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NASA NTRS2024

Finite Element Simulation of the Direct Energy Deposition using Comsol Multiphysics

Direct Energy Deposition (DED) is an emerging technology extensively employed in metal Additive Manufacturing (AM). Despite its widespread industrial application, mathematical modeling in this domain remains challenging. This complexity arises from the intricate nature of the modeling approach and the nonlinear behavior of material parameters across a broad temperature range. Consequently, experimentalists often resort to a trial-and-error method to achieve structures with desired properties. However, this approach can be time-consuming and may not always yield parts with the requisite characteristics, highlighting the necessity for mathematical modeling to enhance manufacturing success. This study focuses on thin-walled manufacturing with a single bead thickness, adjusting laser parameters to produce such structures. The laser cladding speed, typical for DED manufacturing, is considered to be on the order of centimeters per second. The various wall thicknesses and heights are explored to discern the general characteristics of walls manufactured via this DED approach. Our modeling approach diverges from the conventional DED modeling based on activation-deactivation of predefined mesh domains, commonly implemented in many finite element codes. Instead, a method is proposed that effectively models layer cladding and melt pool dynamics, enabling predictions of the microstructure in the resulting structures. The formation mechanisms of cellular, dendritic columnar, and stray (equiaxed) grains, which arise from the interplay between nucleation and growth from the surface is analyzed. The study also examines the feasibility of microstructure formation to demonstrate the various thermal characteristics inherent in wall manufacturing. Our results illustrate how different process parameters influence the temperature gradient and cooling rate of the molten pool, subsequently affecting the primary dendrite arm spacing (PDAS). This modeling technique allows for the investigation of diverse thermal conditions, facilitating the prediction of microstructure and residual stresses in the manufactured parts.

modeling↗
NASA NTRS2011

Shunted Piezoelectric Vibration Damping Analysis Including Centrifugal Loading Effects

Excessive vibration of turbomachinery blades causes high cycle fatigue problems which require damping treatments to mitigate vibration levels. One method is the use of piezoelectric materials as passive or active dampers. Based on the technical challenges and requirements learned from previous turbomachinery rotor blades research, an effort has been made to investigate the effectiveness of a shunted piezoelectric for the turbomachinery rotor blades vibration control, specifically for a condition with centrifugal rotation. While ample research has been performed on the use of a piezoelectric material with electric circuits to attempt to control the structural vibration damping, very little study has been done regarding rotational effects. The present study attempts to fill this void. Specifically, the objectives of this study are: (a) to create and analyze finite element models for harmonic forced response vibration analysis coupled with shunted piezoelectric circuits for engine blade operational conditions, (b) to validate the experimental test approaches with numerical results and vice versa, and (c) to establish a numerical modeling capability for vibration control using shunted piezoelectric circuits under rotation. Study has focused on a resonant damping control using shunted piezoelectric patches on plate specimens. Tests and analyses were performed for both non-spinning and spinning conditions. The finite element (FE) shunted piezoelectric circuit damping simulations were performed using the ANSYS Multiphysics code for the resistive and inductive circuit piezoelectric simulations of both conditions. The FE results showed a good correlation with experimental test results. Tests and analyses of shunted piezoelectric damping control, demonstrating with plate specimens, show a great potential to reduce blade vibrations under centrifugal loading.

Min, James B.↗
NASA NTRS2022

Validation of a High-Fidelity Supersonic Parachute Inflation Dynamics Model and Best Practice

The parachute inflation dynamics (PID) of a Disk-Gap-Band (DGB) parachute system travelling at supersonic velocities in the high-altitude Earth atmosphere is simulated using a high-fidelity, multiphysics, massively-parallel computational framework. The sensitivity of the simulation results with respect to critical modelling and simulation parameters, including the fluid mechanical governing equations (Euler vs Navier-Stokes with RANS turbulence closure vs Navier-Stokes with LES turbulence closer), the interaction between the flow and the suspension lines (accounted for vs not accounted for), the dynamics of the payload (restrained vs free), and the material model of the heterogeneous fabric canopy (Saint-Venant Kirchoff vs mechanics-informed multiscale neural network), is extensively investigated. The parameter investigation is enabled by advancements to the state-of-the-art in the modelling and simulation of the supersonic parachute inflation process, which are presented as part of the computational framework. The predictive quality of the computational framework in the context of supersonic PID is validated by comparison of the simulation results with the experimental results from NASA’s Advanced Supersonic Parachute Research (ASPIRE) project. Through the validation, best practices for the modelling and simulation of supersonic PID are developed and proposed.

Rabinovitch, Jason↗
NASA NTRS2016

My Internship at NASA

My name is Isaac Lopez and I am a junior at the University of Houston majoring in Mechanical Engineering Technology. I will be completing my first tour at the NASA-Johnson Space Center ("JSC") as a Mechanical Engineer within the Human Interfaces Branch. Throughout my tour, I was given the opportunity to work on multiple projects that have expanded my knowledge and interest in acoustics and engineering design. One of the projects I worked on at JSC consisted of doing acoustic simulation of the EVA comm. cap. While working on the comm. cap headset, my main duty consisted of simulating the acoustics of the headset to find a solution to the condensing water that can accumulate and block the acoustic tube, causing attenuation or complete loss of audio in one ear for an astronaut using the EVA. For this project, I had to create a Creo model of the comm. cap so that I would be able to import it into Comsol for acoustic simulation. I also had the opportunity to design a portable and lightweight beam degrader for the EEE Parts and Radiation team. With the help of Creo, I was able to make a CAD design and put together a small working prototype for the radiation team to demonstrate the capabilities that the beam degrader had. In addition to these projects, JSC allowed me to work closely on projects with other interns. I had the opportunity to help another intern with his acoustic diverter, intended to improve the sound quality in Node 1 of the ISS. During this project, I helped with some of the acoustic testing inside the anechoic chamber as well as helping record data during testing at the ISS mock up. During the course of my first tour, I was able to learn and continually improve on my CAD drafting skills. With each project I worked on, I acquired new ways to create and improve various designs with various constraints. Furthermore, I also had the opportunity to work with electrical engineers and learn about the electronic components that would provide control of the beam degrader functions. I was able to take the knowledge, skills and designs I had acquired during my tour at JSC (such as Finite Element Analysis) and apply them to my work on the Comsol Multiphysics software for acoustics simulation. I was also able to use it to do some stress analysis on a proposed design for a proposed Habitat structure. My time at JSC has been invaluable as it helped me grow and more fully-comprehend my major as well as spark an interest in acoustics and how much it relates to mechanical engineering. This internship has taught me that engineering is much more than a profession - it is embedded in our daily lives as a puzzle that requires critical thinking as an everyday challenge that makes life more interesting.

Lopez, Isaac↗
NASA NTRS2023

CESO 22-3: Simulated Excavation Environment for Lunar Operations Follow-on

As more lunar In-Situ Resource Utilization (ISRU) missions are planned and developed, a need was identified for a simulation environment with accurate regolith interaction mechanics that is less computationally expensive than commercially available multiphysics tools. The purpose of the Simulated Excavation Environment for Lunar Operations (SEELO) project was to develop an interactive simulation environment that efficiently models lunar ISRU excavation operations, including soil deformation, while running in faster-than-real-time.

Michael DuPuis↗
NASA NTRSDate not supplied

Particle Impact Simulation and Ignition Prediction

An experimentally calibrated tool is needed to predict if a system is susceptible to failure by particle impact ignition (PI) based on use conditions, materials, and flow geometry. This tool will accelerate new components, evaluating existing hardware, and help disposition anomalies. Conduct particle impact testing with in-situ diagnostics and complementary simulations on subset of key engineering materials (IN718, M400, 316L, 6061, Ti64, Zr) to develop a proof-of-concept predictive tool for assessing the risk of PI for idealized geometries (spherical particles) in realistic environments. Assess particle/target interactions (coefficient of restitution, ignition, kindling) using instrumented particle impact rigs while systematically varying key parameters (materials, particle size, environment, target configuration). Determine key field variables (temperature, strain, stress) in particle impacts using Multiphysics finite element and hydrocode simulations validated through comparison with experimental measurements and observations. Synthesize experiments and simulations into constitutive models for PI that can be integrated with existing computational fluid dynamics (CFD) and Debris Transport Analysis (DTA) tools in future efforts

particle impact↗
NASA NTRS2024

Particle Impact Simulation and Ignition Prediction

An experimentally calibrated tool is needed to predict if a system is susceptible to failure by particle impact ignition (PI) based on use conditions, materials, and flow geometry. This tool will accelerate new components, evaluating existing hardware, and help disposition anomalies. - Conduct particle impact testing with in-situ diagnostics and complementary simulations on subset of key engineering materials (IN718, M400, 316L, 6061, Ti64, Zr) to develop a proof-of-concept predictive tool for assessing the risk of PI for idealized geometries (spherical particles) in realistic environments. - Assess particle/target interactions (coefficient of restitution, ignition, kindling) using instrumented particle impact rigs while systematically varying key parameters (materials, particle size, environment, target configuration). - Determine key field variables (temperature, strain, stress) in particle impacts using Multiphysics finite element and hydrocode simulations validated through comparison with experimental measurements and observations. - Synthesize experiments and simulations into constitutive models for PI that can be integrated with existing computational fluid dynamics (CFD) and Debris Transport Analysis (DTA) tools in future efforts.

Jonathan Tylka↗
NASA NTRSDate not supplied

Multiphysics Computational Analysis of a Perforated Plate Cooling Flow

A multiphysics analysis of a film cooling flow was conducted using a computational fluid dynamics (CFD) solver in conjunction with a conjugate heat transfer (CHT) solver. The film cooling problem consisted of a square nozzle producing a heated subsonic jet over a perforated plate with three sections of 45 cooling holes each. Results from the multiphysics analysis were compared to a CFD-only approach and experimental results. Reynolds-averaged Navier-Stokes (RANS) computations were employed first, with and without the CHT solver. The multiphysics approach provided much closer agreement with experimentally measured plate temperatures than the CFD-only approach. Comparisons of computed velocities and temperatures were also made with experimental data. Hybrid RANS-large eddy simulation calculations employing the Delayed Detached Eddy Simulation (DDES) approach were also conducted within the multiphysics framework. The DDES approach was unable to resolve turbulent structures in the near wall regions. Hence, the RANS part of the DDES model was used in near wall regions, and produced surface temperatures along with velocity and temperature profiles close to the wall that were very similar to the RANS results. The DDES approach did resolve structures in the outer portion of the boundary layer especially near the end of the plate where the boundary layer was thicker. The key result was the improved surface temperatures produced by the multiphysics approach employing CHT over the fluid-only approach.

Computational Fluid Dynamics↗
NASA NTRS1998

Multiphysics Code Demonstrated for Propulsion Applications

The utility of multidisciplinary analysis tools for aeropropulsion applications is being investigated at the NASA Lewis Research Center. The goal of this project is to apply Spectrum, a multiphysics code developed by Centric Engineering Systems, Inc., to simulate multidisciplinary effects in turbomachinery components. Many engineering problems today involve detailed computer analyses to predict the thermal, aerodynamic, and structural response of a mechanical system as it undergoes service loading. Analysis of aerospace structures generally requires attention in all three disciplinary areas to adequately predict component service behavior, and in many cases, the results from one discipline substantially affect the outcome of the other two. There are numerous computer codes currently available in the engineering community to perform such analyses in each of these disciplines. Many of these codes are developed and used in-house by a given organization, and many are commercially available. However, few, if any, of these codes are designed specifically for multidisciplinary analyses. The Spectrum code has been developed for performing fully coupled fluid, thermal, and structural analyses on a mechanical system with a single simulation that accounts for all simultaneous interactions, thus eliminating the requirement for running a large number of sequential, separate, disciplinary analyses. The Spectrum code has a true multiphysics analysis capability, which improves analysis efficiency as well as accuracy. Centric Engineering, Inc., working with a team of Lewis and AlliedSignal Engines engineers, has been evaluating Spectrum for a variety of propulsion applications including disk quenching, drum cavity flow, aeromechanical simulations, and a centrifugal compressor flow simulation.

Lawrence, Charles↗
NASA NTRS1997

An Overview of Three Approaches to Multidisciplinary Aeropropulsion Simulations

The broad scope of aeropropulsion multidisciplinary applications necessitates that a collection of approaches, with distinct capabilities, be developed. Three general approaches to multidisciplinary simulations have been identified. The three approaches; loosely coupled, coupled process, and multiphysics, provide a comprehensive collection of capabilities for multidisciplinary aeropropulsion analysis. At the data access level, or loosely coupled approach of coupling, existing disciplinary simulations are run, data is generated, and made available and used for subsequent analysis. The data must be in the correct format for implementation by the subsequent analysis but the subsequent code need not directly communicate with the previous code. At the process level, or coupled process approach of coupling, individual disciplinary codes are used, similarly to the loosely coupled approach, however, in the coupled process approach the disciplinary codes need to run concurrently with each other. The system of equation coupled approach, or multiphysics approach, addresses those applications whose characteristics require that the disciplines be coupled at the fundamental equation level to accurately, or more efficiently, capture the multidisciplinary physics of the problem. No one of these approaches, by itself, addresses all of the community needs in this area. However, collectively the three approaches encompass all of the multidisciplinary applications which have been identified thus far. Multiple approaches to multidisciplinary simulations will be needed as long as the applications and their requirements remain as diverse as they currently are today.

Lawrence, Charles↗
NASA NTRS2023

Oxidation of Silicon Particles Suspended in Mullite Matrix With Dual-Mode Vacancy Diffusion of Oxygen

Mullite bond coats filled with silicon particles have recently been proposed for the next generation of environmental barrier coatings (EBCs). The sacrificial oxidation of the silicon particles eliminates some of the environmental durability issues associated with traditional EBC designs. To investigate this novel design approach, a mathematical formulation and resulting numerical method have been developed for simulating the oxidation of silicon particles embedded in a mullite matrix. The focus is on the oxidation of the silicon in a dry oxygen environment where the oxidant is presumably oxygen. Oxygen transport from the exterior environment through the mullite is assumed to occur via two lattice defect diffusion mechanisms. As a result, the rate of oxygen transport is dictated by the self-diffusivity of the lattice defects. The numerical method is implemented using the COMSOL Multiphysics® program (COMSOL, Inc.). The method is applied to simulate the oxidation of silicon particles in a mullite pellet in recent oxidation experiments. Numerical results compare favorably with the oxidation behavior observed in the oxidation experiments. The numerical method is also used to investigate the effects of various features of the mullite-silicon particle system on the oxidation behavior.

silicon oxidation↗
NASA NTRS2004

FEM and Multiphysics Applications at NASA/GSFC

FEM software available to the Mechanical Systems Analysis and Simulation Branch at Goddard Space Flight Center (GSFC) include: 1) MSC/Nastran; 2) Abaqus; 3) Ansys/Multiphysics; 4) COSMOS/M; 5) 'Home-grown' programs; 6) Pre/post processors such as Patran and FEMAP. This viewgraph presentation provides additional information on MSC/Nastran and Ansys/Multiphysics, and includes screen shots of analyzed equipment, including the Wilkinson Microwave Anistropy Probe, a micro-mirror, a MEMS tunable filter, and a micro-shutter array. The presentation also includes information on the verification of results.

Loughlin, James↗
NASA NTRSDate not supplied

Pragmatic Stress Prediction on Additively Manufactured Coupons

Prediction of residual stresses from process parameters for additively manufactured large metal parts is computationally expensive. NASA is currently developing meter-scale parts with direct energy deposition. Practically, the predictive computational methods need to efficiently scale-up to meter-scale parts. Coupled thermal-mechanical multi-physics simulations have been developed with the pragmatic method using ABAQUS, COMSOL Multiphysics, ALE3D software. The residual stresses are a result of the manufacturing process which creates thermal cycling of the build layers. The pragmatic method uses lumped thermal layers for stress predictions to reduce computational costs. The stress predictions as well as deformations of the different codes are compared with each other and with ANSYS Additive using identical material models, boundary and initial conditions. The codes were used to simulate three different geometries: a thin wall, hollow cylinder and twin-cantilever part. The coupon parts were then manufactured with Inconel-625. The residual stresses in these parts were measured using X-ray diffraction as well as neutron beam diffraction at NIST. The stress measurements for the two technologies are compared. The pragmatic stress prediction method enabled predictions of the multi-centimeter scale parts using desktop computer workstations in only a few hours for each coupon. The results of the simulated stress predictions compared favorably with the measured stresses even though thermally lumped layers were employed. Finally, a two-meter scale nozzle was simulated using ANSYS Additive. The simulations were used to examine the build orientation trade-space with respect to resulting geometric deformation. The predicted deformations were compared to measurements of an actual subscale part manufactured with direct energy deposition.

Additive Manufacturing↗
NASA NTRSDate not supplied

Pragmatic Stress Prediction on Additively Manufactured Coupons

Prediction of residual stresses from process parameters for additively manufactured large metal parts is computationally expensive. NASA is currently developing meter-scale parts with direct energy deposition. Practically, the predictive computational methods need to efficiently scale-up to meter-scale parts. Coupled thermal-mechanical multi-physics simulations have been developed with the pragmatic method using ABAQUS, COMSOL Multiphysics, ALE3D software. The residual stresses are a result of the manufacturing process which creates thermal cycling of the build layers. The pragmatic method uses lumped thermal layers for stress predictions to reduce computational costs. The stress predictions as well as deformations of the different codes are compared with each other and with ANSYS Additive using identical material models, boundary and initial conditions. The codes were used to simulate three different geometries: a thin wall, hollow cylinder and twin-cantilever part. The coupon parts were then manufactured with Inconel-625. The residual stresses in these parts were measured using X-ray diffraction as well as neutron beam diffraction at NIST. The stress measurements for the two technologies are compared. The pragmatic stress prediction method enabled predictions of the multi-centimeter scale parts using desktop computer workstations in only a few hours for each coupon. The results of the simulated stress predictions compared favorably with the measured stresses even though thermally lumped layers were employed. Finally, a two-meter scale nozzle was simulated using ANSYS Additive. The simulations were used to examine the build orientation trade-space with respect to resulting geometric deformation. The predicted deformations were compared to measurements of an actual subscale part manufactured with direct energy deposition.

pragmatic method↗
NASA NTRS2013

Dynamics and Control of a Disordered System in Space

In this paper, we present some ideas regarding the modeling, dynamics and control aspects of granular spacecraft. Granular spacecraft are complex multibody systems composed of a spatially disordered distribution of a large number of elements, for instance a cloud of N grains in orbit, with N greater than 10(exp 3). These grains can be large (Cubesat-size) or small (mm-size), and can be active, i.e., a fully equipped vehicle capable sensing their own position and attitude, and enabled with propulsion means, or entirely passive. The ultimate objective would be to study the behavior of the single grains and of large ensembles of grains in orbit and to identify ways to guide and control the shape of a cloud composed of these grains so that it can perform a useful function in space, for instance, as an element of an optical imaging system for astrophysical applications. This concept, in which the aperture does not need to be continuous and monolithic, would increase the aperture size several times compared to large NASA observatories such as ATLAST, allowing for a true Terrestrial Planet Imager that would be able to resolve exo-planet details and do meaningful spectroscopy on distant world. In the paper, we address the modeling and autonomous operation of a distributed assembly (the cloud) of large numbers of highly miniaturized space-borne elements (the grains). A multi-scale, multi-physics model is proposed of the dynamics of the cloud in orbit, as well as a control law for cloud shape maintenance, and preliminary simulation studies yield an estimate of the computational effort, indicating a scale factor of approximately N(exp 1.4) as a function of the number of grains. A granular spacecraft can be defined as a collection of a large number of space-borne elements (in the 1000s) designed and controlled such that a desirable collective behavior emerges, either from the interactions among neighboring grains, and/or between the grains and the environment. In this paper, each grain is considered to be a highly miniaturized spacecraft which has limited size and mass, hence it has limited actuation, limited propulsive capability, limited power, limited sensing, limited communication, limited computational resources, limited range of motion, limited lifetime, and may be expendable. The modeling and dynamics of clouds of vehicles is more challenging than with conventional vehicles because we are faced with a probabilistic vehicle composed of a large number of physically disconnected vehicles. First, different scales of motion occur simultaneously in a cloud: translations and rotations of the cloud as a whole (macro-dynamics), relative rotation and translation of one cloud member with respect to another (meso-dynamics), and individual cloud member dynamics (micro-dynamics). Second, the control design needs to be tolerant of the system complexity, of the system architecture (centralized vs. decentralized large scale system control) as well as robust to un-modeled dynamics and noise sources. Figure 1, top left, shows the kinematic parameters of a 1000 element cloud in orbit. The motion of the system is described with respect to a local vertical-local horizontal (LV-LH) orbiting reference frame (x,y,z)=F(sub ORF) of origin O(sub ORF) which rotates with mean motion omega and orbital semi-major axis R(sub 0). The orbital geometry at the initial time is defined in terms of its six orbital elements, and the orbital dynamics equation for point O(sub ORF) is propagated forward in time under the influence of the gravitational field of the primary and other external perturbations, described below. The origin of this frame coincides with the initial position of the center of mass of the system, and the coordinate axes are z along the local vertical, x toward the flight direction, and y in the orbit normal direction. The assumptions we used to model the dynamics are as follows: 1) The inertial frame is fixed at Earth's center. 2) The orbiting Frame ORF follows Keplerian orbit. 3) the cloud system dynamics is referred to ORF. 4) the attitude of each grain uses the principal body frame as body fixed frame. 5) the atmosphere is assumed to be rigidly rotating with the Earth. Regarding the grains forming the cloud: 1) each grain is modeled as a rigid body; 2) a simple attitude estimator provides attitude estimates, 3) a simple guidance logic commands the position and attitude of each grain, 4) a simple local feedback controller based on PD control of local states is used to stabilize the attitude of the vehicle. Regarding the cloud: 1) the cloud as a whole is modeled as an equivalent rigid body in orbit, and 2) an associated graph establishes agent connectivity and enables coupling between modes of motion at the micro and macro scales; 3) a simple guidance and estimation logic is modeled to estimate and command the attitude of this equivalent rigid body; 4) a cloud shape maintenance controller is based on the dynamics of a stable virtual truss in the orbiting frame. Regarding the environmental perturbations acting on the cloud: 1) a non-spherical gravity field including JO (Earth's spherical field) zonal component, J2 (Earth's oblateness) and J3 zonal components is implemented; 2) atmospheric drag is modeled with an exponential model; 3) solar pressure is modeled assuming the Sun is inertially fixed; and 4) the Earth's magnetic field is model using an equivalent dipole model. The equations of motion are written in a referential system with respect to the origin of the orbiting frame and the state is propagated forward in time using an incremental predictor-corrector scheme. A representative cloud with varying number of grains is simulated to identify the limitations in computation time as the number of grains grows. We derive a control law to track a desired surface in the ORF (equivalently to maintain a reference cloud shape) by defining an error from a desired surface shape, and designing a control law that is exponentially stable and reduces the tracking error to zero. Figure 1 (top right) shows a comparison of various requirements for simulation of single spacecraft vs. granular spacecraft, indicating the high degree of complexity that needs to be taken into consideration. The ORF components of control force required by one of the grains is, for this particular case, in the micro-Newton range. However, no attempt has been made yet to reconfigure (or re-orient) the cloud configuration internally, for which forces in the milli-Newton level are expected, depending on the time required to do the reconfiguration. Figure 1, bottom, shows the computation time as a function of the number of grains, indicating an order N(exp 1.43) scaling on a 8 Gb, 1067 MHz RAM MacOSX computer with a 3.06 GHz Intel Core 2 Duo processor. With this metric, the same simulation for a system of N=1000 grains would take 5.4 hours, and 146 hours (i.e., 6 days) for a system with N=10,000 grains. Therefore, efficient ways to simulate this complex system, where not only the time scales of natural system dynamics, but also the sampling times of the Guidance, Navigation, and Control are included, remain to be explored. Additional details on the cloud modeling, dynamics, and control will be described in the paper.

simulation↗
NASA NTRSDate not supplied

Performance of Coupled Physics Solvers for Multidisciplinary Hypersonic Flow Simulations on Several Classes of Computer Architectures

The application of hypersonic flow simulation tools to realistic flight scenarios will require the coupling of multiple physical effects to the baseline fluid dynamics. Such multiphysics effects can include the aerooelastic response of the airframe or engine components, dynamic transport of atmospheric particles, the deformation of solid-fluid interfaces that can ablate, pyrolyze, or erode, as well as a host of other processes, all of which are governed by unique sets of physical equations and models. Coupling multiple (and potentially disparate) physics solvers to a robust compressible flow solver poses additional challenges related to the stability, performance and scalability of the combined solver. The choices made during the software design process can therefore lead to a variation in simulation efficiency across different computer architectures. In this paper, we will consider two representative multiphysics hypersonic flow scenarios: the interaction of solid particulates with the flow field created by a hypersonic lifting body and the aerooelastic deformation of a model airframe under high-Mach-number flow conditions. For these simulations we explore the behavior of several hypersonic simulation tools, including Kestrel, FUN3D, US3D, and JENRE multiphysics framework, on several high performance computing systems containing various CPU and GPU architectures.

architecture↗
NASA NTRS2011

Using Microwaves to Heat Lunar Soil

This slide presentation reviews the use of microwaves to heat lunar soil in order to obtain water. There appears to be large amounts of water in the lunar poles, in Martian areas in lower latitudes and some of the Moons of Jupiter. The presence of water in the south lunar polar region was demonstrated by the Lunar CRater Observation and Sensing Satellite (LCROSS) mission. Microwaves can be used to extract water from lunar soil without excavation. Using microwaves on a lunar soil simulant at least 95% of the water from the regolith permafrost simulant was extracted (2 minutes). The process is modeled using COMSOL Multiphysics Finite Element analysis microwave physics module and demonstrated usingan experiment of an microwave apparatus on a rover.

Ethridge, Edwin C.↗
NASA NTRS2016

Using Simulation to Analyze Acoustic Environments

One of the main projects that was worked on this semester was creating an acoustic model for the Advanced Space Suit in Comsol Multiphysics. The geometry tools built into the software were used to create an accurate model of the helmet and upper torso of the suit. After running the simulation, plots of the sound pressure level within the suit were produced, as seen below in Figure 1. These plots show significant nulls which should be avoided when placing microphones inside the suit. In the future, this model can be easily adapted to changes in the suit design to determine optimal microphone placements and other acoustic properties. Another major project was creating an acoustic diverter that will potentially be used to route audio into the Space Station's Node 1. The concept of the project was to create geometry to divert sound from a neighboring module, the US Lab, into Node 1. By doing this, no new audio equipment would need to be installed in Node 1. After creating an initial design for the diverter, analysis was performed in Comsol in order to determine how changes in geometry would affect acoustic performance, as shown in Figure 2. These results were used to produce a physical prototype diverter on a 3D printer. With the physical prototype, testing was conducted in an anechoic chamber to determine the true effectiveness of the design, as seen in Figure 3. The results from this testing have been compared to the Comsol simulation results to analyze how closely the Comsol results are to real-world performance. While the Comsol results do not seem to closely resemble the real world performance, this testing has provided valuable insight into how much trust can be placed in the results of Comsol simulations. A final project that was worked on during this tour was the Audio Interface Unit (AIU) design for the Orion program. The AIU is a small device that will be used for as an audio communication device both during launch and on-orbit. The unit will have functions including push-to-talk buttons and volume control. With this project, an existing design was modified based on prior feedback that had been received. With the modified design, I created a 3D printed prototype, shown in Figure 4, which was then used in suited evaluations performed by crew members. The feedback received from those evaluations will be utilized to help create the best possible Orion AIU. As a whole, a number of different interesting engineering projects were worked on over the course of this semester. For many of these projects, acoustic simulations provided valuable insight into how different environments would respond to sound. While work is still underway to verify the results of these simulations, the results are fascinating because of the interesting ways that sound waves interact with the environment. Going forward, it will be interesting to see how closely these results can be matched by real-world test data.

Wood, Eric J.↗