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Consort 3 flight experiments

The third sounding rocket payload in the Consort program was launched from the White Sands Missile Range on May 16, 1990. It carried 12 experiments designed to investigate materials processes in low gravity. All of the experiments were reflights from the Consort 2 payload that was launched on November 1989 but failed to achieve microgravity because of a malfunction in the launch vehicle. Four national Centers for the Commercial Development of Space participated in the mission. The payload included five experiments and two accelerometer systems that flew on Consort 1 and seven new experiments, designed and developed since Consort 1. Experiments from Consort 1 incorporated hardware modifications and changes in experimental parameters based on mission results. The new experiments covered a variety of polymeric and biological investigations. A new power distribution and control system designed to provide discrete, computer-supervised, experiment power monitoring and control was flight qualified on Consort 3. Consort 3 featured very late access (3-5 h before launch vs 27-30 h for Consort 1) for installation of sensitive biological specimens. The integrated payload and mission sequence of events are described. Changes in the Consort 1 experiments are defined and the objectives, methods, and expectations for new experiments are discussed.

Wessling, Francis C.↗

Solid-State Architecture Batteries for Enhanced Rechargeability and Safety (SABERS) Beyond Li-Ion: Technology to Enable Next-Generation Sustainable Electric

All-electric vertical take-off and landing vehicles (eVTOL) for urban air mobility (UAM) concepts face numerous challenging technical barriers before their introduction into the consumer marketplace. The primary barrier to overcome is developing an energy storage system that meets rigorous aerospace safety and performance criteria. The performance metrics for eVTOL vehicles are at least two times greater than those of electric ground vehicles. Furthermore, inherently non-flammable batteries are essential for the safe operation of commercial electric aero vehicles. The SABERS concept proposes a battery that meets the critical performance criteria by developing a solid-state architecture battery utilizing a high-capacity sulfur-selenium cathode and lithium metal anode. The combination of sulfur and selenium offers a balanced energy-to-power density ratio, which can be tailored to the specific application by altering the stoichiometric ratios of sulfur to selenium. This hybrid cathode will be developed using NASA-patented holey graphene technology as a highly conductive, ultra-lightweight electrode scaffold. A solid-state electrolyte will be used as a safe, non-flammable replacement for the highly flammable liquid organic electrolytes currently in SOA lithium-ion batteries. This solid-state lithium-sulfur/selenium cell will be designed in a serial stacking configuration to enable the dense packaging of the battery cells. The serial stacking configuration is termed a bipolar stack, which has the advantages of reducing overall cell weight, simplifying the interfaced connections for the cell, and minimizing the cooling requirements. Lastly, the optimization of battery components will occur through a robust and rigorous combination of various computational modeling techniques covering multiple length scales. The expected result will be a fully solid-state battery with operational temperatures up to 150°C, providing the required energy density, discharge rates, and inherent safety to meet the strict aerospace mission performance criteria. The SABERS team employed novel materials development, computational modeling, and design-of-experiments (DOE) optimization studies in their research. This presentation will show the results of these studies and demonstrate a feasible path for solid-state cells with a specific energy greater than 400 Wh/kg to enable electric aircraft.

Computational Modeling↗

Payload Operations Control Center (POCC)

The Spacelab payload operations control center (POCC) timeline analysis program which is used to provide POCC activity and resource information as a function of mission time is described. This program is fully automated and interactive, and is equipped with tutorial displays. The tutorial displays are sufficiently detailed for use by a program analyst having no computer experience. The POCC timeline analysis program is designed to operate on the VAX/VMS version V2.1 computer system.

Shipman, D. L.↗

Science Use Case Design Patterns for Autonomous Experiments

Connecting scientific instruments and robot-controlled laboratories with computing and data resources at the edge, the Cloud or the high-performance computing (HPC) center enables autonomous experiments, self-driving laboratories, smart manufacturing, and artificial intelligence (AI)-driven design, discovery and evaluation. The Self-driven Experiments for Science / Interconnected Science Ecosystem (INTERSECT) Open Architecture enables science breakthroughs using intelligent networked systems, instruments and facilities with a federated hardware/software architecture for the laboratory of the future. It relies on a novel approach, consisting of (1) science use case design patterns, (2) a system of systems architecture, and (3) a microservice architecture. This paper introduces the science use case design patterns of the INTERSECT Architecture. It describes the overall background, the involved terminology and concepts, and the pattern format and classification. It further offers an overview of the 12 defined patterns and 4 examples of patterns of 2 different pattern classes. It also provides insight into building solutions from these patterns. The target audience are computer, computational, instrument and domain science experts working in the field of autonomous experiments.

Engelmann, Christian↗

Optimization and analysis of large chemical kinetic mechanisms using the solution mapping method - Combustion of methane

A method of systematic optimization, solution mapping, as applied to a large-scale dynamic model is presented. The basis of the technique is parameterization of model responses in terms of model parameters by simple algebraic expressions. These expressions are obtained by computer experiments arranged in a factorial design. The developed parameterized responses are then used in a joint multiparameter multidata-set optimization. A brief review of the mathematical background of the technique is given. The concept of active parameters is discussed. The technique is applied to determine an optimum set of parameters for a methane combustion mechanism. Five independent responses - comprising ignition delay times, pre-ignition methyl radical concentration profiles, and laminar premixed flame velocities - were optimized with respect to thirteen reaction rate parameters. The numerical predictions of the optimized model are compared to those computed with several recent literature mechanisms. The utility of the solution mapping technique in situations where the optimum is not unique is also demonstrated.

Frenklach, Michael↗

The impact of distributed computing on education

In this paper, developments in digital computer technology since the early Fifties are reviewed briefly, and the parallelism which exists between these developments and developments in analysis and design procedures of structural engineering is identified. The recent trends in digital computer technology are examined in order to establish the fact that distributed processing is now an accepted philosophy for further developments. The impact of this on the analysis and design practices of structural engineering is assessed by first examining these practices from a data processing standpoint to identify the key operations and data bases, and then fitting them to the characteristics of distributed processing. The merits and drawbacks of the present philosophy in educating structural engineers are discussed and projections are made for the industry-academia relations in the distributed processing environment of structural analysis and design. An ongoing experiment of distributed computing in a university environment is described.

Utku, S.↗

SSSFD manipulator engineering using statistical experiment design techniques

The Satellite Servicer System Flight Demonstration (SSSFD) program is a series of Shuttle flights designed to verify major on-orbit satellite servicing capabilities, such as rendezvous and docking of free flyers, Orbital Replacement Unit (ORU) exchange, and fluid transfer. A major part of this system is the manipulator system that will perform the ORU exchange. The manipulator must possess adequate toolplate dexterity to maneuver a variety of EVA-type tools into position to interface with ORU fasteners, connectors, latches, and handles on the satellite, and to move workpieces and ORUs through 6 degree of freedom (dof) space from the Target Vehicle (TV) to the Support Module (SM) and back. Two cost efficient tools were combined to perform a study of robot manipulator design parameters. These tools are graphical computer simulations and Taguchi Design of Experiment methods. Using a graphics platform, an off-the-shelf robot simulation software package, and an experiment designed with Taguchi's approach, the sensitivities of various manipulator kinematic design parameters to performance characteristics are determined with minimal cost.

Barnes, John↗

Numerical and Theoretical Considerations for the Design of the AVT-183 Diamond-Wing Experimental Investigations

A diamond-wing configuration has been developed to isolate and study blunt-leading edge vortex separation with both computations and experiments. The wing has been designed so that the results are relevant to a more complex Uninhabited Combat Air Vehicle concept known as SACCON. The numerical and theoretical development process for this diamond wing is presented, including a view toward planned wind tunnel experiments. This work was conducted under the NATO Science and Technology Organization, Applied Vehicle Technology panel. All information is in the public domain.

Boelens, Okko J.↗

An experimental and numerical investigation of shock-wave induced turbulent boundary-layer separation at hypersonic speeds

An experiment designed to test and guide computations of the interaction of an impinging shock wave with a turbulent boundary layer is described. Detailed mean flow-field and surface data are presented for two shock strengths which resulted in attached and separated flows, respectively. Numerical computations, employing the complete time-averaged Navier-Stokes equations along with algebraic eddy-viscosity and turbulent Prandtl number models to describe shear stress and heat flux, are used to illustrate the dependence of the computations on the particulars of the turbulence models. Models appropriate for zero-pressure-gradient flows predicted the overall features of the flow fields, but were deficient in predicting many of the details of the interaction regions. Improvements to the turbulence model parameters were sought through a combination of detailed data analysis and computer simulations which tested the sensitivity of the solutions to model parameter changes. Computer simulations using these improvements are presented and discussed.

Marvin, J. G.↗

Algorithms for real-time flutter identification

The work reported here addresses the important algorithm issues necessary to achieve a real-time flutter monitoring system; namely, the guidelines for choosing appropriate model forms, reduction of the parameter convergence transient, handling multiple modes, the effect of overparameterization, and estimate accuracy predictions, both online and for experiment design. An approach for efficiently computing continuous-time flutter parameter Cramer-Rao estimate error bounds has been developed. This enables a convincing comparison of theoretical and simulation results, as well as off-line studies in preparation for a flight test. Theoretical predictions, simulation and flight test results from the NASA/Dryden Drones for Aerodynamic and Structural Test (DAST) Program are compared.

Walker, R. A.↗

Proceedings of Tenth Annual Software Engineering Workshop

Papers are presented on the following topics: measurement of software technology, recent studies of the Software Engineering Lab, software management tools, expert systems, error seeding as a program validation technique, software quality assurance, software engineering environments (including knowledge-based environments), the Distributed Computing Design System, and various Ada experiments.

Source record↗

Design, Creep Performance and Deformation Behavior of an Eta-Phase Strengthened Nickel-Base Alloy for A-USC Power Plant Applications

By utilizing computational thermodynamics in a Design of Experiments approach, it was possible to design and manufacture nickel-base superalloys that are strengthened by the eta phase (Ni3Ti), and that contain no gamma prime (Ni3Al,Ti). The compositions are similar to Nimonic 263, and should be cost-effective, and have more stable microstructures. By varying the aging temperature, the precipitates took on either cellular or Widmanstätten morphologies. The Widmanstätten-based microstructure is thermally stable at high temperatures, and was found to have superior ductility, so development efforts were focused on that microstructure. High temperature tensile test and creep test results indicated that the performance of the new alloys was competitive with Nimonic 263. SEM and TEM microscopy were utilized to determine the deformation mechanisms during creep.

36 MATERIALS SCIENCE↗

The GeantV project: Preparing the future of simulation

Detector simulation is consuming at least half of the HEP computing cycles, and even so, experiments have to take hard decisions on what to simulate, as their needs greatly surpass the availability of computing resources. New experiments still in the design phase such as FCC, CLIC and ILC as well as upgraded versions of the existing LHC detectors will push further the simulation requirements. Since the increase in computing resources is not likely to keep pace with our needs, it is therefore necessary to explore innovative ways of speeding up simulation in order to sustain the progress of High Energy Physics. The GeantV project aims at developing a high performance detector simulation system integrating fast and full simulation that can be ported on different computing architectures, including CPU accelerators. After more than two years of R&D the project has produced a prototype capable of transporting particles in complex geometries exploiting micro-parallelism, SIMD and multithreading. Portability is obtained via C++ template techniques that allow the development of machine- independent computational kernels. Furthermore, a set of tables derived from Geant4 for cross sections and final states provides a realistic shower development and, having been ported into a Geant4 physics list, can be used as a basis for a direct performance comparison.

97 MATHEMATICS AND COMPUTING↗

Additive Manufacturing, Design, Testing, and Fabrication: A Full Engineering Experience at JSC

I worked on several projects this term. While most projects involved additive manufacturing, I was also involved with two design projects, two testing projects, and a fabrication project. The primary mentor for these was Richard Hagen. Secondary mentors were Hai Nguyen, Khadijah Shariff, and fabrication training from James Brown. Overall, my experience at JSC has been successful and what I have learned will continue to help me in my engineering education and profession long after I leave. My 3D printing projects ranged from less than a 1 cubic centimeter to about 1 cubic foot and involved several printers using different printing technologies. It was exciting to become familiar with printing technologies such as industrial grade FDM (Fused Deposition Modeling), the relatively new SLA (Stereolithography), and PolyJet. My primary duty with the FDM printers was to model parts that came in from various sources to print effectively and efficiently. Using methods my mentor taught me and the Stratasys Insight software, I was able to minimize imperfections, hasten build time, improve strength for specific forces (tensile, shear, etc...), and reduce likelihood of a print-failure. Also using FDM, I learned how to repair a part after it was printed. This is done by using a special kind of glue that chemically melts the two faces of plastic parts together to form a fused interface. My first goal with SLA technology was to bring the printer back to operational readiness. In becoming familiar with the Pegasus SLA printer, I researched the leveling, laser settings, and different vats to hold liquid material. With this research, I was successfully able to bring the Pegasus back online and have successfully printed multiple sample parts as well as functional parts. My experience with PolyJet technology has been focused on an understanding of the abilities/limits, costs, and the maintenance for daily use. Still upcoming will be experience with using a composite printer that uses FDM technology to print plastic while laying an internal filament of Kevlar or carbon-fiber inside the printed material. It has been incredible being exposed to this range of technologies and I feel very fortunate to be ready for virtually any kind of printing technology I come across in the future. Design work played a part in my internship this term as well. Working with Hai Nguyen, I was able to design a set of testing tips and a test frame for use with an Arcjet. The testing tips will be made of several different materials that will possibly be used in the heat shield of the Orion space craft. These designs included technical drawings that were presented to the fabrication shop. The frame design was created from 80/20 (a popular brand of frame construction equipment) and included an order form with pricing for fabrication. An independent design was also done for the virtual reality lab. This design was to create a hand-controller based on a previous design. This final design was sent directly to a 3D printer without technical drawings. Overall, my design work has given me experience with using 80/20, helped improve my CAD (Computer Aided Design) proficiency, and increased my knowledge of how to set up technical drawings for fabrication. The final role I have played in this internship has been to assist with testing of the inflatable technology materials working Khadijah Shariff. I began the internship assisting with permeability testing with the initial plan to continue the testing independently after training. Unfortunately, the testing apparatus suffered a technical failure and had funding pulled which cancelled that portion of the project. Further testing with inflatable technology continued with tensile testing of various stitching methods. This testing took place over a two-days and concluded successfully. Final testing was to be more tensile testing but of straps used to connect various inflatable sections. Unfortunately, the needed grips for the tensile tests could not be located and put the testing on hold. It is possible this round of testing will still take place by the end of the internship if the grips can be found. Overall, this portion of the internship has helped me become familiar with one kind of permeability test as well as a popular tensile/compression testing machine. Finally, I also had the chance to be trained using a metal lathe for making very small tips for a soldering iron. These tips will be used to melt threaded brass inserts into 3D printed plastic. Working with James Brown, I was able to successfully machine a brass rod down to as little as 0.064 inches plus or minus 0.001 inches. It was very rewarding to learn how to best use the machine and become familiar with a skill that will undoubtedly be used again in the future. I have been told by several professional engineers that learning to use a lathe and mill will be invaluable skills in the field. This knocks 50 percent of that goal off and I look forward to learning the mill at some point in the future. As is apparent with this list of projects, my internship was not focused on a single over-arching goal. Instead, I was able to gain experience in a myriad of very different areas. I feel like my time here was spent bouncing from one project to the next. Though sometimes difficult to switch gears, it was very rewarding to be a part of so much in so little time. My career and education will be positively impacted by what I have learned at JSC. My experience with 3D printing has improved my ability to handle many issues that may come up in the future with multiple different technologies. The design work I took part in, especially creating technical drawings, will help me better present designs to any engineer or shop I will encounter. My testing experience has helped me become familiar with a popular kind of tensile test machine that will likely be similar to the kinds I will encounter in the future. Finally, my experience with fabrication has given me a rare opportunity, as an engineer, to take part in the fabrication of a part. This experience will help me better tailor my future designs for the manufacturing process and has given me an appreciation for detailed/delicate machining work. My experience at JSC has been successful and will continue to assist me for a long time within the engineering field.

Zusack, Steven↗

Mechanical Prototyping and Manufacturing Internship

The internship was located at the Johnson Space Center (JSC) Innovation Design Center (IDC), which is a facility where the JSC workforce can meet and conduct hands-on innovative design, fabrication, evaluation, and testing of ideas and concepts relevant to NASA's mission. The tasks of the internship included mechanical prototyping design and manufacturing projects in service of research and development as well as assisting the users of the IDC in completing their manufacturing projects. The first project was to manufacture hatch mechanisms for a team in the Systems Engineering and Project Advancement Program (SETMAP) hexacopter competition. These mechanisms were intended to improve the performance of the servomotors and offer an access point that would also seal to prevent cross-contamination. I also assisted other teams as they were constructing and modifying their hexacopters. The success of this competition demonstrated a proof of concept for aerial reconnaissance and sample return to be potentially used in future NASA missions. I also worked with Dr. Kumar Krishen to prototype an improved thermos and a novel, portable solar array. Computer-aided design (CAD) software was used to model the parts for both of these projects. Then, 3D printing as well as conventional techniques were used to produce the parts. These prototypes were then subjected to trials to determine the success of the designs. The solar array is intended to work in a cluster that is easy to set up and take down and doesn't require powered servomechanisms. It could be used terrestrially in areas not serviced by power grids. Both projects improve planetary exploration capabilities to future astronauts. Other projects included manufacturing custom rail brackets for EG-2, assisting engineers working on underwater instrument and tool cases for the NEEMO project, and helping to create mock-up parts for Space Center Houston. The use of the IDC enabled efficient completion of these projects at significantly reduced cost. I acquired and improved manufacturing and prototyping skills during my tour including learning about a CAD (Computer-Aided Design) program called Creo (Creo Parametric; design software), gaining valuable conventional machining experience with lathes, CNC (Computer Numerical Control) milling machines and various other tools, and improving my engineering project communication and collaboration skills. The internship also allowed me to better understand operations at NASA. I plan to work in the aerospace industry or do academic research benefitting space science and exploration, and this internship experience will enable me to have insight into manufacturing processes for research and development.

Grenfell, Peter↗

The FabrIc for Frontier Experiments Project at Fermilab: Computing for Experiments

The FabrIc for Frontier Experiments (FIFE) project is a major initiative within the Fermilab Scientific Computing Division designed to steer the computing model for non-LHC experiments at Fermilab. The FIFE project enables close collaboration between experimenters and computing professionals to serve high-energy physics experiments of differing scope and physics area of study. The project also tracks and provides feedback on the development of common tools for job submission, identity management, software and data distribution, job monitoring, and databases for project tracking. The computing needs of the experiments under the FIFE umbrella continue to increase, and present a complex list of requirements to their service providers. To meet these requirements, recent advances in the FIFE toolset include a new identity management infrastructure, significantly upgraded job monitoring tools, and a workflow management system. We have also upgraded existing tools to access remote computing resources such as GPU clusters and sites outside the United States. We will present these recent advances, highlight the nature of collaboration between the diverse set of experimenters and service providers, and discuss the project's future directions.

43 PARTICLE ACCELERATORS↗

Tractable Experiment Design via Mathematical Surrogates

This presentation summarizes the development and implementation of quantitative design criteria motivated by targeted inference objectives for identifying new, potentially expensive computational or physical experiments. The first application is concerned with estimating features of quantities of interest arising from complex computational models, such as quantiles or failure probabilities. A sequential strategy is proposed for iterative refinement of the importance distributions used to efficiently sample the uncertain inputs to the computational model. In the second application, effective use of mathematical surrogates is investigated to help alleviate the analytical and numerical intractability often associated with Bayesian experiment design. This approach allows for the incorporation of prior information into the design process without the need for gross simplification of the design criterion. Illustrative examples of both design problems will be presented as an argument for the relevance of these research problems.

97 MATHEMATICS AND COMPUTING↗

Progress Summary: Simulating stochastic and additively manufactured foams at large strains and high strain rates

Motivation: Understanding the mechanical response of polymer foams is essential in developing system material models and in designing replacements for legacy pads and cushions. Simulations can help elucidate structure-property relationships and compare local stress distributions to understand aging behavior and improve designs. In many applications,these materials experience significant loadings and computations need the capability to reproduce those conditions. Significance: In designing the compressive and shear response of additively manufactured foams, we expect the curvature of the substrate to influence their mechanical behavior. Progress:We have the capability of mapping planar structures to arbitrary curved surfaces and are currently developing the software and procedures to translate the mapped pattern into a geometrical model that can be imported to either finite element or material point software to evaluate the mechanical response. Figure 1 depicts a four-layer face-centered tetragonal pattern (FCT) mapped to a hemispherical surface. Because the mapping cannot exactly preserve both distances and angles, we expect some local variation in mechanical properties and porosity. These models will help determine the sensitivity of these variations to structure and curvature, optimize the mapping procedure, and inform the design of foams for non-planar surfaces.

36 MATERIALS SCIENCE↗