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Results for “structural optimization”

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 NTRS1984

STAEBL: Structural tailoring of engine blades, phase 2

The Structural Tailoring of Engine Blades (STAEBL) program was initiated at NASA Lewis Research Center in 1980 to introduce optimal structural tailoring into the design process for aircraft gas turbine engine blades. The standard procedure for blade design is highly iterative with the engineer directly providing most of the decisions that control the design process. The goal of the STAEBL program has been to develop an automated approach to generate structurally optimal blade designs. The program has evolved as a three-phase effort with the developmental work being performed contractually by Pratt & Whitney Aircraft. Phase 1 was intended as a proof of concept in which two fan blades were structurally tailored to meet a full set of structural design constraints while minimizing DOC+I (direct operating cost plus interest) for a representative aircraft. This phase was successfully completed and was reported in reference 1 and 2. Phase 2 has recently been completed and is the basis for this discussion. During this phase, three tasks were accomplished: (1) a nonproprietary structural tailoring computer code was developed; (2) a dedicated approximate finite-element analysis was developed; and (3) an approximate large-deflection analysis was developed to assess local foreign object damage. Phase 3 is just beginning and is designed to incorporated aerodynamic analyses directly into the structural tailoring system in order to relax current geometric constraints.

Hirschbein, M. S.↗
DOE OSTI2024

Optimization of Structurally Enhanced Solder Transient Liquid Phase Bonding

High temperature packaging technologies are a necessity for high temperature capable devices. SAC305 solder has an operational limit of 174°C imposed by creep effects which aligns well with current junction temperature limits of 175°C. Wide band gap semiconductor materials have the potential to reach junction temperatures of up to 800°C that are not currently attainable with significant reliability. Capitalizing on this potential will requires substrates and attachments that can operate well beyond the current 175°C standard. Silver sintering pastes have received widespread interest as a high temperature attachment alternative. However, the process requires high pressure bonding in an inert environment to achieve acceptable bond quality. Transient liquid phase (TLP) sintering is capable of good bond quality without pressure requirements but suffers from low thermal conductivity and only slightly reduced cost compared to silver sintering. SAC305 solder contains the same constituent materials for TLP as available copper-tin TLP sintering paste. By introducing engineered surface structures into the bond, intermetallic formation can be accelerated producing a bond similar to TLP sintering but in an ambient environment and for reduced cost. While this process has been demonstrated, it has not yet been optimized. Currently bonds are formed using a 75 μm stencil on substrate surface structures 24 μm tall, covering 19% of the bonding area. The process takes about 4 hours not including the formation of surface structures. Here, this study will center on the effects of stencil thickness and coating methods. Samples will be analyzed by scanning acoustic microscopy, die shear testing and cross sectional scanning acoustic microscopy.

42 ENGINEERING↗
DOE OSTI2024

Quantum annealing-aided design of an ultrathin-metamaterial optical diode

Abstract Thin-film optical diodes are important elements for miniaturizing photonic systems. However, the design of optical diodes relies on empirical and heuristic approaches. This poses a significant challenge for identifying optimal structural models of optical diodes at given wavelengths. Here, we leverage a quantum annealing-enhanced active learning scheme to automatically identify optimal designs of 130 nm-thick optical diodes. An optical diode is a stratified volume diffractive film discretized into rectangular pixels, where each pixel is assigned to either a metal or dielectric. The proposed scheme identifies the optimal material states of each pixel, maximizing the quality of optical isolation at given wavelengths. Consequently, we successfully identify optimal structures at three specific wavelengths (600, 800, and 1000 nm). In the best-case scenario, when the forward transmissivity is 85%, the backward transmissivity is 0.1%. Electromagnetic field profiles reveal that the designed diode strongly supports surface plasmons coupled across counterintuitive metal–dielectric pixel arrays. Thereby, it yields the transmission of first-order diffracted light with a high amplitude. In contrast, backward transmission has decoupled surface plasmons that redirect Poynting vectors back to the incident medium, resulting in near attenuation of its transmission. In addition, we experimentally verify the optical isolation function of the optical diode.

36 MATERIALS SCIENCE↗
NASA NTRS1988

Structural tailoring of high-speed turbine blades (SSME/STAEBL)

Space shuttle main engine (SSME) blades are subject to severe thermal, pressure, and forced vibration environments. Structural optimization provides an automated alternative to time consuming iterations. Any number of analyses, design variables, and constraints can be incorporated in a structural optimization computer code. This idea was applied to develop the code SSME/STAEBL, which is a stand alone code suitable for automated design of SSME turbopump blades. Additions and modifications of STAEBL included in SSME/STAEBL include the following: (1) thermal stress analysis, (2) gas dynamic (pressure) loads, (3) temperature-dependent material and thermal properties, (4) forced vibrations, (5) tip displacement constraints, (6) single crystal material analysis, (7) blade cross-section stacking offsets, and (8) direct time integration algorithm for transient dynamic response.

Rubinstein, Robert↗
DOE OSTI2022

Carboxylate binding prefers two cations to one

Almost all studies of specific ion binding by carboxylates (–COO - ) have considered only a single cation, but clustering of ions and ligands is a common phenomenon. We apply density functional theory to investigate how variations in the number of acetate ligands in binding to two monovalent cations affects ion binding preferences. We study a series of monovalent (Li + , Na + , K + , Cs + ) ions relevant to experimental work on many topics, including ion channels, battery storage, water purification and solar cells. We find that the preferred optimal structure has 3 acetates except for Cs + , which has 2 acetates. The optimal coordination of the cation by the carboxylate O atoms is 4 for both Na + and K + , and 3 for Li + and Cs + . There is a 4-fold coordination minimum just a few kcal mol -1 higher than the optimal 3-fold structure for Li+. For two cations, multiple minima occur in the vicinity of the lowest free energy state. Here we find that, for Li, Na and K, the preferred optimal structure with two cations is favored over a mixture of single cation complexes, providing a basis for understanding ionic cluster formation that is relevant for engineering proteins and other materials for rapid, selective ion transport.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1988

Aeroelastic optimization of a helicopter rotor

Structural optimization of a hingeless rotor is investigated to reduce oscillatory hub loads while maintaining aeroelastic stability in forward flight. Design variables include spanwise distribution of nonstructural mass, chordwise location of blade center of gravity and blade bending stiffnesses (flap, lag and torsion). A comprehensive aeroelastic analysis of rotors, based on a finite element method in space and time, is linked with optimization algorithms to perform optimization of rotor blades. Sensitivity derivatives of blade response, hub loads, and eigenvalues with respect to the design variables are derived using a direct analytical approach, and constitute an integral part of the basic blade response and stability analyses. This approach reduces the computation time substantially; an 80 percent reduction of CPU time to achieve an optimum solution, as compared to the widely adopted finite difference approach. Through stiffness and nonstructural mass distributions, a 60-90 percent reduction in all six 4/rev hub loads is achieved for a four-bladed soft-inplane rotor.

Lim, Joon W.↗
NASA NTRS1995

Structural design using equilibrium programming formulations

Solutions to increasingly larger structural optimization problems are desired. However, computational resources are strained to meet this need. New methods will be required to solve increasingly larger problems. The present approaches to solving large-scale problems involve approximations for the constraints of structural optimization problems and/or decomposition of the problem into multiple subproblems that can be solved in parallel. An area of game theory, equilibrium programming (also known as noncooperative game theory), can be used to unify these existing approaches from a theoretical point of view (considering the existence and optimality of solutions), and be used as a framework for the development of new methods for solving large-scale optimization problems. Equilibrium programming theory is described, and existing design techniques such as fully stressed design and constraint approximations are shown to fit within its framework. Two new structural design formulations are also derived. The first new formulation is another approximation technique which is a general updating scheme for the sensitivity derivatives of design constraints. The second new formulation uses a substructure-based decomposition of the structure for analysis and sensitivity calculations. Significant computational benefits of the new formulations compared with a conventional method are demonstrated.

Scotti, Stephen J.↗
NASA NTRS1989

Error analysis for semi-analytic displacement derivatives with respect to shape and sizing variables

Sensitivity analysis is fundamental to the solution of structural optimization problems. Consequently, much research has focused on the efficient computation of static displacement derivatives. As originally developed, these methods relied on analytical representations for the derivatives of the structural stiffness matrix (K) with respect to the design variables (b sub i). To extend these methods for use with complex finite element formulations and facilitate their implementation into structural optimization programs using the general finite element method analysis codes, the semi-analytic method was developed. In this method the matrix the derivative of K/the derivative b sub i is approximated by finite difference. Although it is well known that the accuracy of the semi-analytic method is dependent on the finite difference parameter, recent work has suggested that more fundamental inaccuracies exist in the method when used for shape optimization. Another study has argued qualitatively that these errors are related to nonuniform errors in the stiffness matrix derivatives. The accuracy of the semi-analytic method is investigated. A general framework was developed for the error analysis and then it is shown analytically that the errors in the method are entirely accounted for by errors in delta K/delta b sub i. Furthermore, it is demonstrated that acceptable accuracy in the derivatives can be obtained through careful selection of the finite difference parameter.

Fenyes, Peter A.↗
NASA NTRS1991

An approximation based global optimization strategy for structural synthesis

A global optimization strategy for structural synthesis based on approximation concepts is presented. The methodology involves the solution of a sequence of highly accurate approximate problems using a global optimization algorithm. The global optimization algorithm implemented consists of a branch and bound strategy based on the interval evaluation of the objective function and constraint functions, combined with a local feasible directions algorithm. The approximate design optimization problems are constructed using first order approximations of selected intermediate response quantities in terms of intermediate design variables. Some numerical results for example problems are presented to illustrate the efficacy of the design procedure setforth.

Sepulveda, A. E.↗
NASA NTRS1990

Structural damping optimization via non-obstructive particle damping technique

A passive vibration damping technique that is referred to as 'Non-Obstructive Particle Damping (NOPD)' is presented. The NOPD technique consists of making small diameter holes (or cavities) at appropriate locations inside vibrating structures and filling these holes to appropriate levels with particles which yield the maximum damping effectiveness for the desired mode (or modes). Powders, spherical shaped, metallic, non-metallic or liquid particles (or mixtures) with different densities, viscosities and adhesive or cohesive characteristics can be used.

Panossian, Hagop V.↗
NASA NTRS1994

Load-limiting landing gear footpad energy absorption system

As a precursor to future manned missions to the moon, an inexpensive, unmanned vehicle that could carry small, scientific payloads to the lunar surface was studied by NASA. The vehicle, called the Common Lunar Lander, required extremely optimized structural systems to increase the potential payload mass. A lightweight energy-absorbing system (LAGFEAS), which also acts as a landing load-limiter was designed to help achieve this optimized structure. Since the versatile and easily tailored system is a load-limiter, it allowed for the structure to be designed independently of the ever-changing landing energy predictions. This paper describes the LAGFEAS system and preliminary verification testing performed at NASA's Johnson Space Center for the Common Lunar Lander program.

Hansen, Chris↗
NASA NTRS1991

Design optimization of space structures

The topology-shape-size optimization of space structures is investigated through Kikuchi's homogenization method. The method starts from a 'design domain block,' which is a region of space into which the structure is to materialize. This domain is initially filled with a finite element mesh, typically regular. Force and displacement boundary conditions corresponding to applied loads and supports are applied at specific points in the domain. An optimal structure is to be 'carved out' of the design under two conditions: (1) a cost function is to be minimized, and (2) equality or inequality constraints are to be satisfied. The 'carving' process is accomplished by letting microstructure holes develop and grow in elements during the optimization process. These holes have a rectangular shape in two dimensions and a cubical shape in three dimensions, and may also rotate with respect to the reference axes. The properties of the perforated element are obtained through an homogenization procedure. Once a hole reaches the volume of the element, that element effectively disappears. The project has two phases. In the first phase the method was implemented as the combination of two computer programs: a finite element module, and an optimization driver. In the second part, focus is on the application of this technique to planetary structures. The finite element part of the method was programmed for the two-dimensional case using four-node quadrilateral elements to cover the design domain. An element homogenization technique different from that of Kikuchi and coworkers was implemented. The optimization driver is based on an augmented Lagrangian optimizer, with the volume constraint treated as a Courant penalty function. The optimizer has to be especially tuned to this type of optimization because the number of design variables can reach into the thousands. The driver is presently under development.

Felippa, Carlos↗
DOE OSTI2025

Additive manufacturing of amorphous metal soft magnetic composites

Soft magnet alloys are used as magnetic cores for electric motors, transformers, wind turbines and other power generation systems. Soft magnetic cores are expensive and time consuming to manufacture in the complex shapes required for next-generation devices using conventional press and sinter powder metallurgy. The objective of this effort is to additively manufacture high performance soft magnets, with reduced cost and reduced material waste and 10x lower energy (core) loss at the high operating frequencies of many electric machines. Laser powder bed fusion additive manufacturing is used as the fabrication method. Electrical steel and amorphous alloys atomized powders are used as a feedstock materials. Magnetic cores are printed in topology optimized structures such as the Hilbert curve because this has been shown to reduce energy losses by minimizing the eddy currents that circulate within the magnet at high frequencies. In our project, we succeed in printing FeSi 3.5wt% and FeSi 6.5wt% electrical steels, and iron-based soft magnetic amorphous alloys in the shape of Hilbert and Peano curve topology optimized structures. We found that the Peano curve has a higher cut-off frequency than the Hilbert curve, and that amorphous alloys have high cut-off frequencies and higher mechanical hardness than electrical steels. Processing conditions such as laser power, scan speed, and hatching pattern were optimized to achieve high density prints, and optimize magnetic performance. We find that the printing of amorphous alloy soft magnetic cores may be technoeconomically feasible for large scale applications such as transformers, for which supply chain issues and the labor costs of manual fabrication of magnetic cores is prohibitive in some cases.

36 MATERIALS SCIENCE↗
NASA NTRS1984

Optimum design of rotor blades for vibration reduction in forward flight

Modern structural optimization techniques are applied to vibration reduction of helicopter rotor blades in forward flight. The objective function minimized consists of the oscillatory vertical hub shears or the hub rolling moments at one particular advance ratio. The behavior constraints are the frequency placements of the blade and the requirement that aeroelastic stability margins, in hover, remain unaffected by the optimization process. The aeroelastic stability and response analysis is based on a fully coupled flap-lag-torsional analysis of the blade. Numerical results are presented for some typical soft-in-plane hingeless rotor configurations indicating a 15-40 percent reduction in vibration levels, as well as a blade which is 20 percent lighter than the initial design. These results imply that structural optimization techniques can yield substantial practical benefits in the design process of rotor systems.

Friedmann, P. P.↗
NASA NTRS1987

Integrated structure electromagnetic optimization of large space antenna reflectors

The requirements for extremely precise and powerful large space antenna reflectors have motivated the development of a procedure for shape control of the reflector surface. A mathematical optimization procedure has been developed which improves antenna performance while minimizing necessary shape correction effort. In contrast to previous work which proposed controlling the rms distortion error of the surface thereby indirectly improving antenna performance, the current work includes electromagnetic (EM) performance calculations as an integral of the control procedure. The application of the procedure to a radiometer design with a tetrahedral truss backup structure demonstrates the potential for significant improvement. The results indicate the benefit of including EM performance calculations in procedures for shape control of large space antenna reflectors.

Padula, Sharon L.↗
NASA NTRS1987

Integrated structural electromagnetic optimization of large space antenna reflectors

The requirements for extremely precise and powerful large space antenna reflectors have motivated the development of a procedure for shape control of the reflector surface. A mathematical optimization procedure has been developed which improves antenna performance while minimizing necessary shape correction effort. In contrast to previous work which proposed controlling the rms distortion error of the surface thereby indirectly improving antenna performance, the current work includes electromagnetic (EM) performance calculations as an integral part of the control procedure. The application of the procedure to a radiometer design with a tetrahedral truss backup structure demonstrates the potential for significant improvement. The results indicate the benefit of including EM performance calculations in procedures for shape control of large space antenna reflectors.

Padula, S. L.↗
NASA NTRS1983

Aeroelastic tailoring of rotor blades for vibration reduction in forward flight

Modern structural optimization techniques are applied to vibration reduction of helicopter rotor blades in forward flight. The objective function minimized consists of the oscillatory vertical hub shears or the hub rolling moments at one particular advance ratio. The behavior constraints are the frequency placements of the blade and the requirement that aeroelastic stability margins, in hover, remain unaffected by the optimization process. The aeroelastic stability and response analysis is based on a fully coupled flap-lag-torsional analysis of the blade. The vertical hub shears and rolling moments used as the objective function are obtained by appropriate integration of the loads acting along the span of the blade combined with a transformation to a hub fixed coordinate system, and a summation over the total number of blades. Numerical results for both a stiff-in-plane and a soft-in-plane configuration are presented, indicating that structural optimization yields the highest benefits when applied to soft-in-plane blade configuration. The results indicate substantial (15-40 percent) reduction in vibration levels, as well as a blade which is 20 percent lighter than the initial design.

Friedmann, P. P.↗