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NASA NTRS2012

Finite Element Models for Electron Beam Freeform Fabrication Process

Electron beam freeform fabrication (EBF3) is a member of an emerging class of direct manufacturing processes known as solid freeform fabrication (SFF); another member of the class is the laser deposition process. Successful application of the EBF3 process requires precise control of a number of process parameters such as the EB power, speed, and metal feed rate in order to ensure thermal management; good fusion between the substrate and the first layer and between successive layers; minimize part distortion and residual stresses; and control the microstructure of the finished product. This is the only effort thus far that has addressed computer simulation of the EBF3 process. The models developed in this effort can assist in reducing the number of trials in the laboratory or on the shop floor while making high-quality parts. With some modifications, their use can be further extended to the simulation of laser, TIG (tungsten inert gas), and other deposition processes. A solid mechanics-based finite element code, ABAQUS, was chosen as the primary engine in developing these models whereas a computational fluid dynamics (CFD) code, Fluent, was used in a support role. Several innovative concepts were developed, some of which are highlighted below. These concepts were implemented in a number of new computer models either in the form of stand-alone programs or as user subroutines for ABAQUS and Fluent codes. A database of thermo-physical, mechanical, fluid, and metallurgical properties of stainless steel 304 was developed. Computing models for Gaussian and raster modes of the electron beam heat input were developed. Also, new schemes were devised to account for the heat sink effect during the deposition process. These innovations, and others, lead to improved models for thermal management and prediction of transient/residual stresses and distortions. Two approaches for the prediction of microstructure were pursued. The first was an empirical approach involving the computation of thermal gradient, solidification rate, and velocity (G,R,V) coupled with the use of a solidification map that should be known a priori. The second approach relies completely on computer simulation. For this purpose a criterion for the prediction of morphology was proposed, which was combined with three alternative models for the prediction of microstructure; one based on solidification kinetics, the second on phase diagram, and the third on differential scanning calorimetry data. The last was found to be the simplest and the most versatile; it can be used with multicomponent alloys and rapid solidification without any additional difficulty. For the purpose of (limited) experimental validation, finite element models developed in this effort were applied to three different shapes made of stainless steel 304 material, designed expressly for this effort with an increasing level of complexity. These finite element models require large computation time, especially when applied to deposits with multiple adjacent beads and layers. This problem can be overcome, to some extent, by the use of fast, multi-core computers. Also, due to their numerical nature coupled with the fact that solid mechanics- based models are being used to represent the material behavior in liquid and vapor phases as well, the models have some inherent approximations that become more pronounced when dealing with multi-bead and multi-layer deposits.

Chandra, Umesh↗

NASA NTRS2009

A CFD Approach to Modeling Spacecraft Fuel Slosh

Energy dissipation and resonant coupling from sloshing fuel in spacecraft fuel tanks is a problem that occurs in the design of many spacecraft. In the case of a spin stabilized spacecraft, this energy dissipation can cause a growth in the spacecrafts' nutation (wobble) that may lead to disastrous consequences for the mission. Even in non-spinning spacecraft, coupling between the spacecraft or upper stage flight control system and an unanticipated slosh resonance can result in catastrophe. By using a Computational Fluid Dynamics (CFD) solver such as Fluent, a model for this fuel slosh can be created. The accuracy of the model must be tested by comparing its results to an experimental test case. Such a model will allow for the variation of many different parameters such as fluid viscosity and gravitational field, yielding a deeper understanding of spacecraft slosh dynamics. In order to gain a better understanding of the dynamics behind sloshing fluids, the Launch Services Program (LSP) at the NASA Kennedy Space Center (KSC) is interested in finding ways to better model this behavior. Thanks to past research, a state-of-the-art fuel slosh research facility was designed and fabricated at Embry Riddle Aeronautical University (ERAU). This test facility has produced interesting results and a fairly reliable parameter estimation process to predict the necessary values that accurately characterize a mechanical pendulum analog model. The current study at ERAU uses a different approach to model the free surface sloshing of liquid in a spherical tank using Computational Fluid Dynamics (CFD) methods. Using a software package called Fluent, a model was created to simulate the sloshing motion of the propellant. This finite volume program uses a technique called the Volume of Fluid (VOF) method to model the interaction between two fluids [4]. For the case of free surface slosh, the two fluids are the propellant and air. As the fuel sloshes around in the tank, it naturally displaces the air. Using the conservation of mass, momentum, and energy equations, as well as the VOF equations, one can predict the behavior of the sloshing fluid and calculate the forces, pressure gradients, and velocity field for the entire liquid as a function of time.

Marsell, Brandon↗

NASA NTRS2014

Computational Investigation of Novel Tip Leakage Mitigation Methods for High Pressure Turbine Blades

This paper presents preliminary findings on a possible approach to reducing tip leakage losses. In this paper a computational study was conducted on the Energy Efficient Engine (EEE) High Pressure Turbine (HPT) rotor tip geometry using the commercial numerical solver ANSYS FLUENT. The flow solver was validated against aerodynamic data acquired in the NASA Transonic Turbine Blade Cascade facility. The scope of the ongoing study is to computationally investigate how the tip leakage and overall blade losses are affected by (1) injection from the tip near the pressure side, (2) injection from the tip surface at the camber line, and (3) injection from the tip surface into the tip separation bubble. The objective is to identify the locations on the tip surface at which to place appropriately configured blowing keeping in mind the film cooling application of tip blowing holes. The validation was conducted at Reynolds numbers of 85,000, 343,000, and 685,000 and at engine realistic flow conditions. The coolant injection simulations were conducted at a Reynolds number of 343,000 based on blade chord and inlet velocity and utilized the SST turbulence model in FLUENT. The key parameters examined are the number of jets, jet angle and jet location. A coolant to inlet pressure ratio of 1.0 was studied for angles of +30 deg, -30 deg, and 90 deg to the local free stream on the tip. For the 3 hole configuration, 3 holes spaced 3 hole diameters apart with length to diameter ratio of 1.5 were used. A simulation including 11 holes along the entire mean camber line is also presented (30 deg toward suction side). In addition, the effect of a single hole is also compared to a flat tip with no injection. The results provide insight into tip flow control methods and can be used to guide further investigation into tip flow control. As noted in past research it is concluded that reducing leakage flow is not necessarily synonymous with reducing losses due to leakage.

Ibrahim, Mounir↗

NASA NTRS2014

Computational Investigation of Novel Tip Leakage Mitigation Methods for High Pressure Turbine Blades

This paper presents preliminary findings on a possible approach to reducing tip leakage losses. In this paper a computational study was conducted on the EEE (Energy Efficient Engine) HPT (High Pressure Turbine) rotor tip geometry using the commercial numerical solver ANSYS FLUENT. The flow solver was validated against aerodynamic data acquired in the NASA Transonic Turbine Blade Cascade facility. The scope of the ongoing study is to computationally investigate how the tip leakage and overall blade losses are affected by 1. injection from the tip near the pressure side, 2. injection from the tip surface at the camber line, and 3. injection from the tip surface into the tip separation bubble. The objective is to identify the locations on the tip surface at which to place appropriately configured blowing keeping in mind the film cooling application of tip blowing holes. The validation was conducted at Reynolds numbers of 85,000, 343,000 and 685,000 and at engine realistic flow conditions. The coolant injection simulations were conducted at a Reynolds number of 343,000 based on blade chord and inlet velocity and utilized the SST turbulence model in FLUENT. The key parameters examined are the number of jets, jet angle and jet location. A coolant to inlet pressure ratio of 1.0 was studied for angles of +30 deg., -30 deg. and 90 deg. to the local free stream on the tip. For the 3 hole configuration, 3 holes spaced 3 hole diameters apart with length to diameter ratio of 1.5 were used. A simulation including 11 holes along the entire mean camber line is also presented (30 degrees toward suction side). In addition, the effect of a single hole is also compared to a flat tip with no injection. The results provide insight into tip flow control methods and can be used to guide further investigation into tip flow control. As noted in past research it is concluded that reducing leakage flow is not necessarily synonymous with reducing losses due to leakage.

Ibrahim, Mounir↗

NASA NTRSDate not supplied

Extended Duration: The SIRIUS 21 Crew Perspective

The SIRIUS (Scientific International Research In a Unique terrestrial Station) missions represent a collaborative effort between NASA and Russia’s Institute for Biomedical Problems (IBMP) to conduct a series of long duration isolation and confinement spaceflight analog missions. Three missions of 17-day, 4-month, and 8-month duration (SIRIUS 17, 19, and 21) have been completed at IBMP’s Ground-Based Experimental Complex / Nazemnyy eksperimental'nyy kompleks (NEK) in Moscow, Russia. The international SIRIUS 21 crew comprising representatives from the United States, United Arab Emirates and Russia recently completed the 8-month analog lunar mission. The extended duration mission included simulated lunar transit, orbital, and surface operations with corresponding deep space communication delay, during which the crew participated in nearly 70 studies, eight of which were sponsored by NASA’s Human Research Program. The studies examined the effect of isolation and confinement on the behavioral health of research subjects, and investigated medical countermeasures, team performance, crew dynamics, crew autonomy, food system risks, consequences of confinement and associated physiological stressors. SIRIUS 21 crewmembers also participated in operational tasks such as Rover and CubeSat assembly, simulated lunar sample assessment, VR activities, robotic arm training, environmental systems monitoring, exercise, greenhouse maintenance and 3D printing. Communication with Mission Control was limited to 30-minute periods every two hours. Since access to the internet and email was restricted, simulated ground support provided the Crew’s primary source of daily news and mission information. This panel discussion will include presentations from the US SIRIUS 21 crewmembers – William Brown and Ashley Kowalski – about their experience participating in the mission and science. A facilitated question and answer session will follow with attendees encouraged to ask questions and join in discussion with the SIRIUS 21 crewmembers about their experiences. William Brown came to SIRIUS 21 with experience spread across multiple industries, including the military, defense contracting, healthcare consulting, software engineering, and logistics. He has lived in the Middle East, Central Asia, and Russia. A former Boren Scholar, Brown is fluent in Russian. He holds a Master of International Business degree from the University of South Carolina’s Darla Moore School of Business. Prior to that, he earned a bachelor’s degree in Russian language, literature, and culture from the University of South Carolina. There, he also completed additional undergraduate coursework in computer science. Ashley Kowalski is a Project Leader in The Aerospace Corporation’s International Partnerships Department, where she works with, represents, and provides technical support to the the U.S. Space Force Space Systems Command International Affairs (SSC/IA) office. Through her numerous national and international assignments (Russia, China, and Germany), she has worked on topics related to international space systems, national security space systems, civil systems (including human spaceflight and civil launch projects), space policy, satellite industry analysis, and satellite manufacturing start-ups. She is proficient in Russian and German, and fluent in Polish. Kowalski received her Bachelor of Science and Master of Science degrees in mechanical and aerospace engineering from George Washington University in 2011 and 2012, respectively.

S. E. Whiting↗

NASA NTRSDate not supplied

Validation of CFD Model Prediction of Flow Boiling Regime Transitions during LN2 Line Chilldown

Propellant storage and transfer during future long-duration missions will involve fuel depot operations in which a donor depot tank is used to fill a receiver spacecraft tank with a cryogenic propellant. Prior to the on-Orbit filling operation both the receiver tank and the transfer line must be cooled. The line chilldown process involves transition between boiling regimes in microgravity that will be quite different from their 1g ground-based counterparts. Since the cryogenic propellant itself will be used to perform the chilldown process, the time constants to cool the wall and the amount of fuel that will be used become important design considerations. In this light, the focus of the present work is to understand the flow boiling characteristics of a cryogenic fluid, namely, liquid nitrogen, during the chill-down of a transfer line using CFD modelling and simulations. The cryogenic chill-down process involves different flow boiling regimes: film boiling, transition boiling and nucleate boiling. The prediction of transition between these regimes in a CFD framework is new and challenging. The present work addresses this challenge by employing a volume-of-fluid (VOF) based methodology with Lee phase change model to predict the film boiling regime of the chill-down process in ANSYS Fluent®. The transition and nucleate boiling regimes are predicted by incorporating a sub-grid model developed by Craft Tech that accounts for bubble nucleation, growth, shedding frequency, and departure diameter. The sub-grid model is implemented into Fluent via a user-defined function for wall-fluid heat flux calculations. The sub-grid model is similar in formulation to the well-known Rensselaer Polytechnic Institute (RPI) boiling model. The model constants are tested for different operating conditions and designated values are reported. The CFD model is validated against published experimental data for liquid nitrogen chill-down of a heated stainless-steel pipe in 1g. Predicted results showing good agreement of wall temperature, rewetting temperature, and transition between film and nucleate boiling with the experimental measurements are presented and discussed.

Boiling regimes↗

NASA NTRSDate not supplied

Predictions of Line Chilldown Boiling Regime Transitions by a Coupled CFD-Sub-Grid Boiling Model Validated against 1G LN2 Experiments

Propellant storage and transfer during future long-duration missions will involve fuel depot operations in which a donor depot tank is used to fill a receiver spacecraft tank with a cryogenic propellant. Prior to the on-Orbit filling operation both the receiver tank and the transfer line must be cooled. The line chilldown process involves transition between boiling regimes in microgravity that will be quite different from their 1g ground-based counterparts. Since the cryogenic propellant itself will be used to perform the chilldown process, the time constants to cool the wall and the amount of fuel that will be used become important design considerations. In this light, the focus of the present work is to capture the flow boiling characteristics of a cryogenic fluid, namely, liquid nitrogen, during the chill-down of a transfer line using CFD modelling and simulations. The cryogenic chill-down process involves different flow boiling regimes: film boiling, transition boiling and nucleate boiling. The prediction of transition between these regimes in a CFD framework is new and challenging. The present work addresses this challenge by employing a volume-of-fluid (VOF) based methodology with Lee phase change model to predict the film boiling regime of the chill-down process in ANSYS Fluent®. The transition and nucleate boiling regimes are predicted by incorporating a sub-grid model that accounts for bubble nucleation, growth, shedding frequency, and departure diameter. The sub-grid model is implemented into Fluent via a user-defined function for wall-fluid heat flux calculations. The sub-grid model is similar in formulation to the well-known Rensselaer Polytechnic Institute (RPI) boiling model. The CFD model is validated against published experimental data for liquid nitrogen chill-down of a heated stainless-steel pipe in 1g. Predicted results shows good agreement of wall temperature, rewetting temperature, and transition between film and nucleate boiling with the experimental measurements for several different LN2 flowrates in the vertical orientation. The strengths and weaknesses of this modeling approach are presented and discussed.

Cryogenic Fluid Management↗

NASA NTRSDate not supplied

CFD Predictions of Boiling Regime Transitions during Line Chilldown validated against a 1G LN2 Experiment

Introduction Before filling a propellant tank on the ground or in Space, the transfer line between the donor and receiver tanks must be cooled down preferably by sacrificing a minimum amount of the cryogenic fluid. The cryogenic line chill-down process involves a transition between different flow boiling regimes, namely, film boiling, transition film boiling, and nucleate boiling which are complex and may be quite gravity-dependent. Capturing these boiling phenomena and predicting the transition between them in a CFD framework is new and challenging both for 1g and microgravity applications. Materials & Methods The present work addresses this challenge by employing a two-phase Eulerian approach in the context of a homogeneous fluid mixture together with the Lee phase change model to capture the film boiling regime of the chill-down process using ANSYS Fluent®. The nucleate boiling regime is predicted by incorporating an in-house developed sub-grid model that accounts for bubble nucleation, bubble growth, bubble departure diameter, and their shedding frequency. The sub-grid model is encoded and implemented into Fluent via a user-defined function for the wall-fluid heat flux calculations. The mathematical formulation and numerical implementation of the CFD model are described in detail. The coupled CFD-Subgrid model is validated against published experimental data for liquid nitrogen chill-down of a heated stainless-steel pipe in 1g. Results Numerical simulation results show good agreements between the CFD predictions of the wall temperature evolution, rewetting temperature, and transition between film and nucleate boiling, with the experimental measurements published by Darr et al [2] for several different LN2 flowrates in the vertical pipe orientation. The CFD predictions for the wall temperature distribution indicate a rapid quenching of the wall at two upstream and downstream temperature sensing locations as compared to the experimental measurement. The only tuning parameter in the CFD model is the Lee mass transfer coefficient. The CFD Model predicts the Liedenfrost rewetting temperature in close agreement with the experiment. This marks a transition between stable and transitionary flow boiling regimes. The CFD-predicted boiling curve for the downstream sensor location is also compared against its experimental counterpart and indicates that the model is able to predict all the key temperature and heat flux parameters during the transitions from stable to transitionary film boiling to nucleate boiling in close agreement with the experiment. A sequence of predicted volume fraction, and temperature contours depicting these transitions will be presented.

Evaporation Condensation↗

NASA NTRS1989

Convection and chemistry effects in CVD: A 3-D analysis for silicon deposition

The computational fluid dynamics code FLUENT has been adopted to simulate the entire rectangular-channel-like (3-D) geometry of an experimental CVD reactor designed for Si deposition. The code incorporated the effects of both homogeneous (gas phase) and heterogeneous (surface) chemistry with finite reaction rates of important species existing in silane dissociation. The experiments were designed to elucidate the effects of gravitationally-induced buoyancy-driven convection flows on the quality of the grown Si films. This goal is accomplished by contrasting the results obtained from a carrier gas mixture of H2/Ar with the ones obtained from the same molar mixture ratio of H2/He, without any accompanying change in the chemistry. Computationally, these cases are simulated in the terrestrial gravitational field and in the absence of gravity. The numerical results compare favorably with experiments. Powerful computational tools provide invaluable insights into the complex physicochemical phenomena taking place in CVD reactors. Such information is essential for the improved design and optimization of future CVD reactors.

Gokoglu, S. A.↗

NASA NTRS1990

A numerical and experimental analysis of reactor performance and deposition rates for CVD on monofilaments

The computational fluid dynamics (CFD) code FLUENT is adopted to simulate a cylindrical upflow reactor designed for chemical vapor deposition (CVD) on monofilaments. Equilibrium temperature profiles along the fiber and quartz reactor wall are experimentally measured and used as boundary conditions in numerical simulations. Two-dimensional axisymmetric flow and temperature fields are calculated for hydrogen and argon; the effect of free convection is assessed. The gas and surface chemistry is included for predicting silicon deposition from silane. The model predictions are compared with experimentally measured silicon CVD rates. Inferences are made for optimum conditions to obtain uniformity.

Gokoglu, S. A.↗

NASA NTRS1990

Effect of convection on the microstructure of a lamellar eutectic growing with a stepped interface

A two dimensional model developed to study the influence of convective flow on the concentration field ahead of a growing lamellar eutectic is described when one phase projects out into the melt creating a stepped interface. The two dimensional convective flow field, which is periodic in the horizontal direction, was computed numerically using the software FLUENT. The velocity field generated due to the flow of melt over the steps was then incorporated into a finite difference scheme employed to solve the concentration field. The average interfacial composition was calculated and converted to lamellar spacing using the Jackson and Hunt minimum supercooling criterion. It was found that a stepped interface is more sensitive to convection than a planar interface.

Seth, Jayshree↗

NASA NTRS1991

Flow visualization and computational studies of a reverse flow circular combustor

The development of a reverse-flow circular combustor is described in terms of the visualization techniques that are employed to optimize the flow and mixing of fuel and air. The Fluent computer program is used in conjunction with flow visualization studies to investigate the performance of the combustor. The combustor has multiple mini-combustion zones (MCZs) and fuel injection nozzles along its circular geometry, and the fuel injection design is modeled to determine temperature distribution, including the performance at the combustor exit. The yellow dye smoke used in the visualization demonstrated desirable flow patterns with rapid circulation patterns within the MCZs and extensive interaction between the channel flow and the MCZs. The results are similar to those of CFD models, and the main conclusions are that fuel atomization can be further optimized and that the fuel injector nozzle can control swirls, fuel spray angle, and jet penetration.

Ghorashi, B.↗

NASA NTRS1990

Long duration exposure facility solar illumination data package

A post flight solar illumination data package was created by the LDEF thermal analysis data group in support of the LDEF science office data group. The data presented was prepared with the Thermal Radiation Analysis System (TRASYS) program. Ground tracking data was used to calculate daily orbital beta angles for the calculation of resultant fluxes. This data package will be useful in calculation of solar illumination fluent for a variety of beta angle orbital conditions encountered during the LDEF mission.

Berrios, William M.↗

NASA NTRS1991

Thermal calibration and analysis of a Bridgman flight furnace

A combination of computer modeling and experimental measurements is proposed which permits the calibration of the temperature profile for a spacecraft flight furnace. The Fluent code based on the finite difference method uses the furnace set-point temperatures as boundary conditions to model a Bridgman directional solidification furnace. Experimental measurements are employed as a comparison for the numerical analysis, and the radial gradients and wall temperatures are selected when the calculated values are sufficiently close to those from measurements. The calculations are found to agree with experimental data, and some results of the modeling are given which relate to specific furnace parameters. The CFD approach facilitates the transposition of furnace calibration to microgravitational operation in addition to providing precise initial radial temperature gradients and furnace-wall temperatures.

Knuteson, D. J.↗

NASA NTRS1991

Effect of convection on the microstructure of a lamellar eutectic growing with a stepped interface

Seth, Jayshree↗

NASA NTRS1992

Applications of CFD and visualization techniques

In this paper, three applications are presented to illustrate current techniques for flow calculation and visualization. The first two applications use a commercial computational fluid dynamics (CFD) code, FLUENT, performed on a Cray Y-MP. The results are animated with the aid of data visualization software, apE. The third application simulates a particulate deposition pattern using techniques inspired by developments in nonlinear dynamical systems. These computations were performed on personal computers.

Saunders, James H.↗

NASA NTRS1992

Numerical modeling tools for chemical vapor deposition

Development of general numerical simulation tools for chemical vapor deposition (CVD) was the objective of this study. Physical models of important CVD phenomena were developed and implemented into the commercial computational fluid dynamics software FLUENT. The resulting software can address general geometries as well as the most important phenomena occurring with CVD reactors: fluid flow patterns, temperature and chemical species distribution, gas phase and surface deposition. The physical models are documented which are available and examples are provided of CVD simulation capabilities.

Jasinski, Thomas J.↗

NASA NTRS1993

Application of an unstructured grid flow solver to planes, trains and automobiles

Rampant, an unstructured flow solver developed at Fluent Inc., is used to compute three-dimensional, viscous, turbulent, compressible flow fields within complex solution domains. Rampant is an explicit, finite-volume flow solver capable of computing flow fields using either triangular (2d) or tetrahedral (3d) unstructured grids. Local time stepping, implicit residual smoothing, and multigrid techniques are used to accelerate the convergence of the explicit scheme. The paper describes the Rampant flow solver and presents flow field solutions about a plane, train, and automobile.

Spragle, Gregory S.↗