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Results for “Additive Process Modeling”

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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS1981

A model for simulation and processing of radar images

A model for recording, processing, presentation, and analysis of radar images in digital form is presented. The observed image is represented as having two random components, one which models the variation due to the coherent addition of electromagnetic energy scattered from different objects in the illuminated areas. This component is referred to as fading. The other component is a representation of the terrain variation which can be described as the actual signal which the radar is attempting to measure. The combination of these two components provides a description of radar images as being the output of a linear space-variant filter operating on the product of the fading and terrain random processes. In addition, the model is applied to a digital image processing problem using the design and implementation of enhancement scene. Finally, parallel approaches are being employed as possible means of solving other processing problems such as SAR image map-matching, data compression, and pattern recognition.

Stiles, J. A.↗
NASA NTRSDate not supplied

Large Scale and Multi-Alloy Rocket Engine Component Development using Various Metal Additive Manufacturing Techniques

The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing (AM) for use in liquid rocket engine component design, development, and testing since 2010. These AM techniques have been demonstrated to significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The focus at the NASA MSFC for these metal additive manufacturing techniques include laser powder-bed fusion (L-PBF), blown powder directed energy deposition (DED), arc-based deposition, and Laser Wire Direct Closeout (LWDC). A variety of components have been evaluated and tested including thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. To support these component applications in harsh environments, NASA has advanced a variety of “standard” additive manufacturing alloys such as those in the superalloy-family and also evolved new alloys including GRCop-84, GRCop-42, NASA HR-1, and JBK-75. The purpose of this presentation is to discuss the various component programs at the NASA MSFC using AM to develop, fabricate, and test combustion devices hardware and the evolution of the new additive alloys. One of these projects that will be highlighted is Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), which includes new process development for large scale AM components, multi-metallic AM components, including unique component designs using additive manufacturing. Additional information will be provided on the development of other components, hot-fire testing, post-processing of AM techniques including surface enhancements (polishing) techniques, material and process characterization, future development programs, and dissemination of data to industry partners.

Additive Manufacturing↗
NASA NTRS1983

A common geometric data-base approach for computer-aided manufacturing of wind-tunnel models and theoretical aerodynamic analysis

A more automated process to produce wind tunnel models using existing facilities is discussed. A process was sought to more rapidly determine the aerodynamic characteristics of advanced aircraft configurations. Such aerodynamic characteristics are determined from theoretical analyses and wind tunnel tests of the configurations. Computers are used to perform the theoretical analyses, and a computer aided manufacturing system is used to fabricate the wind tunnel models. In the past a separate set of input data describing the aircraft geometry had to be generated for each process. This process establishes a common data base by enabling the computer aided manufacturing system to use, via a software interface, the geometric input data generated for the theoretical analysis. Thus, only one set of geometric data needs to be generated. Tests reveal that the process can reduce by several weeks the time needed to produce a wind tunnel model component. In addition, this process increases the similarity of the wind tunnel model to the mathematical model used by the theoretical aerodynamic analysis programs. Specifically, the wind tunnel model can be machined to within 0.008 in. of the original mathematical model. However, the software interface is highly complex and cumbersome to operate, making it unsuitable for routine use. The procurement of an independent computer aided design/computer aided manufacturing system with the capability to support both the theoretical analysis and the manufacturing tasks was recommended.

See, M. J.↗
NASA NTRS2021

Melt Pool Imaging using a Configurable Architecture Additive Testbed System

This paper describes the inline (coaxial to laser) near infrared (NIR) camera sensor on the Configurable Architecture Additive Testbed (CAAT). The CAAT is an instrument that provides the capability to investigate laser based additive manufacturing (AM) processes and is configured for the metal powder bed fusion process. A low cost NIR camera is radiometrically calibrated to obtain coaxial, inline, imagery of laser generated melt pools. The camera capabilities, system optical path, and the uncertainty in the temperature measurement from NIR surface area scans on a bare titanium alloy plate are presented and discussed. The surface radiance measurements are compared to optical microscopy images of the melt pool width and depth. A metallic additive manufacturing process thermal model is developed in order to predict thermal distributions during laser scanning. The predicted thermal distributions by the model for different configurations are compared to the coaxial NIR measurements and discussed.

Additive manufacturing↗
NASA NTRSDate not supplied

The Repair Maintenance and Fabrication Facility in the Common Habitat Architecture

The Common Habitat Architecture seeks to increase the habitability of long-duration human spaceflight systems. A key aspect of this is vehicle survivability. Missions beyond low Earth orbit need onboard capabilities for Repair, Maintenance, And Fabrication (RMAF) to overcome potential contingency scenarios. Strategies employed in historic human spaceflight such as redundancy management, reliability, sparing, orbital replacement units, and aborts may be insufficient by themselves. Based on subject matter input, a list of 53 critical failures defining a set of incidents that can render a key spacecraft subsystem inoperable were generated. A subsequent analysis found that a robust in-space RMAF system capable of performing 14 key functions can potentially repair a subsystem plagued by any of these failures. An ancillary benefit is this capability may provide psychological benefits to the crew, by enabling greater self-sufficiency in earth-independent problem solving. A basic RMAF facility has been defined for the Common Habitat, consisting of five workstations. A work bench and computer workstation provide a multipurpose horizontal work surface, computing interface, and tools storage. A CNC machining center provides a subtractive manufacturing capability for metals and plastics. A multi-material 3D printing facility provides additive manufacturing capabilities for plastic, metals, and printed electronics. A welding facility is used for joining metal components where a higher strength is needed than can be achieved with fasteners or adhesives. A glovebox facility is used to perform work that is too hazardous for any of the other workstations. This may include hardware brought in from outside the spacecraft that could potentially contaminate the cabin environment. Forward work includes considering the accommodation of additional manufacturing processes not modeled in the current system, assessing the ability of systems to operate in partial gravity and microgravity environments, incorporation of the system into the Common Habitat Computer Aided Design (CAD) model, bottoms-up mass estimating, and a crew time analysis.

Habitat↗
NASA NTRS1999

Improved Modeling in a Matlab-Based Navigation System

An innovative approach to autonomous navigation is available for low earth orbit satellites. The system is developed in Matlab and utilizes an Extended Kalman Filter (EKF) to estimate the attitude and trajectory based on spacecraft magnetometer and gyro data. Preliminary tests of the system with real spacecraft data from the Rossi X-Ray Timing Explorer Satellite (RXTE) indicate the existence of unmodeled errors in the magnetometer data. Incorporating into the EKF a statistical model that describes the colored component of the effective measurement of the magnetic field vector could improve the accuracy of the trajectory and attitude estimates and also improve the convergence time. This model is identified as a first order Markov process. With the addition of the model, the EKF attempts to identify the non-white components of the noise allowing for more accurate estimation of the original state vector, i.e. the orbital elements and the attitude. Working in Matlab allows for easy incorporation of new models into the EKF and the resulting navigation system is generic and can easily be applied to future missions resulting in an alternative in onboard or ground-based navigation.

Deutschmann, Julie↗
NASA NTRS1990

Transatmospheric vehicle research

Research was conducted into the alternatives to the supersonic combustion ramjet (scramjet) engine for hypersonic flight. A new engine concept, the Oblique Detonation Wave Engine (ODWE) was proposed and explored analytically and experimentally. Codes were developed which can couple the fluid dynamics of supersonic flow with strong shock waves, with the finite rate chemistry necessary to model the detonation process. An additional study was conducted which compared the performance of a hypersonic vehicle powered by a scramjet or an ODWE. Engineering models of the overall performances of the two engines are included. This information was fed into a trajectory program which optimized the flight path to orbit. A third code calculated the vehicle size, weight, and aerodynamic characteristics. The experimental work was carried out in the Ames 20MW arc-jet wind tunnel, focusing on mixing and combustion of fuel injected into a supersonic airstream. Several injector designs were evaluated by sampling the stream behind the injectors and analyzing the mixture with an on-line mass spectrometer. In addition, an attempt was made to create a standing oblique detonation wave in the wind tunnel using hydrogen fuel. It appeared that the conditions in the test chamber were marginal for the generation of oblique detonation waves.

Adelman, Henry G.↗
NASA NTRSDate not supplied

Powder Bed Fusion Laser Beam Metals Additive Manufacturing: Process Monitoring Approaches for Qualification and Certification

The use of in-situ process monitoring is of interest to lower the cost of inspection for the qualification of powder bed fusion laser beam metal (PBF-LB/M) additively manufactured (AM) parts. Precise monitoring of the PBF-LB/M AM build process constitutes a multi-scale and multi-discipline task. There are several significant challenges to the in-situ approach: the synchronization of sensor signals to process steps; the physical interpretation and classification of sensor signals; managing very large datasets; and comparing the inputs with the observed monitoring signals. At NASA Langley Research Center, a configurable architecture additive testbed has been developed to monitor the build process with synchronized sensors. The philosophy and method adopted for the synchronization of the cameras with laser power and position throughout a complex PBF-LB/M AM build will be described. The synchronized in-situ monitoring signals are compared with ex-situ nondestructive inspection, x-ray computed tomography (XCT). Such comparisons permit a better understanding of how the sequential process actions of LPBF-AM can affect build quality. The multi-scale and complex process of printing additively manufactured (AM) parts can have unexpected, but predictable, build conditions that result in material microstructure variability. This presentation will describe an additive manufacturing model-based process metric (AM-PM) computational method that is a fully parallel reduced order modeling approach developed to evaluate the evolution of AM processes. This method couples the known sequence of the AM process with a physically informed nearest neighbors’ calculation to map the conditions of a part-scale build. The result is a map of the build that is derived directly from build files or in-situ process monitoring sensors. The methodology of the approach will be described and mapped to the porosity observed from XCT for a complex PBF-LB/M build. Such comparative results develop understanding of how the sequential process actions can affect the PBF-LB/M AM build quality and microstructure variability.

Laser Powder Bed Fusion↗
NASA NTRSDate not supplied

Improved Treatment of Snow Over Ice Sheets in the NASA GISS Climate Model: Towards Ice Sheet–Climate Coupling

Representing the interactions between ice sheets and climate is essential for more accurate prediction of climate change and sea level rise. Ice sheets interact with the overlying atmosphere via the accumulation of snow and its compaction into firn, then ice, as well as the melting of surface snow and ice and the creation of runoff water. Getting an adequate representation of heat transfer, compaction, and melting processes is essential for an accurate representation of snow on land ice in global climate models. We are implementing an improved snow model on top of land ice as part of an effort to couple the NASA GISS climate model with the PISM ice sheet model. The new snow model includes additional layers and processes that are not currently incorporated (e.g., liquid water retention, percolation and refreezing, and snow densification), and mass and energy transfer methods that are consistent with both static ice sheets (with implicit iceberg fluxes) and interactive ice sheets (with explicit dynamics). We are tuning the densification scheme of this snow model with temperature and density data from common FirnCover and SumUp observations at locations in the accumulation zone of Greenland, and we compare the resulting density profiles to other SumUp density profiles in Greenland and Antarctica. We will assess the impact of this new snow model in climate model simulations with a static ice sheet compared with the previous (simpler) 2-layer snow model. Finally, we aim to use the non-coupled simulations as a baseline to assess the impact of dynamic coupling with an interactive ice sheet model.

snow↗
NASA NTRS2006

Test Capability Enhancements to the NASA Langley 8-Foot High Temperature Tunnel

The NASA Langley 8-Foot High Temperature Tunnel produces true enthalpy environments simulating flight from Mach 4 to Mach 7, primarily for airbreathing propulsion and aerothermal/thermo-structural testing. Flow conditions are achieved through a methane-air heater and nozzles producing aerodynamic Mach numbers of 4, 5 or 7 and have exit diameters of 8 feet or 4.5 feet. The 12-ft long free-jet test section, housed inside a 26-ft vacuum sphere, accommodates large test articles. Recently, the facility underwent significant upgrades to support hydrocarbon fueled scramjet engine testing and to expand flight simulation capability. The upgrades were required to meet engine system development and flight clearance verification requirements originally defined by the joint NASA-Air Force X-43C Hypersonic Flight Demonstrator Project and now the Air Force X-51A Program. Enhancements to the 8-Ft. HTT were made in four areas: 1) hydrocarbon fuel delivery; 2) flight simulation capability; 3) controls and communication; and 4) data acquisition/processing. The upgrades include the addition of systems to supply ethylene and liquid JP-7 to test articles; a Mach 5 nozzle with dynamic pressure simulation capability up to 3200 psf, the addition of a real-time model angle-of-attack system; a new programmable logic controller sub-system to improve process controls and communication with model controls; the addition of MIL-STD-1553B and high speed data acquisition systems and a classified data processing environment. These additions represent a significant increase to the already unique test capability and flexibility of the facility, and complement the existing array of test support hardware such as a model injection system, radiant heaters, six-component force measurement system, and optical flow field visualization hardware. The new systems support complex test programs that require sophisticated test sequences and precise management of process fluids. Furthermore, the new systems, such as the real-time angle of attack system and the new programmable logic controller enhance the test efficiency of the facility. The motivation for the upgrades and the expanded capabilities is described here.

Harvin, S. F.↗
NASA NTRS2014

Computer Modeling of Direct Metal Laser Sintering

A computational approach to modeling direct metal laser sintering (DMLS) additive manufacturing process is presented. The primary application of the model is for determining the temperature history of parts fabricated using DMLS to evaluate residual stresses found in finished pieces and to assess manufacturing process strategies to reduce part slumping. The model utilizes MSC SINDA as a heat transfer solver with imbedded FORTRAN computer code to direct laser motion, apply laser heating as a boundary condition, and simulate the addition of metal powder layers during part fabrication. Model results are compared to available data collected during in situ DMLS part manufacture.

Cross, Matthew↗
NASA NTRS2016

Progress of Aircraft System Noise Assessment with Uncertainty Quantification for the Environmentally Responsible Aviation Project

Aircraft system noise predictions have been performed for NASA modeled hybrid wing body aircraft advanced concepts with 2025 entry-into-service technology assumptions. The system noise predictions developed over a period from 2009 to 2016 as a result of improved modeling of the aircraft concepts, design changes, technology development, flight path modeling, and the use of extensive integrated system level experimental data. In addition, the system noise prediction models and process have been improved in many ways. An additional process is developed here for quantifying the uncertainty with a 95% confidence level. This uncertainty applies only to the aircraft system noise prediction process. For three points in time during this period, the vehicle designs, technologies, and noise prediction process are documented. For each of the three predictions, and with the information available at each of those points in time, the uncertainty is quantified using the direct Monte Carlo method with 10,000 simulations. For the prediction of cumulative noise of an advanced aircraft at the conceptual level of design, the total uncertainty band has been reduced from 12.2 to 9.6 EPNL dB. A value of 3.6 EPNL dB is proposed as the lower limit of uncertainty possible for the cumulative system noise prediction of an advanced aircraft concept.

Thomas, Russell H.↗
NASA NTRS1999

Simulation of 1986 South China Sea Monsoon with a Regional Climate Model

A Regional Land-Atmosphere Climate Simulation System (RELACS) project is being developed at NASA Goddard Space Flight Center. One of the major goals of RELACS is to use a regional scale model with improved physical processes and in particular land-related processes, to understand the role of the land surface and its interaction with convection and radiation as well as the water/energy cycles in the IndoChina/South China Sea (SCS) region. The Penn State/NCAR MM5 atmospheric modeling system, a state of the art atmospheric numerical model designed to simulate regional weather and climate, has been successfully coupled to the Parameterization for Land-Atmosphere-Cloud Exchange (PLACE) land surface model. The original MM5 model (without PLACE) includes the option for either a simple slab soil model or a five-layer soil model (MRF) in which the soil moisture availability evolves over time. However, the MM5 soil models do not include the effects of vegetation, and thus important physical processes such as evapotranspiration and interception are precluded. The PLACE model incorporates vegetation type and has been shown in international comparisons to accurately predict evapotranspiration and runoff over a wide variety of land surfaces. The coupling of MM5 and PLACE creates a numerical modeling system with the potential to more realistically simulate atmosphere and land surface processes including land-sea interaction, regional circulations such as monsoons, and flash flood events. In addition, the Penn State/NCAR MM5 atmospheric modeling system has been: (1) coupled to the Goddard Ice Microphysical scheme; (2) coupled to a turbulent kinetic energy (TKE) scheme; (3) modified to ensure cloud budget balance; and (4) incorporated initialization with the Goddard EOS data sets at NASA/Goddard Laboratory for Atmospheres. The improved MM5 with two nested domains (60 and 20 km horizontal resolution) was used to simulate convective activity over IndoChina and the South China Sea, during the monsoon season, from May 6 to May 20, 1986. The model results captured several dominant observed features, such as twin cyclones, a depression system over the Bay of Bengal, strong south-westerly winds over IndoChina before and during the on-set of convection over the SCS, and a vortex over the SCS. Two additional MM5 runs with different land process models, Blackadar and MRF, were performed, and their results are compared to the run with PLACE. The preliminary results indicate that the MM5 results using PLACE and Blackadar are in very good agreement, but the results using MRF do not contain the south-westerly wind over IndoChina prior to the on-set of convection over the SCS.

Tao, W. -K.↗
NASA NTRS1991

Navigation of the TSS-1 mission

The Tethered Satellite System Mission was analyzed to determine its impacts on the Mission Control Center (MCC) Navigation section's ability to maintain an accurate state vector for the Space Shuttle during nominal and off-nominal flight operations. Tether dynamics expected on the Shuttle introduces new phenomena when determining the best estimation of its position and velocity. In the analysis, emphasis was placed on determining the navigation state vectors accuracies resulting when the tether induced forces were and were not modeled as an additional acceleration upon processing tracking measurements around a TSS-1 trajectory. Results of the analyses show that when the forces are not modeled in the state vector generation process, the resulting solution state reflects a solution about the center of gravity of the tethered system and not that of the orbiter. The Navigation team's ability to provide accurate state vector estimates necessary for trajectory planning are impeded. In addition to this consequent, is an impact on Onboard Navigation state vector accuracies. These analyses will show that in order to preserve an accurate state onboard the orbiter a new operational procedure would have to be adopted.

Jackson, Timothy C.↗
NASA NTRS1986

Extending the granularity of representation and control for the MIL-STD CAIS 1.0 node model

The Common APSE (Ada 1 Program Support Environment) Interface Set (CAIS) (DoD85) node model provides an excellent baseline for interfaces in a single-host development environment. To encompass the entire spectrum of computing, however, the CAIS model should be extended in four areas. It should provide the interface between the engineering workstation and the host system throughout the entire lifecycle of the system. It should provide a basis for communication and integration functions needed by distributed host environments. It should provide common interfaces for communications mechanisms to and among target processors. It should provide facilities for integration, validation, and verification of test beds extending to distributed systems on geographically separate processors with heterogeneous instruction set architectures (ISAS). Additions to the PROCESS NODE model to extend the CAIS into these four areas are proposed.

Rogers, Kathy L.↗
NASA NTRS1972

Operations and maintenance manual for a scale-model lunar roving vehicle

A one-sixth scale model of the lunar roving vehicle used in the Apollo 15 mission was built and instrumented to conduct model studies of vehicle mobility. The model was free running under radio control and was equipped with a lightweight telemetry transmitter that allowed 16 channels of data to be gathered simultaneously. String payout and fifth-wheel devices were developed to measure vehicle velocity. Other real-time measurements included wheel torque, wheel speed, center-of-gravity accelerations, and steering forces. Calibration, operations, and maintenance procedures were worked out. Details of the development of the instrumentation, its maintenance, and some of the problems encountered, are recorded serve as a preliminary operations and maintenance manual for this specific model. In addition, information regarding soil processing and testing that may be useful to NASA personnel planning mobility research with the model in soil is furnished.

Lessem, A. S.↗
NASA NTRSDate not supplied

Feasibility of Additive Manufacturing for Thermal Protection Systems

Thermal Protection Systems (TPS) use advanced materials to protect vehicles from aerodynamic heating during atmospheric entry. Manufacturing of these composite materials is often very time consuming and labor-intensive. Leveraging the additive manufacturing FDM (Fused Deposition Modeling) process enables NASA to design and manufacture advanced ablative TPS materials while reducing manufacturing time and cost. Since additive manufacturing is an automated process, it ensures part consistency over the entire heat shield area. The purpose for this presentation will be three-fold. 1) Introduce novel low-density ablative materials capable of utilizing additive manufacturing capabilities 2) show feasibility of additively manufacturing TPS coupons using the downselected TPS materials 3) Side by side comparison of high temperature test results for printable paste and state of the art low-density ablators

T. Boghozian↗