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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Counterrotating-Shoulder Mechanism for Friction Stir Welding

A counterrotating-shoulder mechanism has been proposed as an alternative to the mechanism and fixtures used in conventional friction stir welding. The mechanism would internally react most or all of the forces and torques exerted on the workpiece, making it unnecessary to react the forces and torques through massive external fixtures. In conventional friction stir welding, a rotating pin tool is inserted into, and moved along, a weld seam. As the pin tool moves, it stirs together material from the opposite sides of the seam to form the weld. A large axial plunge force must be exerted upon the workpiece through and by the pin tool and a shoulder attached above the pin tool in order to maintain the pressure necessary for the process. The workpiece is secured on top of an anvil, which supports the workpiece against the axial plunge force and against the torque exerted by the pin tool and shoulder. The anvil and associated fixtures must be made heavy (and, therefore, are expensive) to keep the workpiece stationary. In addition, workpiece geometries must be limited to those that can be accommodated by the fixtures. The predecessor of the proposed counterrotating-shoulder mechanism is a second-generation, self-reacting tool, resembling a bobbin, that makes it possible to dispense with the heavy anvil. This tool consists essentially of a rotating pin tool with opposing shoulders. Although the opposing shoulders maintain the necessary pressure without need to externally apply or react a large plunge force, the torque exerted on the workpiece remains unreacted in the absence of a substantial external fixture. Depending on the RPM and the thickness of the workpiece, the torque can be large. The proposed mechanism (see figure) would include a spindle attached to a pin tool with a lower shoulder. The spindle would be coupled via splines to the upper one of three bevel gears in a differential drive. The middle bevel gear would be the power-input gear and would be coupled to the upper and lower bevel gears. The lower bevel gear would be attached to the upper shoulder and would slide and rotate freely over the spindle. The spindle would be fastened by its threaded upper end to an external submechanism that would exert axial tension on the spindle to load the workpiece in compression between the shoulders. By reducing or eliminating (relative to the use of a self reacting tool) the torque that must be reacted externally, the use of the proposed tool would reduce the tendency toward distortion or slippage of the workpiece. To begin a weld, the spindle would be inserted through a hole in the workpiece or run-on tab at the beginning of the seam and fastened to the loading submechanism. Rotation and axial loading would be increased gradually from zero and, after a time to be determined by trial and error, translation along the weld seam would be increased gradually from zero to a steady weld speed. The weld would be ended by running the mechanism off the workpiece or, if the lower shoulder were detachable, by detaching the lower shoulder from the spindle and pulling the pin tool out.

Nunes, Arthur C., Jr.↗
NASA NTRS2009

What was Learned from Numerical Simulations of F-16XL (CAWAPI) at Flight Conditions

Nine groups participating in the CAWAPI project have contributed steady and unsteady viscous simulations of a full-scale, semi-span model of the F-16XL aircraft. Three different categories of flight Reynolds/Mach number combinations were computed and compared with flight-test measurements for the purpose of code validation and improved understanding of the flight physics. Steady-state simulations are done with several turbulence models of different complexity with no topology information required and which overcome Boussinesq-assumption problems in vortical flows. Detached-eddy simulation (DES) and its successor delayed detached-eddy simulation (DDES) have been used to compute the time accurate flow development. Common structured and unstructured grids as well as individually-adapted unstructured grids were used. Although discrepancies are observed in the comparisons, overall reasonable agreement is demonstrated for surface pressure distribution, local skin friction and boundary velocity profiles at subsonic speeds. The physical modeling, be it steady or unsteady flow, and the grid resolution both contribute to the discrepancies observed in the comparisons with flight data, but at this time it cannot be determined how much each part contributes to the whole. Overall it can be said that the technology readiness of CFD-simulation technology for the study of vehicle performance has matured since 2001 such that it can be used today with a reasonable level of confidence for complex configurations.

Rizzi, Arthur↗
NASA NTRS2006

Instruments for Reading Direct-Marked Data-Matrix Symbols

Improved optoelectronic instruments (specially configured digital cameras) for reading direct-marked data-matrix symbols on the surfaces of optically reflective objects (including specularly reflective ones) are undergoing development. Data-matrix symbols are two-dimensional binary patterns that are used, like common bar codes, for automated identification of objects. The first data-matrix symbols were checkerboard-like patterns of black-and-white rectangles, typically existing in the forms of paint, ink, or detachable labels. The major advantage of direct marking (the marks are more durable than are painted or printed symbols or detachable labels) is offset by a major disadvantage (the marks generated by some marking methods do not provide sufficient contrast to be readable by optoelectronic instruments designed to read black-and-white data-matrix symbols). Heretofore, elaborate lighting, lensing, and software schemes have been tried in efforts to solve the contrast problem in direct-mark matrix- symbol readers. In comparison with prior readers based on those schemes, the readers now undergoing development are expected to be more effective while costing less. All of the prior direct-mark matrix-symbol readers are designed to be aimed perpendicularly to marked target surfaces, and they tolerate very little angular offset. However, the reader now undergoing development not only tolerates angular offset but depends on angular offset as a means of obtaining the needed contrast, as described below. The prototype reader (see Figure 1) includes an electronic camera in the form of a charge-coupled-device (CCD) image detector equipped with a telecentric lens. It also includes a source of collimated visible light and a source of collimated infrared light for illuminating a target. The visible and infrared illumination complement each other: the visible illumination is more useful for aiming the reader toward a target, while the infrared illumination is more useful for reading symbols on highly reflective surfaces. By use of beam splitters, the visible and infrared collimated lights are introduced along the optical path of the telecentric lens, so that the target is illuminated and viewed from the same direction.

Schramm, Harry F.↗
NASA NTRS2012

Magnetic Field Effects on Plasma Plumes

Here, we will discuss our numerical studies of plasma jets and loops, of basic interest for plasma propulsion and plasma astrophysics. Space plasma propulsion systems require strong guiding magnetic fields known as magnetic nozzles to control plasma flow and produce thrust. Propulsion methods currently being developed that require magnetic nozzles include the VAriable Specific Impulse Magnetoplasma Rocket (VASIMR) [1] and magnetoplasmadynamic thrusters. Magnetic nozzles are functionally similar to de Laval nozzles, but are inherently more complex due to electromagnetic field interactions. The two crucial physical phenomenon are thrust production and plasma detachment. Thrust production encompasses the energy conversion within the nozzle and momentum transfer to a spacecraft. Plasma detachment through magnetic reconnection addresses the problem of the fluid separating efficiently from the magnetic field lines to produce maximum thrust. Plasma jets similar to those of VASIMR will be studied with particular interest in dual jet configurations, which begin as a plasma loops between two nozzles. This research strives to fulfill a need for computational study of these systems and should culminate with a greater understanding of the crucial physics of magnetic nozzles with dual jet plasma thrusters, as well as astrophysics problems such as magnetic reconnection and dynamics of coronal loops.[2] To study this problem a novel, hybrid kinetic theory and single fluid magnetohydrodynamic (MHD) solver known as the Magneto-Gas Kinetic Method is used.[3] The solver is comprised of a "hydrodynamic" portion based on the Gas Kinetic Method and a "magnetic" portion that accounts for the electromagnetic behaviour of the fluid through source terms based on the resistive MHD equations. This method is being further developed to include additional physics such as the Hall effect. Here, we will discuss the current level of code development, as well as numerical simulation results

Ebersohn, F.↗
NASA NTRS2012

Influence of Containment on the Growth of Silicon-Germanium: A Materials Science Flight Project

This investigation involves the comparison of results achieved from three types of crystal growth of germanium and germanium-silicon alloys: (1) Float zone growth (2) Bridgman growth (3) Detached Bridgman growth crystal The fundamental goal of the proposed research is to determine the influence of containment on the processing-induced defects and impurity incorporation in germanium-silicon (GeSi) crystals (silicon concentration in the solid up to 5 at%) for three different growth configurations in order to quantitatively assess the improvements of crystal quality possible by detached growth.

Volz, M. P.↗
NASA NTRS2013

Computational Studies of Magnetic Nozzle Performance

An extensive literature review of magnetic nozzle research has been performed, examining previous work, as well as a review of fundamental principles. This has allow us to catalog all basic physical mechanisms which we believe underlie the thrust generation process. Energy conversion mechanisms include the approximate conservation of the magnetic moment adiabatic invariant, generalized hall and thermoelectric acceleration, swirl acceleration, thermal energy transformation into directed kinetic energy, and Joule heating. Momentum transfer results from the interaction of the applied magnetic field with currents induced in the plasma plume., while plasma detachment mechanisms include resistive diffusion, recombination and charge exchange collisions, magnetic reconnection, loss of adiabaticity, inertial forces, current closure, and self-field detachment. We have performed a preliminary study of Hall effects on magnetic nozzle jets with weak guiding magnetic fields and weak expansions (p(sub jet) approx. = P(sub background)). The conclusion from this study is that the Hall effect creates an azimuthal rotation of the plasma jet and, more generally, creates helical structures in the induced current, velocity field, and magnetic fields. We have studied plasma jet expansion to near vacuum without a guiding magnetic field, and are presently including a guiding magnetic field using a resistive MHD solver. This research is progressing toward the implementation of a full generalized Ohm's law solver. In our paper, we will summarize the basic principle, as well as the literature survey and briefly review our previous results. Our most recent results at the time of submittal will also be included. Efforts are currently underway to construct an experiment at the University of Michigan Plasmadynamics and Electric Propulsion Laboratory (PEPL) to study magnetic nozzle physics for a RF-thruster. Our computational study will work directly with this experiment to validate the numerical model, in order to study magnetic nozzle physics and optimize magnetic nozzle design. Preliminary results from the PEPL experiment will also be presented.

Ebersohn, Frans H.↗
NASA NTRS2012

Active Upper-atmosphere Chemistry and Dynamics from Polar Circulation Reversal on Titan

Saturn's moon Titan has a nitrogen atmosphere comparable to Earth's, with a surface pressure of 1.4 bar. Numerical models reproduce the tropospheric conditions very well but have trouble explaining the observed middle-atmosphere temperatures, composition and winds. The top of the middle-atmosphere circulation has been thought to lie at an altitude of 450 to 500 kilometres, where there is a layer of haze that appears to be separated from the main haze deck. This 'detached' haze was previously explained as being due to the colocation of peak haze production and the limit of dynamical transport by the circulation's upper branch. Herewe report a build-up of trace gases over the south pole approximately two years after observing the 2009 post-equinox circulation reversal, from which we conclude that middle-atmosphere circulation must extend to an altitude of at least 600 kilometres. The primary drivers of this circulation are summer-hemisphere heating of haze by absorption of solar radiation and winter-hemisphere cooling due to infrared emission by haze and trace gases; our results therefore imply that these effects are important well into the thermosphere (altitudes higher than 500 kilometres). This requires both active upper-atmosphere chemistry, consistent with the detection of high-complexity molecules and ions at altitudes greater than 950 kilometres, and an alternative explanation for the detached haze, such as a transition in haze particle growth from monomers to fractal structures.

Titan Atmosphere↗
NASA NTRS2015

Unsteady Three-Dimensional Simulation of a Shear Coaxial GO2/GH2 Rocket Injector with RANS and Hybrid-RAN-LES/DES Using Flamelet Models

Historically, the analysis and design of liquid rocket engines (LREs) has relied on full‐scale testing and one‐dimensional empirical tools. The testing is extremely expensive and the one‐dimensional tools are not designed to capture the highly complex, and multi‐dimensional features that are inherent to LREs. Recent advances in computational fluid dynamics (CFD) tools have made it possible to predict liquid rocket engine performance, stability, to assess the effect of complex flow features, and to evaluate injector‐driven thermal environments, to mitigate the cost of testing. Extensive efforts to verify and validate these CFD tools have been conducted, to provide confidence for using them during the design cycle. Previous validation efforts have documented comparisons of predicted heat flux thermal environments with test data for a single element gaseous oxygen (GO2) and gaseous hydrogen (GH2) injector. The most notable validation effort was a comprehensive validation effort conducted by Tucker et al. [1], in which a number of different groups modeled a GO2/GH2 single element configuration by Pal et al [2]. The tools used for this validation comparison employed a range of algorithms, from both steady and unsteady Reynolds Averaged Navier‐Stokes (U/RANS) calculations, large‐eddy simulations (LES), detached eddy simulations (DES), and various combinations. A more recent effort by Thakur et al. [3] focused on using a state‐of‐the‐art CFD simulation tool, Loci/STREAM, on a two‐dimensional grid. Loci/STREAM was chosen because it has a unique, very efficient flamelet parameterization of combustion reactions that are too computationally expensive to simulate with conventional finite‐rate chemistry calculations. The current effort focuses on further advancement of validation efforts, again using the Loci/STREAM tool with the flamelet parameterization, but this time with a three‐dimensional grid. Comparisons to the Pal et al. heat flux data will be made for both RANS and Hybrid RANSLES/ Detached Eddy simulations (DES). Computation costs will be reported, along with comparison of accuracy and cost to much less expensive two‐dimensional RANS simulations of the same geometry.

Westra, Doug G.↗
NASA NTRS2015

F-16XL Hybrid Reynolds-Averaged Navier-Stokes/Large Eddy Simulation on Unstructured Grids

This study continues the Cranked Arrow Wing Aerodynamics Program, International (CAWAPI) investigation with the FUN3D and USM3D flow solvers. CAWAPI was established to study the F-16XL, because it provides a unique opportunity to fuse fight test, wind tunnel test, and simulation to understand the aerodynamic features of swept wings. The high-lift performance of the cranked-arrow wing planform is critical for recent and past supersonic transport design concepts. Simulations of the low speed high angle of attack Flight Condition 25 are compared: Detached Eddy Simulation (DES), Modi ed Delayed Detached Eddy Simulation (MDDES), and the Spalart-Allmaras (SA) RANS model. Iso- surfaces of Q criterion show the development of coherent primary and secondary vortices on the upper surface of the wing that spiral, burst, and commingle. SA produces higher pressure peaks nearer to the leading-edge of the wing than flight test measurements. Mean DES and MDDES pressures better predict the flight test measurements, especially on the outer wing section. Vorticies and vortex-vortex interaction impact unsteady surface pressures. USM3D showed many sharp tones in volume points spectra near the wing apex with low broadband noise and FUN3D showed more broadband noise with weaker tones. Spectra of the volume points near the outer wing leading-edge was primarily broadband for both codes. Without unsteady flight measurements, the flight pressure environment can not be used to validate the simulations containing tonal or broadband spectra. Mean forces and moment are very similar between FUN3D models and between USM3D models. Spectra of the unsteady forces and moment are broadband with a few sharp peaks for USM3D.

Park, Michael A.↗
NASA NTRS2017

Influence of Containment on the Growth of Germanium-Silicon in Microgravity

This investigation involves the comparison of results achieved from three types of crystal growth of germanium and germanium-silicon alloys: Float zone growth, Bridgman growth, and Detached Bridgman growth. The fundamental goal of the proposed research is to determine the influence of containment on the processing-induced defects and impurity incorporation in germanium-silicon (GeSi) crystals (silicon concentration in the solid up to 5%) for three different growth configurations in order to quantitatively assess the improvements of crystal quality possible by detached growth.

Volz, M. P.↗
NASA NTRS2021

Analysis of Arc Welding Process in Space

This work is motivated by NASA plans to conduct welding experiments on the ISS. It is expected that deployment of welding and additive manufacturing technologies in the space environment has the potential to revolutionise how orbiting platforms are designed, manufactured, and assembled. However, the structure, composition and quality of a weld is extremely dependent on the environment and can be difficult to control in space. Shielding gases would also be tough to manage as gases behave differently in zero gravity and airless environments. Additional points of concern are related to the spatter and sparks dynamics in space. Therefore, there is a need for a more basic understanding of welding processes by computational modelling. To provide such an insight we developed state of art models of the ARC torch, droplet detachment and transfer, and the melt pool build up using magnetohydrodynamics approximation and level set method for two-phase liquid metal/-gas flow modelling. Two finite element models were built using 2D axisymmetric geometry in COMSOL Multiphysics®: (i) stationary model of the ARC torch and (ii) dynamical model of droplet detachment and transfer. Both models demonstrate reasonable agreement with earlier experimental observations and high sensitivity to the temperature dependence of the thermophysical parameters on the system materials. The models were used to provide physical insight into ARC welding in various environments and geometries. It was shown, in particular, that there is a significant probability of gas bubbles trapping in the meltpool and a possibility of unbounded wondering of sparks in the welding chamber in zero gravity. In addition, we estimated metal evaporation rate that may be hazardous in the confined environment of the ISS. These issues raise concern of quality of the weld and safety for ISS applications.

ARC welding↗
NASA NTRSDate not supplied

Simulating Meteor Ablation at the Hypersonic Materials Environmental Test System

The ablation mechanisms of stony meteorite material and a terrestrial analog were investigated at the Hypersonic Materials Environmental Test System (HyMETS) facility at NASA’s Langley Research Center. The primary analyte (Tamdakht-H5) and arc-jet test conditions were chosen to simulate the entry of an ordinary chondrite through the Earth’s mesosphere. Basalt was selected to compare the meteorite response against material with enhanced polymerization and an elevated concentration of volatile species. The initial ablation process for each material commences with the vaporization of volatile species and germination of a viscous melt layer on the stagnation surface. However, each material exhibited distinct mass loss mechanisms, with basalt recessing at twice the rate of Tamdakht. Inspection of high-speed video and chemical analysis of the post-test melt layer suggests the dominant mode of mass loss of Tamdakht is expressed through the vaporization of volatile compounds. Vaporization rates of Tamdakht are 18x higher than basalt under the most severe test conditions which provides enhanced thermal shielding. Furthermore, Tamdakht produces a relatively stable melt flow, as evidenced by perpetual growth at the sidewall and the exiguous detachment of molten material into the flow. The ablation mechanism of basalt is markedly different from Tamdakht and is governed by volatile species in the virgin material. The dominant mode of mass loss for basalt is attributed to the detachment of large sections of the stagnation surface near the edge radius. An additional but subordinate mode of mass loss is assigned to the removal of melt flow as it passes over the edge radius, where shear forces overcome the rheological properties of the molten matter. Finally, mechanistic details will be discussed in terms of designing future test campaigns, developing meteorite-based materials response models, and impacting the broader scope of the Asteroid Threat Assessment Project (ATAP).

Meteor Ablation↗
NASA NTRS2024

Computational Techniques to Generate Space Launch System Aerodynamic Databases

This document describes the reasoning and trade studies used to evaluate tools for constructing the aerodynamic lineload databases for the liftoff and transition phases of flight for the Space Launch System. Three computational fluid dynamics codes (USM3D, FUN3D, Kestrel) were investigated with various turbulence models, as well as detached eddy simulation variants for the launch vehicle in free air and in proximity to the tower. Decisions were made mostly based on results from brief developmental studies performed in response to specific, unforeseen challenges that were encountered in the analysis of a given configuration. The need to develop databases in a timely manner, as well as accurately capture the expected leeward-wake flowfield characteristics, led to the selection of the Kestrel flow solver with its delayed detached eddy simulation method, the Spalart-Allmaras turbulence model, and the adaptive mesh refinement capability in the off-body Cartesian grid region.

Karen A. Deere↗
NASA NTRS1963

Phenomena of Pneumatic Tire Hydroplaning

Recent research on pneumatic tire hydroplaning has been collected and summarized with the aim of describing what is presently known about the phenomena of tire hydroplaning. A physical description of tire hydroplaning is given along with formulae for estimating the ground speed at which it occurs. Eight manifestations of tire hydroplaning which have been experimentally observed are presented and discussed. These manifestations are: detachment of tire footprint, hydrodynamic ground pressure, spin-down of wheel, suppression of tire bow wave, scouring action of escaping fluid in tire-ground footprint region, peaking of fluid displacement drag, loss in braking traction, and loss of tire directional stability. The vehicle, pavement, tire, and fluid parameters of importance to tire hydroplaning are listed and described. Finally, the hazards of tire hydroplaning to ground and air-vehicle-ground performance are listed, and procedures are given to minimize these effects.

HYDROPLANE↗
NASA NTRS1966

Bench vise adapter grips tubing securely and safely

Plastic self-compressing adapter with grooves, attached to the jaws of a bench vise, secures thin-wall tubing vertically or horizontally during cutting and flaring operations without marring or damaging it. Magnets incorporated in both sections of the adapter prevent detachment from the jaws when the vise is opened.

Howland, B. T.↗
NASA NTRS1966

The origin of tektites.

Origin of Moung Nong type tektities detached by meteoritic impact, considering lunar origin based on diffusion rates in silicates

METEORITE COLLISION↗