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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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Rapid Retooling for Emergency Response with Hybrid Manufacturing

The global manufacturing industry has served as a keystone in supporting the weight of emergency response operations during the coronavirus disease (COVID-19) pandemic. Development of core technologies necessary to prevent the spread of COVID-19, including Personal Protective Equipment, infection testing kits, and vaccine research supplies, requires intensive manufacturing operations to support a population at scale. The production of these items is traditionally dependent on the tool and die industry, requiring imports of steel castings from overseas suppliers. The United States (U.S.) manufacturing industry was left isolated and unprepared as international borders closed overnight and normal supply chains were cut. This technical note provides a forward-looking approach at the benefits of hybrid manufacturing processes to provide rapid reconfiguration capabilities in the U.S. tool and die industry. A demonstration in rapid production of new tooling is provided to illustrate these benefits. Finally, emerging hybrid technologies are discussed in pursuit of more flexible manufacturing operations.

42 ENGINEERING↗

NREL Supply Chain & Circular Economy Capabilities

NREL and JISEA have many supply chain competencies and capabilities. Utilizing these tools and with funding by the DOE Office of Science through the National Virtual Biotechnology Laboratory, a consortium of DOE national laboratories focused on response to COVID-19, provided by the Coronavirus CARES Act, an NREL team prepared case studies regarding necessary PPE to combat COVID.

analysis↗

Additive manufacturing for COVID-19: Devices, materials, prospects, and challenges

The current COVID-19 pandemic has caused the shortage of personal protective equipment (PPE) where improvised manufacturing in particular 3D printing has addressed many needs. This prospective discusses the current global crisis, then follows the wide interest in addressing the shortage of medical devices and PPEs used for treatment and protection against pathogens. An overview of the 3D printing process with polymer materials is given followed by the different 3D printing projects of PPEs and medical devices that emerged for the pandemic (including validation/testing). The potential for rapid prototyping with different polymer materials and eventual high-throughput production is emphasized.

36 MATERIALS SCIENCE↗

Large Satellite Bus Reliability

NASA is proposing to build a small space station in Cis-lunar orbit called Deep Space Gateway (DSG). At the heart of the DSG is the Power and Propulsion Element (PPE) which is conceptually similar to previously designed and operated satellite buses. A satellite bus is composed of the satellite spacecraft infrastructure minus the payload, and generally includes power, propulsion, avionics, and guidance, navigation and control. In November of 2017, five companies were awarded contracts by NASA to research PPE designs. In order to better understand the reliability of large satellite buses which may be the starting point of the PPE, NASA used Weibull analysis to evaluate spacecraft with similar masses and design life to the PPE. In addition, a subset of the large satellites which had satellite buses manufactured by any one of the five companies was also evaluated. This paper provides the results of the reliability analysis and compares the reliability of the general population of large satellites to the reliability associated with large satellite buses manufactured by the five companies currently studying PPE options.

Bus↗

Prototyping of N95 Respirators Using Additive Manufacturing NETL NLVB (Final Report)

Final report for National Energy Technology Laboratory (NETL) project involving the use of advanced manufacturing and 3D printing technologies to help address personal protective equipment (PPE) shortages due to COVID-19. Work was performed in support of Joint DOE Laboratory Plan for Manufacturing Medical Supplies and funded through the DOE Office of Science.

3D Printing↗

Benchtop assessment of sealing efficacy and breathability of additively manufactured (AM) face masks

The onset of the 2019 novel coronavirus disease (COVID-19) led to a shortage of personal protective equipment (PPE), medical devices, and other medical supplies causing many stakeholders and the general public alike to turn to additive manufacturing (AM) as a stopgap when normally accessible devices were not available. However, without a method to test these AM constructs, there continued to be a disconnect between AM suppliers and the community’s needs. The objective of this study was to characterize the pressure drop and leakage of four different publicly available AM face mask models with two filter material combinations, as well as to investigate the impact of frame modification techniques including the use of foam strips and hot-water face forming to improve fit when the masks are donned on manikin head forms. AM face mask frame designs were downloaded from public repositories during the early stages of the COVID-19 pandemic. AM face masks were fabricated and tested on manikin head forms within a custom chamber containing dry aerosolized NaCl. Pressure drops, particle penetration, and leakage were evaluated for various flow rates and NaCl concentrations. Results indicated that filter material combination and frame modification played a major role in the overall performance of the AM face masks studied. Filter material combinations showed improved performance when high filtration fabric was used, and the cross-sectional area of the fabric was increased. AM frame modifications appeared to improve AM face mask leakage performance by as much as 69.6%.

36 MATERIALS SCIENCE↗

National Virtual Biotechnology Laboratory: Report on Rapid R&D Solutions to the COVID-19 Crisis

With funding from the CARES Act, the U.S Department of Energy (DOE) established the National Virtual Biotechnology Laboratory (NVBL) in March 2020 to address key challenges associated with the COVID-19 crisis. NVBL brought together the broad scientific and technical expertise and resources of DOE’s 17 national laboratories to help tackle medical supply short ages, discover potential drugs to fight the virus, develop and validate COVID-19 testing methods, model disease spread and impact across the nation, and understand virus transport in buildings and the environment. National laboratory resources leveraged for this effort include a suite of world-leading user facilities broadly available to the research community, such as light and neutron sources, nanoscale science research centers, sequencing and biocharacterization facilities, and high-performance computing facilities. Within months, NVBL teams produced innovations in materials and advanced manufacturing that mitigated shortages in test kits and personal protective equipment (PPE), creating nearly 1,000 new jobs. They used DOE’s high-performance computers and light and neutron sources to identify promising candidates for antibodies and antivirals that universities and drug companies are now evaluating. NVBL researchers also developed new diagnostic targets and sample collection approaches, and supported U.S. Food and Drug Administration (FDA), Centers for Disease Control and Prevention (CDC), and U.S. Department of Defense (DoD) efforts to establish national guidelines used in administering millions of tests. Researchers used artificial intelligence and high-performance computing to produce near-real-time data analysis to forecast disease transmission, stress on public health infrastructure, and economic impact, which supported decision-makers at the local, state, and national levels. NVBL teams also studied how to control indoor virus movement to minimize uptake and protect human health. NVBL’s accomplishments demonstrate not only the powerful resource represented by DOE’s national laboratories working together to meet national needs, but also the effectiveness of the integrated NVBL framework for rapidly responding to emergencies with research and development (R&D) solutions. As the fight against COVID continues, sustained efforts are needed to confront this pandemic as well as future threats. Examples include: 1) Establishing “supply chains on demand” to meet emergency production needs by leveraging the materials and manufacturing expertise of DOE national laboratories and developing advances in electronics, sensing, robotics, and automation capabilities; 2) Improving the speed and robustness of drug discovery by integrating experimental platforms with DOE’s computational and experimental user facilities, which provide unique resources to support the discovery of high-potential therapeutic agents; 3) Protecting public, environmental, and animal health by developing new testing protocols and instrumentation adaptable to diverse sample types (both physiological and environmental) to quickly detect a wide range of pathogens and monitor other biorisks; 4) Supporting near-real-time data needs of decision-makers at the local, regional, state, and national levels by advancing data curation, analysis, and modeling using artificial intelligence and new data science tools for managing and evaluating large diverse datasets; 5) Harnessing DOE’s expertise in environmental modeling to design rooms and air handling for offices, classrooms, restaurants, and other structures to minimize biorisk transmissions. Going forward, NVBL is poised to apply the unique capabilities and expertise of the national laboratory complex to future national and international emergencies, both natural and engineered. Through this framework, the Office of Science will continue to be an integral component of agency wide efforts to prepare for and respond to biorisks and other crises.

42 ENGINEERING↗

Enhancing Worker Safety During Off-Site Construction of Energy-Efficient, Low-Carbon Exterior Envelope

The construction industry is not doing enough to embrace off-site modular construction. It is a missed opportunity for optimized energy efficiency because prefabricated exterior wall envelopes are lower in cost and faster and easier to install. Factory off-site construction offers improved safety for construction workers because work is done in a controlled environment, but lack of intent, understanding, and data is also a missed opportunity for enhancing worker safety. This research looks specifically at the prefabricated wall exterior envelope in the context of safety. The research question is "off-site factories build with ease of energy efficiency and lowered carbon emissions, but is the process safer?" This research was funded by NREL Student Training in Applied Research (STAR) program, University Partnerships Program, and Wells Fargo Bank. Key finding is that modular and prefabricated construction are perceived to be safer, but the accident rates are much higher than in the general construction and manufacturing industries. Proposed solutions to decrease accidents in off-site prefabricated construction includes safety training for workers, provide movable kiosks with PPE at workstations, ensure tools are well-maintained and place safety posters in visible locations. Future work includes improving worker safety to increase worker productivity, perform pilot demonstration, work with factory designers for new modular layout for worker safety, i.e., easy access to PPE kiosks, and work closely with OSHA so that they take notice of this safety niche.

drywall↗

Gateway at the Crossroads of Sustainable Lunar Exploration

The Gateway Program has made substantial design and development progress toward delivering a small, human-tended lunar space station purposefully designed to enable sustainable human exploration. The Program integrates partners and providers organizationally and physically as part of the spacecraft. The Power and Propulsion Element (PPE) and the Habitation and Logistics Outpost (HALO) with the European System Providing Refueling, Infrastructure and Telecommunications (ESPRIT) HALO Lunar Communications System (HLCS) have begun manufacturing the long lead components and will be launched first as a Co-Manifested Vehicle (CMV). The International Habitat (I-Hab) and ESPRIT Refueling Module (ERM) are passing life cycle milestones and include capabilities key for human crewmembers, such as windows, private sleeping quarters, and galley functions. The Logistics Module (LM) may provide a variety of services to Gateway depending on each mission. Requirements for the airlock have been developed, including requests that it support the integrated spacecraft with functions like augmenting heat rejection capabilities, and interfaces with new spacesuits will soon be developed in more detail. As a critical element of the architecture for solar system exploration, Gateway implements key tenets and features of international interoperability standards necessary to operate with multiple visiting vehicles and lunar assets, especially avionics, communications, and docking. Specific choices such as software architecture and standards, power standards, and robotics standards make it possible to utilize heritage or proprietary technology, yet still operate as one spacecraft. Engineering teams are evaluating many possible future missions to be executed at or utilizing the Gateway. The system architecture protects for an evolvable, extensible, and flexible capability. Designing systems robust enough to serve as a cornerstone of exploration activities for decades while remaining adaptable is not without its challenges. The detailed integration activities have revealed challenges and the need to mature key technologies. Refueling is a key component of achieving long life for Gateway, with unique operations to plan, safety concerns to mitigate, and risk reduction activities to conduct to better understand the system. The constraints and impacts of the design of visiting vehicles is also an important concern, with orientation constraints, control of attitude and orbit of the Gateway with docked visiting vehicles. Tradeoffs between robust maintainable systems and lightweight, compact systems must be balanced. Opportunities still exist for adding additional advanced capabilities to increase and extend Gateway’s benefits, such as intravehicular robotics, autonomous Guidance Navigation and Control (GN&C), and augmented control propulsion, heat rejection, or other services.

Molly S Anderson↗

Gateway at the Crossroads of Sustainable Lunar Exploration

The Gateway Program has made substantial design and development progress toward delivering a small, human-tended lunar space station purposefully designed to enable sustainable human exploration. The Program integrates partners and providers organizationally and physically as part of the spacecraft. The Power and Propulsion Element (PPE) and the Habitation and Logistics Outpost (HALO) with the European System Providing Refueling, Infrastructure and Telecommunications (ESPRIT) HALO Lunar Communications System (HLCS) have begun manufacturing the long lead components and will be launched first as a Co-Manifested Vehicle (CMV). The International Habitat (I-Hab) and ESPRIT Refueling Module (ERM) are passing life cycle milestones and include capabilities key for human crewmembers, such as windows, private sleeping quarters, and galley functions. The Logistics Module (LM) may provide a variety of services to Gateway depending on each mission. Requirements for the airlock have been developed, including requests that it support the integrated spacecraft with functions like augmenting heat rejection capabilities, and interfaces with new spacesuits will soon be developed in more detail. As a critical element of the architecture for solar system exploration, Gateway implements key tenets and features of international interoperability standards necessary to operate with multiple visiting vehicles and lunar assets, especially avionics, communications, and docking. Specific choices such as software architecture and standards, power standards, and robotics standards make it possible to utilize heritage or proprietary technology, yet still operate as one spacecraft. Engineering teams are evaluating many possible future missions to be executed at or utilizing the Gateway. The system architecture protects for an evolvable, extensible, and flexible capability. Designing systems robust enough to serve as a cornerstone of exploration activities for decades while remaining adaptable is not without its challenges. The detailed integration activities have revealed challenges and the need to mature key technologies. Refueling is a key component of achieving long life for Gateway, with unique operations to plan, safety concerns to mitigate, and risk reduction activities to conduct to better understand the system. The constraints and impacts of the design of visiting vehicles is also an important concern, with orientation constraints, control of attitude and orbit of the Gateway with docked visiting vehicles. Tradeoffs between robust maintainable systems and lightweight, compact systems must be balanced. Opportunities still exist for adding additional advanced capabilities to increase and extend Gateway’s benefits, such as intravehicular robotics, autonomous Guidance Navigation and Control (GN&C), and augmented control propulsion, heat rejection, or other services.

Molly S Anderson↗

Final CTAP Report

Sandia will provide technical assistance to Helpful Engineering to develop and test the Universal Citizen Protection Device (UCPD) which is a UV-based filter-less PPE concept that aims to keep the Sars-CoV-2 virus out of eyes, nose and mouth with a 99%+ reliability. The heart of the device would be a concealed UV Chamber that decontaminates all air going in and out of the PPE. Helpful Engineering’s goal is to build this device to be reusable and cost less than $100 to construct and can be worn for 8 hours. The UCPD is an open source project, and once developed, prototyped, tested and approved, it will be shared with interested manufacturers globally.

42 ENGINEERING↗

Evaluation of an Additively Manufactured Respirator for Personnel Protection from Particulates

Additively manufactured respirators (AMRs) made using rigid plastic can be fitted with repurposed filter media to yield a wearable mask capable of passing a quantitative fit test with criteria set for commercial, N95 health care particulate respirators. This has been verified through an evaluation study assessing AMR masks fabricated using open-source design files and a commercial fused-filament fabrication machine, using N95 filter cloth and a P100 respirator cartridge. A few examples of filter media not designed for human respiratory protection were also evaluated in an AMR mask but did not demonstrate filtering sufficient to pass the N95 test criteria. All attributes of an AMR mask system must be considered during design and when testing performance, including the mask frame, gasket, and the cord used to secure the mask to the face. AMR masks are not the same as commercially available respiratory masks. If AMR masks are used as personal protective equipment (PPE) during a crisis when there is a shortage of regular PPE it is important that wearers are fully informed of the differences, tradeoffs, and risks associated with their use. Quantitative fit testing and proper training on how to don and doff the AMR mask are important to help achieve the best possible outcome when they are used.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Datasets and U-Net Model for "A Deep Learning Based Framework to Identify Undocumented Orphaned Oil and Gas Wells from Historical Maps: a Case Study for California and Oklahoma"

This dataset has results and the model associated with the publication Ciulla et al., (2024). It contains a U-Net semantic segmentation model (unet_model.h5) and associated code implemented in tensorflow 2.0 for the model training and identification of oil and gas well symbols in USGS historical topographic maps (HTMC). Given a quadrangle map (7.5 minutes), downloadable at this url: https://ngmdb.usgs.gov/topoview/, and a list of coordinates of the documented wells present in the area, the model returns the coordinates of oil and gas symbols in the HTMC maps. For reproducibility of our workflow, we provide a sample map in California and the documented well locations for the entire State of California (CalGEM_AllWells_20231128.csv) downloaded from https://www.conservation.ca.gov/calgem/maps/Pages/GISMapping2.aspx. Additionally, the locations of 1,301 potential undocumented orphaned wells identified using our deep learning framework or the counties of Los Angeles and Kern in California, and Osage and Oklahoma in Oklahoma are provided in the file found_potential_UOWs.zip. The results of the visual inspection of satellite imagery in Osage County is in the file visible_potential_UOWs.zip. The dataset also includes a custom tool to validate the detected symbols in the HTMC maps (vetting_tool.py). More details about the methodology can be found in the associated paper: Ciulla, F., Santos, A., Jordan, P., Kneafsey, T., Biraud, S.C., and Varadharajan, C. (2024) A Deep Learning Based Framework to Identify Undocumented Orphaned Oil and Gas Wells from Historical Maps: a Case Study for California and Oklahoma. Accepted for publication in Environmental Science and Technology. The geographical coordinates provided correspond to the locations of potential undocumented orphaned oil and gas wells (UOWs) extracted from historical maps. The actual presence of wells need to be confirmed with on-the-ground investigations. For your safety, do not attempt to visit or investigate these sites without appropriate safety training, proper equipment, and authorization from local authorities. Approaching these well sites without proper personal protective equipment (PPE) may pose significant health and safety risks. Oil and gas wells can emit hazardous gasses including methane, which is flammable, odorless and colorless, as well as hydrogen sulfide, which can be fatal even at low concentrations. Additionally, there may be unstable ground near the wellhead that may collapse around the wellbore. This dataset was prepared as an account of work sponsored by the United States Government. While this document is believed to contain correct information, neither the United States Government nor any agency thereof, nor the Regents of the University of California, nor any of their employees, makes any warranty, express or implied, or assumes any legal responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by its trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof, or the Regents of the University of California. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof or the Regents of the University of California.

Artificial Intelligence↗

International Space Station (ISS) Emergency Mask (EM) Development

The Emergency Mask (EM) is considered a secondary response emergency Personal Protective Equipment (PPE) designed to provide respiratory protection to the International Space Station (ISS) crewmembers in response to a post-fire event or ammonia leak. The EM is planned to be delivered to ISS in 2012 to replace the current air purifying respirator (APR) onboard ISS called the Ammonia Respirator (AR). The EM is a one ]size ]fits ]all model designed to fit any size crewmember, unlike the APR on ISS, and uses either two Fire Cartridges (FCs) or two Commercial Off-the-Shelf (COTS) 3M(Trademark). Ammonia Cartridges (ACs) to provide the crew with a minimum of 8 hours of respiratory protection with appropriate cartridge swap ]out. The EM is designed for a single exposure event, for either post ]fire or ammonia, and is a passive device that cannot help crewmembers who cannot breathe on their own. The EM fs primary and only seal is around the wearer fs neck to prevent a crewmember from inhaling contaminants. During the development of the ISS Emergency Mask, several design challenges were faced that focused around manufacturing a leak free mask. The description of those challenges are broadly discussed but focuses on one key design challenge area: bonding EPDM gasket material to Gore(Registered Trademark) fabric hood.

Toon, Katherine P.↗