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At least 163 records · Page 9

Deceptive Infusion of Data: A Novel Data Masking Paradigm for High-Valued Systems

This work addresses how analysts of a high-valued system (e.g., nuclear reactor, aircraft turbine designs) can extract findable, accessible, interoperable, and reusable scientific data for public dissemination to artificial intelligence and machine-learning (AI/ML) researchers in a manner that cannot be reverse-engineered, potentially compromising sensitive or proprietary information. State-of-the-art methods address this problem through data masking techniques, which allow access to a subset of the information while obfuscating private and potentially identifying information (e.g., personally identifying medical data). These methods are unsuitable for industrial engineering processes, where AI/ML tools need explicit access to all the data available to draw the best inference about the system to help optimize its performance and identify its vulnerabilities, etc. Our novel deceptive infusion of data paradigm provides a solution to this conundrum by developing a mathematical approach capable of concealing the identity of the system while providing full access to all the features employed by AI/ML tools to ensure their optimal performance.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Novel Application of Machine Learning Techniques for Rapid Source Apportionment of Aerosol Mass Spectrometer Datasets

In this work, we apply machine learning approaches sparse multinomial logistic regression to classify aerosol mass spectrometer (AMS) unit mass resolution (UMR) data followed by an ensemble regression technique for source apportionment of organic aerosols (OA). The classifier was trained on 60 well characterized laboratory and positive matrix factorization (PMF) deconvolved reference spectra to identify eight OA types. These include four laboratory-derived secondary organic aerosol (SOA) spectra, which include isoprene photooxidation SOA, isoprene epoxydiols (IEPOX) SOA, a monoterpene SOA type that includes a-pinene and ß-pinene SOA, and aromatic SOA from oxidation of naphthalene and m-xylene precursors, as well as PMF deconvolved spectra for three primary organic aerosol (POA) types, namely, hydrocarbon-like organic aerosol (HOA), biomass burning organic aerosol (BBOA), and cooking OA (COA), and a more oxidized oxygenated OA type (MO-OOA). A 5-fold cross-validation strategy, repeated 10 times, was used to assess the classifier’s performance. The classifier had high classification accuracy for COA, aromatic SOA, and isoprene SOA spectra but incorrectly classified ~9% by number of MO-OOA spectra as BBOA, 12% of BBOA spectra as HOA (and vice versa), and 18% of IEPOX-SOA spectra as aromatic SOA. Next, an ensemble regression model was trained on an artificially generated dataset consisting of mixtures of different OA types to assess its ability to predict fractional mass abundances from classification probabilities of various OA species obtained from the multinomial logistic regression classifier trained on the reference spectra. Ultimately, the proposed approach was applied for source apportionment of aircraft-based AMS measurements of OA UMR spectra during the HI-SCALE field campaign. On two representative days (May 6th and 18th, 2016), the algorithm determined that ~50-60% of OA by mass was MO-OOA, which represented a highly aged organic aerosol mixture from different sources. On both days, BBOA was determined to contribute less than 10% to OA by mass. However, on May 18th, the aromatic SOA fraction was higher compared to that on May 6th. The proposed approach is capable of rapidly analyzing AMS data in real time, making it suitable for applications where rapid source apportionment of AMS OA spectra is desirable.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Carbon Nanotube and Graphene Oxide Reinforced Composites for Lightning Strike Protection of Composite Structures

Carbon fiber reinforced plastics (CFRP) composites have become the primary materials in the aerospace industry. Future transportation means, such as urban air mobility (UAM), will be employing CFRP structures. However, lightning strike damage on composite structures is a serious concern. CFRP composites possess low through-thickness electrical conductivity (≈ 1 S/m), which can cause extreme resistive heat in the event of lightning strikes. Research on polymeric lightning strike protection has gained momentum in the past few years. Researchers have studied various conductive fillers to improve the CFRP performance against lightning strikes. Carbon nanotubes (CNTs) and graphene oxide (GO) have been studied as future lightning Strike Protection (LSP) materials the most. The use of CNT and GO-based composites has shown improved mechanical properties and improved electrical conductivity of the composites. Researchers investigated CNTs and GO as the fillers to the matrix system, sizing the carbon fibers and the surface coating on top of the CFRP surface. This chapter highlights the remarkable improvement in the lightning damage suppression of CNT and GO-based composites and their structural applications. Special attention is given to their potential use as LSP material in future aircraft.

Kumar, Vipin↗

Assessing Secondary Ice Production in Continental Clouds Based on AMF Synergistic Remote Sensing Observations

Ice crystals play an important role in radiation and precipitation formation. However, the prediction of ice number concentration has proven to be problematic, because the predicted concentration of ice nucleating particles is often smaller than the observed by several orders of magnitude. This difference between the observed and the predicted number concentration has been explained by so-called secondary ice production (SIP), which includes hypothesized mechanisms like rime splintering, shattering of large frozen drops, and ice-ice collision breakup. To better observe SIP and understand its frequency, production rate, and impact on cloud evolution, we developed a new method for retrieving microphysical properties of concurrent pristine ice and snow aggregates from X-band polarimetric radar observations. Compared to aircraft cloud probe measurements, our retrieved total number concentration and ice water content are overestimated by 98% and 44%, respectively, which outperforms other empirical relationships. The capability of quantifying pristine ice number concentration, which is the most essential observable in SIP studies, opens a new opportunity to build a long-term record of SIP from surface-based radar measurements. We have also conducted simulations using a cloud-resolving model to evaluate the representativeness of the parameterizations of three SIP mechanisms and for studying the impact of SIP on a frontal system. We found a surprisingly good agreement between the observed and retrieved pristine ice number concentrations. The good performance is attributed to the rime splintering process in the temperature zone between–3° and –8°C, and to the ice-ice collision breakup process at higher altitudes. The impact of the shattering of large frozen drops appears minimal. Apart from the enhancement of ice number concentration and increased horizontal coverage of pristine ice, the addition of three SIP processes does not change cloud evolutions dramatically in our simulations.

58 GEOSCIENCES↗

High temperature thick film sensor development based on doped lanthanum chromites refractory semiconductors materials

High temperature advanced sensing materials have generated high demand due the high accuracy temperature measurements requirements for process optimization, controlling and sensing. Some technological applications of harsh conditions sensing include monitoring tiles of space shuttles, rotating bearings in aircraft engines, turbines, jet engines dynamics and chemical reactors. High temperature conditions limit the sensing strategies, where typically traditional metal thermocouples are unstable, and the sensing options are limited to optical spectroscopy methods. Recently, refractory semiconductors thick- and thin-film thermocouples have been developed and, in many cases, preferred over conventional metallic thermocouples due their spatial resolution, and capability of direct deposition on any surface. Rare earth chromites ceramics materials, exhibit some properties of interest for high temperature sensing technologies development, such as: high microstructure and sintering stability, excellent conductive behavior at high temperatures, and matching thermal expansion coefficients relative to other conductors and refractory ceramics. In this work, high performance ultra-high temperature thermocouples using p-type and n-type doped lanthanum chromites materials were fabricated and tested at temperatures up to 1500 o C. Thermoelectric voltage, Seebeck Coefficients were established for all devices, evidencing high stability and performance in prolongated operational time and harsh conditions.

20 FOSSIL-FUELED POWER PLANTS↗

Dependence of CCN closure relationship with organic fraction from two airborne field campaigns over mid-latitude land and ocean

This study investigates the relationship between measured and calculated cloud condensation nuclei (CCN) number concentration and its dependence with organic fraction utilizing aircraft observations from The Aerosol and Cloud Experiments in the Eastern North Atlantic (ACE-ENA, 2017–2018) and The Holistic Interactions of Shallow Clouds, Aerosols, and Land Ecosystems (HI-SCALE, 2016) campaigns, which represent midlatitude marine and continental environments, respectively. For the ACE-ENA marine region, aerosol and CCN concentrations were significantly higher in summer than in winter, whereas at continental site for HI-SCALE, aerosol and CCN concentrations showed no pronounced differences between spring and autumn. Using aerosol chemical composition and number size distribution data, CCN concentrations at various supersaturations are calculated based on Köhler theory and then compared with observations from CCN counter. The results show that CCN closure performs well at both sites with a slight overestimation, with mean closure ratio (CR) of 1.13 and 1.17, respectively. Further investigation reveals that CR at lower supersaturation perform better than that at higher supersaturation. The dependence of CR on organic mass fraction (MForg) varies by environment: for marine aerosols, CR decreases with increasing organic fraction at lower supersaturations, whereas continental aerosols exhibit a consistent overestimation, with CR decreasing as organic fraction increases at higher supersaturations. This study provides key insights into CCN characteristics over midlatitude marine and continental environments, emphasizing the necessity of incorporating size-resolved chemical composition and mixing states into future model parameterizations, and contributing to a better understanding of aerosol–cloud interactions.

ACE-ENA field campaign↗

Ocean surface radiation measurement best practices

Ocean surface radiation measurement best practices have been developed as a first step to support the interoperability of radiation measurements across multiple ocean platforms and between land and ocean networks. This document describes the consensus by a working group of radiation measurement experts from land, ocean, and aircraft communities. The scope was limited to broadband shortwave (solar) and longwave (terrestrial infrared) surface irradiance measurements for quantification of the surface radiation budget. Best practices for spectral measurements for biological purposes like photosynthetically active radiation and ocean color are only mentioned briefly to motivate future interactions between the physical surface flux and biological radiation measurement communities. Topics discussed in these best practices include instrument selection, handling of sensors and installation, data quality monitoring, data processing, and calibration. It is recognized that platform and resource limitations may prohibit incorporating all best practices into all measurements and that spatial coverage is also an important motivator for expanding current networks. Thus, one of the key recommendations is to perform interoperability experiments that can help quantify the uncertainty of different practices and lay the groundwork for a multi-tiered global network with a mix of high-accuracy reference stations and lower-cost platforms and practices that can fill in spatial gaps.

54 ENVIRONMENTAL SCIENCES↗

A rotorcraft in-flight ice detection framework using computational aeroacoustics and Bayesian neural networks

Abstract This work develops a novel ice detection framework specifically suitable for rotorcraft using computational aeroacoustics and Bayesian neural networks. In an offline phase of the work, the acoustic signature of glaze and rime ice shapes on an oscillating wing are computed. In addition, the aerodynamic performance indicators corresponding to the ice shapes are also monitored. These performance indicators include the lift, drag, and moment coefficients. A Bayesian neural network is subsequently trained using projected Stein variational gradient descent to create a mapping from the acoustic signature generated by the iced wings to predict their performance indicators along with quantified uncertainty that is highly important for time- and safety-critical decision-making scenarios. While the training is carried out fully offline, usage of the Bayesian neural network to make predictions can be conducted rapidly online allowing for an ice detection system that can be used in real time and in-flight.

42 ENGINEERING↗

Investigation of grid-based vorticity-velocity large eddy simulation off-body solvers for application to overset CFD

Accurately predicting unsteady wakes and vortex-dominated flows is essential to a wide range of engineering applications, including aircraft, rotorcraft, shipboard operations, bio-inspired unsteady flight and propulsion, wind turbines, and urban flows. While current CFD software can model the complete flow field and wake system, the computational costs incurred in high Reynolds number unsteady turbulent flow simulations often remain prohibitive for routine engineering use, particularly for applications involving moving components. Prior work has demonstrated that by adopting a vorticity-velocity formulation in a grid-based off-body flow solver (VorTran-M and VorTran-M2) one can lower these costs by several orders of magnitude when compared to conventional approaches. This paper describes the extensions made to VorTran-M2 to support turbulent flows, and associated benchmarking activity to assess its performance for problems involving strong stretching and diffusion processes, whose competing contributions to the vorticity field are core drivers of turbulent flow evolution. Predictions are presented for: (i) the Kida-Pelz problem whose inviscid form is of mathematical interest due to its apparent formation of singular flow in finite time; and (ii) the Taylor Green vortex arrangement, which has been extensively studied as a fundamental simulation challenge in the turbulent modeling community. Here, the results are used to evaluate the overall predictive ability and performance of two sub-grid scale models incorporated into VorTran-M2. Results indicate that the computational cost savings seen previously for inviscid and convection dominated problems extend to turbulent flow simulations supporting the viability of VorTran-M2 as a low cost means for accurately modeling the far-field and background flow, particularly when long duration vorticity evolution is of interest.

42 ENGINEERING↗

A Bimodal Diagnostic Cloud Fraction Parameterization. Part I: Motivating Analysis and Scheme Description

Cloud fraction parameterizations are beneficial to regional, convection-permitting numerical weather prediction. For its operational regional midlatitude forecasts, the Met Office uses a diagnostic cloud fraction scheme that relies on a unimodal, symmetric subgrid saturation-departure distribution. This scheme has been shown before to underestimate cloud cover and hence an empirically based bias correction is used operationally to improve performance. This first of a series of two papers proposes a new diagnostic cloud scheme as a more physically based alternative to the operational bias correction. The new cloud scheme identifies entrainment zones associated with strong temperature inversions. Additionally, for model grid boxes located in this entrainment zone, collocated moist and dry Gaussian modes are used to represent the subgrid conditions. The mean and width of the Gaussian modes, inferred from the turbulent characteristics, are then used to diagnose cloud water content and cloud fraction. It is shown that the new scheme diagnoses enhanced cloud cover for a given gridbox mean humidity, similar to the current operational approach. It does so, however, in a physically meaningful way. Using observed aircraft data and ground-based retrievals over the southern Great Plains in the United States, it is shown that the new scheme improves the relation between cloud fraction, relative humidity, and liquid water content. An emergent property of the scheme is its ability to infer skewed and bimodal distributions from the large-scale state that qualitatively compare well against observations. A detailed evaluation and resolution sensitivity study will follow in Part II.

54 ENVIRONMENTAL SCIENCES↗

Designing Unmanned Aerial Survey Monitoring Program to Assess Floating Litter Contamination

Monitoring marine contamination by floating litter can be particularly challenging since debris are continuously moving over a large spatial extent pushed by currents, waves, and winds. Floating litter contamination have mostly relied on opportunistic surveys from vessels, modeling and, more recently, remote sensing with spectral analysis. This study explores how a low-cost commercial unmanned aircraft system equipped with a high-resolution RGB camera can be used as an alternative to conduct floating litter surveys in coastal waters or from vessels. The study compares different processing and analytical strategies and discusses operational constraints. Collected UAS images were analyzed using three different approaches: (i) manual counting (MC), using visual inspection and image annotation with object counts as a baseline; (ii) pixel-based detection, an automated color analysis process to assess overall contamination; and (iii) machine learning (ML), automated object detection and identification using state-of-the-art convolutional neural network (CNNs). Our findings illustrate that MC still remains the most precise method for classifying different floating objects. ML still has a heterogeneous performance in correctly identifying different classes of floating litter; however, it demonstrates promising results in detecting floating items, which can be leveraged to scale up monitoring efforts and be used in automated analysis of large sets of imagery to assess relative floating litter contamination.

Almeida, Sílvia (ORCID:0000000320636826)↗

Comparative Study on Deep Learning Methods for Defect Identification and Classification in Composite Aerostructure Material

Aircraft structures are required to have a high level of quality to satisfy their need for light weight, efficient flight, and withstanding high loads over their lifespan. These aerostructures are typically made from composite material due to their good tensile strength and resistance to compression. To ensure their structural integrity, the composite material requires inspection for common flaws such as porosity, delaminations, voids, foreign object debris, and other defects. Ultrasonic testing (UT) is a popular non-destructive inspection (NDI) technique used for effectively evaluating composite material. Current inspection methods rely heavily on human experience and are extremely time consuming. Therefore, there is a need for the development of techniques to reduce the manual inspection time. This work compares the performance of different deep learning-based methods in the identification and classification of defects. Deep learning has shown great promise in numerous fields, and we show its effectiveness in the evaluation of composite aerostructure material. Furthermore, the methods developed here are both highly reliable with a top recall value of 98.63% as well as extremely efficient requiring an average of 4 seconds during the inferencing stage to evaluate new composites.

composites↗

The DataHawk2 uncrewed aircraft system for atmospheric research

Abstract. The DataHawk2 (DH2) is a small, fixed-wing, uncrewed aircraft system, or UAS, developed at the University of Colorado (CU) primarily for taking detailed thermodynamic measurements of the atmospheric boundary layer. The DH2 weighs 1.7 kg and has a wingspan of 1.3 m, with a flight endurance of approximately 60 min, depending on configuration. In the DH2's most modern form, the aircraft carries a Vaisala RSS-421 sensor for pressure, temperature, and relative humidity measurements, two CU-developed infrared temperature sensors, and a CU-developed fine-wire array, in addition to sensors required to support autopilot function (pitot tube with pressure sensor, GPS receiver, inertial measurement unit), from which wind speed and direction can also be estimated. This paper presents a description of the DH2, including information on its design and development work, and puts the DH2 into context with respect to other contemporary UASs. Data from recent field work (MOSAiC, the Multidisciplinary drifting Observatory for the Study of Arctic Climate) is presented and compared with radiosondes deployed during that campaign to provide an overview of sensor and system performance. These data show good agreement across pressure, temperature, and relative humidity as well as across wind speed and direction. Additional examples of measurements provided by the DH2 are given from a variety of previous campaigns in locations ranging from the continental United States to Japan and northern Alaska. Finally, a look toward future system improvements and upcoming research campaign participation is given.

54 ENVIRONMENTAL SCIENCES↗

Evaluating Model Robustness for Defect Identification and Classification in a Composite Aerostructure Material

Aircraft structures are required to have a high level of quality to satisfy their need for light weight, efficient flight, and withstanding high loads over their lifespan. These aerostructures are typically made from a composite material due to their good tensile strength and resistance to compression. To ensure their structural integrity, the composite material requires inspection for common flaws such as porosity, delaminations, voids, foreign object debris, and other defects. Ultrasonic testing (UT) is a popular non-destructive inspection (NDI) technique used for effectively evaluating the composite material. Current inspection methods rely heavily on human experience and are extremely time consuming. Therefore, there is a need for the development of techniques to reduce the manual inspection time. This work compares the performance of different deep learning-based methods in the identification and classification of defects. Deep learning has shown great promise in numerous fields, and we show its effectiveness in the evaluation of the composite aerostructure material. The methods developed here are both highly reliable with a top recall value of 98.64% as well as extremely efficient requiring an average of 4 s during the inferencing stage to evaluate new composites. Lastly, we investigate model robustness to concept drift by measuring its performance over time.

36 MATERIALS SCIENCE↗

SSTDR and FDR Detection of Un-Energized and Energized Cable Anomalies Including Thermal Degradation Using Machine Learning

Historically, cables are initially qualified for nuclear power plant use for 40 years. As plants extend their operating license to 60 and 80 years, continued use of these cables must shift to a performance-based approach since it is cost prohibitive to completely replace cables that are likely still capable of performing their design function. A variety of cable tests are available and are commonly applied during outages when the cables can be taken out of service. Frequency domain reflectometry (FDR) is one of these test methods that is being more broadly accepted and used because it not only detects anomalies along the cable with a low-voltage signal that does not stress the cable insulation, but the technique also locates the anomalies. This supports follow-up local inspection and local repair or partial replacement of a damaged cable segment. Currently, FDR testing is only applied to cables that are taken out of service since the test instrument would be damaged by operational voltages. A related technology that has found some acceptance in the aircraft and rail industry is spread spectrum time domain reflectometry (SSTDR). This technology has been implemented with a custom commercial instrument by LiveWire Innovation that is designed to operate on live cables up to 1000 volts and with a bandwidth of 48 MHz. Initial evaluation by the Pacific Northwest National Laboratory (PNNL) of the Live Wire system indicated that a broader bandwidth (BW) SSTDR may be better for many kinds of flaws. This led PNNL to develop an SSTDR laboratory instrument suitable for tests up to 500 MHz bandwidth. Testing on energized cables is also desirable for online monitoring systems so an inductive clamshell coupler was developed that allows energized cables to be tested up to at least 5 kV and likely higher voltage levels. Dielectric spectroscopy and tan delta testing plus various laboratory destructive tests were included in this data acquisition campaign directed to feed a machine learning (ML) study. With these kinds of developments, online energized cable tests may be possible with industrial adoption of such hardware advances but it will be completely impractical to have highly skilled data analysts continually examine these complex signals for indications of damage or compromised conditions. If online testing is to be implemented in new test hardware, it must be accompanied by software that can interpret the signals and alert plant operators of changing or degraded conditions. The thermally aged, shielded cable investigated here was separately treated for ML analysis. Visual analysis of electrical data showed generally increasing peaks where the cable entered and exited the oven. These peaks were not exactly aligned with expected locations, but these differences were attributed to velocity of propagation calibration errors. Only supervised ML was applied to the thermally aged data as this data was only available shortly before the committed publication date of this report. The supervised ML was structured to divide the 0 to 70-day responses as ‘normal’ from 0 to 35 days or ‘anomalous’ from 36 to 70 days, based on cable tensile elongation at break (EAB) insulation characterization. Using 80% of the data for training and 20% for testing, the supervised ML predicted normal versus anomalous was 70% accurate. Important conclusions include: • Accuracy to predict the presence of cable damage is improved from the 2023 effort by more training data. Weighted accuracies for comparisons among the instruments ranged from 67 to 89 % for unsupervised ML and 71 to 99% for supervised ML. • Based on the synthetic data tests, the unsupervised models are more generalizable to unseen anomalies. The Multi-Layer Perceptron classifier (MLP) model reported as high as 99.7% accuracy on the test data, but this dropped to 58.3% when tested on the synthetic data. In contrast, the unsupervised Pointwise model only achieved 89.7% accuracy on the experimental data but reported 78.3% accuracy on the synthetic data. • The best anomaly indicators are higher frequency (400 MHz BW) FDR data. Other tests may be interesting but for this study, this was the best predicter.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

T-Type Modular DC Circuit Breaker (T-Breaker) for Future DC Networks

The developed T-Type Modular DC Circuit Breaker (T-Breaker) technology offers an all-in-one solution to challenges in DC networks. This includes swift fault detection and protection, power transient stability, and power quality improvement, achieved through the utilization of wide bandgap (WBG) power semiconductors and energy storage devices. The T-Breaker not only facilitates rapid fault current detection and interruption but also implements fault current limiting through active insertion of storage devices or by operating WBG devices in the saturation region. Additionally, with the assistance of energy storage devices, potential overvoltage issues on power devices induced by control signal misalignment can be mitigated. The T-Breaker can be regulated to perform shunt current injection/absorption using the vertical arm and series voltage insertion via the horizontal arm, thereby enhancing DC system stability during voltage or load power fluctuation transients. The OSU team and Raytheon team actively worked together on designing, fabricating, assembling, and testing of two T-Breaker prototypes. The first prototype is rated at 1 kV, 500 A with half-bridge (unipolar) structure to validate the T-Breaker concept. The second prototype is rated at 20 kV, 50 A with full-bridge (bipolar) topology which can reach an efficiency of 99.977%, realize a power density of 60.2 MW/m3, and eliminate the 500-A fault current with a fault response time of around 20 µs. The prototypes show great feasibility of adopting this technology in multiple applications including electrified aircraft, super charging stations, data centers, etc.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Model Sensitivities of Biomass-Burning Aerosol Chemical Aging, Sulfate Formation, and Cloud Droplet Activation in the Southeastern Atlantic Using CESM and E3SM

Biomass-burning smoke drives large uncertainty in climate projections of the Earth's radiative balance. This is due to the chemical and physical evolution of smoke and its impact on clouds and radiation. Here we focus on the southeastern Atlantic region and its inflow of African biomass-burning smoke during August 2017. We evaluate smoke properties and processes in two coupled earth-system models, the Energy Exascale Earth System Model (E3SM) and Community Earth System Model (CESM). These are compared against in situ aircraft observations from two field campaigns, ObseRvations of Aerosols above CLouds and their intEractionS (ORACLES) and CLoud–Aerosol–Radiation Interaction and Forcing: Year 2017 (CLARIFY-2017). Observations reveal an increase and subsequent decrease in smoke mean diameter, and a steady decrease in the mass ratio of organic aerosol (OA) to black carbon aerosol (BC) (OA:BC) over 4–12 days of aging, neither captured by the base models. Implementation of a photolytic loss scheme for secondary organic aerosol (SOA)—as a proxy for other heterogeneous volatilization chemistry—and a ∼1-day conversion for primary OA to SOA significantly improves the representation of this loss. In the boundary layer, both models show dimethyl sulfide driving a large increase in the sulfate aerosol mass fraction from the free troposphere, which is consistent with observations. Finally, models tend to underpredict cloud droplet number concentration partially due to weak modeled turbulent updraft strength, and model performance improves when the parameterized turbulent updraft strength is increased substantially. These results are expected to provide insights into future model development to reduce climate model uncertainties.

54 ENVIRONMENTAL SCIENCES↗

Demo 5: RapidClave Technology Demonstrations – Round II (Task 2)

The purpose of this project task was to make automotive composite part manufacturing more cost competitive for low volume production and thereby drive composite application innovation. The strategy was to incorporate low-cost preforming, snap cure resins, and RapidClave® processing to create an alternative to conventional automotive composite manufacturing based on SMC. The program used RapidClave® technology from Globe Machine Manufacturing, fast-curing (“snap cure”) epoxy resins from Hexion, and conformable/stretchable glass fiber reinforcement mats produced by Owens Corning for rapid preforming. O’Gara Armoring retrofits vehicles to meet special security needs, such as larger doors to facilitate easier entry into the vehicle. O’Gara has a variety of custom vehicles in need of custom doors that require affordable tooling to produce approximately 100 ship sets/year. The project focused on a composite door panel application provided by O’Gara that is currently made by manual chopped fiber spray-up processing. UDRI reverse-engineered the current composite door panel and created tooling for use in the RapidClave®. UDRI designed an improved composite door using MultiMat fiberglass reinforcement from Owens Corning. UDRI made snap cure resin films from Hexion resin. Finally, UDRI conducted molding trials to compare autoclave processing with RapidClave® processing. The technical goals of the project were to reduce tooling cost by 50% as compared to SMC compression molding and to reduce cycle time by 50% compared to current manual spray-up process. The approach to reduce tool costs is based on use of single sided tooling for use at 100 psi, as compared to matched metal SMC tooling. An added benefit realized from the program is that the Owens Corning mat provided more uniform thickness and improved performance. Tensile and flexural strengths and moduli were increased by at least 50%. This task also demonstrated a 75% decrease in cycle time. O’Gara is evaluating the technology demonstrated in this project for some of their current production. Additionally, there are new products O’Gara is pursuing which require higher production rates than their current products. O’Gara has identified these new products as good candidates for the RapidClave® technology. The cost advantages demonstrated by this project would then lead to significant economic development. In conclusion, this task successfully combined the RapidClave® technology from Globe with a snap cure epoxy resin film system from Hexion and preform material from Owens Corning. Further research is needed to better map the technical limits such as cycle time of these technologies. Additionally, the technology should be extended in terms of size and shape to include large parts outside of automotive applications, such as a small aircraft fuselage.

36 MATERIALS SCIENCE↗