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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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NASA NTRS2013

Verification and Validation Studies for the LAVA CFD Solver

The verification and validation of the Launch Ascent and Vehicle Aerodynamics (LAVA) computational fluid dynamics (CFD) solver is presented. A modern strategy for verification and validation is described incorporating verification tests, validation benchmarks, continuous integration and version control methods for automated testing in a collaborative development environment. The purpose of the approach is to integrate the verification and validation process into the development of the solver and improve productivity. This paper uses the Method of Manufactured Solutions (MMS) for the verification of 2D Euler equations, 3D Navier-Stokes equations as well as turbulence models. A method for systematic refinement of unstructured grids is also presented. Verification using inviscid vortex propagation and flow over a flat plate is highlighted. Simulation results using laminar and turbulent flow past a NACA 0012 airfoil and ONERA M6 wing are validated against experimental and numerical data.

Validation↗

NASA NTRS2015

Verification of a Viscous Computational Aeroacoustics Code Using External Verification Analysis

The External Verification Analysis approach to code verification is extended to solve the three-dimensional Navier-Stokes equations with constant properties, and is used to verify a high-order computational aeroacoustics (CAA) code. After a brief review of the relevant literature, the details of the EVA approach are presented and compared to the similar Method of Manufactured Solutions (MMS). Pseudocode representations of EVA's algorithms are included, along with the recurrence relations needed to construct the EVA solution. The code verification results show that EVA was able to convincingly verify a high-order, viscous CAA code without the addition of MMS-style source terms, or any other modifications to the code.

Computational↗

NASA NTRS2015

Verification of a Viscous Computational Aeroacoustics Code using External Verification Analysis

Computational↗

NASA NTRS2017

Stabilized Finite Elements in FUN3D

A Streamlined Upwind Petrov-Galerkin (SUPG) stabilized finite-element discretization has been implemented as a library into the FUN3D unstructured-grid flow solver. Motivation for the selection of this methodology is given, details of the implementation are provided, and the discretization for the interior scheme is verified for linear and quadratic elements by using the method of manufactured solutions. A methodology is also described for capturing shocks, and simulation results are compared to the finite-volume formulation that is currently the primary method employed for routine engineering applications. The finite-element methodology is demonstrated to be more accurate than the finite-volume technology, particularly on tetrahedral meshes where the solutions obtained using the finite-volume scheme can suffer from adverse effects caused by bias in the grid. Although no effort has been made to date to optimize computational efficiency, the finite-element scheme is competitive with the finite-volume scheme in terms of computer time to reach convergence.

Anderson, W. Kyle↗

NASA NTRS2019

Reliability Estimation for Mission Extension NASA Approach/Recommendations

Present NASA's current and recommended concepts for Mission Extension and De-orbit reliability Methodologies. NASA's current and recommended approaches ensuring de-orbit requirements are not unnecessarily driving mission design efforts or adding incresed costs or risks to manufacturing solutions without providing benefit to missionsand will assist in moving reliability estimation from piece part performance estimates to component history and system-level testing based estimations.

SMA↗

NASA NTRSDate not supplied

Economical Third-Order Methods for Accurate Surface Heating Predictions on Simplex Element Meshes

A node-centered edge-based finite volume discretization of the compressible Navier-Stokes equations is presented with the heat flux reformulated as a first order system. A dissipation vector is derived for the reformulated system, such that the heat flux can be upgraded to O(h^3) on simplex element meshes in the same fashion as the inviscid fluxes. The method of manufactured solutions is used to demonstrate this uniform order property in heat flux. This new system is shown to efficiently produce accurate surface heating predictions on hypersonic hemisphere flow using an anisotropic simplex element mesh, achieving O(h^3) accuracy at relatively low computational cost compared to similar methods.

Computational Fluid Dynamics↗

NASA NTRS2014

Badger COMET Compartmentalized Onboard Material Extrusion Technology

In response to the 2014 NASA Academic Innovation Challenge, the University of Wisconsin – Madison team presents the design of a collapsible Fused Deposition Modeling (FDM) system for in situ manufacturing in a space habitat environment, the Badger Compartmentalized Onboard Material Extrusion Technology (COMET). The proposed mechanism incorporates one year of design and testing on an array of current additive manufacturing techniques, with the goal of providing a reliable and maintainable manufacturing solution. Seven Level 1 requirements were employed to guide the design process, based on information in the challenge, communications with NASA, and the evolving systems feedback of project work groups. These requirements provided a baseline for the development of the System Requirements Document (SRD, Appendix I), which framed the design of the system. The design requirements deemed critical to the success of the systems are as follows: - The system shall compose an FDM workstation capable of producing parts within industry standard tolerances. - The system shall reduce to a minimum of 50 percent or less of its deployed volume when not in use, and must collapse without the need for disassembly. - The system shall meet all relevant NASA safety and functional standards. The final design for the Badger COMET was selected from multiple design iterations, which balanced the critical design requirements listed above with system reliability, with the final goal of providing a minimal system weight. The system collapses in the vertical direction, allowing for a maximum reduction in volume. Guide rods and precision, anti-backlash lead screws provide all linear movement in the device. Stepper motors were chosen to actuate each system axis, due to their high precision and repeatable accuracy. The system is controlled through an on-board computer system and embedded electronics package.

Frederick T. Elder↗

NASA NTRS1978

Manufacturing process applications team (MATeam)

Activities of the manufacturing applications team (MATeam) in effecting widespread transfer of NASA technology to aid in the solution of manufacturing problems in the industrial sector are described. During the program's first year of operation, 450 companies, industry associations, and government agencies were contacted, 150 manufacturing problems were documented, and 20 potential technology transfers were identified. Although none of the technology transfers has been commercialized and put in use, several are in the applications engineering phase, and others are in the early stages of implementation. The technology transfer process is described and guidelines used for the preparation of problems statements are included.

Bangs, E. R.↗

NASA NTRS1981

Liquid immersion apparatus for minute articles

Apparatus is disclosed for immersing minute integrated circuit chips in an etching solution in manufacturing integrated circuits during research and development. The apparatus includes a holder, having a handle and basket support for carrying a removable unitary basket and lid structure where fluid flow-through passages are formed, and wherein graduated openings in the handle provide for adjustably supporting the basket in a breaker at a desired level.

Belcher, J. G., Jr.↗

NASA NTRS1984

The G-002 JUFO-1 payload: Its objectives and results

The JUFO-1 payload basically consists of the mechanical support structure with two shock isolated mounting shelves for the experiment hardware and the service systems. For the envisaged operation time of 72 hours, three 28 VDC batteries, with a total capacity of approx 1,7 kWh are chosen as a partially redundant power source. Data are acquired by a 12 bit PCM system and stored on a tape recorder. Five experiments were conducted: (1) growth of a liquid KH2PO4 salt solution; (2) manufacturing of nickel catalysts; (3) transport mechanisms of heavy metals in water cress shoots; (4) determining the influence of cosmic radiation on four different plant seeds; and (5) use of a microprocessor-sequencer for payload control and sequencing at a low power consumption.

Schmitt, G.↗

NASA NTRS2000

Age and Stress Prediction

Genoa is a software product that predicts progressive aging and failure in a variety of materials. It is the result of a SBIR contract between the Glenn Research Center and Alpha Star Corporation. Genoa allows designers to determine if the materials they plan on applying to a structure are up to the task or if alternate materials should be considered. Genoa's two feature applications are its progressive failure simulations and its test verification. It allows for a reduction in inspection frequency, rapid design solutions, and manufacturing with low cost materials. It will benefit the aerospace, airline, and automotive industries, with future applications for other uses.

Source record↗

NASA NTRS2008

From Lunar Regolith to Fabricated Parts: Technology Developments and the Utilization of Moon Dirt

The U.S. Space Exploration Policy has as a cornerstone the establishment of an outpost on the moon. This lunar outpost wil1 eventually provide the necessary planning, technology development, testbed, and training for manned missions in the future beyond the Moon. As part of the overall activity, the National Aeronautics and Space Administration (NASA) is investigating how the in situ resources can be utilized to improve mission success by reducing up-mass, improving safety, reducing risk, and bringing down costs for the overall mission. Marshall Space Flight Center (MSFC), along with other NASA centers, is supporting this endeavor by exploring how lunar regolith can be mined for uses such as construction, life support, propulsion, power, and fabrication. An infrastructure capable of fabrication and nondestructive evaluation will be needed to support habitat structure development and maintenance, tools and mechanical parts fabrication, as well as repair and replacement of space-mission hardware such as life-support items, vehicle components, and crew systems, This infrastructure will utilize the technologies being developed under the In Situ Fabrication and Repair (ISFR) element, which is working in conjunction with the technologies being developed under the In Situ Resources Utilization (ISRU) element, to live off the land. The ISFR Element supports the Space Exploration Initiative by reducing downtime due to failed components; decreasing risk to crew by recovering quickly from degraded operation of equipment; improving system functionality with advanced geometry capabilities; and enhancing mission safety by reducing assembly part counts of original designs where possible. This paper addresses the need and plan for understanding the properties of the lunar regolith to determine the applicability of using this material in a fabrication process. This effort includes the development of high fidelity simulants that will be used in fabrication processes on the ground to drive down risk and increase the Technology Readiness Level (TRL) prior to implementing this capability on the moon. Also discussed in this paper is the on-going research using Electron Beam Melting (EBM) technology as a possible solution to manufacturing parts and spares on the Moon's surface.

McLemore, C. A.↗

NASA NTRSDate not supplied

Composites From in-Situ Consolidation Automated Fiber Placement of Thermoplastics for High-Rate Aircraft Manufacturing

The National Aeronautics and Space Administration (NASA) project Hi-Rate Composites Aircraft Manufacturing (HiCAM) aims to significantly increase commercial aircraft composite structures manufacturing rate. Thermoplastic composites offer attractive solutions to rapid manufacturing due to their ability to be formed and consolidated quickly. NASA has a particular interest in assessing composite structure manufacturing utilizing an in-situ consolidation automated fiber placement (AFP) of thermoplastics (ICAT) process employing current state-of-the-art laser heating systems. Three semi-crystalline polyaryletherketone (PAEK) thermoplastic tape materials were characterized to ascertain the ICAT process parameters. The required laser power settings were determined at Electroimpact, Inc., measuring material temperatures utilizing a forward looking infrared (FLIR) thermal imaging camera and thermocouples. The material temperature, tool temperature, and placement speed were varied for resulting consolidation quality assessment. The resulting temperature data were also utilized to calibrate thermal analysis models under development at NASA. The experimental temperature data confirmed analytical results. The quality of the resulting test panels was evaluated by both non-destructive evaluation as well as destructively by photo-microscopy. The effect on interlaminar strength was determined by short beam strength testing. Test results of carbon fiber laminates fabricated by ICAT using polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and low-melt polyaryletherketone (LM-PAEK) at various placement temperatures and placement speeds are presented.

thermoplastic composites↗

NASA NTRSDate not supplied

Automated Ply-by-Ply Lamination and In-Situ Consolidation of Thermoplastic Composite High-Contour Stiffeners for High-Rate Aircraft Manufacturing

To meet the future demand of the commercial aircraft market, composite aircraft manufacturing rates must significantly increase. NASA’s Hi-Rate Composites Aircraft Manufacturing (HiCAM) program addresses this need to advance aircraft composite manufacturing technologies. Thermoplastic composites offer a promising solution to these manufacturing demands and present an opportunity for Northrop Grumman to bring the benefits of its Automated Stiffener Forming (ASF) technology to thermoplastic processing. Within HiCAM, Northrop Grumman is evolving the ASF technology for ply-by-ply, in-situ processing of thermoplastic composite materials. The modular process accommodates flexibility in the laminate stacking, while allowing for ply drops, ply additions, and yaw, pitch, and roll in the laminate geometry. To adapt the ASF process for thermoplastics, heating technologies and roller compaction processes were investigated by manufacturing flat test coupons. These panels were evaluated by photo-microscopy, non-destructive inspection, and short beam shear tests and results were compared against baseline autoclave coupons. The results of the laminates fabricated via ASF are presented.

out of autoclave↗

NASA NTRS2022

Development of Advanced Manufacturing Approaches for Single-Piece Launch Vehicle Structures

Advanced, near-net shape manufacturing methods have the potential to enable production of structures with fewer welds and reduced machining requirements. Two such methods that are suitable for the manufacturing of single-piece, stiffened barrel-shaped structures are presented. The first solution deployed existing manufacturing technology to produce a thick-walled barrel with integrally machined stiffeners. In this study, an 8-ft. diameter barrel was produced and subjected to a buckling test. Data on the manufacturing and testing of this barrel are provided and compared against the traditional multi-piece weld construction approach. The single-piece barrel resulted in a 28% greater load carrying capacity than the welded barrel. A second solution utilized a novel flow-forming technique to produce the barrel and stiffeners in one process without the need for welding or machining. This is an emerging manufacturing method known as the Integrally Stiffened Cylinder (ISC) process. This innovative process is being evaluated for launch vehicle and commercial aircraft manufacturing. The one-piece, stiffened ISC barrels, which have been successfully fabricated at 10 ft. in diameter, offer a direct replacement for conventional multi-piece, welded or riveted structures. A cost-benefit analysis for launch vehicle cryogenic propellant tanks estimated that the ISC process offers up to a 50% reduction in manufacturing costs and a 10% reduction in mass.

integrally stiffened cylinder (ISC)↗

NASA NTRSDate not supplied

Automated Ply-By-Ply Lamination and in-Situ Consolidation of Dry Carbon Fiber Non-Crimp Fabrics for High-Rate Aircraft Manufacturing of Structural Aircraft Components

NASA’s Hi-Rate Composites Aircraft Manufacturing (HiCAM) program addresses market needs to advance structural aircraft composite manufacturing technologies to significantly increase production rates. Dry, non-crimp fabric (NCF) carbon materials infused with advanced resin systems offer a promising solution to these manufacturing demands. Northrop Grumman’s Automated Stiffener Forming (ASF) technology has been adapted for ply-by-ply, in-situ processing of NCF materials. The modular ASF process accommodates flexibility in the laminate stacking, while allowing for ply drops, ply additions, and yaw, pitch, and roll in the laminate geometry. To adapt the ASF process for NCF materials, heating technologies and roller compaction processes were designed and tested on representative structural aircraft part geometries. Key success criteria for the ASF process with NCF materials is forming quality and preform compaction. Trials were performed with multiple NCF materials: unidirectional up to quad-axial formats. The NCF constituents, veils, stitching, and binders, were evaluated with the ASF process. The material performance in the ASF process and the resulting preform quality are presented.

dry carbon fiber materials↗

NASA NTRSDate not supplied

Automated Ply-By-Ply Lamination and in-Situ Consolidation of Dry Carbon Fiber Non-Crimp Fabrics for High-Rate Aircraft Manufacturing of Structural Aircraft Components

dry carbon fiber materials↗

NASA NTRS2004

Accuracy and Precision in the Southern Hemisphere Additional Ozonesondes (SHADOZ) Dataset in Light of the JOSIE-2000 Results

Since 1998 the Southern Hemisphere ADditional OZonesondes (SHADOZ) project has provided over 2000 ozone profiles over eleven southern hemisphere tropical and subtropical stations. Balloon-borne electrochemical concentration cell (ECC) ozonesondes are used to measure ozone. The data are archived at: &ttp://croc.gsfc.nasa.gov/shadoz>. In analysis of ozonesonde imprecision within the SHADOZ dataset, Thompson et al. [JGR, 108,8238,20031 we pointed out that variations in ozonesonde technique (sensor solution strength, instrument manufacturer, data processing) could lead to station-to-station biases within the SHADOZ dataset. Imprecisions and accuracy in the SHADOZ dataset are examined in light of new data. First, SHADOZ total ozone column amounts are compared to version 8 TOMS (2004 release). As for TOMS version 7, satellite total ozone is usually higher than the integrated column amount from the sounding. Discrepancies between the sonde and satellite datasets decline two percentage points on average, compared to version 7 TOMS offsets. Second, the SHADOZ station data are compared to results of chamber simulations (JOSE-2000, Juelich Ozonesonde Intercomparison Experiment) in which the various SHADOZ techniques were evaluated. The range of JOSE column deviations from a standard instrument (-10%) in the chamber resembles that of the SHADOZ station data. It appears that some systematic variations in the SHADOZ ozone record are accounted for by differences in solution strength, data processing and instrument type (manufacturer).

Witte, Jacquelyn C.↗