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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Platform for Remote Deployment and Training for Enhanced Building Operation Practices (Building Re-Tuning and On-going Commissioning)

While a building’s energy usage is driven largely by its design and use, building operator behavior has a strong influence on its energy consumption. This project developed and piloted a specific, data-driven coaching methodology to help operators understand how they can adjust operations and/or affect no/low-cost repairs or upgrades to their specific building HVAC systems to reduce energy consumption. Named BuildingCoach, the operational optimization method used is based on the Building Re-tuning approach developed by the Pacific Northwest National Laboratory. A building operations analytics market has matured over the past decade, though its potential to affect energy-saving changes has not been fully realized. Training operators to understand the methods for operational optimization with the explicit approach of using building-system performance data is hypothesized to create a more effective, longer lasting result in building energy efficiency, and this strategy is the fundamental premise of this project. With the support of an Industry Advisory Board, the project succeeded in developing materials and recruiting for and delivering three pilot cohorts. Deliverables included twenty-two self-paced training modules (accessed via a Learning Management System) and a web-based platform that includes access to real-time building system data and a repository for building system documentation. The project set out to have 100 participants from 50 buildings in three pilot cohorts. In the end, there were 28 participants from 17 buildings, i.e., a significant shortfall. The first two pilot cohorts had only two buildings in each, and this was partially due to difficulties in deploying the Building Operator Coaching Solution (“the BOCS”), which is technology that extracts the data from the controls network and presents it as prescribed for coaching. In the third cohort, the project team deployed the BOCS successfully to 13 buildings, the methodology was piloted as intended, and numerous opportunities for optimization were identified. The BuildingCoach business plan charts a path to an economically sustainable effort. However, even with a licensing model captured in the final version of the business plan, the scalability is still limited to keeping less than 1,000 buildings affected by 2033. Even so, there are unexplored paths to greater scalability that are being considered. CUNY BPL is working to perpetuate and grow the use of BuildingCoach. As of this writing, about twenty buildings have either been connected or will be connected with operators coached / to be coached in the NYC municipal portfolio, twelve buildings across four campuses in NY State will use BuildingCoach, a NY upstate county wishes for six or seven buildings to participate with the support of funding from NYSERDA, and others have also expressed interest. In the decades to come, there will be an increasing percentage of large and mid-sized buildings that incorporate automated system optimization (ASO), and the building operators’ role will shift to spend more time on maintenance and monitoring. Meanwhile, programs such as BuildingCoach will play a critical role in optimizing operations. And, regardless of the emergence of ASO, operators will still need to understand how their systems operate so that they can monitor them properly. Within that context, BuildingCoach is an important step towards operators’ understanding of efficient building system operations.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1999

Pin Load Control Applied to Retractable Pin Tool Technology and Its Characterization

Until the development of retractable pin tool (RPT) technology, friction stir welding (FSW) was limited to constant thickness joining of aluminum materials and the choices of keyhole elimination focused on traditional fusion and plug weld repair techniques. An invention, US Patent Number 5,893,507, "Auto-Adjustable Pin Tool for Friction Stir Welding" assigned to NASA, demonstrated an approach to resolve these serious drawbacks. This approach brings forth a technique that allows the crater, or keyhole, to be closed out automatically at the end of the weld joint without adding any additional equipment or material. Also the probe length can be varied automatically in the weld joint to compensate for material thickness changes, such as, in a tapered joint. This paper reports the effects of pin extension and retraction rates in the weld joint and its correlation to weld quality. The investigation utilized a pin load-detecting device that was integrated in the Phase IIA RPT designed by Boeing for NASA/MSFC. The RPT modification provided pin load data that was accessed and used to eliminate root side indications and determine pin manipulation rates necessary to produce consistence homogeneous joints.

Olegoetz, P.↗
NASA NTRS2000

Pin Load Control Applied to Retractable Pin Tool Technology and its Characterization

Until the development of retractable pin tool (RPT) technology, friction stir welding (FSW) was limited to constant thickness joining of aluminum materials and the choices of keyhole elimination focused on traditional fusion and plug weld repair techniques. An invention, US Patent Number 5,893,507, "Auto-Adjustable Pin Tool for Friction Stir Welding" assigned to NASA, demonstrated an approach to resolve these serious drawbacks. This approach brings forth a technique that allows the crater, or keyhole, to be closed out automatically at the end of the weld joint without adding any additional equipment or material. Also the probe length can be varied automatically in the weld joint to compensate for material thickness changes, such as, in a tapered joint. This paper reports the effects of pin extension and retraction rates in the weld joint and its correlation to weld quality. The investigation utilized a pin load-detecting device that was integrated in the Phase 2A RPT designed by Boeing for NASA/MSFC. The RPT modification provided pin load data that was accessed and used to eliminate root side indications and determine pin manipulation rates necessary to produce consistence homogeneous joints.

Oelgoetz, Peter A.↗
DOE OSTI2023

Distribution Grid Impacts of Community Solar [Slides]

Community solar (CS) projects often face uncertain interconnection costs and fees associated with distribution grid infrastructure upgrades required to connect the project. These costs can determine the economic viability of a CS project, but they are difficult to assess. Cost uncertainty can discourage new projects and prevent communities from accessing the benefits of community solar projects. At the same time, CS deployment strategies hold potential to defer or avoid some distribution costs due to new loads. To mitigate CS interconnection costs, it is important to find least-cost combinations of distribution system infrastructure solutions (transformer upgrades, reconductoring, voltage regulators, storage), and to understand how location of CS projects within a feeder impact distribution grid upgrade costs. This study aims to quantify CS impacts on the distribution grid and provide policy and regulatory insights and CS deployment strategies to address them. It is the first analysis that has systematically studied the technical impacts of community solar projects on a wide range of distribution feeders using state-of-the-art optimization and power flow tools. The analysis employs Berkeley Lab’s novel Least-cost Optimal Distribution Grid Expansion (LODGE) model, a deterministic version of the REPAIR model, that optimally upgrades hundreds or even thousands of distribution circuits or feeders. This is the first application of the LODGE model. LODGE finds the least-cost portfolio of traditional distribution system upgrades to integrate CS in combination with alternative solutions, such as utility-owned storage and downsizing CS capacity. Working with a set of least-cost solutions per feeder allows us to benchmark, compare and find techno-economic trends in CS interconnection.

14 SOLAR ENERGY↗
NASA NTRS1998

Injector Mixing Efficiency Experiments

Various optical diagnostic techniques such as laser induce fluorescence, Raman spectroscopy, laser Doppler velocimetry, and laser light scattering have been employed to study the flowfield downstream of a single injector element in a optically accessible rocket chamber at Penn State for a number o years. These techniques have been used with both liquid and gaseous oxygen at pressures up to 1000 psia which is the limit of the facility. The purpose of the test programs at Penn State were to develop the techniques and to study the flow field from various injector designs. To extend these studies to higher pressure and ultimately to multiple injectors require the capabilities of the Marshall Space Flight Center. These studies will extend the data base available for the various injector designs to higher pressure as well as to determine the interaction between multiple injectors. During this effort the Princeton Instruments ICCD camera was set up and checked out. The functionality of the system has been thoroughly checked and the shutter compensation time was found to be not working. The controller was returned to the manufacturer for warranty repair. The sensitivity has been measured and found to be approximately 60 counts per photon at maximum gain which agrees with the test data supplied by the manufacturer. The actual value depends on wavelength. The Princeton Instruments camera was been installed in a explosion proof tube for use with the rocket combustor. A 35 mm camera was also made ready for taking still photos inside the combustor. A fiber optic was used to transmit the laser light from an argon-ion laser to the rocket combustor for the light scattering images. This images were obtained for a LOX-hydrogen swirl coax injector. Several still photos were also obtained with the 35 mm camera for these firings.

Moser, Marlow D.↗
DOE OSTI2023

Manufacturing Demonstration Facility: Development and Evaluation of Hybrid Manufacturing Toolpaths

The integration of additive manufacturing (AM) capabilities on Computer Numerical Control (CNC) systems allows for the expansion of additive manufacturing to a wide range of part and tool repair operations. This multi-tasking integration, termed hybrid manufacturing, has been researched by others in the past, and Autodesk has been critical in developing process planning and toolpath algorithms for hybrid systems. Objectives and Tasks: Hybrid manufacturing systems enable both additive and subtractive capabilities in a single manufacturing workcell. These systems have the potential to impact a variety of industries, including the tool and die industry due to their repair, refurbishment, and complex geometry manufacturing capabilities. While there has been significant development of toolpath planning for both subtractive and additive processes independently, there has been little, if any, development of hybrid toolpath planning to integrate both processes during the manufacturing design and toolpath generation stage of a product’s lifecycle. Furthermore, additive toolpath planning has been limited to planar manufacturing, but this limitation could be overcome as hybrid CNC machines have multi-axis control. The objectives of this research include: - Development and demonstration of independent three-, four-, and five-axis toolpath generation algorithms for both additive and subtractive processes, and - Development, demonstration, and integration of three-, four-, and five-axis hybrid process planning and toolpath generation algorithms for hybrid additive and subtractive processes. The team will leverage the widely used Autodesk Fusion 360 product design and manufacturing (CAD/CAM) platform to achieve these objectives. Autodesk will provide the expertise in CAD tools, as well as access to their new CAD/CAM manufacturing tools (3-, 4-, and 5-axis milling, additive toolpath generation). ORNL will provide expertise in additive manufacturing toolpath generation, process planning, and manufacturing validation. By the end of the program, the team will have developed and validated multi-axis milling, additive manufacturing, and hybrid manufacturing on an industrial hybrid CNC system (Mazak 500-VC).

42 ENGINEERING↗
NASA NTRS2012

Benefits of a Single-Person Spacecraft for Weightless Operations

Historically, less than 20 percent of crew time related to extravehicular activity (EVA) is spent on productive external work.1 A single-person spacecraft with 90 percent efficiency provides productive new capabilities for maintaining the International Space Station (ISS), exploring asteroids, and servicing telescopes or satellites. With suits, going outside to inspect, service or repair a spacecraft is time-consuming, requiring pre-breathe time, donning a fitted space suit, and pumping down an airlock. For ISS, this is between 12.5 and 16 hours for each EVA, not including translation and work-site set up. The work is physically demanding requiring a day of rest between EVAs and often results in suit-induced trauma with frequent injury to astronauts fingers2. For maximum mobility, suits use a low pressure, pure oxygen atmosphere. This represents a fire hazard and requires pre-breathing to reduce the risk of decompression sickness (bends). With virtually no gravity, humans exploring asteroids cannot use legs for walking. The Manned Maneuvering Unit offers a propulsive alternative however it is no longer in NASA s flight inventory. FlexCraft is a single person spacecraft operating at the same cabin atmosphere as its host so there is no risk of the bends and no pre-breathing. This allows rapid, any-time access to space for repeated short or long EVAs by different astronauts. Integrated propulsion eliminates hand-over-hand translation or having another crew member operate the robotic arm. The one-size-fits-all FlexCraft interior eliminates the suit part inventory and crew time required to fit all astronauts. With a shirtsleeve cockpit, conventional displays and controls are used and because the work is not strenuous no rest days are required. Furthermore, there is no need for hand tools because manipulators are equipped with force multiplying end-effectors that can deliver the precise torque for the job.

Griffin, Brand N.↗
NASA NTRS2012

Process Sensitivity, Performance, and Direct Verification Testing of Adhesive Locking Features

Phase I: The use of adhesive locking features or liquid locking compounds (LLCs) (e.g., Loctite) as a means of providing a secondary locking feature has been used on NASA programs since the Apollo program. In many cases Loctite was used as a last resort when (a) self-locking fasteners were no longer functioning per their respective drawing specification, (b) access was limited for removal & replacement, or (c) replacement could not be accomplished without severe impact to schedule. Long-term use of Loctite became inevitable in cases where removal and replacement of worn hardware was not cost effective and Loctite was assumed to be fully cured and working. The NASA Engineering & Safety Center (NESC) and United Space Alliance (USA) recognized the need for more extensive testing of Loctite grades to better understand their capabilities and limitations as a secondary locking feature. These tests, identified as Phase I, were designed to identify processing sensitivities, to determine proper cure time, the correct primer to use on aerospace nutplate, insert and bolt materials such as A286 and MP35N, and the minimum amount of Loctite that is required to achieve optimum breakaway torque values. The .1900-32 was the fastener size tested, due to wide usage in the aerospace industry. Three different grades of Loctite were tested. Results indicate that, with proper controls, adhesive locking features can be successfully used in the repair of locking features and should be considered for design. Phase II: Threaded fastening systems used in aerospace programs typically have a requirement for a redundant locking feature. The primary locking method is the fastener preload and the traditional redundant locking feature is a self-locking mechanical device that may include deformed threads, non-metallic inserts, split beam features, or other methods that impede movement between threaded members. The self-locking resistance of traditional locking features can be directly verified during assembly by measuring the dynamic prevailing torque. Adhesive locking features or LLCs are another method of providing redundant locking, but a direct verification method has not been used in aerospace applications to verify proper installation when using LLCs because of concern for damage to the adhesive bond. The reliability of LLCs has also been questioned due to failures observed during testing with coupons for process verification, although the coupon failures have often been attributed to a lack of proper procedures. It is highly desirable to have a direct method of verifying the LLC cure or bond integrity. The purpose of the Phase II test program was to determine if the torque applied during direct verification of an adhesive locking feature degrades that locking feature. This report documents the test program used to investigate the viability of such a direct verification method. Results of the Phase II testing were positive, and additional investigation of direct verification of adhesive locking features is merited.

Golden, Johnny L.↗
NASA NTRS1991

NSI operations center

The NASA Science Internet (NSI) Network Operations Staff is responsible for providing reliable communication connectivity for the NASA science community. As the NSI user community expands, so does the demand for greater interoperability with users and resources on other networks (e.g., NSFnet, ESnet), both nationally and internationally. Coupled with the science community's demand for greater access to other resources is the demand for more reliable communication connectivity. Recognizing this, the NASA Science Internet Project Office (NSIPO) expands its Operations activities. By January 1990, Network Operations was equipped with a telephone hotline, and its staff was expanded to six Network Operations Analysts. These six analysts provide 24-hour-a-day, 7-day-a-week coverage to assist site managers with problem determination and resolution. The NSI Operations staff monitors network circuits and their associated routers. In most instances, NSI Operations diagnoses and reports problems before users realize a problem exists. Monitoring of the NSI TCP/IP Network is currently being done with Proteon's Overview monitoring system. The Overview monitoring system displays a map of the NSI network utilizing various colors to indicate the conditions of the components being monitored. Each node or site is polled via the Simple Network Monitoring Protocol (SNMP). If a circuit goes down, Overview alerts the Network Operations staff with an audible alarm and changes the color of the component. When an alert is received, Network Operations personnel immediately verify and diagnose the problem, coordinate repair with other networking service groups, track problems, and document problem and resolution into a trouble ticket data base. NSI Operations offers the NSI science community reliable connectivity by exercising prompt assessment and resolution of network problems.

Zanley, Nancy L.↗
NASA NTRS2018

NASA: 60 Years and Counting...

Sputnik launched on 4 Oct 1057. On July 29, 1958, Eisenhower signed the National Aeronautics and Space Act, the creation of NASA. The Soviets launched the first human into orbit, Yuri Gagarin, on April 12, 1961. On 5 May 1961, Alan Shepard's Freedom 7 Mercury capsule lifted off at 9:34 a.m. from Launch Complex 5 at Cape Canaveral Air Force Station, and flew a suborbital trajectory lasting 15 minutes and 22 seconds, America's first man in space. On 25 May 1961, Kennedy delivered a speech to a joint session of Congress. In that speech, he stated "I believe that this nation should commit itself to achieving the goal, before this decade is out, of landing a man on the moon and returning him safely to the earth." The rest, as they say, is history. Project Mercury, the first U.S. program to put humans in space, made 25 flights, six of which carried astronauts between 1961 and 1963. The Gemini program primarily tested equipment and mission procedures and trained astronauts and ground crews for future Apollo missions to the Moon. Exactly eight years, one month and 26 days after President Kennedy challenged Americans to reach for the Moon, Project Apollo landed the first humans on the lunar surface and returned them safely to Earth. In 1973, Skylab expeditions paved the way for the International Space Station. Over 30 years, NASA's space shuttle fleet, ”Columbia, Challenger, Discovery, Atlantis and Endeavour,” flew 135 missions and carried 355 different people to space. The space shuttle carried people into orbit repeatedly; launched, recovered and repaired satellites; conducted cutting-edge research; and built the largest structure in space, the International Space Station. Tragically, NASA lost two crews of seven in the 1986 Challenger accident and the 2003 Columbia accident. The International Space Station is a model for global cooperation and scientific advancements that is enabling growth of private industry in low-Earth orbit and development of new technologies to advance human space exploration. Built between 1998 and 2011, the space station has housed humans continuously since Nov. 2, 2000. NASA has contracted with commercial companies SpaceX, Orbital ATK, and Sierra Nevada Corporation to deliver science investigations, cargo, and supplies to the crews living in space, and soon Boeing and SpaceX will transport astronauts to and from the station. Today, NASA is working on many fronts to advance man's presence in space. NASA's Exploration Campaign will establish U.S. preeminence in cislunar space through the operations and the deployment of a U.S.-led Lunar Orbital Platform-Gateway (LOPG). Together with the Orion and SLS Programs, the LOPG is central to advancing and sustaining human space exploration goals, and is the unifying single stepping off point for human cislunar operations, lunar surface access and missions to Mars. As one might expect, EMC for all this activity is challenging, to say the least. In the next half-hour or so, I will talk about some of those challenges and how the different programs are meeting them.

Scully, Bob↗
NASA NTRS2011

External Tank - The Structure Backbone

The External Tank forms the structural backbone of the Space Shuttle in the launch configuration. Because the tank flies to orbital velocity with the Space Shuttle Orbiter, minimization of weight is mandatory, to maximize payload performance. Choice of lightweight materials both for structure and thermal conditioning was necessary. The tank is large, and unique manufacturing facilities, tooling, handling, and transportation operations were required. Weld processes and tooling evolved with the design as it matured through several block changes, to reduce weight. Non Destructive Evaluation methods were used to assure integrity of welds and thermal protection system materials. The aluminum-lithium alloy was used near the end of the program and weld processes and weld repair techniques had to be refined. Development and implementation of friction stir welding was a substantial technology development incorporated during the Program. Automated thermal protection system application processes were developed for the majority of the tank surface. Material obsolescence was an issue throughout the 40 year program. The final configuration and tank weight enabled international space station assembly in a high inclination orbit allowing international cooperation with the Russian Federal Space Agency. Numerous process controls were implemented to assure product quality, and innovative proof testing was accomplished prior to delivery. Process controls were implemented to assure cleanliness in the production environment, to control contaminants, and to preclude corrosion. Each tank was accepted via rigorous inspections, including non-destructive evaluation techniques, proof testing, and all systems testing. In the post STS-107 era, the project focused on ascent debris risk reduction. This was accomplished via stringent process controls, post flight assessment using substantially improved imagery, and selective redesigns. These efforts were supported with a number of test programs to simulate combined environments. Processing improvements included development and use of low spray guns for foam application, additional human factors considerations for production, use of high fidelity mockups during hardware processing with video review, improved tank access, extensive use of non destructive evaluation, and producibility enhancements. Design improvements included redesigned bipod fittings, a bellows heater, a feedline camera active during ascent flight, removal of the protuberance airload ramps, redesigned ice frost ramps, and titanium brackets replaced aluminum brackets on the liquid oxygen feedline. Post flight assessment improved due to significant addition of imagery assets, greatly improving situational awareness. The debris risk was reduced by two orders of magnitude. During this time a major natural disaster was overcome when Katrina damaged the manufacturing facility. Numerous lessons from these efforts are documented within the paper.

Welzyn, Kenneth↗
NASA NTRS2019

Shockwave/Boundary-Layer Interaction Studies Performed in the NASA Langley 20-Inch Mach 6 Air Tunnel

This paper highlights results from a collaborative study performed by The University of Tennessee Space Institute (UTSI) and NASA Langley Research Center on the Shockwave/Boundary-Layer Interaction (SWBLI) generated by a cylindrical protuberance on a flat plate in a Mach 6 flow. The study was performed in the 20-Inch Mach 6 Air Tunnel at NASA Langley Research Center and consisted of two separate entries. In the first entry, simultaneous high-speed schlieren and high-speed pressure-sensitive paint (PSP) imaging – which was performed for the first time in the 20-Inch Mach 6 facility at NASA Langley – were performed as well as simultaneous high-speed schlieren and oil-flow imaging. In the second entry, the model configuration was modified to increase the size of the interaction region. High-speed schlieren and infrared thermography (IR) surface imaging were performed in this second entry. The goal of these tests was to characterize the SBLI in the presence of a laminar, transitional, and turbulent boundary layer using high-speed optical imaging techniques. AoA = sting angle-of-attack (°) dcylinder = cylinder diameter (mm) dtrip = cylindrical tripping element diameter (mm) Δshock = shock stand-off distance (mm) hcylinder = cylinder height (mm) htrip = cylindrical tripping element height (mm) HSS = high-speed schlieren M∞ = freestream Mach number PSP = pressure-sensitive paint Re∞ = freestream unit Reynolds number (m-1) SWBLI = shockwave/boundary-layer interaction θplate = model plate angle (°) Introduction his paper highlights two experimental entries performed in the 20-Inch Mach 6 Air Blowdown Tunnel at NASA Langley Research Center in collaboration with The University of Tennessee Space Institute (UTSI). The purpose of these entries was to characterize the dynamic shockwave/boundary-layer interaction (SWBLI) between a vertical cylinder on a flat plate and laminar, transitional (XSWBLI), and turbulent (SWTBLI) boundary layers with a freestream Mach number of 6 using non-intrusive optical diagnostics. Experiments performed by Murphree et al.1,2 were among the first to specifically characterize XSWBLI induced by a vertical cylinder on a flat plate geometry using several optical measurement techniques. Recent optical studies of XSWBLI phenomenon have been performed by UTSI at Mach 2 in their low-enthalpy blow wind tunnel3-8 and by Texas A&M University and UTSI at Mach numbers of 6 and 7 in their Adjustable Contour Expansion wind tunnel.9 The experiments described in this paper were intended to complement previous studies by expanding the freestream unit Reynolds number range, Re∞, over which the XSWBLI phenomena has been observed. Additionally these experiments, made possible under NASA’s new facility funding model under the Aeronautics Evaluation and Test Capabilities (AETC) project, promoted collaboration between university and NASA researchers. The initial entry in the 20-Inch Mach 6 Air Tunnel at NASA Langley occurred in December of 2016. Originally, testing was to occur in November of 2016 in the 31-Inch Mach 10 Air Tunnel at NASA Langley. This facility was chosen so that the XSWBLI phenomenon could be observed at much higher Mach numbers than had previously been attempted in ground test experiments. The model selected for this experiment, a 10° half-angle wedge with a sharp leading edge (described in detail in section II.B), had previously been used by Danehy et al. [10] for boundary layer transition studies using the nitric oxide planar laser-induced fluorescence (NO PLIF) flow visualization technique. In that work, it was determined that transition could be induced downstream of a single htrip = 1-mm tall, dtrip = 4-mm diameter cylindrical tripping element and that the streamwise location of the transition could be changed for a single Re∞ by changing the model angle-of-attack (AoA) (see Fig. A3 in Ref. [10] for more details). Based on the findings of that work, a decision was made to use the wedge model with the cylindrical tripping element to trip the boundary layer flow ahead of a cylindrical protuberance in order to achieve a XSWBLI. Unfortunately, the 31-Inch Mach 10 facility had been taken offline for repairs in October of 2016 and a decision was made to move the test to the 20-Inch Mach 6 facility. Since the behavior of the boundary layer with the chosen model configuration had not been studied before in that facility and the available test time was limited, the entry was considered to be exploratory and was used to collect spatially-resolved and time-resolved flow and surface visualization data that would be used to inform a second entry. Test techniques included simultaneous high-speed schlieren (HSS) captured at 160 kHz and high-speed pressure sensitive paint captured at 10 kHz as well as oil flow visualization, captured at 750 Hz. The second entry in the 20-Inch Mach 6 facility occurred in June and July of 2017. In this follow-on test, modifications to the wind tunnel model were made based on observations made during the first entry and included removing the cylindrical tripping element, increasing the size of the cylinder used to induce the SWBLI to increase the size of the interaction while simultaneously improving spatial resolution, and using a swept ramp array, similar to that described in Ref. [11], to trip the flow to turbulence. Simultaneous HSS (captured at 140 kHz, 100 kHz, and 40 kHz) and conventional IR thermography (captured at 30 Hz) imaging were performed simultaneously in this follow-on entry. This paper is intended to serve as a summary of the work performed during these two entries, to detail lessons learned from each entry, and to highlight some of the datasets acquired. Details on the experimental setup, model configuration, and techniques used are provided. Papers providing a more rigorous analysis of data acquired during the second entry, including statistical, spectral, and modal decomposition methods, can be found in Refs. [12,13]. An entry examining XSWBLI in the 31-Inch Mach 10 Blowdown Wind Tunnel facility is currently planned for mid-to-late calendar year 2019, pending the success of facility repairs. The work performed and described in this paper and the upcoming entry in the 31-Inch Mach 10 facility at NASA Langley have been made possible by NASA’s new facility funding model under the Aeronautics Evaluation and Test Capabilities (AETC) project. Wind Tunnel Facility All experiments discussed in this paper were performed in the 20-Inch Mach 6 Air Tunnel at NASA Langley Research Center. Specific details pertaining to this facility can be found in Refs. [14,15], with only a brief description of the facility provided here. For both entries, the nominal freestream unit Reynolds number was varied between 1.8×106 m-1 (0.5×106 ft-1) and 26.3×106 m-1 (8×106 ft-1). The nominal stagnation pressure was varied between 0.21 MPa and 3.33 MPa and the nominal stagnation temperature was varied between 480 K and 520 K to achieve the desired Re∞ condition. For all runs, the nominal freestream Mach number was 6. The nearly square test section is 520.7-mm (20.5-inches) wide by 508-mm (20-inches) high. Two 431.8-mm (17-inch) diameter windows made of Corning 7940, Grade 5F schlieren-quality glass serve as the side walls of the tunnel and provide optical access for the high-speed schlieren measurements. A rectangular window made of the same material as the side windows served as the top wall of the test section and provided optical access for the high-speed PSP and oil flow measurements. For the second entry, this top window was replaced with a Zinc Selenide (ZnSe) window with an anti-reflection coating capable of passing IR wavelengths between 8μm and 12μm with greater than 98% transmittance. The model was sting supported by a strut attached to a hydraulic system that allows for the model pitch angle to be adjusted between -5° to +55°. For the first entry, an initial pitch/pause sweep of the model AoA was performed to observe the resulting SWBLI. Ultimately, however, the sting pitch angle for this entry was fixed at +10.0° so that the angle of the top surface of the wedge relative to the streamwise axis of the tunnel (referred to herein as the plate angle, θplate), was θplate = 0°. For the second entry, θplate = 0° and θplate = -13.25° were initially tested with the swept ramp array (discussed in the following section) to determine which orientation produced conditions most favorable for XSWBLI to occur based on the heating signatures observed over the top surface of the model in the IR thermography images. Based on these initial tests, θplate = -13.25° was set for the remainder of the runs in the second entry. For both entries, any model changes were performed in a housing located beneath the closed test section. Prior to performing a run of the tunnel, the housing was sealed and the tunnel started. Once the appropriate freestream conditions were achieved, the model was injected into the test section using a hydraulic injection system. B. Model Geometry For all runs, a 10° half-angle (20° full-angle) wedge model with a sharp leading edge was used. The model is described in detail in Refs. [10,16]. The top surface of the sharp leading edge of the model extended 47.8 mm from its upstream-most edge to a junction with the upstream edge of a stainless steel top plate that then extended an (a) (c) (b) Fig. 1 (a) Schematic of top surface of wedge model with gas seeding insert, (b) perspective view of the model in the 20-Inch Mach 6 tunnel with centerline pressure orifices on sharp leading edge, and (c) a perspective view of the model with stainless steel (top) and SLA middle insert (bottom) during the first entry. Flow occurs from left to right.

Bathel, Brett F.↗
NASA NTRS2017

Tracking Historical NASA EVA Training: Lifetime Surveillance of Astronaut Health (LSAH) Development of the EVA Suit Exposure Tracker (EVA SET)

During a spacewalk, designated as extravehicular activity (EVA), an astronaut ventures from the protective environment of the spacecraft into the vacuum of space. EVAs are among the most challenging tasks during a mission, as they are complex and place the astronaut in a highly stressful environment dependent on the spacesuit for survival. Due to the complexity of EVA, NASA has conducted various training programs on Earth to mimic the environment of space and to practice maneuvers in a more controlled and forgiving environment. However, rewards offset the risks of EVA, as some of the greatest accomplishments in the space program were accomplished during EVA, such as the Apollo moonwalks and the Hubble Space Telescope repair missions. Water has become the environment of choice for EVA training on Earth, using neutral buoyancy as a substitute for microgravity. During EVA training, an astronaut wears a modified version of the spacesuit adapted for working in water. This high fidelity suit allows the astronaut to move in the water while performing tasks on full-sized mockups of space vehicles, telescopes, and satellites. During the early Gemini missions, several EVA objectives were much more difficult than planned and required additional time. Later missions demonstrated that "complex (EVA) tasks were feasible when restraints maintained body position and underwater simulation training ensured a high success probability".1,2 EVA training has evolved from controlling body positioning to perform basic tasks to complex maintenance of the Hubble Space Telescope and construction of the International Space Station (ISS). Today, preparation is centered at special facilities built specifically for EVA training, such as the Neutral Buoyancy Laboratory (NBL) at NASA's Johnson Space Center ([JSC], Houston) and the Hydrolab at the Gagarin Cosmonaut Training Centre ([GCTC], Star City, outside Moscow). Underwater training for an EVA is also considered hazardous duty for NASA astronauts. This activity places astronauts at risk for decompression sickness and barotrauma as well as various musculoskeletal disorders from working in the spacesuit. The medical, operational and research communities over the years have requested access to EVA training data to better understand the risks. As a result of these requests, epidemiologists within the Lifetime Surveillance of Astronaut Health (LSAH) team have compiled records from numerous EVA training venues to quantify the exposure to EVA training. The EVA Suit Exposure Tracker (EVA SET) dataset is a compilation of ground-based training activities using the extravehicular mobility unit (EMU) in neutrally buoyant pools to enhance EVA performance on orbit. These data can be used by the current ISS program and future exploration missions by informing physicians, researchers, and operational personnel on the risks of EVA training in order that future suit and mission designs incorporate greater safety. The purpose of this technical report is to document briefly the various facilities where NASA astronauts have performed EVA training while describing in detail the EVA training records used to generate the EVA SET dataset.

Laughlin, Mitzi S.↗
DOE OSTI2026

Portable and Cost-Effective Device for Reliable Detection of Counterfeit and Non-compliant Refrigerants in Diverse Applications

Counterfeit refrigerants pose significant challenges to safety, system reliability, and operational effectiveness due to their harmful contaminants or incompatible chemical compositions. Utilizing these noncompliant products can lead to reduced efficiency, equipment failures, and expensive repairs. Additionally, heightened demand for alternative refrigerants during the industry's transition has created supply gaps, enabling counterfeit products to proliferate. Accurate detection and analysis tools are therefore essential to verify refrigerant authenticity and ensure system integrity in diverse applications. This paper presents the development of a portable device designed for reliable identification and detailed analysis of refrigerant composition. By integrating precision gas sampling, controlled pressure regulation, and automated sensor technology, the device not only detects deviations from standard refrigerant properties but also provides a comprehensive composition breakdown. Pre-calibrated sensors measure the refrigerant gas to identify specific concentrations and contaminants, with an intuitive LED-based indicator system ensuring quick interpretation of results. The user-friendly interface enables operators to select refrigerant types for targeted testing, further enhancing accuracy and usability for field technicians. Comprehensive testing was conducted on mildly flammable A2L refrigerants, showcasing the device’s robustness and adaptability in analyzing composition and detecting discrepancies. The device demonstrated consistent accuracy across a range of refrigerant samples, affirming its reliability in diverse operational environments. Its design minimizes contamination risks during sampling and provides detailed composition results within 90 seconds, ensuring efficient and precise analysis. With a projected price point under $150, the proposed solution delivers affordability alongside its lightweight portability and straightforward operation. Unlike complex and costly alternatives, such as gas chromatography systems, this device provides an accessible option for technicians, customs personnel, and industry operators in need of quick and effective refrigerant verification. Compatible with both current formulations and emerging refrigerant technologies, the device addresses critical counterfeit detection needs across a range of applications. By delivering accurate composition analysis and counterfeit identification, this innovation enhances system performance, safety, and operational reliability in crucial industries.

Cheekatamarla, Praveen [ORNL] (ORCID:0000000248827↗
DOE OSTI2023

H2A.X promotes endosperm-specific DNA methylation in Arabidopsis thaliana

Background: H2A.X is an H2A variant histone in eukaryotes, unique for its ability to respond to DNA damage, initiating the DNA repair pathway. H2A.X replacement within the histone octamer is mediated by the FAcilitates Chromatin Transactions (FACT) complex, a key chromatin remodeler. FACT is required for DEMETER (DME)-mediated DNA demethylation at certain loci in Arabidopsis thaliana female gametophytes during reproduction. Here, we sought to investigate whether H2A.X is involved in DME- and FACT-mediated DNA demethylation during reproduction. Results: H2A.X is encoded by two genes in Arabidopsis genome, HTA3 and HTA5. We generated h2a.x double mutants, which displayed a normal growth profile, whereby flowering time, seed development, and root tip organization, S-phase progression and proliferation were all normal. However, h2a.x mutants were more sensitive to genotoxic stress, consistent with previous reports. H2A.X fused to Green Fluorescent Protein (GFP) under the H2A.X promoter was highly expressed especially in newly developing Arabidopsis tissues, including in male and female gametophytes, where DME is also expressed. We examined DNA methylation in h2a.x developing seeds and seedlings using whole genome bisulfite sequencing, and found that CG DNA methylation is decreased genome-wide in h2a.x mutant endosperm. Hypomethylation was most striking in transposon bodies, and occurred on both parental alleles in the developing endosperm, but not the embryo or seedling. h2a.x-mediated hypomethylated sites overlapped DME targets, but also included other loci, predominately located in heterochromatic transposons and intergenic DNA. Conclusions: Our genome-wide methylation analyses suggest that H2A.X could function in preventing access of the DME demethylase to non-canonical sites. Overall, our data suggest that H2A.X is required to maintain DNA methylation homeostasis in the unique chromatin environment of the Arabidopsis endosperm.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2026

Model-based, in-situ, non-destructive qualification and certification of parts made by autonomous additive manufacturing

To address the significant productivity challenges associated with the qualification and certification (Q&C) tasks of additively manufactured (AM) parts, which have traditionally relied on rigorous post‐build inspection and testing, we propose an integrated framework that combines model‐based qualification and certification (MBQ&C) with autonomous additive manufacturing (AAM). MBQ&C employs high‐fidelity predictive models, developed within the Integrated Computational Materials Engineering (ICME) paradigm, to simulate process–structure–property–performance relationships for assessing a part’s fitness for use. Since predictive models are commonly machine learning (ML)-based or reduced-order surrogates of validated physics models, they run efficiently, enabling timely inference. In parallel, the self-driving AAM utilises ML-based adaptive, closed‐loop control strategies to avoid, mitigate, or repair defects and anomalies during fabrication, thereby increasing the likelihood of producing acceptable parts. A key feature of the combined AAM-MBQ&C framework is that predictive models explicitly incorporate defects or anomalies that persist after the build, using instance-specific data captured via in-situ sensing. This customisation enables a build‐specific assessment of fitness for use, rather than relying on nominal or generic parameters. Such individualised evaluation provides a robust basis for Q&C-related acceptance decisions relating to each build. Additionally, the rapid solution capabilities of ML or reduced-order models enable the determination of a part’s suitability for service shortly after build completion. As the framework matures, it has the potential to substantially reduce reliance on conventional point‐design approaches—such as time‐consuming post‐build computed tomography scanning and costly destructive testing. Thus, the AAM-MBQ&C framework represents a transformative, scalable strategy for quality assurance of AM components, as parts produced within a stable, validated, and certified envelope can be certified with reduced testing. Key benefits include: (1) significant gains in Q&C productivity through efficient, model-centric assessment; (2) performance-based classification of defects into critical and non-critical categories; (3) the ability to predict potential deviations in the performance of parts affected by real-time, adaptive process control interventions relative to those produced under a certified process, and (4) the enabling of virtual Q&C for service environments that are difficult, hazardous, or impractical to access or reproduce experimentally. Collectively, these capabilities strengthen the business case for AM, particularly for high‐consequence and mission‐critical applications. Finally, although this work focuses on powder-based AM, the proposed techniques could be extended to AM processes employing alternative feedstock forms.

Gunasegaram, Dayalan↗
NASA NTRSDate not supplied

An Open-Science Approach to Address Individual Response to Simulated GCR In Genetically Diverse Populations of Mice and Humans

This project addresses the challenge of understanding and predicting individual radiation sensitivity by integrating genetics, demographics and biomarker characteristics across species (mice and humans). We hypothesize that ex vivo DNA repair response to GCR components is a central determinant of cancer risk from space radiation and can serve as a biomarker of radiation risk in combination with genetics. Automated image quantification of 53BP1+ radiation-induced foci (RIF) during the first 4-48 h post-irradiation was performed as a function of dose and LET in non-immortalized primary skin fibroblasts derived from 76 mice across 15 strains (5 inbred reference strains and 10 collaborative-cross strains) exposed to X rays (0.1, 1 and 4 Gy), 350 MeV/n 40Ar and 600 MeV/n 56Fe (1.1 and 3 particles/100sq. μm), as well as in peripheral blood mononuclear cells (PBMCs) from 768 healthy donors (matched ethnicity, 50/50 male/female, 18-70 years old) exposed to gamma rays (0.1 and 1 Gy), 350 MeV/n 28Si, 350 MeV/n 40Ar and 600 MeV/n 56Fe (1.1 and 3 particles/100sq. μm). A genome-wide association study (GWAS) was performed on the mouse strains between DNA damage responses to space radiation and single nucleotide polymorphisms (SNPs). We found SNPs, which were significantly associated to the RIF phenotype, mapped to genes and pathways that are functionally linked to health hazards for deep space exploration (e.g. carcinogenesis, nervous system damage and immune dysfunction). Some of these SNPs were located within protein coding regions, potentially interfering with protein functions and providing promising genetic targets for countermeasures. We also found correlations between both spontaneous and radiation-induced DNA damage and SNPs mapped to pathways associated with cellular metabolism. GWAS is undergoing for the human data. All data have been made available via the NASA Space Biology Open-Science database (genelab.nasa.gov) and we will discuss how various genomic and transcriptomic datasets can be accessed for modeling and integrated using machine learning methods for discovering new radiation biology.

Sylvain V Costes↗
NASA NTRS2022

NASA Utilization of Space Nuclear Systems for Robotic and Human Exploration Missions: Response to EO 13972: Promoting Small Nuclear Reactors for National Defense and Space Exploration

Space Nuclear Systems (SNS) technology development offers a wide range of capabilities to support NASA’s current and future missions. Executive Order (EO) 13972, “Promoting Small Modular Reactors for National Defense and Space Exploration” [1], issued 5 January 2021, directs NASA to define requirements for NASA utilization of nuclear energy systems for human and robotic exploration missions through 2040 and analyze the costs and benefits of such requirements.” Although it is premature to define requirements and cost for future exploration missions that have not yet been formulated, this report describes planned objectives and missions by 2040 that are enabled or enhanced by nuclear systems while taking into account a number of unique considerations for nuclear energy in the space environment. Nuclear energy systems are enabling for space missions and critical capabilities where conventional forms of energy production are impractical or impossible due to mass constraints, mission duration, or distance from the Sun. Space nuclear technologies available or in development for use by 2040 utilize radioisotope decay or nuclear fission and fall into three categories: heat, power, and propulsion. Current applications utilize radioisotope power systems that provide consistent and reliable performance in the sub-kilowatt power range. More advanced SNS can enable new mission objectives where high energy density solutions are critical, or where access to solar solutions is prohibitive. Higher power radioisotope and fission systems are under development within NASA for a wide variety of human exploration and science mission applications. Planned missions designed to use radioisotope systems include Dragonfly, a rotorcraft that will explore the surface of Titan, and Persephone, a mission concept for a Pluto orbiter. Nuclear fission systems have the key advantage of providing significantly higher power, lower mass solutions from tens to even thousands of kilowatts. Fission power is enabling to a sustained human presence on the Moon and developing a robust lunar economy. Fission propulsion is enabling for missions within and beyond cis-lunar space. This report examines NASA-envisioned mission applications and associated performance needs for SNS over the next twenty years leading to 2040 along with the unique technical considerations posed by space nuclear technology development. This includes engineering and operational logistics for ground handling, thermal management, survival of the space environment, operational safety, power requirements, and service longevity. Safety to the public, the NASA work force, and agency assets remains a top priority for NASA and particular attention is given to this aspect in the design, hardware assembly, ground operation, launch, and mission operation of an SNS. NASA relies on the Department of Energy as nuclear authority and its legacy of rigorous safety procedures as standards for ground development, test, transportation, and launch site operation. The principal concern is preventing unintended radiological release to the public or environment. Radioisotope system experience has established processes, including ground operation, transportation, and launch, that are considered directly applicable to emerging fission systems; however, fission systems have unique design needs that impact the safety and performance requirements. High efficiency power conversion from both fission and radioisotope systems requires high operating temperatures necessitating both passive and active thermal management to maintain safe and nominal operating conditions. Effective cooling and waste heat rejection have special considerations for space applications, whether in zero-g or reduced gravity. Fluid and heat transfer within the reactor system is not anticipated to be impacted by reduced or zero-g environments. Cryogenic working fluids and propellant supplies utilized in some space nuclear applications will need low mass, high capacity cryocoolers to meet the long-term storage and near zero-boiloff needs. Integrated, high power density SNS capable of being packaged in a single vehicle is a key consideration for NASA. Due to concerns for complexity and reliability, in space reactor assembly and reactor refueling are not current design considerations. Expanding into a new era for space exploration depends on mass-efficient, high-energy solutions to power deep-space vehicles, operate in harsh environments, and increase mission flexibility. NASA nuclear technology investments are targeting power for surface operations and propulsion for fast-transit, deep-space missions, all with the ability to reliably operate without the need for repair or refueling. NASA’s goals, enabled by nuclear technologies, provide for exciting advances in scientific objectives and human exploration, ushering in a new space age that enables a human presence on bodies beyond our Earth.

nuclear↗