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NASA NTRS2022

KSC Headquarters Building Area SWMU 104 Soil Interim Measure Report for LOC 2D and LOC 2E Kennedy Space Center, Florida

This Interim Measure (IM) Report for Location of Concern (LOC) 2D and LOC 2E summarizes the activities associated with implementation of an IM to address soil and concrete contamination at the Kennedy Space Center (KSC) Headquarters Building Area (KHQA) located at KSC, Florida. KHQA has been designated Solid Waste Management Unit (SWMU) 104 under KSC’s Resource Conservation and Recovery Act Corrective Action Program. The IM consisted of excavating/removing residual polychlorinated biphenyl (PCB) contamination in soil and concrete from two separate areas, LOC 2D and LOC 2E, which were associated with electrical transformer locations. IM activities were conducted in accordance with the Interim Measure Work Plan (IMWP), Revision 1, for KHQA dated June 2018, which was approved by the Florida Department of Environmental Protection in a correspondence letter dated April 2016 and the United States Environmental Protection Agency in a correspondence letter dated August 2018. The objective of the IM was to remove all remaining contaminated media with total PCB concentrations greater than the State of Florida Residential Soil Cleanup Target Level (RSCTL) (0.5 milligrams per kilogram [mg/kg]). This cleanup goal meets unrestrictive re-use conditions in Florida, and is below federal regulations for PCB Bulk Remediation Waste Cleanup of 1 mg/kg for high occupancy, unrestricted use areas, as outlined in 40 Code of Federal Regulations (CFR) 761.61(a). The timeline of the IM was coordinated with demolition of the former KSC Headquarters Building (demolished in 2021) in order to safely remove contaminated media after electrical equipment was de-energized and removed from the site. Excavation activities were conducted between January 10, 2022, and February 8, 2022, and included two waste streams for off-site disposal: (1) PCB-remediation waste greater than or equal to 50 mg/kg, and (2) PCB-remediation waste less than 50 mg/kg. A total of approximately 347 cubic yards (478 tons) of PCB-contaminated soil and concrete was initially removed from the LOC 2D and LOC 2E areas, as defined in the IMWP. An additional 4.35 tons of soil and concrete were removed based on verification sampling, which was conducted until the cleanup goal was achieved. The total area of excavation from both LOC 2D and LOC 2E was approximately 5,186 square feet (0.12 acres), and excavation depths ranged from 0.5 to 4.0 feet below land surface Excavated soils and concrete were stockpiled based on waste stream and subsequently transported and disposed of at Waste Connections of Osceola County, LLC – JED Landfill in St. Cloud, Florida (PCBs less than 50 mg/kg) or the Chemical Waste Management Landfill in Emelle, Alabama (PCBs greater than or equal to 50 mg/kg). Following excavation, clean backfill was brought to the site and provided to the Demolition Contractor to complete backfill and grading in conjunction with their final site restoration activities from building demolition. Post-IM groundwater sampling was conducted in May 2022 at three monitoring wells installed in April 2022 to confirm that PCBs did not leach into groundwater. These wells were installed where the highest PCB concentrations were detected at LOC 2D, LOC 2E, and from the Building Perimeter IM (previously completed in 2020). All PCB results in groundwater were non-detect. Volatile organic compounds were also analyzed based on potential past use of solvents in transformers with PCB-dielectric fluids and the potential release of dielectric fluids containing volatile organic compounds, and all results were non-detect. Based on completion of a successful IM at LOC 2D and LOC 2E, as well as previous remedial actions that have addressed other contamination at KHQA (SWMU 104), No Further Action without controls will be recommended for SWMU 104. NASA will submit separate Site Rehabilitation Completion Order request documentation for SWMU 104 to support an NFA without controls recommendation.

PCB↗
DOE OSTI2021

BISON: A Flexible Code for Advanced Simulation of the Performance of Multiple Nuclear Fuel Forms

BISON is a nuclear fuel performance application built using the Multiphysics Object-Oriented Simulation Environment (MOOSE) finite element library. One of its major goals is to have a great amount of flexibility in how it is used, including in the types of fuel it can analyze, the geometry of the fuel being modeled, the modeling approach employed, and the dimensionality and size of the models. Fuel forms that can be modeled include standard light water reactor fuel, emerging light water reactor fuels, tri-structural isotropic fuel particles, and metallic fuels. BISON is a platform for research in nuclear fuel performance modeling while simultaneously serving as a tool for the analysis of nuclear fuel designs. Recent research in BISON includes techniques such as the extended finite element method for fuel cracking, exploration of high-burnup light water reactor fuel behavior, swelling behavior of metallic fuels, and central void formation in mixed-oxide fuel. BISON includes integrated documentation for each of its capabilities, follows rigorous software quality assurance procedures, and has a growing set of rigorous verification and validation tests.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Acceptance Testing of the Scorpius Sweep Magnet

A beam-dump magnet for Scorpius has been defined by LANL and designed and built by Radiabeam Technologies. Initial verification of the Radiabeam design used a magnetic field model provided by Radiabeam and analyzed by LANL tools during September 2021. Simulations indicated that the design was sufficient to meet deflection requirements to protect sensitive equipment in the case of a failed target. In January 2022, the magnet was fabricated and Radiabeam conducted measurements of the magnetic field as a function of position. The measurements deviate somewhat from the simulation. In particular, the peak magnetic field is 10-15% smaller in magnitude than expected from simulation. This note compares the magnetic field measurements to simulation and to measurements of the existing DARHT magnet, which was designed for the same purpose. We show a comparison of the measured beam deflection performance between Scorpius and DARHT and show updated results of LANL’s electron beam tracking code using the Scorpius measurements. Using field measurements we find that the DARHT magnet will deflect a 19.6 MeV electron beam by 46.6° and the Scorpius magnet will deflect by 44.6°. These results show that the as-built Scorpius magnet has met design requirements for beam deflection.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRS2014

Coupled Fluid-Structure Interaction Analysis of Solid Rocket Motor with Flexible Inhibitors

Flexible inhibitors are generally used in solid rocket motors (SRMs) as a means to control the burning of propellant. Vortices generated by the flow of propellant around the flexible inhibitors have been identified as a driving source of instabilities that can lead to thrust oscillations in launch vehicles. Potential coupling between the SRM thrust oscillations and structural vibration modes is an important risk factor in launch vehicle design. As a means to predict and better understand these phenomena, a multidisciplinary simulation capability that couples the NASA production CFD code, Loci/CHEM, with CFDRC's structural finite element code, CoBi, has been developed. This capability is crucial to the development of NASA's new space launch system (SLS). This paper summarizes the efforts in applying the coupled software to demonstrate and investigate fluid-structure interaction (FSI) phenomena between pressure waves and flexible inhibitors inside reusable solid rocket motors (RSRMs). The features of the fluid and structural solvers are described in detail, and the coupling methodology and interfacial continuity requirements are then presented in a general Eulerian-Lagrangian framework. The simulations presented herein utilize production level CFD with hybrid RANS/LES turbulence modeling and grid resolution in excess of 80 million cells. The fluid domain in the SRM is discretized using a general mixed polyhedral unstructured mesh, while full 3D shell elements are utilized in the structural domain for the flexible inhibitors. Verifications against analytical solutions for a structural model under a steady uniform pressure condition and under dynamic modal analysis show excellent agreement in terms of displacement distribution and eigenmode frequencies. The preliminary coupled results indicate that due to acoustic coupling, the dynamics of one of the more flexible inhibitors shift from its first modal frequency to the first acoustic frequency of the solid rocket motor. This insight could have profound implications for SRM and flexible inhibitor designs for current and future launch vehicles including SLS.

Yang, H. Q.↗
DOE OSTI2025

Species Transport Framework Development in SAM for System-Level Tritium Source Term Analysis

The SAM code is under development as a modern system-level modeling and simulation tool for advanced non–light water reactor safety analyses, with recent efforts to add capabilities to evaluate radiological source term risks in these novel reactor concepts. By leveraging the established system-level multiphysics thermal-hydraulic models in SAM, a framework for tightly coupled species transport modeling has been integrated into the code for engineering-scale source term evaluation. This species transport framework was first applied to the simulation of tritium, which is a well-known source term in conventional light water reactors. Tritium poses a unique risk in salt-cooled reactors, especially those with lithium-bearing salts such as the fluoride salt–cooled high-temperature reactor (FHR) concept, as tritium is generated in the salt coolant in significant quantities due to neutron interactions. A compounding factor is the increased mobility of tritium at high temperatures, which is able to permeate through metals while also potentially being retained in graphite pebbles and structures. Engineering-scale models for the tritium transport pathways in a FHR have been developed using the new species transport framework in SAM. The capabilities are assessed through analytical verification problems and validated with data from a graphite retention experiment. In conclusion, the system-level model is demonstrated by performing an initial estimate of baseline tritium generation and flows in a generic reference SAM FHR model, setting a foundation for future studies of source term transient analysis with the potential for further multiscale and multiphysics integration.

SAM↗
DOE OSTI2019

Towards Multifluid Multiphysics Continuum Plasma Simulation for Modeling Magnetically-driven Experiments on Z

Magnetically driven experiments supporting pulsed-power utilize a wide range of configurations, including wire-arrays, gas-puffs, flyer plates, and cylindrical liners. This experimental flexibility is critical to supporting radiation effects, dynamic materials, magneto-inertial-fusion (MIF), and basic high energy density laboratory physics (HEDP) efforts. Ultimately, the rate at which these efforts progress is limited by our understanding of the complex plasma physics of these systems. Our effort has been to begin to develop an advanced algorithmic structure and a R&D code implementation for a plasma physics simulation capability based on the five-moment multi-fluid / full-Maxwell plasma model. This model can be used for inclusion of multiple fluid species (e.g., electrons, multiple charge state ions, and neutrals) and allows for generalized collisional interactions between species, models for ionization/recombination, magnetized Braginskii collisional transport, dissipative effects, and can be readily extended to incorporate radiation transport physics. In the context of pulsed-power simulations this advanced model will help to allow SNL to computationally simulate the dense continuum regions of the physical load (e.g. liner implosions, flyer plates) as well as partial power-flow losses in the final gap region of the inner MITL. In this report we briefly summarize results of applying a preliminary version of this model in the context of verification type problems, and some initial magnetic implosion relevant prototype problems. The MIF relevant prototype problems include results from fully-implicit / implicit-explicit (IMEX) resistive MHD as well as full multifluid EM plasma formulations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

HYSPLIT/MACCS Atmospheric Dispersion Model Technical Documentation and Benchmark Analysis

The nuclear accident consequence analysis code MACCS has traditionally modeled dispersion during downwind transport using a Gaussian plume segment model. MACCS is designed to estimate consequence measures such as air concentrations and ground depositions, radiological doses, and health and economic impacts on a statistical basis over the course of a year to produce annualaveraged output measures. The objective of this work is to supplement the Gaussian atmospheric transport and diffusion (ATD) model currently in MACCS with a new option using the HYSPLIT model. HYSPLIT/MACCS coupling has been implemented, with HYSPLIT as an alternative ATD option. The subsequent calculations in MACCS use the HYSPLIT-generated air concentration, and ground deposition values to calculate the same range of output quantities (dose, health effects, risks, etc.) that can be generated when using the MACCS Gaussian ATD model. Based on the results from the verification test cases, the implementation of the HYSPLIT/MACCS coupling is confirmed. This report contains technical details of the HYSPLIT/MACCS coupling and presents a benchmark analysis using the HYSPLIT/MACCS coupling system. The benchmark analysis, which involves running specific scenarios and sensitivity studies designed to examine how the results generated by the traditional MACCS Gaussian plume segment model compare to the new, higher fidelity HYSPLIT/MACCS modeling option, demonstrates the modeling results that can be obtained by using this new option. The comparisons provided herein can also help decision-makers evaluate the potential benefit of using results based on higher fidelity modeling with the additional computational burden needed to perform the calculations. Three sensitivity studies to investigate the potential impact of alternative modeling options, regarding 1) input meteorological data set, 2) method to estimate stability class, and 3) plume dispersion model for larger distances, on consequence results were also performed. The results of these analyses are provided and discussed in this report.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Updates to Relevance Vector Machine: Multiclass Classification, Variable Selection, and Proof-of-Concept Application to Safeguards Fresh Fuel Verification using List-Mode Neutron Collar Data

To expand the capabilities of safeguards authorities to verify the integrity of fresh fuel assemblies, Oak Ridge National Laboratory has retrofit the existing electronics of the JCC-71 uranium neutron coincidence collar, which contains 18 3 He neutron detectors and an external 241 AmLi(α, n) neutron interrogation source arranged to surround a fresh nuclear fuel assembly. The new electronics system allows analysts to record list-mode neutron multiplicity data in addition to the singles and doubles rates that are currently measured. Based on previous proof-of-concept research, analysis of these new data will identify off-normal fuel configurations in an assembly and characterize or localize the specific partial fuel defects. The purpose of this report it to document the analysis algorithm development and then to demonstrate its capability for the safeguards verification of fresh fuel assemblies using list mode neutron collar data. To analyze the complex list-mode data collected with the upgraded uranium neutron collar, multivariate classification algorithms are being developed using a novel classification method, the relevance vector machine. This approach may be applied to multiclass problems to estimate the probability that test data belongs to one of many possible classes of data. In addition, our method identifies the most useful variables/channels for making predictions, which illuminates the basis for the model’s predictions, and this interpretability is largely unique among data analytics methods. Variable selection occurs during model training and parameter tuning and does not need any external hyperparameter tuning routines. Finally, we apply the modified relevance vector machine to a simulated dataset of list-mode neutron collar data generated with the radiation transport code MCNP. The method can correctly identify off-normal fuel configurations, categorize the data according to four fuel defect scenarios, and rank the channels in the data according to prediction utility. For nuclear safeguards applications, it is concluded that this method has the potential to increase the sensitivity and reliability to detect missing fuel rods from a standard 17 x 17 Pressurized Water Reactor (PWR) fresh fuel assembly. Within this analysis, “off-normal” (i.e., missing fuel rods) were correctly classified in 17 simulated test scenarios with one quarter (25%) of the fresh fuel rods missing using a training data set of 58 simulated measurements.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2016

Fuselage Versus Subcomponent Panel Response Correlation Based on ABAQUS Explicit Progressive Damage Analysis Tools

Analysis performed in this study substantiates the need for high fidelity vehicle level progressive damage analyses (PDA) structural models for use in the verification and validation of proposed sub-scale structural models and to support required full-scale vehicle level testing. PDA results are presented that capture and correlate the responses of sub-scale 3-stringer and 7-stringer panel models and an idealized 8-ft diameter fuselage model, which provides a vehicle level environment for the 7-stringer sub-scale panel model. Two unique skin-stringer attachment assumptions are considered and correlated in the models analyzed: the TIE constraint interface versus the cohesive element (COH3D8) interface. Evaluating different interfaces allows for assessing a range of predicted damage modes, including delamination and crack propagation responses. Damage models considered in this study are the ABAQUS built-in Hashin procedure and the COmplete STress Reduction (COSTR) damage procedure implemented through a VUMAT user subroutine using the ABAQUS/Explicit code.

Gould, Kevin E.↗
NASA NTRS1997

Prediction and Verification of Ductile Crack Growth from Simulated Defects in Strength Overmatched Butt Welds

Defects that develop in welds during the fabrication process are frequently manifested as embedded flaws from lack of fusion or lack of penetration. Fracture analyses of welded structures must be able to assess the effect of such defects on the structural integrity of weldments; however, the transferability of R-curves measured in laboratory specimens to defective structural welds has not been fully examined. In the current study, the fracture behavior of an overmatched butt weld containing a simulated buried, lack-of-penetration defect is studied. A specimen designed to simulate pressure vessel butt welds is considered; namely, a center crack panel specimen, of 1.25 inch by 1.25 inch cross section, loaded in tension. The stress-relieved double-V weld has a yield strength 50% higher than that of the plate material, and displays upper shelf fracture behavior at room temperature. Specimens are precracked, loaded monotonically while load-CMOD measurements are made, then stopped and heat tinted to mark the extent of ductile crack growth. These measurements are compared to predictions made using finite element analysis of the specimens using the fracture mechanics code Warp3D, which models void growth using the Gurson-Tvergaard dilitant plasticity formulation within fixed sized computational cells ahead of the crack front. Calibrating data for the finite element analyses, namely cell size and initial material porosities are obtained by matching computational predictions to experimental results from tests of welded compact tension specimens. The R-curves measured in compact tension specimens are compared to those obtained from multi-specimen weld tests, and conclusions as to the transferability of R-curves is discussed.

Nishioka, Owen S.↗
DOE OSTI2023

Physics Basis, Optimization, and Control for Integrated 3D Edge Long-pulse Tokamak Scenarios

The aim of this project with international collaborations (PI: J.-K. Park of Princeton Plasma Physics Laboratory) is to develop a unified physics basis and predictive capability for the control of edge-localized modes (ELMs) with optimized non-axisymmetric (3D) fields, by leveraging the unique research capabilities of international KSTAR tokamak in Korea. At the University of California, Irvine, we use a fusion simulation code GTC to study the effects of the 3D magnetic fields (including both magnetic islands and stochastic magnetic field lines) on microturbulence. We focus on the effects of 3D equilibrium on turbulent and neoclassical transport that leads to ELM suppression. During the project period, the UCI team of this collaboration has made significant progress in understanding turbulent transport in 3D geometry including both tokamaks with RMP and stellarators. Four UCI postdoctoral researchers, Drs. Javier Nicolau, Gyungjin Choi, Pengfei Liu, and Xishuo Wei were partially supported by this project and collaborating with the entire project team. We have published 4 journal papers and gave several invited talks. This project advance physics understand of 3D effects on microturbulence, specially effects of magnetic islands. It will contribute to the DOE SciDAC ISEP project in the area of GTC development for general 3D geometry capability, rigorous verification and validation, and readiness for the emerging exascale computing. Through collaborations with computational scientists, the project helps to advance high performance computing in the area of GPU acceleration, linear solver, and data management.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2009

Efficient Multidisciplinary Analysis Approach for Conceptual Design of Aircraft with Large Shape Change

The conceptual and preliminary design processes for aircraft with large shape changes are generally difficult and time-consuming, and the processes are often customized for a specific shape change concept to streamline the vehicle design effort. Accordingly, several existing reports show excellent results of assessing a particular shape change concept or perturbations of a concept. The goal of the current effort was to develop a multidisciplinary analysis tool and process that would enable an aircraft designer to assess several very different morphing concepts early in the design phase and yet obtain second-order performance results so that design decisions can be made with better confidence. The approach uses an efficient parametric model formulation that allows automatic model generation for systems undergoing radical shape changes as a function of aerodynamic parameters, geometry parameters, and shape change parameters. In contrast to other more self-contained approaches, the approach utilizes off-the-shelf analysis modules to reduce development time and to make it accessible to many users. Because the analysis is loosely coupled, discipline modules like a multibody code can be easily swapped for other modules with similar capabilities. One of the advantages of this loosely coupled system is the ability to use the medium- to high-fidelity tools early in the design stages when the information can significantly influence and improve overall vehicle design. Data transfer among the analysis modules are based on an accurate and automated general purpose data transfer tool. In general, setup time for the integrated system presented in this paper is 2-4 days for simple shape change concepts and 1-2 weeks for more mechanically complicated concepts. Some of the key elements briefly described in the paper include parametric model development, aerodynamic database generation, multibody analysis, and the required software modules as well as examples for a telescoping wing, a folding wing, and a bat-like wing. The paper also includes the verification of a medium-fidelity aerodynamic tool used for the aerodynamic database generation with a steady and unsteady high-fidelity CFD analysis tool for a folding wing example.

Chwalowski, Pawel↗
NASA NTRS1989

Probabilistic design analysis using Composite Loads Spectra (CLS) coupled with Probabilistic Structural Analysis Methodologies (PSAM)

Composite loads spectra (CLS) were applied to generate probabilistic loads for use in the PSAM nonlinear evaluation of stochastic structures under stress (NESSUS) finite element code. The CLS approach allows for quantifying loads as mean values and distributions around a central value rather than maximum or enveloped values typically used in deterministic analysis. NESSUS uses these loads to determine mean and perturbation responses. These results are probabilistically evaluated with the distributional information from CLS using a fast probabilistic integration (FPI) technique to define response distributions. The main example discussed describes a method of obtaining load descriptions and stress response of the second-stage turbine blade of the Space Shuttle Main Engine (SSME) high-pressure fuel turbopump (HPFTP). Additional information is presented on the on-going analysis of the high pressure oxidizer turbopump discharge duct (HPOTP) where probabilistic dynamic loads have been generated and are in the process of being used for dynamic analysis. Example comparisons of load analysis and engine data are furnished for partial verification and/or justification for the methodology.

Newell, J. F.↗
NASA NTRS2008

Virtual Satellite

Virtual Satellite (VirtualSat) is a computer program that creates an environment that facilitates the development, verification, and validation of flight software for a single spacecraft or for multiple spacecraft flying in formation. In this environment, enhanced functionality and autonomy of navigation, guidance, and control systems of a spacecraft are provided by a virtual satellite that is, a computational model that simulates the dynamic behavior of the spacecraft. Within this environment, it is possible to execute any associated software, the development of which could benefit from knowledge of, and possible interaction (typically, exchange of data) with, the virtual satellite. Examples of associated software include programs for simulating spacecraft power and thermal- management systems. This environment is independent of the flight hardware that will eventually host the flight software, making it possible to develop the software simultaneously with, or even before, the hardware is delivered. Optionally, by use of interfaces included in VirtualSat, hardware can be used instead of simulated. The flight software, coded in the C or C++ programming language, is compilable and loadable into VirtualSat without any special modifications. Thus, VirtualSat can serve as a relatively inexpensive software test-bed for development test, integration, and post-launch maintenance of spacecraft flight software.

Hammrs, Stephan R.↗
DOE OSTI2020

Enhancement of risk informed validation framework for external hazard scenario

In recent years, the U.S. Nuclear Regulatory Commission (USNRC) and the International Atomic Energy Agency (IAEA) have developed methodologies to assess the vulnerabilities of nuclear plants against site specific extreme hazards. In many cases, advanced simulation tools are being considered to simulate multi-physics, multi-scale phenomena and to evaluate vulnerability of nuclear facilities. The credibility of advanced simulation tools is assessed based on a formal verification, validation, and uncertainty quantification procedure. One of the key limitations in validation is the lack of relevant experimental data at system-level. This limitation leads to a decrease in the confidence of system-level risk predictions. Therefore, a robust validation framework is needed to formalize the confidence in predictive capability of advanced simulation results. Additionally, this study enhances the existing risk informed validation methodology, originally proposed by Kwag et al. [1] and Bodda et al. [2], by developing additional attributes and a new set of validation indicies for a complete and wider applicability of the framework. In this manuscript, the methodology to identify the critical path that leads to the system-level failure is illustrated. The overall validation is checked for completeness and consistency by comparing the critical path for both the system-level simulation and experimental models. The applicability of the code for an intended application is represented in terms of various maturity levels and helps in the process of decision making.

42 ENGINEERING↗
NASA NTRS2022

Flight Rule Design, Implementation, Verification, and Validation for the Psyche Mission

NASA Jet Propulsion Lab (JPL)’s upcoming mission Psyche will begin its journey to the asteroid (16) Psyche in late 2022 in an effort to better understand its origins and, in turn, better understand our own. Operating the spacecraft safely will require the dedicated efforts of a small team that understands the spacecraft’s operational constraints, as well as a set of powerful spacecraft models designed to catch command errors that can pose risks to mission success. One of the responsibilities of the operations team is to ensure adherence to a set of Flight Rules written by spacecraft and instrument experts that are designed to mitigate these risks. Psyche’s innovations in Flight Rule design principles and advancements in the tools and processes used to implement and check Flight Rules are discussed. A comparison of Psyche’s approach to Flight Rules to other JPL missions will provide lessons learned for future missions that must perform constraint checking during operations. Flight Rule development faces several major challenges. First, flight rule developers must work with Subject Matter Experts (SME) to write the rules in a way that captures the intent of the constraint in a straightforward, enforceable manner. Second, software implementers must correctly interpret flight rules into code so that it meets the original intent of the SME. Finally, a means must be provided for SMEs to validate flight rule implementations without requiring them to understand the underlying software. Innovative processes intended to efficiently close the loop between stakeholders and software developers are described, such as the use of test-driven development to provide stakeholders with easy-to-review implementations. New guidelines for flight rule writing, designed to address these challenges, are described for future missions to adopt and build upon. Psyche Mission System has a variety of new and heritage tools that improve in the Flight Rule validation and checking process. Psyche developed a powerful, new tool called RandSEQ and made significant improvements to Octopusjam, two valuable tools that aid the development of Flight Rule unit tests. Advancements in the models and processes for performing sequence validation with SEQuence GENerator (SEQGEN), the primary, high-heritage tool used for automated flight rule checks on Psyche, are described. The development of new software and the advancements to existing software put Psyche at the forefront of Flight Rule technology. All missions must perform detailed constraint checking, so a comparison of Psyche’s approach to some of these items to the approaches taken by other missions such as Dawn, M2020, and Europa Clipper is done, specifically to examine SME-developer communication, tools used, and development process. Lessons learned from this comparison will be provided.

Weise, Tim↗
DOE OSTI2021

Deployment of the Finite Volume Method in Pronghorn for Gas and Salt cooled Pebble Bed Reactors

This report summarizes the activities related to ”Complete FHR and HTGR pebble bed simulator, including initial validation” funded by the NEAMS thermal-hydraulics focus area. The activity revolves around the coarse-mesh thermal-hydraulics code Pronghorn and its application to gas and salt cooled Pebble bed reactor (PBR). The main difference between gas and salt cooled PBR from a thermal-hydraulics perspective is the fluid. To address the difference in fluid behavior, two separate approaches are implemented in the MOOSE Navier Stokes module: 1) a Boussinesq approximation and 2) a fully compressible formulation. The developed finite volume method capabilities are used for improving pre-existing gas-cooled and salt-cooled pebble-bed reactor models. A steady-state, multiphysics gas-cooled pebble-bed reactor model is created that couples the equilibrium core depletion capability developed in previous work, and the finite volume method capability developed for this report. The salt-cooled pebble-bed reactor model is upgraded to use the incompressible finite volume method capability and then extended to three spatial dimensions. Finally, several verification-and-validation exercises performed with Pronghorn are documented using the verification-and-validation report of the MooseDoc system. The goal of this effort to document the verification-and-validation level of Pronghorn and improve stakeholder confidence in the results obtained with Pronghorn.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS2012

The Pursuit of K: Reflections on the Current State-of-the-Art in Stress Intensity Factor Solutions for Practical Aerospace Applications

The elastic stress intensity factor (SIF, commonly denoted as K) is the foundation of practical fracture mechanics (FM) analysis for aircraft structures. This single parameter describes the first-order effects of stress magnitude and distribution as well as the geometry of both structure/component and crack. Hence, the calculation of K is often the most significant step in fatigue analysis based on FM. This presentation will provide several reflections on the current state-of-the-art in SIF solution methods used for practical aerospace applications, including a brief historical perspective, descriptions of some recent and ongoing advances, and comments on some remaining challenges. Newman and Raju made significant early contributions to practical structural analysis by developing closed-form SIF equations for surface and corner cracks in simplified geometries, often based on empirical fits of finite element (FE) solutions. Those solutions (and others like them) were sometimes revised as new analyses were conducted or limitations discovered. The foundational solutions have exhibited striking longevity, despite the relatively "coarse" FE models employed many decades ago. However, in recent years, the accumulation of different generations of solutions for the same nominal geometry has led to some confusion (which solution is correct?), and steady increases in computational capabilities have facilitated the discovery of inaccuracies in some (not all!) of the legacy solutions. Some examples of problems and solutions are presented and discussed, including the challenge of maintaining consistency with legacy design applications. As computational power has increased, the prospect of calculating large numbers of SIF solutions for specific complex geometries with advanced numerical methods has grown more attractive. Fawaz and Andersson, for example, have been generating literally millions of new SIF solutions for different combinations of multiple cracks under simplified loading schemes using p-version FE methods. These data are invaluable, but questions remain about their practical use, because the tabular databases of key results needed to support practical life analysis can occupy gigabytes of storage for only a few classes of geometries. The prospect of using such advanced numerical methods to calculate in real time only those K solutions actually needed to support a specific crack growth analysis is also tempting, but the stark reality is that the computational cost is still so high that the approach is not practical except for specific, critical application problems. Some thoughts are offered about alternative paradigms. Compounding approaches are some of the earliest building blocks of SIF development for more complex geometries. These approaches are especially attractive because of their very low computational cost and their conceptual robustness; they are, in some ways, an intriguing contrast and complement to the brute-force numerical methods. In recent years, researchers at NRC-Canada have published remarkable results showing how compounding approaches can be used to generate accurate solutions for very difficult problems. Examples are provided of some successes--and some limitations--using this approach. These closed-form, tabulated numerical, and compounding approaches have typically been used for simple remote loading with simple load paths to the crack. However, many significant cracks occur in complex stress gradient fields. This is a job for weight function (WF) methods, where the arbitrary stress distribution on the crack plane in the corresponding uncracked body (typically determined using FE methods) is used to determine K. Several significant recent advances in WF methods and solutions are highlighted here. Fueled by advanced 3D numerical methods, many new solutions have been generated for classic geometries such as surface and corner cracks with wide ranges of geometrical validity. A new WF formulation has also be developed for part-through cracks considering the arbitrary stress gradients in all directions in the crack plane (so-called bivariant solutions). Basic WF methods have recently been combined with analytical expressions for crack plane stresses to develop a large family of accurate SIF solutions for corner, surface, and through cracks at internal or external notches with very wide ranges of shapes, sizes, acuities, and offsets. Finally, WF solutions are much faster than FE or boundary element solutions, but can still be much slower than simple closed-form solutions, especially for bivariant solutions that can require 2D numerical integration. Novel pre-integration and dynamic tabular methods have been developed that substantially increase the speed of these advanced WF solutions. The practical utility of advanced SIF methods, including both WF and direct numerical methods, is greatly enhanced if the FM life analysis can be directly and efficiently linked with digital models of the actual structure or component (e.g., FE models for stress analysis). Two recent advances of this type will be described. One approach directly interfaces the FM life analysis with the FE model of the uncracked component (including stress results). Through a powerful graphical user interface, simplified FM life models can be constructed (and visualized) directly on the component model, with the computer collecting the geometry and stress gradient information needed for the life calculation. An even more powerful paradigm uses expert logic to automatically build an optimum simple fracture model at any and every desired location in the component model, perform the life calculation, and even generate fatigue crack growth life contour maps, all with minimal user intervention. This paradigm has also been extended to the automatic calculation of fracture risk, considering uncertainty or variability in key input parameters such as initial crack size or location. Another new integrated approach links the engineering life analysis, the component model, and a 3D numerical fracture analysis built with the same component model to generate a table of SIF values at a specific location that can then be employed efficiently to perform the life calculation. Some attention must be given to verification and validation (V&V) issues and challenges: how good are these SIF solutions, how good is good enough, and does anyone believe the life answer? It is important to think critically about the different sources of error or uncertainty and to perform V&V in a hierarchal, building-block manner. Some accuracy issues for SIF solutions, for example, may actually involve independent material behavior issues, such as constraint loss effects for crack fronts near component surfaces, and can be a source of confusion. Recommendations are proposed for improved V&V approaches. This presentation will briefly but critically survey the range of issues and advances mentioned above, with a particular view towards assembling an integrated approach that combines different methods to create practical tools for real-world design and analysis problems. Examples will be selectively drawn from the recent literature, from recent enhancements in the NASGRO and DARWIN computer codes, and from previously unpublished research

CraigMcClung, R.↗