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Multiscale and Multiphysics Modeling of Additive Manufacturing of Advanced Materials

The objective of this proposed project is to research and develop a prediction tool for advanced additive manufacturing (AAM) processes for advanced materials and develop experimental methods to provide fundamental properties and establish validation data. Aircraft structures and engines demand materials that are stronger, useable at much higher temperatures, provide less acoustic transmission, and enable more aeroelastic tailoring than those currently used. Significant improvements in properties can only be achieved by processing the materials under nonequilibrium conditions, such as AAM processes. AAM processes encompass a class of processes that use a focused heat source to create a melt pool on a substrate. Examples include Electron Beam Freeform Fabrication and Direct Metal Deposition. These types of additive processes enable fabrication of parts directly from CAD drawings. To achieve the desired material properties and geometries of the final structure, assessing the impact of process parameters and predicting optimized conditions with numerical modeling as an effective prediction tool is necessary. The targets for the processing are multiple and at different spatial scales, and the physical phenomena associated occur in multiphysics and multiscale. In this project, the research work has been developed to model AAM processes in a multiscale and multiphysics approach. A macroscale model was developed to investigate the residual stresses and distortion in AAM processes. A sequentially coupled, thermomechanical, finite element model was developed and validated experimentally. The results showed the temperature distribution, residual stress, and deformation within the formed deposits and substrates. A mesoscale model was developed to include heat transfer, phase change with mushy zone, incompressible free surface flow, solute redistribution, and surface tension. Because of excessive computing time needed, a parallel computing approach was also tested. In addition, after investigating various methods, a Smoothed Particle Hydrodynamics Model (SPH Model) was developed to model wire feeding process. Its computational efficiency and simple architecture makes it more robust and flexible than other models. More research on material properties may be needed to realistically model the AAM processes. A microscale model was developed to investigate heterogeneous nucleation, dendritic grain growth, epitaxial growth of columnar grains, columnar-to-equiaxed transition, grain transport in melt, and other properties. The orientations of the columnar grains were almost perpendicular to the laser motion's direction. Compared to the similar studies in the literature, the multiple grain morphology modeling result is in the same order of magnitude as optical morphologies in the experiment. Experimental work was conducted to validate different models. An infrared camera was incorporated as a process monitoring and validating tool to identify the solidus and mushy zones during deposition. The images were successfully processed to identify these regions. This research project has investigated multiscale and multiphysics of the complex AAM processes thus leading to advanced understanding of these processes. The project has also developed several modeling tools and experimental validation tools that will be very critical in the future of AAM process qualification and certification.

Liou, Frank↗

Design of Accumulators and Liquid/Gas Charging of Single Phase Mechanically Pumped Fluid Loop Heat Rejection Systems

For single phase mechanically pumped fluid loops used for thermal control of spacecraft, a gas charged accumulator is typically used to modulate pressures within the loop. This is needed to accommodate changes in the working fluid volume due to changes in the operating temperatures as the spacecraft encounters varying thermal environments during its mission. Overall, the three key requirements on the accumulator to maintain an appropriate pressure range throughout the mission are: accommodation of the volume change of the fluid due to temperature changes, avoidance of pump cavitation and prevention of boiling in the liquid. The sizing and design of such an accumulator requires very careful and accurate accounting of temperature distribution within each element of the working fluid for the entire range of conditions expected, accurate knowledge of volume of each fluid element, assessment of corresponding pressures needed to avoid boiling in the liquid, as well as the pressures needed to avoid cavitation in the pump. The appropriate liquid and accumulator strokes required to accommodate the liquid volume change, as well as the appropriate gas volumes, require proper sizing to ensure that the correct pressure range is maintained during the mission. Additionally, a very careful assessment of the process for charging both the gas side and the liquid side of the accumulator is required to properly position the bellows and pressurize the system to a level commensurate with requirements. To achieve the accurate sizing of the accumulator and the charging of the system, sophisticated EXCEL based spreadsheets were developed to rapidly come up with an accumulator design and the corresponding charging parameters. These spreadsheets have proven to be computationally fast and accurate tools for this purpose. This paper will describe the entire process of designing and charging the system, using a case study of the Mars Science Laboratory (MSL) fluid loops, which is en route to Mars for an August 2012 landing.

HRS↗

Thermal Deformation and RF Performance Analyses for the SWOT Large Deployable Ka-Band Reflectarray

A large deployable antenna technology for the NASA Surface Water and Ocean Topography (SWOT) Mission is currently being developed by JPL in response to NRC Earth Science Tier 2 Decadal Survey recommendations. This technology is required to enable the SWOT mission due to the fact that no currently available antenna is capable of meeting SWOT's demanding Ka-Band remote sensing requirements. One of the key aspects of this antenna development is to minimize the effect of the on-orbit thermal distortion to the antenna RF performance. An analysis process which includes: 1) the on-orbit thermal analysis to obtain the temperature distribution; 2) structural deformation analysis to get the geometry of the antenna surface; and 3) the RF performance with the given deformed antenna surface has been developed to accommodate the development of this antenna technology. The detailed analysis process and some analysis results will be presented and discussed by this paper.

thermal distorsion↗

Effect of Interfacial Turbulence and Accommodation Coefficient on CFD Predictions of Pressurization and Pressure Control in Cryogenic Storage Tank

Laminar models agree closely with the pressure evolution and vapor phase temperature stratification but under-predict liquid temperatures. Turbulent SST k-w and k-e models under-predict the pressurization rate and extent of stratification in the vapor but represent liquid temperature distributions fairly well. These conclusions seem to equally apply to large cryogenic tank simulations as well as small scale simulant fluid pressurization cases. Appropriate turbulent models that represent both interfacial and bulk vapor phase turbulence with greater fidelity are needed. Application of LES models to the tank pressurization problem can serve as a starting point.

Condensation Evaporation↗

Non-Contact Thermal Characterization of NASA's HERMeS Hall Thruster

The thermal characterization test of NASA's 12.5-kW Hall Effect Rocket with Magnetic Shielding has been completed. This thruster was developed to support a number of potential Solar Electric Propulsion Technology Demonstration Mission concepts, including the Asteroid Redirect Robotic Mission concept. As a part of the preparation for this characterization test, an infrared-based, non-contact thermal imaging system was developed to measure the temperature of various thruster surfaces that are exposed to high voltage or plasma. An in-situ calibration array was incorporated into the setup to improve the accuracy of the temperature measurement. The key design parameters for the calibration array were determined in a separate pilot test. The raw data from the characterization test was analyzed though further work is needed to obtain accurate anode temperatures. Examination of the front pole and discharge channel temperatures showed that the thruster temperature was driven more by discharge voltage than by discharge power. Operation at lower discharge voltages also yielded more uniform temperature distributions than at higher discharge voltages. When operating at high discharge voltage, increasing the magnetic field strength appeared to have made the thermal loading azimuthally more uniform.

Hall Thrusters↗

Reduced Boil-Off System Sizing

NASA is currently developing cryogenic propellant storage and transfer systems for future space exploration and scientific discovery missions by addressing the need to raise the technology readiness level of cryogenic fluid management technologies. Cryogenic propellants are baselined in many propulsion systems due to their inherently high specific impulse; however, their low boiling points can cause substantial boil-off losses over time. Recent efforts such as the Reduced Boil-off Testing and the Active Thermal Control Scaling Study provide important information on the benefit of an active cooling system applied to LH2 propellant storage. Findings show that zero-boil off technologies can reduce overall mass in LH2 storage systems when low Earth orbit loiter periods extend beyond two months. A significant part of this mass reduction is realized by integrating two stages of cooling: a 20 K stage to intercept heat at the tank surface, and a 90 K stage to reduce the heat entering the less efficient 20 K stage. A missing element in previous studies, which is addressed in this paper, is the development of a direct method for sizing the 90 K cooling stage. Such a method requires calculation of the heat entering both the 90 K and 20 K stages as compared to the overall system masses, and is reliant upon the temperature distribution, performance, and unique design characteristics of the system in question. By utilizing the known conductance of a system without active thermal control, the heat being intercepted by a 90 K stage can be calculated to find the resultant lift and mass of each active thermal control stage. Integral to this is the thermal conductance of the cooling straps and the broad area cooling shield, key parts of the 90 K stage. Additionally, a trade study is performed to show the ability of the 90 K cooling stage to reduce the lift on the 20 K cryocooler stage, which is considerably less developed and efficient than 90 K cryocoolers.

Cryogenic fluid management↗

Optimized Heat Pipe Backup Cooling System Tested with a Stirling Convertor

Advanced Stirling Radioisotope Generator (ASRG) is an attractive energy system for select space missions, and with the addition of a VCHP, it becomes even more versatile. The ASRG is powered through thermal energy from decaying radioisotopes acting as General Purpose Heat Sources (GPHS). A Stirling engine converts the thermal energy to electrical energy and cools the GPHS [2]. The Stirling convertor must operate continuously to maintain acceptable temperatures of the GPHS and protect their cladding. The addition of alkali metal VCHP allows the Stirling to cycle on and off during a mission and can be used as a backup cooling system. The benefits of being able to turn the Stirling off are: allowing for a restart of the Stirling and reducing vibrations for sensitive measurements. The VCHP addition should also increase the efficiency of the Stirling by providing a uniform temperature distribution at the heat transfer interface into the heater head.

Stirling Radioisotope Generator↗

Lithium Inventory of 2 Solar Mass Red Clump Stars in Open Clusters: A Test of the Helium Flash Mechanism

The temperature distribution of field Li-rich red giants suggests the presence of a population of Li-rich red clump (RC) stars. One proposed explanation for this population is that all stars with masses near 2 solar mass experience a shortlived phase of Li-richness at the onset of core He-burning. Many of these stars have low C-12/C-13, a signature of deep mixing that is presumably associated with the Li regeneration. To test this purported mechanism of Li enrichment, we measured abundances in 38 RC stars and 6 red giant branch (RGB) stars in four open clusters selected to have RC masses near 2 solar mass. We find six Li-rich stars (A(Li) greater than or equal to 1.50 dex) of which only two may be RC stars. None of the RC stars have Li exceeding the levels observed in the RGB stars, but given the brevity of the suggested Li-rich phase and the modest sample size, it is probable that stars with larger Li-enrichments were missed simply by chance. However, we find very few stars in our sample with low C-12/C-13. Such low C-12/C-13, seen in many field Li-rich stars, should persist even after lithium has returned to normal low levels. Thus, if Li synthesis during the He flash occurs, it is a rare, but potentially long-lived occurrence rather than a short-lived phase for all stars. We estimate a conservative upper limit of the fraction of stars going through a Li-rich phase to be less than 47%, based on stars that have low C-12/C-13 for their observed A(Li).

Li-rich red giants↗

The Structure of the Local Hot Bubble

Diffuse X-rays from the Local Galaxy (DXL) is a sounding rocket mission designed to quantify and characterize the contribution of Solar Wind Charge eXchange (SWCX) to the Diffuse X-ray Background and study the properties of the Local Hot Bubble (LHB). Based on the results from the DXL mission, we quantified and removed the contribution of SWCX to the diffuse X-ray background measured by the ROSAT All Sky Survey. The cleaned maps were used to investigate the physical properties of the LHB. Assuming thermal ionization equilibrium, we measured a highly uniform temperature distributed around kT = 0.097 keV +/- 0.013 keV (FWHM) +/- 0.006 keV(systematic). We also generated a thermal emission measure map and used it to characterize the three-dimensional (3D) structure of the LHB, which we found to be in good agreement with the structure of the local cavity measured from dust and gas.

X-rays↗

Augmented Method to Improve Thermal Data for the Figure Drift Thermal Distortion Predictions of the JWST OTIS Cryogenic Vacuum Test

The JWST Optical Telescope Element (OTE) assembly is the largest optically stable infrared-optimized telescope currently being manufactured and assembled, and is scheduled for launch in 2018. The JWST OTE, including the 18 segment primary mirror, secondary mirror, and the Aft Optics Subsystem (AOS) are designed to be passively cooled and operate near 45K. These optical elements are supported by a complex composite backplane structure. As a part of the structural distortion model validation efforts, a series of tests are planned during the cryogenic vacuum test of the fully integrated flight hardware at NASA JSC Chamber A. The successful ends to the thermal-distortion phases are heavily dependent on the accurate temperature knowledge of the OTE structural members. However, the current temperature sensor allocations during the cryo-vac test may not have sufficient fidelity to provide accurate knowledge of the temperature distributions within the composite structure. A method based on an inverse distance relationship among the sensors and thermal model nodes was developed to improve the thermal data provided for the nanometer scale WaveFront Error (WFE) predictions. The Linear Distance Weighted Interpolation (LDWI) method was developed to augment the thermal model predictions based on the sparse sensor information. This paper will encompass the development of the LDWI method using the test data from the earlier pathfinder cryo-vac tests, and the results of the notional and as tested WFE predictions from the structural finite element model cases to characterize the accuracies of this LDWI method.

Thermal Modeling↗

Zero-Boil-Off Tank (ZBOT) Experiment: Ground-Based Validation of Self-Pressurization and Pressure Control Two-Phase CFD Model

Integral to all phases of NASA's projected space and planetary expeditions is affordable and reliable cryogenic fluid storage for use in propellant or life support systems. Cryogen vaporization due to heat leaks into the tank from its surroundings and support structure can cause self-pressurization relieved through venting. This has led to a desire to develop innovative pressure control designs based on mixing of the bulk tank fluid together with some form of active or passive cooling to allow storage of the cryogenic fluid with zero or reduced boil-off. The Zero-Boil-Off Tank (ZBOT) Experiments are a series of small scale tank pressurization and pressure control experiments aboard the International Space Station (ISS) that use a transparent volatile simulant fluid in a transparent sealed tank to delineate various fundamental fluid flow, heat and mass transport, and phase change phenomena that control storage tank pressurization and pressure control in microgravity. The hardware for ZBOT-1 flew to ISS on the OA-7 flight in April 2017 and operations are planned to begin in September 2017, encompassing more than 90 tests. This paper presents preliminary results from ZBOT's ground-based research delineating both pressurization and pressure reduction trends in the sealed test tank. Tank self-pressurization tests are conducted under three modes: VJ heating, strip heating and simultaneous VJ and strip heating in attempt to simulate heat leaks from the environment, the support structure and both. The jet mixing pressure control studies are performed either from an elevated uniform temperature condition or from thermally stratified conditions following a self-pressurization run. Jet flow rates are varied from 2-25 cm/s spanning a range of jet Re number in laminar, transitional, and turbulent regimes and a range of Weber numbers covering no ullage penetration, partial penetration and complete ullage penetration and break-up (only in microgravity). Numerical prediction of a two-phase CFD model are compared to experimental 1g results to both validate the model and also indicate the effect of the residual non-condensable gas on evolution of pressure and temperature distributions in the tank during pressurization and pressure control.

microgravity evaporation condensatio↗

Sensitivity of Different Types of Observations to NASA GEOS Hurricane Analyses and Forecasts

The 2017 Atlantic hurricane season was the 5th most active, featuring 17 named storms, the highest number of major hurricanes since 2005, and by far the costliest season on record. African easterly waves often serve as the seeding circulation for a large portion of hurricanes (i.e. tropical storms with wind over 74mph in the Atlantic and Northeast Pacific). Warm SST, moist air, and low wind shear are the main requirements for tropical cyclones to develop and maintain hurricane strength. In terms of hurricane propagation (so called hurricane tracks), Atlantic hurricanes typically propagate around the periphery of the subtropical ridge called the Bermuda High (Azores High), riding along its strongest winds. If the high is positioned to the east, then hurricanes generally propagate northeastward around the high's western edge into the open Atlantic Ocean without making land fall. If the high is positioned to the west and extends far enough to the south, storms are blocked from curving north and forced to continue west towards Florida, Cuba, and the Gulf of Mexico. If we have accurate atmospheric temperature distribution, which is directly related to atmospheric wave patterns, wind distributions, moisture distribution, and SST distribution in the analyses, we will have better NWP skills in hurricane analyses including hurricane intensity and tracks. Assimilating various observation data are supposed to play these roles in the analyses. To examine impacts of different types of observation data on NASA Goddard Earth Observing System (GEOS) model hurricane analyses and forecasts during the period of 2017 summer, this study performs data denial experiments using GEOS Atmospheric Data Assimilation System (ADAS), which is based on the hybrid 4D-EnVar GSI algorithm. Various types of observations such as microwave sounders, infrared sounders, TCvitals, and conventional data are removed in the experiments. In addition, the interaction between the different observation groups as certain instruments are removed from the analysis is investigated in detail using adjoint based forecast sensitivity observation impact (FSOI).

Hurricane↗

Ice Roughness and Thickness Evolution on a Business Jet Airfoil

Experiments were performed in the Icing Research Tunnel at NASA Glenn Research Center (GRC) to investigate the ice roughness and thickness evolution on a 152.4-cm (60-in.) chord business jet airfoil exposed to both Appendix C and Appendix O (SLD - Super-cooled Large Droplet) icing conditions. The resulting measurements demonstrate that the average non-dimensional roughness and the stagnation point thickness scalings are similar to those demonstrated on symmetric wings. However, the surface variations of roughness and thickness exhibit significant differences from those observed on symmetric airfoils. The source of the roughness and thickness differences is the result of surface pressure, velocity and temperature distribution differences from the suction to the pressure sides of the airfoil. LEWICE (LEWis ICE accretion program - software developed at NASA Lewis Research Center - former name of the GRC) simulations are used to further investigate the influences of local collection efficiency and the local freezing fraction on the resulting ice roughness and thickness spatial variations.

icing codes↗

Transient Heater Analysis for Orion Thermal Vacuum Testing

The Space Environments Complex (SEC) at NASA's Plum Brook Station is currently being prepared to perform thermal vacuum testing of the Orion spacecraft. This thermal vacuum, or T-VAC test will be run for a period of 60 days, which will be the longest such test ever conducted at SEC. The Orion Crew Module (CM) and Service Module (SM) will undergo T-VAC testing in SEC's Space Simulation Vacuum Chamber to ensure the functionality of these systems in a high vacuum environment at extremely cold temperatures. The T-VAC test setup in SEC was modeled and simulated in Thermal Desktop. The initial results from thermal analysis showed areas on the chamber floor to reach very low temperatures, which were below the minimum operating range of certain hardware located on or near the chamber floor. These hardware including elastomeric seals on the GN2 piping, bearing pads and O-rings are essential to both test and the operation of the SEC facility, and must be kept well above -20°F throughout the duration of the T-VAC test. Thus, further analysis was conducted to include the placement of patch heaters on the chamber floor in an effort to increase the temperature near colder areas on the floor. The results and findings from this analysis showed that using these heaters will result in a favorable temperature distribution on the chamber floor. This paper will discuss the methods used in the analysis, and the results obtained to determine the optimal configuration of these heaters on the chamber floor.

Wilhite, Jarred↗

Transient Heater Analysis for Orion Thermal Vacuum Testing

The Space Environments Complex (SEC) at NASA’s Plum Brook Station is currently being prepared to perform thermal vacuum testing of the Orion spacecraft. This thermal vacuum, or T-VAC test will be run for a period of 60 days, which will be the longest such test ever conducted at SEC. The Orion Crew Module (CM) and Service Module (SM) will undergo T-VAC testing in SEC’s Space Simulation Vacuum Chamber to ensure the functionality of these systems in a high vacuum environment at extremely cold temperatures. The T-VAC test setup in SEC was modeled and simulated in Thermal Desktop. The initial results from thermal analysis showed areas on the chamber floor to reach very low temperatures, which were below the minimum operating range of certain hardware located on or near the chamber floor. These hardware including elastomeric seals on the GN2 piping, bearing pads and O-rings are essential to both test and the operation of the SEC facility, and must be kept well above -20°F throughout the duration of the T-VAC test. Thus, further analysis was conducted to include the placement of patch heaters on the chamber floor in an effort to increase the temperature near colder areas on the floor. The results and findings from this analysis showed that using these heaters will result in a favorable temperature distribution on the chamber floor. This paper will discuss the methods used in the analysis, and the results obtained to determine the optimal configuration of these heaters on the chamber floor.

Wilhite, Jarred↗

NuSTAR Detection of X-Rays Concurrent with Gamma-Rays in the Nova V5855 Sgr

We report the first detection of hard (>10 keV) X-ray emission simultaneous with gamma-rays in a nova eruption. Observations of the nova V5855 Sgr carried out with the NuSTAR satellite on Day 12 of the eruption revealed faint, highly absorbed thermal X-rays. The extreme equivalent hydrogen column density toward the X-ray emitting region (∼3 × 10(exp 24 per sq.cm) indicates that the shock producing the X-rays was deeply embedded within the nova ejecta. The slope of the X-ray spectrum favors a thermal origin for the bulk of the emission, and the constraints of the temperature in the shocked region suggest a shock velocity compatible with the ejecta velocities inferred from optical spectroscopy. While we do not claim the detection of nonthermal X-rays, the data do not allow us to rule out an additional, fainter component dominating at energies above 20 keV, for which we obtained upper limits. The inferred luminosity of the thermal X-rays is too low to be consistent with the gamma-ray luminosities if both are powered by the same shock under standard assumptions regarding the efficiency of nonthermal particle acceleration and the temperature distribution of the shocked gas.

Nelson, Thomas↗

Local and Remote Mean and Extreme Temperature Response to Regional Aerosol Emissions Reductions

The climatic implications of regional aerosol and precursor emissions reductions implemented to protect human health are poorly understood. We investigate the mean and extreme temperature response to regional changes in aerosol emissions using three coupled chemistry–climate models: NOAA GFDL CM3, NCAR CESM1, and NASA GISS-E2. Our approach contrasts a long present-day control simulation from each model (up to 400 years with perpetual year 2000 or 2005 emissions) with 14 individual aerosol emissions perturbation simulations (160–240 years each). We perturb emissions of sulfur dioxide (SO2) and/or carbonaceous aerosol within six world regions and assess the statistical significance of mean and extreme temperature responses relative to internal variability determined by the control simulation and across the models. In all models, the global mean surface temperature response (perturbation minus control) to SO2 and/or carbonaceous aerosol is mostly positive (warming) and statistically significant and ranges from +0.17 K (Europe SO2) to -0.06 K (US BC). The warming response to SO2 reductions is strongest in the US and Europe perturbation simulations, both globally and regionally, with Arctic warming up to 1 K due to a removal of European anthropogenic SO2 emissions alone; however, even emissions from regions remote to the Arctic, such as SO2 from India, significantly warm the Arctic by up to 0.5 K. Arctic warming is the most robust response across each model and several aerosol emissions perturbations. The temperature response in the Northern Hemisphere midlatitudes is most sensitive to emissions perturbations within that region. In the tropics, however, the temperature response to emissions perturbations is roughly the same in magnitude as emissions perturbations either within or outside of the tropics. We find that climate sensitivity to regional aerosol perturbations ranges from 0.5 to 1.0 K (W m(exp -2))(exp -1) depending on the region and aerosol composition and is larger than the climate sensitivity to a doubling of CO2 in two of three models. We update previous estimates of regional temperature potential (RTP), a metric for estimating the regional temperature responses to a regional emissions perturbation that can facilitate assessment of climate impacts with integrated assessment models without requiring computationally demanding coupled climate model simulations. These calculations indicate a robust regional response to aerosol forcing within the Northern Hemisphere midlatitudes, regardless of where the aerosol forcing is located longitudinally. We show that regional aerosol perturbations can significantly increase extreme temperatures on the regional scale. Except in the Arctic in the summer, extreme temperature responses largely mirror mean temperature responses to regional aerosol perturbations through a shift of the temperature distributions and are mostly dominated by local rather than remote aerosol forcing.

Westervelt, Daniel M.↗

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