless processing is an important tool for thermophysical property measurements and materials research. The freedom from a crucible allows processing of liquid materials in a metastable undercooled state, as well as allowing processing of high temperature and highly reactive melts. Electrostatic levitation (ESL) is a containerless method which provides a number of unique advantages, including the decoupling of positioning force from sample heating, the ability to operate in ultra-high vacuum or at moderate gas pressure (approximately 3 atm), and the ability to process non-conducting materials. ESL also has the potential to reduce internal flow velocities below those possible with electromagnetic, acoustic, or aero-acoustic techniques. The ESL facility at NASA's Marshall Space Flight Center (MSFC) is in use for thermophysical property measurements and materials research by a number of different internal and external investigators. The methods for obtaining access to the facility, as well as a summary of current capabilities and some future directions will be discussed. In electrostatic levitation, the acceleration of gravity (or residual acceleration in reduced gravity) is opposed by the action of an applied electric field on a charged sample. This positioning method is applicable to any material which can be electrically charged, whether solid or liquid, conducting, or insulating. Because the position of the sample is unstable, a 3-dimensional active control loop rapidly adjusts the applied field to maintain levitation and minimize motion of the sample. Heating lasers melt the sample, and may be adjusted to maintain specified thermal profiles. Microgravity allows electrostatic levitation to work even more effectively. With the need to cancel less than 1 milli-g, the applied field required is reduced from approximately 10 MV/m to approximately 10 kV/m. Alternatively, a microgravity ESL can position larger samples than is possible on the ground, or it can position samples which maintain their charge poorly. Microgravity also reduces the effects of buoyant convection and sedimentation. In the MSFC ESL, many different classes of experiments and measurements have been demonstrated in collaboration with many investigators. These capabilities include heat capacity measurement, phase diagram determination, and nucleation and growth experiments including nucleation rate, TTT curves, and phase selection. We have demonstrated the capability of triggering recalescence of an undercooled liquid sample without loss of levitation. Currently under development are techniques for measuring the surface tension, viscosity, and density of levitated samples, as well as other thermophysical properties. Expanded levitation capabilities including various gas environments for sample processing, sample rotation control and management of thermal gradients are under development for the MSFC ESL. Containerless processing allows research on materials which may not be processed any other way. Electrostatic levitation extends the range of containerless processing to include many materials and classes of materials which cannot be processed by conventional electromagnetic, acoustic, or aerodynamic levitation techniques.

Rogers, Jan↗

Human-Centered and Explainable Artificial Intelligence in Nuclear Operations

Nuclear power plants in the United States are critical to the nation’s energy security, accounting for 20% of all electricity produced for the power grid. As energy needs grow, 100 gigawatts of additional nuclear power will be necessary by 2050, more than double the current capacity. Realizing this target requires cutting-edge technology like artificial intelligence (AI) and machine learning (ML) that can bring about significant increases in the level of automation. Human-centered AI (HCAI) is a combination of human-centered design (human factors, human-in-the-loop, etc.) with AI/ML to help produce an efficient and reliable system with full consideration for human engagement. This paper provides a comprehensive and novel discussion of HCAI considerations in nuclear power, introducing unique applications for the existing fleet as well as new advanced reactor designs. We include real-life use cases of AI applications to work management processes at nuclear power sites and highlight lessons learned for HCAI.

Hall, Anna↗

Closed cycle MHD power generation experiments in the NASA Lewis Facility

Many modifications were made in the MHD facility. These include a redesign of the MHD duct interior, addition of mixing bars, increased electrical isolation of all the high temperature components from each other and from ground, and experimentation with various cesium seed vaporization and injection techniques. With the exception of the cesium system which needs further improvement the above modifications were quite successful and resulted in improvements in generator performance. The facility was run for a total of 400 hours in the past year, with 70 hours of this operation at temperatures of 2000 K or more with hot generator walls. With the exception of replacing one cracked brick in the MHD channel no repairs were required in the high temperature loop components for the duration of these tests. Uniform Faraday and Hall voltage profiles were obtained and the Faraday open circuit voltage varied from 90 to 100 percent of the ideal uBh. The magnitudes of the measured parameters are: Faraday open circuit voltage approximately 70 V, total Faraday current approximately 20 A, Hall voltage approximately 250 V, power output approximately 300 W, and power density .036 W/cu cm.

Sovie, R. J.↗

A unique control system simulator for the evaluation of pulsed plasma thrusters

Because of the low thrust characteristics of solid-propellant pulsed plasma thrusters and their operational requirement to operate in a vacuum environment, unique and sensitive test techniques are required. A technique evolved for testing and evaluating pulsed plasma thrusters in an open- or closed-loop system mode employs a unique air bearing platform as a single-axis simulator on which the thruster is mounted. The simulator described was developed to evaluate pulsed plasma thrusters in the low micropound range; however, the simulator can be extended to cover the operational range of currently developed millipound thrusters.

Dahlgren, J. B.↗

Integrated aeroservoelastic analysis capability with X-29A analytical comparisons

An extension of the program STARS (a general-purpose structural analysis program) has been developed; this extension implements a complete aeroservoelastic analysis capability. Previous capabilities included finite-element modeling as well as statics, buckling, vibration, dynamic response, and flutter analyses. This paper presents a description and the formulation of STARS in its current state along with example dynamic, aeroelastic, and aeroservoelastic analyses pertaining to the X-29A aircraft. These examples include vibration analysis results as well as flutter analysis results obtained by the conventional k method and the velocity root-contour solution. Finally, selected open- and closed-loop aeroservoelastic analysis results based on a hybrid formulation are compared to illustrate, using the calculated frequency responses, the interactions of structures, aerodynamics, and flight controls.

Gupta, K. K.↗

What Multilevel Parallel Programs do when you are not Watching: A Performance Analysis Case Study Comparing MPI/OpenMP, MLP, and Nested OpenMP

With the current trend in parallel computer architectures towards clusters of shared memory symmetric multi-processors, parallel programming techniques have evolved that support parallelism beyond a single level. When comparing the performance of applications based on different programming paradigms, it is important to differentiate between the influence of the programming model itself and other factors, such as implementation specific behavior of the operating system (OS) or architectural issues. Rewriting-a large scientific application in order to employ a new programming paradigms is usually a time consuming and error prone task. Before embarking on such an endeavor it is important to determine that there is really a gain that would not be possible with the current implementation. A detailed performance analysis is crucial to clarify these issues. The multilevel programming paradigms considered in this study are hybrid MPI/OpenMP, MLP, and nested OpenMP. The hybrid MPI/OpenMP approach is based on using MPI [7] for the coarse grained parallelization and OpenMP [9] for fine grained loop level parallelism. The MPI programming paradigm assumes a private address space for each process. Data is transferred by explicitly exchanging messages via calls to the MPI library. This model was originally designed for distributed memory architectures but is also suitable for shared memory systems. The second paradigm under consideration is MLP which was developed by Taft. The approach is similar to MPi/OpenMP, using a mix of coarse grain process level parallelization and loop level OpenMP parallelization. As it is the case with MPI, a private address space is assumed for each process. The MLP approach was developed for ccNUMA architectures and explicitly takes advantage of the availability of shared memory. A shared memory arena which is accessible by all processes is required. Communication is done by reading from and writing to the shared memory.

Jost, Gabriele↗

Membrane-Based Water Evaporator for a Space Suit

A membrane-based water evaporator has been developed that is intended to serve as a heat-rejection device for a space suit. This evaporator would replace the current sublimator that is sensitive to contamination of its feedwater. The design of the membrane-based evaporator takes advantage of recent advances in hydrophobic micropore membranes to provide robust heat rejection with much less sensitivity to contamination. The low contamination sensitivity allows use of the heat transport loop as feedwater, eliminating the need for the separate feedwater system used for the sublimator. A cross section of the evaporator is shown in the accompanying figure. The space-suit cooling loop water flows into a distribution plenum, through a narrow annulus lined on both sides with a hydrophobic membrane, into an exit plenum, and returns to the space suit. Two perforated metal tubes encase the membranes and provide structural strength. Evaporation at the membrane inner surface dissipates the waste heat from the space suit. The water vapor passes through the membrane, into a steam duct and is vented to the vacuum environment through a back-pressure valve. The back-pressure setting can be adjusted to regulate the heat-rejection rate and the water outlet temperature.

Ungar, Eugene K.↗

CisLunar Habitat Internal Architecture Design Criteria

BACKGROUND: In preparation for human exploration to Mars, there is a need to define the development and test program that will validate deep space operations and systems. In that context, a Proving Grounds CisLunar habitat spacecraft is being defined as the next step towards this goal. This spacecraft will operate differently from the ISS or other spacecraft in human history. The performance envelope of this spacecraft (mass, volume, power, specifications, etc.) is being defined by the Future Capabilities Study Team. This team has recognized the need for a human-centered approach for the internal architecture of this spacecraft and has commissioned a CisLunar Phase-1 Habitat Internal Architecture Study Team to develop a NASA reference configuration, providing the Agency with a "smart buyer" approach for future acquisition. THE CISLUNAR HABITAT INTERNAL ARCHITECTURE STUDY: Overall, the CisLunar Habitat Internal Architecture study will address the most significant questions and risks in the current CisLunar architecture, habitation, and operations concept development. This effort is achieved through definition of design criteria, evaluation criteria and process, design of the CisLunar Habitat Phase-1 internal architecture, and the development and fabrication of internal architecture concepts combined with rigorous and methodical Human-in-the-Loop (HITL) evaluations and testing of the conceptual innovations in a controlled test environment. The vision of the CisLunar Habitat Internal Architecture Study is to design, build, and test a CisLunar Phase-1 Habitat Internal Architecture that will be used for habitation (e.g. habitability and human factors) evaluations. The evaluations will mature CisLunar habitat evaluation tools, guidelines, and standards, and will interface with other projects such as the Advanced Exploration Systems (AES) Program integrated Power, Avionics, Software (iPAS), and Logistics for integrated human-in-the-loop testing. The mission of the CisLunar Habitat Internal Architecture Study is to become a forcing function to establish a common understanding of CisLunar Phase-1 Habitation Internal Architecture design criteria, processes, and tools. The scope of the CisLunar Habitat Internal Architecture study is to design, develop, demonstrate, and evaluate a Phase-1 CisLunar Habitat common module internal architecture based on design criteria agreed to by NASA, the International Partners, and Commercial Exploration teams. This task is to define the CisLunar Phase-1 Internal Architecture Government Reference Design, assist NASA in becoming a "smart buyer" for Phase-1 Habitat Concepts, and ultimately to derive standards and requirements from the Internal Architecture Design Process. The first step was to define a Habitat Internal Architecture Design Criteria and create a structured philosophy to be used by design teams as a filter by which critical aspects of consideration would be identified for the purpose of organizing and utilizing interior spaces. With design criteria in place, the team will develop a series of iterative internal architecture concept designs which will be assessed by means of an evaluation criteria and process. These assessments will successively drive and refine the design, leading to the combination and down-selection of design concepts. A single refined reference design configuration will be developed into in a medium-to-high fidelity mockup. A multi-day human-in-the-loop mission test will fully evaluate the reference design and validate its configuration. Lessons learned from the design and evaluation will enable the team to identify appropriate standards for Phase-1 CisLunar Habitat Internal Architecture and will enable NASA to develop derived requirements in support of maturing CisLunar Habitation capabilities. This paper will describe the criteria definition process, workshop event, and resulting CisLunar Phase-1 Habitat Internal Architecture Design Criteria.

Jones, R.↗

Investigating the Response of Loop Plasma to Nanoflare Heating Using RADYN Simulations

We present the results of 1D hydrodynamic simulations of coronal loops that are subject to nanoflares, caused by either in situ thermal heating or nonthermal electron (NTE) beams. The synthesized intensity and Doppler shifts can be directly compared with Interface Region Imaging Spectrograph (IRIS) and Atmospheric Imaging Assembly (AIA) observations of rapid variability in the transition region (TR) of coronal loops, associated with transient coronal heating. We find that NTEs with high enough low-energy cutoff (EC) deposit energy in the lower TR and chromosphere, causing blueshifts (up to approximately 20 kilometers per second) in the IRIS Si IV lines, which thermal conduction cannot reproduce. The EC threshold value for the blueshifts depends on the total energy of the events (approximately 5 kiloelectronvolts for 1024 ergs, up to 15 kiloelectronvolts for 1025 ergs). The observed footpoint emission intensity and flows, combined with the simulations, can provide constraints on both the energy of the heating event and EC. The response of the loop plasma to nanoflares depends crucially on the electron density: significant Si IV intensity enhancements and flows are observed only for initially low-density loops (less than 10 (sup 9) per cubic centimeter). This provides a possible explanation of the relative scarcity of observations of significant moss variability. While the TR response to single heating episodes can be clearly observed, the predicted coronal emission (AIA 94 Angstroms) for single strands is below current detectability and can only be observed when several strands are heated closely in time. Finally, we show that the analysis of the IRIS Mg II chromospheric lines can help further constrain the properties of the heating mechanisms.

Sun: Corona↗

Materials for Advanced Ultra-Supercritical (A-USC) Steam Turbines --- A-USC Component Demonstration

The U.S. Advanced Ultra-Supercritical (A-USC) Consortium was formed in 2001 as a government/industry program, sponsored by the U.S. Department of Energy (DOE) and the Ohio Coal Development Office (OCDO) and cost shared by industrial and not-for-profit partners. The purpose of the consortium was to advance the state of the art for power generation by evaluating and developing materials that allow the use of advanced steam cycles in coal-based power plants. These advanced cycles, with steam temperatures up to 1400°F (760°C), can increase the efficiency of coal-fired boilers from an average of 35% (current U.S. fleet) to more than 45% higher heating value (HHV) (>49% lower heating value [LHV]). The increase in a plant’s efficiency is limited unless new materials able to withstand these higher operating temperatures and pressures are identified and approved for use. The A-USC Consortium identified these needed materials during earlier phases of the program. It developed the welding and joining techniques along with manufacturing processes for casting and wrought products made from these new high-nickel alloys. It subjected these materials to extensive laboratory and steam loop testing. It then obtained ASME code approval for their use in U.S. boiler systems. The program’s successes leave this last remaining activity (ComTest Phase 2) that the U.S. utility industry has recommended to be accomplished prior to commercialization. The focus of the activity is the evaluation and demonstration of commercial readiness for “full scale” components to be made from these nickel-based alloy materials and provided by a U.S. domestic supply chain that is new to working with these alloys. According to studies completed by the Electric Power Research Institute (EPRI), the cost of an A-USC plant is approximately 20% higher than a non-A-USC plant because of its use of nickel-based alloys needed for the high temperature operating conditions. However, CO 2 reductions of approximately 30% from the current fleet average provide a strong incentive for its consideration. The actual costs and perceived value for CO 2 abatement will determine whether new or retrofitted plants are undertaken, although decisions to build A-USC plants in India would indicate its economic feasibility while also being part of a global carbon emissions strategy. The work by the A-USC Consortium, prior to the start of the ComTest project, has included lab scale and pilot scale materials testing, both in air and oxy-combustion. This testing has included air-cooled and steam-cooled “loops” that were installed into existing operating utility boilers to gain exposure of these materials to realistic conditions of high temperature and corrosion caused by the constituents in the coal ash. The A-USC Consortium also gained ASME Code approval of the Inconel 740 material, has cast and extruded the largest high nickel precipitation hardened alloys, and developed unique welding techniques to avoid problems identified by the competing European program. However, as valuable as these material test loops and accomplishments have been for obtaining information, their scale is below that required to minimize the risk associated for a U.S. utility to build a multibillion-dollar A-USC power plant. To reduce the final identified risk barrier to full-scale commercialization of these advanced materials and systems, the A-USC Consortium (guided by a utility industry advisory committee) has identified the key areas of the technology they desire to see as being capable of full-scale manufacturing and/or fabrication from an identified, capable U.S. domestic supplier base. A significant amount of work was accomplished during Phase 1 to identity the components, as well as the component size, that would be manufactured from advanced alloys such as Inconel 740H or Haynes 282 alloys. Pathways to supply these components for ComTest have been identified, as well as any further development that would be required. The Phase 2 effort used Phase 1 findings for designing these key full-scale components for A-USC boilers and turbines to include large castings; extrusions, forgings, fabrication of water walls and steam loops with headers from advanced materials, raw material (such as pipe extrusion billets) are at the commercial readiness level to permit advancement to a demonstration project. The Phase 2 work scope was addressed by a diverse team, including government, industry, and not-for-profit partners. The work scope under Phase 2 addressed fabrication of components identified as being outside of the proven capabilities of the existing supply chain, including the following: Steam turbine rotor forging and Haynes 282 nozzle carrier casting Superheater and reheater header and tube assemblies Large-diameter pipe extrusions and forgings Test valve articles to support ASME Code approval. In addition, key fabrication steps were completed, including boiler weld overlays and simulated field repairs. Throughout, extensive inspection and quality assurance testing of the components were performed. The team worked to advance ASME Code approval for key components and processes. Although much of the focus of ComTest Phase 2 was the high-temperature nickel-based alloy materials, a broader range of materials were incorporated, which would be representative of the materials used in full-scale A-USC power plant applications and have cross-cutting applicability on other high-temperature power generation options, such as advanced nuclear, supercritical CO 2 cycles, and central solar receivers. This report that has been submitted is organized in the following manner: Section 1 contains an Executive Summary. Section 2 discusses the ComTest project background and organization. Section 3 discusses project management and reporting. Section 4 discusses the procurement of nickel-based alloy and other A-USC materials and components. Section 5 discusses the fabrication of procurement of nickel-based alloy and other A-USC materials and components. Section 6 discusses the fabrication of cast nickel-based A-USC steam turbine components. Section 7 discusses the fabrication of forged nickel-based A-USC steam turbine piping and steam pipe components. Section 8 discusses the qualification of pressure relieve valves (PRVs) for A-USC power plants. Section 9 discusses proposed plans for future evaluation of A-USC components. Section 10 contains the summary and conclusion.

01 COAL, LIGNITE, AND PEAT↗