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The investigations of the reports to 4 on wings of small aspect ratio are continued. The present report deals with the results of the three- and six-component measurements and the flow pictures of the triangular wing series with the aspect ratio Lambda = 3 to Lambda = 1.
The results of pretesting and performance testing of Stack 564 are reported. The design features, progress in fabrication and plans for assembly of Stack 800 are given. The status of endurance testing of Stack 560 is reported. The design, fabrication, test procedures and preliminary tests of the 10 kW double counterflow reformer and the reformer test stand are described. Results of vendor contacts to define the performance and cost of fuel conditioning system components are reported. The results of burner tests and continuing development of the BOLTAR program are reported.
Qualifying large-scale metal additive manufacturing (M-AM) technologies such as wire arc additive manufacturing (WAAM) can be challenging. This is especially significant in precipitation hardened martensitic stainless steels like SS 17-4PH, where thermal histories induce location-specific microstructural variability and property anisotropy. The Department of Defense (DOD) and the United States Army Combat Capabilities Development Command Ground Vehicle Systems Center (GVSC) Ground Vehicle Materials Engineering (GVME) aim to build robust and qualified large-scale M-AM workflows that could reduce the time and cost through quick and informed evaluation, testing, and development of feedstock, processes, and parts. The report presents the findings from the collaborative efforts between Oak Ridge National Laboratory (ORNL) and the U.S. Army GVSC GVME. The aim of this project was to develop a geometric feature-based qualification framework for WAAM of SS 17-4PH components. This report outlines selection methodology of representative build geometries, optimization of WAAM process parameters, in-situ monitoring, microstructure-property evaluation, thermal simulations, as well as data visualization techniques incorporated in this project. The results from this project demonstrate a clear understanding of thermal history dependent phase evolution and consequent location-specific property variations in WAAM of SS 17-4PH. These results in conjunction with the data-driven methodologies used in this project are expected to reduce qualification timelines, improve predictability, and accelerate the development of reliable feature-based qualification strategies for part production via large-scale M-AM technologies.
A method of diffusion bonding and fluxless brazing of aluminum containing components is reported. The aluminum surfaces are freed of any aluminum oxide coating and are coated with a polymeric sealer which can be thermally removed leaving essentially no residue. The polymeric sealer is being removed in a substantially oxygen free environment, and the aluminum components are then being brazed or diffusion bonded without the use of a flux to remove oxide coating.
A preliminary report on the Active Optical System Components Experiment is presented. This experiment contained 136 components in a six-inch deep tray including lasers, infrared detectors and arrays, ultraviolet light detectors, light-emitting diodes, a light modulator, flash lamps, optical filters, glasses, and samples of surface finishes. The experimental results for those component characteristics appear as much related to the passage of time as to the effects of the space environment, but organic materials and extreme-infrared reflectivity of black paints show unexpected changes.
A preliminary report on the Active Optical System Components Experiment is presented. This experiment contained 136 components in a six inch deep tray including lasers, infrared detectors and arrays, ultraviolet light detectors, light-emitting diodes, a light modulator, flash lamps, optical filters, glasses, and samples of surface finishes. Thermal, mechanical, and structural considerations leading to the design of the tray hardware are discussed. In general, changes in the retested component characteristics appear as much related to the passage of time as to the effects of the space environment, but organic materials, multilayer optical interference filters, and extreme-infrared reflectivity of black paints show unexpected changes.
This report concerns two types of optical components: multilayer filters and mirrors, and self-scanned imaging arrays using charge coupled device (CCD) readouts. For the filters and mirrors, contamination produces a strong reduction in transmittance in the ultraviolet spectral region, but has little or no effect in the visible and infrared spectral regions. Soft substrates containing halides are unsatisfactory as windows or substrates. Materials choice for dielectric layers should also reflect such considerations. Best performance is also found for the harder materials. Compaction of the layers and interlayer diffusion causes a blue shift in center wavelength and loss of throughput. For sensors using CCD's, shifts in gate voltage and reductions in transfer efficiency occur. Such effects in CCD's are in accord with expectations of the effects of the radiation dose on the device. Except for optical fiber, degradation of CCD's represents the only ionizing-radiation induced effect on the Long Duration Exposure Facility (LDEF) optical systems components that has been observed.
Finite element models were developed of a floor-equipped, frame and stringer stiffened composite cylinder including a coarse finite element model of the structural components, a coarse finite element model of the acoustic cavities above and below the beam-supported plywood floor, and two dense models consisting of only the structural components. The report summarizes the geometry, the element properties, the material and mechanical properties, the beam cross-section characteristics, the beam element representations and the boundary conditions of the composite cylinder models. The expressions used to calculate the group speeds for the cylinder components are presented.
This article reports on preliminary results of a study conducted to examine how temporary electrical overstress seed fault conditions in discrete power electronic components that cannot be detected with reliability tests but impact longevity of the device. These defects do not result in formal parametric failures per datasheet specifications, but result in substantial change in the electrical characteristics when compared with pristine device parameters. Tests were carried out on commercially available 600V IGBT devices using transmission line pulse (TLP) and system level ESD stress. It was hypothesized that the ESD causes local damage during the ESD discharge which may greatly accelerate degradation mechanisms and thus reduce the life of the components. This hypothesis was explored in simulation studies where different types of damage were imposed to different parts of the device. Experimental results agree qualitatively with the simulation for a number of tests which will motivate more in-depth modeling of the damage.
This report concerns the energy spectra and abundances of ions with atomic number, Z, in the interval 2 greater than or equal to Z and Z less than or equal to 36 and energies approximately 3-20 MeV/amu for solar and interplanetary quiet periods between November 1994 and April 1998 as measured by the large-geometry LEMT telescope on the Wind spacecraft near Earth. The energy spectra show the presence of galactic (GCR) and 'anomalous' cosmic ray (ACR) components, depending on the element. ACR components are reported for Mg and Si for the first time at 1 AU and the previous observation of S and Ar is confirmed. However, only GCR components are clearly apparent for the elements Ca, Ti, Cr, Fe, as well as for C. New limits are placed on a possible ACR contribution for other elements, including Kr.
We report the energy spectra and abundances of ions with atomic number, Z, in the interval Z is greater than or equal to 2 and Z is less than or equal to 36 and energies approximately 3-20 MeV/amu for solar and interplanetary quiet periods between 1994 November and 1998 April as measured by the large-geometry Low Energy Matrix Telescope (LEMT) telescope on the Wind spacecraft near Earth. The energy spectra show the presence of galactic (GCR) and "anomalous" cosmic ray (ACR) components, depending on the element. ACR components are reported for Mg and Si for the first time at 1 AU and the previous observation of S and Ar is confirmed. However, only GCR components are clearly apparent for the elements Ca, Ti, Cr, Fe, as well as for C. New limits are placed on a possible ACR contribution for other elements, including Kr.
This document is the final report for the Clearfield disassembly evaluation and a continuation of the KSC postflight assessment for the RSRM-29 flight set. All observed hardware conditions were documented on PFOR's and are included in Appendices A, B, and C. Appendices D and E contain the measurements and safety factor data for the nozzle and insulation components. This report, along with the KSC Ten-Day Postflight Hardware Evaluation Report (TWR-64221), represents a summary of the RSRM-29 hardware evaluation. Disassembly evaluation photograph numbers are logged in TWA-1990. The RSRM-29 flight set disassembly evaluations described in this document were performed at the RSRM Refurbishment Facility in Clearfield, Utah. The final factory joint demate occurred on September 9, 1993. Detailed evaluations were performed in accordance with the Clearfield PEEP, TWR-50051, Revision A. All observations were compared against limits that are also defined in the PEEP. These limits outline the criteria for categorizing the observations as acceptable, reportable, or critical. Hardware conditions that were unexpected and/or determined to be reportable or critical were evaluated by the applicable CPT and tracked through the PFAR system.
The final report for the Clearfield disassembly evaluation and a continuation of the KSC postflight assessment for the RSRM-28 (STS-53) RSRM flight set is presented. All observed hardware conditions were documented on PFOR's and are included in Appendices A through C. Appendices D and E contain the measurements and safety factor data for the nozzle and insulation components. This report, along with the KSC Ten-Day Postflight Hardware Evaluation Report (TWR-64215), represents a summary of the RSRM-28 hardware evaluation. The as-flown hardware configuration is documented in TWR-63638. Disassembly evaluation photograph numbers are logged in TWA-1989. The RSRM-28 flight set disassembly evaluations described were performed at the RSRM Refurbishment Facility in Clearfield, Utah. The final factory joint demate occurred on July 15, 1993. Additional time was required to perform the evaluation of the stiffener rings per special issue 4.1.5.2 because of the washout schedule. The release of this report was after completion of all special issues per program management direction. Detailed evaluations were performed in accordance with the Clearfield PEEP, TWR-50051, Revision A. All observations were compared against limits that are also defined in the PEEP. These limits outline the criteria for categorizing the observations as acceptable, reportable, or critical. Hardware conditions that were unexpected and/or determined to be reportable or critical were evaluated by the applicable team and tracked through the PFAR system.
The final report for the Clearfield disassembly evaluation and a continuation of the KSC postflight assessment for the 360T026 (STS-47) Redesigned Solid Rocket Motor (RSRM) flight set is provided. All observed hardware conditions were documented on PFOR's and are included in Appendices A, B, and C. Appendices D and E contain the measurements and safety factor data for the nozzle and insulation components. This report, along with the KSC Ten-Day Postflight Hardware Evaluation Report (TWR-64203), represents a summary of the 360T026 hardware evaluation. The as-flown hardware configuration is documented in TWR-60472. Disassembly evaluation photograph numbers are logged in TWA-1987. The 360T026 flight set disassembly evaluations described were performed at the RSRM Refurbishment Facility in Clearfield, Utah. The final factory joint demate occurred on 12 April 1993. Detailed evaluations were performed in accordance with the Clearfield Postflight Engineering Evaluation Plan (PEEP), TWR-50051, Revision A. All observations were compared against limits that are also defined in the PEEP. These limits outline the criteria for categorizing the observations as acceptable, reportable, or critical. Hardware conditions that were unexpected and/or determined to be reportable or critical were evaluated by the applicable CPT and tracked through the PFAR system.
Industry equipment reliability and asset management programs are essential elements that help ensure the safe and economical operation of nuclear power plants. The effectiveness of these programs is addressed in several industry-developed and regulatory programs. The Risk-Informed Asset Management (RIAM) project is tasked to develop tools in support of the equipment reliability and asset management programs at nuclear power plants. These tools are designed to create a direct bridge between component health/lifecycle data and decision making (e.g., maintenance scheduling and project prioritization). The goal of this article is to provide a guide for specific use cases that the RIAM project is targeting. We have grouped uses cases into three main areas. The first area focuses on the analysis of equipment reliability data with a particular emphasis on condition-based data, such as test/surveillance reports and component monitoring data. The second area focuses on the integration of equipment reliability into system/plant reliability models to determine system/plant health and identify the components that are critical to maintain an operational system. Lastly, the third area manages plant resources, such as maintenance activities and replacement scheduling using optimization methods. Here the primary focus is on supporting typical system engineer decisions regarding maintenance activity scheduling and component aging management. This is performed in a risk-informed context where the term “risk” is broadly constructed to include both plant reliability and economics. This framework combines data analytics tools to analyze equipment reliability data with risk-informed methods designed to support system engineer decisions (e.g., maintenance and replacement schedules, optimal maintenance posture) in a customizable workflow.
During research and development for NASA’s X-57 Maxwell all-electric aircraft project, the efficiency and power density requirements of its electric propulsion subsystem components were met, but aspects of integrating its powertrain subsystems proved problematic. Electromagnetic interference (EMI) from the cruise motor controller (CMC) was a significant challenge for the project. This problem was exacerbated by the lack of EMI requirements imposed on subsystem powertrain components. This report presents the results of EMI testing of the X-57 high lift motor controller (HLMC) at the NASA Glenn Research Center’s EMI Laboratory. For reference, the conducted emissions are compared to DO–160G and MIL–STD–61G conducted emissions limits. After the EMI test, mitigation of the conducted emissions using lightweight EMI chokes produced at NASA Glenn was evaluated using the Fast Fourier Transform (FFT) capability of an oscilloscope in the hardware development laboratory. This process can contribute to the rapid prototyping of electric powertrain components and EMI filters and improve the likelihood of successful EMI qualification at the component and system levels.
Automated cloud detection and tracking is an important step in assessing changes in radiation budgets associated with global climate change via remote sensing. Data products based on satellite imagery are available to the scientific community for studying trends in the Earth's atmosphere. The data products include pixel-based cloud masks that assign cloud-cover classifications to pixels. Many cloud-mask algorithms have the form of decision trees. The decision trees employ sequential tests that scientists designed based on empirical astrophysics studies and simulations. Limitations of existing cloud masks restrict our ability to accurately track changes in cloud patterns over time. In a previous study we compared automatically learned decision trees to cloud masks included in Advanced Very High Resolution Radiometer (AVHRR) data products from the year 2000. In this paper we report the replication of the study for five-year data, and for a gold standard based on surface observations performed by scientists at weather stations in the British Islands. For our sample data, the accuracy of automatically learned decision trees was greater than the accuracy of the cloud masks p < 0.001.
This report documents the AMMT program’s development and submission of a draft ASME Code Case to qualify Laser Powder Bed Fusion (L PBF) Type 316H stainless steel for Section III, Divi-sion 5 Class A and SM high temperature nuclear applications. It summarizes the technical basis, the comprehensive high temperature mechanical test database assembled between 2023–2026, and the proposed code language and qualification framework submitted to ASME. The work was co-ordinated across multiple national laboratories and leverages prior ASME efforts to integrate additive manufacturing into the Boiler & Pressure Vessel Code. The body of the report describes the experimental database and analysis supporting the Code Case: tensile, creep, fatigue, creep fatigue, and thermal aging tests collected from multiple additive manufacturing sites, machine types, and powder lots, with material processed by a solution anneal heat treatment. The dataset — including both full size and subsized specimens and tests oriented parallel and perpendicular to build direction — shows limited tensile anisotropy, tensile properties comparable to wrought 316H, creep strength within the scatter of wrought material, but markedly reduced creep ductility above about 650 °C associated with rapid σ phase formation in L PBF microstructures. The draft Code Case itself prescribes a staged qualification model (manufacturing process qualification, component qualification, and per build witness testing), treats L PBF components as equivalent to Type 316 weld metal for design and inspection, and requires mechanical, chemical, and metallographic controls tied to ASTM/ISO 52946. Key acceptance criteria include tensile tests within a 90% prediction interval of the AMMT dataset, a creep fatigue screening test adapted from ASME Section III, Division 5, Subsection HB, HBB 2800 but with the cycle acceptance reduced to 100 for L PBF material, and double volumetric inspection of production components. The report concludes that the present data support treating L PBF 316H as analogous to conventional fusion weld metal for Division 5 design and inspection, while highlighting important caveats: the σ phase driven loss of creep ductility above ~650 °C, preliminary indications of enhanced creep fatigue sensitivity in some lots, and remaining gaps in long term aging and additional cyclic testing. Recommended next actions include completing outstanding cyclic and long duration creep/aging tests on the solution annealed condition, supporting inclusion of the 316H chemistry and heat treatment in ASTM/ISO 52946, and continuing engagement with ASME and NRC during balloting and review to enable industry adoption.