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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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At least 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
NASA NTRS1994

A Chebyshev Collocation Method for Moving Boundaries, Heat Transfer, and Convection During Directional Solidification

Free and moving boundary problems require the simultaneous solution of unknown field variables and the boundaries of the domains on which these variables are defined. There are many technologically important processes that lead to moving boundary problems associated with fluid surfaces and solid-fluid boundaries. These include crystal growth, metal alloy and glass solidification, melting and name propagation. The directional solidification of semi-conductor crystals by the Bridgman-Stockbarger method is a typical example of such a complex process. A numerical model of this growth method must solve the appropriate heat, mass and momentum transfer equations and determine the location of the melt-solid interface. In this work, a Chebyshev pseudospectra collocation method is adapted to the problem of directional solidification. Implementation involves a solution algorithm that combines domain decomposition, finite-difference preconditioned conjugate minimum residual method and a Picard type iterative scheme.

Zhang, Yiqiang↗
DOE OSTI2024

Stress localization investigation of additively manufactured GRCop-42 thin-wall structure

A full-field crystal plasticity (CP) framework is presented for the GRCop-42 alloy to study microscopic mechanical behavior and local stress heterogeneities. The microstructures of additively manufactured (AM) materials are often unique relative to conventionally processed materials, and the local thermal histories drive these differences during the build process. These thermal histories depend on the process parameters (laser power, scan speed, and scan strategy) and the part geometry. Prior research has shown that the mechanical properties of thin-walled structures can vary significantly with wall thickness due to changes in the thermal boundary conditions during manufacturing. It is, therefore, desirable to perform CP simulations based on the phenomenological constitutive model to predict the local mechanical responses induced by microstructural heterogeneities. This work generates representative microstructures based on experimentally collected grain information (i.e., texture) for grain scale stress analysis, and the material constitutive parameters are calibrated using the experimental mechanical testing data. Here, we specifically investigated the effect of crystallographic texture and grain morphologies on the size-dependent mechanical properties of AM GRCop-42. The selection of appropriate material properties for implementing an effective free surface boundary condition and the influence of adjacent buffer layers are also discussed. Analysis of local field results reveals a strong correlation between stress localization and the initial grain orientation. However, no significant relationship between the misorientation of the individual adjacent grains and the average misorientation is observed.

36 MATERIALS SCIENCE↗
NASA NTRS1990

Boundary layer receptivity to unsteady free-stream pressure gradients

A linear triple-deck theory is applied to an examination of the response of a boundary layer to short-scale variations in an unsteady free-stream disturbance field. Two-dimensional incompressible flows are considered, and a locally-parallel Blasius mean flow is assumed. A simple pulsating pressure source and a traveling pressure field in the free-stream are modeled by introducing appropriate pressure sources in the upper deck of the triple-deck structure. The modification in unsteady thickness is obtained for these cases, the results are related to the Tollmien-Schlichting instability wave, and the generation of unstable Tollmien-Schlichting waves for both experiments modeled is confirmed.

Heinrich, Roland A. E.↗
DOE OSTI2022

A Boundary Topology Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing

Minimizing the mass in electric machines while maintaining superior performance has become a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization for light-weighting electric machines using traditional approaches typically explore a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods like cell-based density approaches suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary TO where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the IEA-15MW radial flux direct-drive wind turbine generator. The free-from boundary TO resulted in smooth and concise shapes that can be easily additively manufactured with upto 20-ton reduction in electrical steel mass.

additive manufacturing↗
NASA NTRS1987

Effects of nozzle-exit boundary-layer conditions on excitability of heated free jets

This paper reports an experimental study on the effects of nozzle-exit boundary-layer conditions on the excitability of heated free jets. The results were obtained at a Mach number 0.8 and total temperatures of 300 K and 670 K. External acoustic excitation was used to excite the jet. The excitation frequencies ranged up to 6 KHZ and the excitation levels were up to 150 dB. A level of 147 dB was used for most of the test points. Nozzle-exit boundary-layer characteristics were controlled by boundary layer tripping upstream of the nozzle exit plane. It has been shown that the free jet mixing rate strongly depends on the boundary-layer characteristics at the nozzle exit. Further, it appears that jets with a thin laminar nozzle-exit boundary layer are more selective about the optimum excitation frequency than those with a thick turbulent nozzle-exit boundary layer. Finally, for the jet of Mach number 0.8, it appears that free jet mixing and development may be controlled by flow excitation as well as by nozzle-exit boundary-layer modifications.

Lepicovsky, J.↗
DOE OSTI2022

A New Shape Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing: Preprint

Minimizing the mass in electric machines while maintaining superior performance is a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization (TO) for lightweighting electric machines using traditional approaches typically explores a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods, such as cell-based density approaches, suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary TO where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning-based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque, and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the International Energy Agency (IEA) 15-MW radial flux direct-drive wind turbine generator. The free-form boundary TO resulted in smooth and concise shapes that can be easily additively manufactured with up to a 20-ton reduction in electrical steel mass.

additive manufacturing↗
NASA NTRS1994

Adaptive-wall wind-tunnel research at Ames Research Center: A retrospective

This paper reviews adaptive-wall wind-tunnel research conducted at Ames Research Center between 1978 and 1988. This research focused on developing ways to apply the concept of adaptive walls in transonic test sections with ventilated walls. In the approach pursued at Ames, local mass flow through slotted test-section walls was controlled by adjusting the pressure in compartments of a segmented plenum; the flow measurements required to test compatibility of the wind-tunnel flow with free-air boundary conditions were made using a laser velocimeter; empirical influence coefficients were used to predict how pressure changes in the plenum would effect the flow. Both two- and three-dimensional proof-of-concept experiments were conducted in a small indraft wind tunnel. Subsequently, a two-dimensional test section was demonstrated in the Ames 2x2 ft. Transonic Wind Tunnel-a wind tunnel representative of a production facility. The 2x2 ft.tests showed large reductions of wall interference; however, the time required to make the necessary flow measurements and plenum pressure adjustments far exceeded what would be acceptable for production testing. This was primarily because the imaginary surface where free-air compatibility was tested had to be separated from the test section walls to avoid the complex, viscous flow adjacent to the walls. It is unlikely that the Ames approach to adaptive walls will be applied in production wind tunnels. The two biggest unresolved problems are how to quickly and accurately make the necessary flow measurements and how to predict the effects of wall adjustments. In contrast, flexible-wall technology for two-dimensional testing is ready for application in production wind tunnels. However, neither the ventilated- nor flexible-wall approach has been shown to be a technically viable and cost-effective solution to the three-dimensional adaptive wall problem.

Schairer, Edward T.↗
DOE OSTI2020

Effect of geometric and magnetic boundary conditions on magnetic islands in 3D force-free ideal MHD equilibria

Three-dimensional boundary features and magnetic perturbations affect the magnetic topology of the force-free ideal MHD equilibria formed within a given volume. The use of the PSI-Tet 3D finite-element equilibrium code reveals the existence of magnetic islands inside such equilibria within boundaries with three-dimensional features in configurations that directly depend on the natures of those features. Here, the nature and limits of the influence of such features are explored, as is the influence of flux boundary conditions to qualitatively identify the structure of magnetic islands in Taylor state equilibria with three-dimensional boundary conditions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1997

Improvements in Block-Krylov Ritz Vectors and the Boundary Flexibility Method of Component Synthesis

A method of dynamic substructuring is presented which utilizes a set of static Ritz vectors as a replacement for normal eigenvectors in component mode synthesis. This set of Ritz vectors is generated in a recurrence relationship, proposed by Wilson, which has the form of a block-Krylov subspace. The initial seed to the recurrence algorithm is based upon the boundary flexibility vectors of the component. Improvements have been made in the formulation of the initial seed to the Krylov sequence, through the use of block-filtering. A method to shift the Krylov sequence to create Ritz vectors that will represent the dynamic behavior of the component at target frequencies, the target frequency being determined by the applied forcing functions, has been developed. A method to terminate the Krylov sequence has also been developed. Various orthonormalization schemes have been developed and evaluated, including the Cholesky/QR method. Several auxiliary theorems and proofs which illustrate issues in component mode synthesis and loss of orthogonality in the Krylov sequence have also been presented. The resulting methodology is applicable to both fixed and free- interface boundary components, and results in a general component model appropriate for any type of dynamic analysis. The accuracy is found to be comparable to that of component synthesis based upon normal modes, using fewer generalized coordinates. In addition, the block-Krylov recurrence algorithm is a series of static solutions and so requires significantly less computation than solving the normal eigenspace problem. The requirement for less vectors to form the component, coupled with the lower computational expense of calculating these Ritz vectors, combine to create a method more efficient than traditional component mode synthesis.

Carney, Kelly Scott↗
NASA NTRS1934

Investigation of Boundary Layers on an Airplane Wing in Free Flight

This report describes the equipment and method developed for recording the boundary layers on the surface of an airfoil in free flight. The results are in close agreement with the wind-tunnel tests of other experimenters. The intensity of the turbulent boundary layer, even at the much higher Reynolds Numbers reached, is determinable with Gruschwitz's formulas, although it was impossible to definitely establish a direct relationship between the turbulent boundary layer and the Reynolds Number within the limits of the obtained accuracy. The observations on the transition from laminar to turbulent flow check with previous wind-tunnel tests and calculations.

Stuper, J↗
DOE OSTI2024

Hole‐Carrier‐Dominant Transport in 2D Single‐Crystal Copper

Abstract In 2D noble metals like copper, the carrier scattering at grain boundaries has obscured the intrinsic nature of electronic transport. However, it is demonstrated that the intrinsic nature of transport by hole carriers in 2D copper can be revealed by growing thin films without grain boundaries. As even a slight deviation from the twin boundary is perceived as grain boundaries by electrons, it is only through the thorough elimination of grain boundaries that the hidden hole‐like attribute of 2D single‐crystal copper can be unmasked. Two types of Fermi surfaces, a large hexagonal Fermi surface centered at the zone center and the triangular Fermi surface around the zone corner, tightly matching to the calculated Fermi surface topology, confirmed by angle‐resolved photoemission spectroscopy (ARPES) measurements and vivid nonlinear Hall effects of the 2D single‐crystal copper account for the presence of hole carriers experimentally. This breakthrough suggests the potential to manipulate the majority carrier polarity in metals by means of grain boundary engineering in a 2D geometry.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Mutual Diffusion Coefficients and Refractive Index Increments of K 2 SO 4 (aq) at 298.15 K from Rayleigh Interferometry

Here, isothermal mutual diffusion coefficients (interdiffusion coefficients) were measured for K 2 SO 4 (aq) at 298.15 ± 0.005 K, at numerous concentrations ranging from dilute solutions to near saturation (0.59648 mol∙dm -3 ; 0.61349 mol∙kg -1 ) under free diffusion boundary conditions, using high precision Rayleigh interferometry. Under the experimental conditions these diffusion coefficients are on the volume-fixed reference frame D v . Two series of experiments were performed, the first using the traditional experimental approach with a mercury lamp source and with the interference patterns being recorded on glass photographic plates, and the second with a He-Ne laser light source and computerized data acquisition using a photodiode array. The results from both series of experiments are in excellent agreement, and generally yield diffusion coefficients precise to at least 0.002 x 10 -9 m 2 ∙s 1 (0.15% to 0.19%) and in most cases to 0.001 x 10 -9 m 2 ∙s -1 (0.07% to 0.1%). These experiments also yield accurate values of the refractive index differences for the solution pairs used in the diffusion experiments. The new diffusion coefficients are compared to two sets of published values of diffusion coefficients for K 2 SO 4 (aq) which are somewhat discrepant from each other. This study extends and complements our earlier work on the diffusion coefficients of the most common brine salts: NaCl(aq), KCl(aq), MgCl 2 (aq), CaCl 2 (aq), Na 2 SO 4 (aq), ] MgSO 4 (aq), NaHCO 3 (aq), and KHCO 3 (aq) at 298.15 K.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Sigma phase evolution and nucleation mechanisms revealed by atom probe tomography in a 347H stainless steel

The size evolution and phase composition of sigma phases were investigated for a 347H stainless steel subject to isothermal aging at 750 °C for up to 10,000 h. Scanning electron microscopy reveals that sigma phases are present before 336 h aging and they continue to grow for all aging times studied. Atom probe tomography shows little variation in the sigma phase composition with aging time up to 10,000 h, and only the C content decreases with aging time. The comparison of C concentration suggests that the sigma phase does not nucleate within the C-depleted matrix or precipitate free grain boundaries, leaving dissolving metastable M 23 C 6 as the only possible nucleation site. Based on the experimental results and thermodynamic simulations, the desirable Nb concentration is discussed to reduce the kinetics of sigma phase growth, and possible design directions are suggested to improve 347H.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Atomic motifs govern the decoration of grain boundaries by interstitial solutes

Abstract Grain boundaries, the two-dimensional defects between differently oriented crystals, tend to preferentially attract solutes for segregation. Solute segregation has a significant effect on the mechanical and transport properties of materials. At the atomic level, however, the interplay of structure and composition of grain boundaries remains elusive, especially with respect to light interstitial solutes like B and C. Here, we use Fe alloyed with B and C to exploit the strong interdependence of interface structure and chemistry via charge-density imaging and atom probe tomography methods. Direct imaging and quantifying of light interstitial solutes at grain boundaries provide insight into decoration tendencies governed by atomic motifs. We find that even a change in the inclination of the grain boundary plane with identical misorientation impacts grain boundary composition and atomic arrangement. Thus, it is the smallest structural hierarchical level, the atomic motifs, that controls the most important chemical properties of the grain boundaries. This insight not only closes a missing link between the structure and chemical composition of such defects but also enables the targeted design and passivation of the chemical state of grain boundaries to free them from their role as entry gates for corrosion, hydrogen embrittlement, or mechanical failure.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Thermodynamics of electrolyte solutions near charged surfaces: Constant surface charge vs constant surface potential

Electric double layers are ubiquitous in science and engineering and are of current interest, owing to their applications in the stabilization of colloidal suspensions and as supercapacitors. While the structure and properties of electric double layers in electrolyte solutions near a charged surface are well characterized, there are subtleties in calculating thermodynamic properties from the free energy of a system with charged surfaces. These subtleties arise from the difference in the free energy between systems with constant surface charge and constant surface potential. In this work, we present a systematic, pedagogical framework to properly account for the different specifications on charged bodies in electrolyte solutions. Our approach is fully variational—that is, all free energies, boundary conditions, relevant electrostatic equations, and thermodynamic quantities are systematically derived using variational principles of thermodynamics. We illustrate our approach by considering a simple electrolyte solution between two charged surfaces using the Poisson–Boltzmann theory. Our results highlight the importance of using the proper thermodynamic potential and provide a general framework for calculating thermodynamic properties of electrolyte solutions near charged surfaces. Specifically, we present the calculation of the pressure and the surface tension between two charged surfaces for different boundary conditions, including mixed boundary conditions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

A Hybrid Lagrangian/Eulerian Collocated Velocity Advection and Projection Method for Fluid Simulation

Abstract We present a hybrid particle/grid approach for simulating incompressible fluids on collocated velocity grids. Our approach supports both particle‐based Lagrangian advection in very detailed regions of the flow and efficient Eulerian grid‐based advection in other regions of the flow. A novel Backward Semi‐Lagrangian method is derived to improve accuracy of grid based advection. Our approach utilizes the implicit formula associated with solutions of the inviscid Burgers’ equation. We solve this equation using Newton's method enabled by C 1 continuous grid interpolation. We enforce incompressibility over collocated, rather than staggered grids. Our projection technique is variational and designed for B‐spline interpolation over regular grids where multiquadratic interpolation is used for velocity and multilinear interpolation for pressure. Despite our use of regular grids, we extend the variational technique to allow for cut‐cell definition of irregular flow domains for both Dirichlet and free surface boundary conditions.

Gagniere, S.↗