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

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ROAM: A Remotely Operated Accelerator Monitor

Monitoring accelerators in operation is a well known challenge due to the radiation environment. However, there are significant benefits in being able to deploy particular sensors in specific locations of accelerator enclosures for monitoring or troubleshooting purposes. Learning from experience at other labs, we used Commercial Off The Shelf (COTS) components and an open source robot control software framework (ROS) to build a remotely controlled robot platform including a standard suite of instruments such as cameras, LIDAR, and ultrasound, with the ability to incorporate other ad-hoc sensors for specific measurements, such as a Gamma radiation monitor. Special attention was given to the robot's ability to maintain safety in the high risk environment of an accelerator, with multiple failure contingencies in place to ensure collision free operation. Testing was performed to prove the platform's viability and showcase its capability for accelerator monitoring.

Thayer, Thomas C.↗

Use of Commercial Off-The-Shelf Parts with 3-D Printed Connectors for Powered Air Purifying Respirators

This report presents preliminary results from the performance evaluation of a powered air purifying respirator (PAPR) assembled from commercial off-the-shelf (COTS) parts. Cost is a major limiting factor to PAPR adoption in healthcare. Moreover, the lack of standardization for filters and batteries poses a challenge for clinics and hospitals. Rapid prototyping of connectors, both mechanical and electrical, offers a possible solution in addressing both issues. We used 3-D printed connectors to assemble COTS components into a prototype PAPR. Large-scale manufacturing of 3-D printed connectors may be accomplished by converting the computer-aided design (CAD) drawings to pressure-injection molds.

42 ENGINEERING↗

Low-Cost, Accessible Vaccine Cooler Options

In response to cold chain management requirements for COVID-19 vaccines, Los Alamos National Laboratory has investigated, built, and demonstrated viability for different cryogenic storage options. With ease-of-access and affordability in mind, these cooler units have been built using commercial off-the-shelf (COTS) components. The team was also able to design a testing method for evaluating the performance of the different vaccine cooler options as part of the Technology Evaluation and Demonstration program. The tested cooler units demonstrated compatibility with either dry ice or liquid nitrogen as the cryogen, along with several commercial solvents. This compatibility demonstration would potentially offer sufficient flexibility for temperature control continuity. Next steps are to investigate industry interest in supporting field testing of the cooler units.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

SULI Research Report Paper

The Intelligence and Space Research Group 4 (ISR-4) at the Los Alamos National Laboratory focuses on signal processing and developing space electronics for various national security missions. The Space and Atmospheric Burst Reporting System (SABRS) is a sensing payload designed for nuclear detonation detection. As the sensors from previous payloads become obsolete, the requirement for a novel payload design increases. SABRS Prime is the successor to the previous SABRS payloads and is scheduled for delivery in 2028. As part of the SABRS Prompt Gamma Instrument Interface Board, high frequency signals from silicon photomultiplier tubes need to be split and subsequently transmitted to the Analog to Digital Converter. Prior to developing the Space Grade Instrument Interface Board, evaluation modules with Commercial off-the-shelf (COTS) components are evaluated and tested under rigorous conditions. Verification of power levels and gain specifications are some of the important steps taken during the evaluation stage. Working on the Signal Splitting Board has enabled me to work with various schematic software applications and learn more about the processes behind designing space grade electronic components. In addition, I conducted research on efficiency improvements for space-based power systems. Changes in design approaches were found to be the most significant sources of improvement. Being able to interact with researchers and peers across various scientific disciplines has given me a better insight into my future pursuits. Working in a R&D environment has cemented my decision to work on space applications for Quantum Sensing and pursue a PhD in Electrical Engineering. The SULI internship program at the Los Alamos National Laboratory has helped me develop the skillset of a researcher, understand the rigorous processes behind developing space grade hardware, and improve my critical thinking abilities to support the development of reliable instrumentation for deep space missions.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

Update on PIP-II beam pattern generator upgrade

The beam pattern generator enables the transfer of beam pulses from the PIP-II linac to the Booster ring, the two RF systems being non-harmonically related. It is synchronized to the timing system to provide beam arrival information to the downstream accelerator subsystems. The design is being upgraded with COTS components and is being developed with a collaboration with SLAC.The pattern generation, digital signal processing and the user interface to an external EPICS server are integrated onto the ARM processor of the SOCFPGA. The progress of the system development is described.

Varghese, P. [Fermilab]↗

Evaluation of COTS Electronics by Power Spectrum Analysis and Multivariate Data Analysis

Power spectrum analysis (PSA) is a fast, non-destructive, sensitive method for examining commercial off-the-shelf ( COTS ) electronic components. These features make PSA attractive for both component screening and surveillance in support of component reliability efforts. Current analysis methods limit the utility of PSA due to the need to manually examine the results of analysis to identify anomalous parts. This study demonstrates the development and application of a workflow to automate the screening of COTS electronic components. Further, this study demonstrates the use of multivariate algorithms to assess aging of Zener diodes. These workflows can be readily extended to other components, combining the benefits of PSA and multivariate analysis to screen and evaluate COTS electronic components.

42 ENGINEERING↗

Technical Performance and Cost Optimization of Unobtrusive Multi-static Serial LiDAR Imager (UMSLI) for Wide-area Surveillance and Identification of Marine Life at Marine Energy Installations

Florida Atlantic University developed an underwater optical monitoring system prototype - Unobtrusive Multi-static Serial LiDAR Imager (UMSLI) - suitable for marine energy full project lifecycle observation (baseline, commissioning, and decommissioning), with an automated real-time classification of marine animals. With precursor 2014 DOE funding (award DE-EE0006787), a prototype UMSLI was demonstrated in a controlled laboratory environment and achieved a TRL 6. This EERE DE-EE0007828 award aimed to both increase the TRL of the UMSLI by improving the technology performance (e.g., increase distance of marine animal target detection capability, add additional species classification capabilities, improve the system performance during the day, etc.) and reduce the cost. The UMSLI presents a novel application of underwater distributed Light Detection And Ranging (LiDAR), an advanced remote sensing method that uses light in the form of laser pulses for an application, this paired with an algorithm provides 360 degrees underwater detection, imaging, and classification of marine life. This solution for underwater monitoring of biota preserves the advantages of traditional optical and acoustic solutions while overcoming many associated disadvantages for marine energy site environmental monitoring, such as difficulties in species detection and classification in low light or night and turbid environments. This new approach is a purposefully designed, reconfigurable adaptation of an existing class 3B laser technology into one UMSLI instrument that can be easily mounted on or around different classes of marine energy equipment, such as devices to capture ocean current energy or wave energy. The system uses relatively low average power, utilizes far-red (> 635nm) laser illumination to be invisible and eye-safe to marine animals, is compact, and cost-effective. The equipment is designed for long-term, maintenance-free operations (i.e., current design is targeting more than 7 days continuous operation), to inherently generate a sparse primary dataset that only includes detected anomalies, and to allow robust real-time automated animal classification and identification with a low data bandwidth requirement. The technology’s overarching goal for application, is a system that can be deployed to collect pre-installation baseline species observations at a proposed marine energy deployment site with minimal post-processing overhead. The envisioned system will also produce high-resolution imagery of marine animals through a wide range of conditions and support automated tracking and notification of the presence of managed animals within established perimeters of marine energy equipment to satisfy deployed marine energy projects’ endangered and threatened species monitoring requirements. Through the current project, we demonstrated the UMSLI prototype in an operational environment and increased the UMSLI’s Technology Readiness Level from 6 to 7. The project resulted in many novel technologies, including: 1) an eye-safe red laser based, low-cost LiDAR system that can detect targets up to 10 meters distance; 2) the GAN-based machine learning underwater LiDAR image enhancement technique (this is the first known application of GAN technique in underwater LiDAR); 3) LiDAR-based real-time automated detection capabilities; and 4) a template matching based automated classification tool. These technologies build a solid foundation for future efforts to develop an extended range electro-optical monitoring system suitable for marine energy deployments. In addition to technology development, a key lesson learned is that addressing regulatory and safety requirements must be front and center in any marine energy monitoring applications.

16 TIDAL AND WAVE POWER↗

Magnetic Gears: The Key to Robust, Cost-Effective Hydropower Drivetrains

Based on previous demonstrated success at fabricating 5 and 10 kW scale magnetic gearbox (MGB) prototypes, Emrgy and its partners (the project team) proposed to design and construct a 100 kW scale MGB with a 30:1 gear ratio for the low-head hydro applications. The Statement of Project Objectives included tasks covering: 1) Market Applicability; 2) Technical Metrics; 3) Design (initial); 4) Electromagnetic (EM) Load and Structural Analysis; 5) Modal Analysis; 6) Sealing Design and 7) Final Design during Budget Period 1. Budget Period 2 included tasks covering: 1) Materials Procurement and Test Plan Development; 2) Assembly; and 3) Testing. The Market Applicability study (Task 1) led to a clear conclusion and recommendation toward “Low Head” technologies for maximum market share of both New Stream Reach development as well as powering Non-Powered Dams. The findings of this study also identified the opportunity for a larger scale magnetic gearbox-based drive train as a function of increased torque, as opposed to increased speed. The Technical Metrics Study (Task 2) concluded a horizontal orientation was preferred, examined potential loss mechanisms, concluded that a Halbach Array magnetic design was preferred, established a 30:1 gear ratio as optimal, and established a power rating of 100 kW as optimal. The subsequent initial and final detailed design process included electro-magnetic (EM) load and structural analysis (Task 4), a Modal analysis (for vibration) (Task 5), and a sealing design (Task 6) to assure water impermeability. The final design package (Task 7) included 729 individual parts, 117 unique part numbers, and 15 assemblies. In order to facilitate procurement, the full bill of materials was broken down into several sub-components: 1) custom magnetic parts; 2) custom machined parts; 3) custom casted parts; and 4) commercial off the shelf (COTS) parts. The casted parts were fabricated by Oak Ridge National Laboratory (ORNL) via a Cooperative Research and Development Agreement (CRADA) with Emrgy and funded by the Advanced Manufacturing Office (AMO). The procurement effort (Task 8) ultimately covered three time periods based on challenges encountered in meeting the budgeted cost for the prototype. Following the first effort in the early stages of Budget Period 2 in 2017, a no-cost time extension was granted to seek alternative fabrication and procurement options. The project was re-booted in 2020 based on the new ORNL CRADA that would focus on five (5) of the more difficult and expensive parts using their advanced manufacturing expertise. Procurement efforts for the other custom machined parts resulted in quotations that still exceeded the budget by more than $\$$100k. This was, in part, also due to the concurrent COVID-19 pandemic that caused both supply chain disruptions and labor shortages. As the project continued, pricing and availability degraded further. In Q2 FY’22, it was decided to not proceed with the fabrication of the prototype (Task 9) based on budgetary limitations. Outcomes included a full and detailed design of a 100 kW magnetic gearbox and associated indented bill of materials (BOM) and CAD drawings, a full assembly instruction manual with an associated BOM for materials necessary to support assembly, the fabrication of the double Halbach magnetic array for the rotor/stator system, fabrication of five (5) sand-casted/machined parts (via CRADA with ORNL) and an initial draft of a comprehensive testing plan. The most significant non-outcome was the actual fabrication and testing of the prototype gearbox based on budget limitations. Lessons learned included the need for an Application / Design / Cost trade analysis to better elucidate the cost potential of the MGB in the projected volumes anticipated for future demand. This would better establish the efficacy of the original cost target ($\$$0.80/Watt) and/or the need for reconsideration of designs and applications. Likewise, additional consideration of the prototype nature of the gearbox – single use, short lifetime, etc. - either as a separate exercise or in place of the design process completed, to reduce the cost of the demonstration prototype device. Additionally, project continuity was cited as a significant risk based on the loss of the primary design engineering firm after Budget Period 1. A design analysis exercise was conducted at the conclusion of the project to identify potential areas for cost reduction. One concept considered was the removal of the inner ring of magnets (with associated changes in the outer ring magnets) to enable a horizontal collapse of the design. It was estimated this could reduce cost by 10-25% without impacting performance.

13 HYDRO ENERGY↗

CROWBAR: Natively Fuzzing Trusted Applications Using ARM CoreSight

Abstract Trusted execution environments (TEE) are deployed on many platforms to provide both confidentiality and integrity, and their extensive use offers a secure environment for privacy-sensitive operations. Despite TEE prevalence in the smartphone and tablet market, vulnerability research into TEE security is relatively rare. This is, in part, due to the strong isolation guarantees provided by its implementation. In this paper, we propose a hardware assisted fuzzing framework, CROWBAR, that bypasses TEE isolation to natively evaluate trusted applications (TAs) on mobile devices by leveraging ARM CoreSight components. CROWBAR performs feedback-driven fuzzing on commercial, closed source TAs while running in a TEE protected environment. We implement CROWBAR on 2 prototype commercial-off-the-shelf (COTS) smartphones and one development board, finding 3 unique crashes in 5 closed source TAs that are previously unreported in the TrustZone fuzzing literature.

Shan, Haoqi↗

PRINTED, PLANAR MICROWAVE CONNECTOR WITH MULTIPLE SIGNAL LINES

Microwave connectors with a planar geometry have been demonstrated using additive manufacturing techniques. This planar form factor is expected to enable connectors to be integrated directly with other components onto a printed circuit board. The connectors were developed with multiple signal lines that will increase the density of signal connections to PCBs, eliminating the physical constraints of single-signal COTS microwave connectors. This work developed electromagnetic models (using Ansys HFSS) of these planar connectors to predict performance and optimize connector design. Materials and printing processes were developed to fabricate the connectors based on high-temperature PEEK thermoplastics. The multiple signal connectors were designed to operate over the 1-6GHz band and are built upon the single signal printed planar geometry connector introduced in a previous paper [1].

Additive Manufacturing↗

Biocompatible Electrostatic Layered Systems for Viral Elimination in the Nose/Throat

An anti-viral coating for the nose & throat is needed to quickly address the spread of COVID-19 infections and to aid future pandemics. Current nasal delivery systems are typically a 1-spray homogenous solution, which is convenient but may not be as efficient or durable as a multi-spray solution that contains a binding layer to anchor the anti-viral components. Many of the current nasal solutions being investigated to aid in pandemic response have solution-based mechanisms of action and are quickly cleared from the nose/mouth limiting their efficacy lifetime. A multi-spray approach utilizing strong intermolecular forces between polymeric materials and anti-viral agents to provide a robust biocompatible coating is expected to have increased physical and chemical properties to combat viral infection. This work evaluated which tailored biocompatible materials are needed to generate a layered system to combat viral infection. This layered system takes advantage of electrostatic interactions to bind anti-viral components, shown in Figure 1. Proof of concept success was demonstrated through cell toxicity studies and anti-viral assays on both the individual layer components and the complete layered system. Project work began with chemical modifications of Xantham Gum to hydrolyzing xanthan gum to give a negatively charged polymer with varying degrees of ionic character and investigate bonding efficiencies. However, this was abandoned in favor of comparing COTS available materials listed in Table 1 (Results section). Concentration and adhesion studies were performed on layers created using the listed polymeric materials and anti-viral agents. Finally, biocompatibility of materials, layers, and coating system were confirmed through cytotoxicity studies and the efficacy of the anti-viral properties tested with phi6 bacteriophage as a SARS-CoV2 surrogate.

36 MATERIALS SCIENCE↗

Glove-based sensors for multimodal monitoring of natural sweat

Sweat sensors targeting exercise or chemically induced sweat have shown promise for noninvasive health monitoring. Natural thermoregulatory sweat is an attractive alternative as it can be accessed during routine and sedentary activity without impeding user lifestyles and potentially preserves correlations between sweat and blood biomarkers. We present simple glove-based sensors to accumulate natural sweat with minimal evaporation, capitalizing on high sweat gland densities to collect hundreds of microliters in just 30 min without active sweat stimulation. Sensing electrodes are patterned on nitrile gloves and finger cots for in situ detection of diverse biomarkers, including electrolytes and xenobiotics, and multiple gloves or cots are worn in sequence to track overarching analyte dynamics. Direct integration of sensors into gloves represents a simple and low-overhead scheme for natural sweat analysis, enabling sweat-based physiological monitoring to become practical and routine without requiring highly complex or miniaturized components for analyte collection and signal transduction.

42 ENGINEERING↗

Digitally Optimized Autonomous Robotic System for Hanford Waste Tank Handling [Slides]

Idaho National Laboratory (INL) is developing a robotic system and digital twin to perform monitoring, inspection, and mapping of underground tank pits at the Hanford Site, operated by the U.S. Department of Energy (USDOE). The Autonomous Pit Exploration System (APES) will consist of four primary components: an electric vehicle truck with a robotic system developed by INL to deploy payloads into the tanks through small diameter preexisting risers, a robotic arm developed by Florida International University (FIU) for the purposes of deploying a variety of payloads into the tank pit environment, and a small robotic COTS crawler platform for examining the bottom of the pits.

42 - ENGINEERING↗

A novel approach to mitigating the potential release of radioisotopes under fire conditions - enhancing fire resiliency of radiological contamination fixatives during deactivation & decommissioning activities

Savannah River National Laboratory (SRNL), in close collaboration with the Florida International University Applied Research Center (FIU ARC), successfully executed a technology development activity on behalf of the Department of Energy, Office of Environmental Management (DOE EM). The purpose of the activity was to improve the capability of fixative technologies in immobilizing residual contamination when exposed to thermal stressors as postulated in accident scenarios in Basis for Interim Operations (BIO) documents across the DOE EM complex. The effort resulted in the test and evaluation of a down-selected, commercial-off-the-shelf (COTS) intumescent technology in a radioactive environment at the Savannah River Site (SRS) Building 235-F Plutonium Fuel Form (PuFF) Facility and highlighted the potential use of this technology as a stand-alone, fire retardant fixative. Furthermore, this activity highlighted significant shortfalls in common fixatives currently used to support decommissioning activities and brought to the forefront the need for a methodical, uniformed approach to certifying fixative technologies for operational use in Deactivation and Decommissioning (D&D) activities. An essential component of this research was to evaluate the state of industry fixatives currently in use and set the foundation for comparison to alternative technological solutions. A baseline of five (5) commonly used fixatives and decontamination gels (hereafter collectively referred to as fixatives) was conducted, and notable shortfalls and deficiencies were revealed, particularly when exposed to thermal, water, and other environmental stressors. At temperatures as low as 300 °F - 400 °F (148.89 °C – 204.44 °C), all commonly used fixatives melted from the substrates within 3-5 minutes of exposure, resulting in contaminant transport. Significant degradation in terms of mass loss, desiccation, and off-gassing occurred, and the chemical breakdown of the polymer was so complete researchers assessed there would likely have been a release of residual contamination. Additional vulnerabilities became evident when exposed to water immersion and high humidity; existing fixatives took up water, swelling and frequently delaminating from the substrate, once again increasing the likelihood of a contaminant release.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Architecture Of A Multi-channel Data Streaming Device With An Fpga As A Coprocessor

The design of a data acquisition system often involves the integration of a Field Programmable Gate Array (FPGA) with analog front-end components to achieve precise timing and control. Reuse of these hardware systems can be difficult since they need to be tightly coupled to the communications interface and timing requirements of the specific ADC used. A hybrid design exploring the use of FPGA as a coprocessor to a traditional CPU in a dataflow architecture is presented. Reduction in the volume of data and gradual transitioning of data processing away from a hard real-time environment are both discussed. Chief design concerns, including data throughput and precise synchronization with external stimuli, are addressed. The discussion is illustrated by the implementation of a multi-channel digital integrator, a device based entirely on commercial off-the-shelf (COTS) equipment.

Nogiec, Jerzy M.↗

Gallium Arsenide Semiconductor Opening Switches: Enabling Nanosecond High Powering Pulsed Systems

The goal of this work awas to investigate design manufacturing semiconductor opening switches (SOS) in both silicon and gallium arsenide (GaAs). Solid-state opening switches are critical components for pulsed power systems and applications in directed energy, dielectric wall accelerators, and novel semiconductor manufacturing techniques. Under this funding, we have developed silicon SOS designs that suppresses an unwanted prepulse, increases the peak output voltage by about 10 percent, and reduces the pulse rise time by ~ 4x compared with more conventional profiles. Through this effort we have improved device fabrication and bonding techniques. Additionally, work on this the GaAs opening switch has defined a unique application space that these devices are suited for. GaAs opening switches have short risetimes and pulse widths compared to silicon devices, however the short carrier lifetime of GaAs makes the circuit design more challenging than in silicon. For high PRF operation, the lifetime of the GaAs is an advantage compared to silicon. TCAD simulations of GaAs devices have been used to optimize a GaAs profile. Additionally, we have designed pulsers with sub 50ns reserve pump times and tested GaAs COTs PIN diodes in them.

42 ENGINEERING↗