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NASA NTRS1976

Theoretical optimization and parametric study of n-on-p Al/x/Ga/1-x/As-GaAs graded band-gap solar cell

A comprehensive theoretical model of the graded band-gap Al(x)Ga(1-x)As-GaAs solar cell is used to optimize the n-on-p cell. The model includes power losses due to surface, bulk, and junction minority-carrier recombination, series resistance, and photon reflection from an SiO antireflection coating of optimum thickness. The optimized cell has a junction depth/graded band-gap layer thickness of 1.0 micron, respective donor and acceptor concentrations of 4 x 10 to the 17th power and 2 x 10 to the 17th power per cu cm, and a surface AlAs mode fraction of x = 0.35. The optimized graded band-gap cell has an air-mass-zero efficiency of 17.7% (not corrected for a 13% front surface contact area) and is shown to be less sensitive than a similar n-on-p GaAs cell to material degradation in the form of decreased minority-carrier diffusion lengths and increased surface-recombination velocity

Hutchby, J. A.↗

DOE OSTI2024

Multiphysics Design Optimization and Additive Manufacturing of Nuclear Components (Final CRADA Report - Executive Summary)

Westinghouse Electric Company (WEC) actively participated in the advancement of the nuclear fuel and reactor design space and requested the help of Oak Ridge National Laboratory (ORNL) in the creation of a new design tool set. This report details the creation of a collection of software tool sets that are linked together to collectively assist WEC design engineers in developing novel ideas outside the normal scope of traditional nuclear fuel and reactor design formulas. Specifically, Siemens HEEDS, a design space exploration and parametric optimization software, monitored and changed parameters in a collection of softwares to meet the team’s objective. The HEEDS parametric optimization method, SHERPA, was developed to control the Siemens NX CAD platform to adjust the native CAD of a hexahedral spacer grid. This new geometry can be used to execute a topological design optimization by the NX Topology software add-in. The resulting geometry is additively manufacturable. This topological optimization occurred twice—once on the spacer grid’s spring, and once on the dimple geometry. These new geometries were imported by Siemens’ STAR-CCM+, a multiphysics structural and fluid dynamic computational solver in which the spring geometry is deflected to match the rod insertion configuration. Along with the dimple geometry, this new deflected spring was used to complete a hydraulic assessment of a single-unit cell comprising one rod, one spring, and two dimples. The HEEDS SHERPA algorithm ranks the design based on the final mass of the unit cell and the hydraulic pressure drop performance. The ORNL team demonstrated the ability to use this software and provided engineering judgement to apply modern aerospace aerodynamic design. The effort has been focused on thinking outside the conventional design space and redesigning a spacer grid to perform beyond the WEC set objectives. Furthermore, the ORNL team also demonstrated that the HEEDS optimization routine can independently develop a design that meets the WEC design goals. Although these designs were at a low technology readiness level, their demonstration confirmed the team’s capability to create novel advanced nuclear concepts.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRSDate not supplied

Optimization-Based Parametric Design via High-Fidelity Simulation: Overview + Examples

Design-Build-Test approaches for developing spaceflight hardware are prohibitively time and cost intensive and often lead to suboptimal mechanism designs. Approaches that couple machine learning and high-fidelity physics simulation could eliminate the need for hardware prototyping and dramatically accelerate the engineering design cycle, ultimately reducing cost. This talk presents a modular NASA-developed toolchain to optimize hardware mechanisms in a virtual environment using numerical optimization and multi-body physics simulation and includes example applications related to rigid wheel design for autonomous rovers and computational fluid dynamics.

optimization↗

DOE OSTI2024

Learning Constrained Parametric Differentiable Predictive Control Policies With Guarantees

We present differentiable predictive control (DPC), a method for offline learning of constrained neural control policies for nonlinear dynamical systems with performance guarantees. We show that the sensitivities of the parametric optimal control problem can be used to obtain direct policy gradients. Specifically, we employ automatic differentiation (AD) to efficiently compute the sensitivities of the model predictive control (MPC) objective function and constraints penalties. To guarantee safety upon deployment, we derive probabilistic guarantees on closed-loop stability and constraint satisfaction based on indicator functions and Hoeffding’s inequality. We empirically demonstrate that the proposed method can learn neural control policies for various parametric optimal control tasks. In particular, we show that the proposed DPC method can stabilize systems with unstable dynamics, track time-varying references, and satisfy nonlinear state and input constraints. Our DPC method has practical time savings compared to alternative approaches for fast and memory-efficient controller design. Specifically, DPC does not depend on a supervisory controller as opposed to approximate MPC based on imitation learning. We demonstrate that, without losing performance, DPC is scalable with greatly reduced demands on memory and computation compared to implicit and explicit MPC while being more sample efficient than model-free reinforcement learning (RL) algorithms.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1959

Optimization of Parametric Constants for Creep-Rupture Data by Means of Least Squares

An objective method utilizing least squares is presented for the determination of the optimum parametric constants for stress-rupture data. The method is applied to both isostress and isothermal data for the parameters proposed by Larson and Miller, Manson and Haferd, and by Dorn. Several examples are treated in detail, and it was found that the method gives good results. It is shown that the values of the constants for the parameter proposed by Manson and Haferd are not critical as long as Ta and log ta appear in the proper combination. In addition to optimization, the chief utility of the method lies in the fact that it gives the same results for a given set of data no matter who makes the analysis, which is not the case for the graphical methods presently employed.

Manson, S. S.↗

NASA NTRS1983

Perfect bell nozzle parametric and optimization curves

Nozzle contour data for untruncated Bell nozzles with expansion area ratios to 6100 and a specific heat ratio of 1.2 are provided. Curves for optimization of nozzles for maximum thrust coefficient within a given length, surface area, or area ratio are included. The nozzles are two dimensional axisymmetric and calculations were performed using the method of characteristics. Drag due to wall friction was included in the final thrust coefficient.

Tuttle, J. L.↗

DOE OSTI2022

DED Additively Manufactured HEAs Optimized via Parametric Study of Functionally Graded Materials

Complex concentrated alloys (CCAs) are a system of alloys composition of nearly equiatomic elements, creating a state of high configurational entropy in the material. These alloys are of interest for various industrial applications due to their high strength and hardness, wide operational temperature range, creep and diffusion resistance, and radiation resistance. In the current work CoCrFeNi-base CCAs are synthesize by combining three commonly industrial alloys: IN718, SS316L, and 70Co30Cr (commercially known as Stellite 21), in-situ utilizing directed energy deposition (DED) additive manufacturing (AM). One bulk specimen is fabricated with a 1:1:1 ratio of IN718, SS316L, and 70Co30Cr where IN718 is a source of nickel and chrome, SS316 is a source of iron and chrome, and 70Co30Cr is a source of cobalt and supplemental chrome. Additionally, a functionally graded material (FGM) of the identified CCA system from SS316 was fabricated with 10 layers, where the initial five layers are the base material of SS316L and graded by steps of 20% to transition to the CCA system. Overall build quality, microstructure, compositional distribution, phases analysis, and microhardness were studied by laser optical microscopy, scanning election microscopy (SEM), energy dispersive spectroscopy (EDS), X-ray diffraction analysis (XRD), and Vickers microhardness techniques. Overall build quality showed a successful bulk build with acceptable density, however unmelted particles are observed in the as-built alloy. Compositional results show that the system meets the Boltzmann’s hypothesis definition of an HEA, and that an FCC CCA was produced with increased hardness, small grain size, and superior hardness properties to the SS316L substrate. While initial XRD results show predominately FCC structure, EDS analysis of interdendritic regions show the existence of Laves phases in the material. The fabrication of an FGM CCA allowed for potential screening of additional alloy mixes which may be of interest to explore in future research, and the resulting composition is compared to predicted values. This novel method of CCA fabrication results in substantial cost savings of these CCA systems over traditional methods.

36 MATERIALS SCIENCE↗

NASA NTRS2012

On Optimal Control of Non-Autonomous Switched Systems with a Fixed Mode Sequence

We consider differentiability with respect to the switch times of the value function of an optimal control problem for a non-autonomous switched system. The control variables are the switch times between the modes and the input in each mode. We provide a method to compute the derivative of the cost function given a nominal input. Then, we view the optimal control problem as a parametrized optimization problem in which the switch times are the parameters and the optimization is over the set of feasible inputs of each mode. From this point of view, we provide conditions under which the continuity and differentiability of the optimal value function, that is the cost function optimized over the inputs, can be guaranteed.

Kamgarpour, Maryam↗

DOE OSTI2024

Optimization-Inspired Pin-Fin Array for Supercritical Carbon Dioxide Recuperator

Additively manufactured heat exchangers are one possible route to cost-effective sCO 2 power cycles. In this paper, experimental results are obtained for two helical pin fin tubes that were designed following parametric optimization of the fin array. Neither the numerical optimization nor the experimental testing have been previously reported in the literature. The two tube designs were, (1) the optimization inspired design, and (2) the optimization-inspired design with a fin diameter increased by a factor of 2. To characterize the print, the designs were scanned using X-ray computed tomography to measure feature sizes and heat transfer area. The optimization was conducted in a commercial, computational fluid dynamics code. The code solved the Reynolds Averaged Navier-Stokes (RANS) and energy equations with turbulence closure provided by the shear stress transport (SST) k-ω model. In the experiments, the Nusselt number augmentation was measured using the Wilson plot technique and the friction factor was determined with mass flow and pressure drop measurements. The experimental testing indicated that the optimization-inspired design had a friction factor that was four times less than the baseline tube design at equal Nusselt number. Additionally, the optimization-inspired design had a 14% improvement in Nusselt number, at equal friction factor, relative to the best performing computational fluid dynamics (CFD) trial points. Tube design (2), with the larger diameter pin fins, had similar performance, within experimental error, as the tube with the smaller diameter pin fins (1). Both tubes achieved overall fin array efficiencies near 1. A performance factor, V/V 0 , equal to the volume of the enhanced heat exchanger divided by the volume of the baseline (no-fins) heat exchanger, is recommended to quantify internal cooling performance. In conclusion, the experimental shell and tube heat exchanger, using the additively manufactured tube, is competitive with printed circuit heat exchangers in its pressure drop class and could be further improved by optimizing a shell-and-tube heat exchanger utilizing this heat transfer enhancement feature.

42 ENGINEERING↗

NASA NTRSDate not supplied

Computational Fluid Dynamic Optimization of an Experimental Rotating Detonation Rocket Engine Nozzle

A parametric optimization study is performed on the nozzle of a laboratory rotating detonation rocket engine (RDRE) using a three-dimensional computational fluid dynamic simulation. The primary optimization objective is maximum nozzle thrust. The basic nozzle configuration is a shrouded, truncated plug. The fluid in the RDRE chamber leading to the nozzle is choked at its exit so that its cyclic behavior is unaffected by any changes to the nozzle design. Optimization is performed for a single operating point. Parameters varied are the overall nozzle area expansion ratio and the fraction of the expansion area that is provided by the shroud. These two parameters indirectly affect the angle of the plug nozzle cone, and the bluff body area associated with its truncation. Nozzle thrust is evaluated as the difference between the thrust of the RDRE chamber-plus-nozzle combination and that of the chamber alone. The nozzle produces approximately 20% of the total engine thrust. The baseline nozzle is found to perform well, yielding 58.1% of the thrust calculated for a notional ideal RDRE nozzle which can instantaneously change shape to allow isentropic expansion of every fluid element. Optimization improves the performance, bringing the nozzle thrust to 70.0% of the notional ideal, and total engine thrust (chamber-plus-nozzle) to 94% of the ideal.

detonation↗

NASA NTRSDate not supplied

Computational Fluid Dynamic Optimization of an Experimental Rotating Detonation Rocket Engine Nozzle

detonation↗

DOE OSTI2022

Learning high-dimensional parametric maps via reduced basis adaptive residual networks

We propose a scalable framework for the learning of high-dimensional parametric maps via adaptively constructed residual network (ResNet) maps between reduced bases of the inputs and outputs. When just few training data are available, it is beneficial to have a compact parametrization in order to ameliorate the ill-posedness of the neural network training problem. By linearly restricting high-dimensional maps to informed reduced bases of the inputs, one can compress high-dimensional maps in a constructive way that can be used to detect appropriate basis ranks, equipped with rigorous error estimates. A scalable neural network learning framework is thus to learn the nonlinear compressed reduced basis mapping. Unlike the reduced basis construction, however, neural network constructions are not guaranteed to reduce errors by adding representation power, making it difficult to achieve good practical performance. Inspired by recent approximation theory that connects ResNets to sequential minimizing flows, we present an adaptive ResNet construction algorithm. This algorithm allows for depth-wise enrichment of the neural network approximation, in a manner that can achieve good practical performance by first training a shallow network and then adapting. We prove universal approximation of the associated neural network class for $L^2_v$ functions on compact sets. Our overall framework allows for constructive means to detect appropriate breadth and depth, and related compact parametrizations of neural networks, significantly reducing the need for architectural hyperparameter tuning. Numerical experiments for parametric PDE problems and a 3D CFD wing design optimization parametric map demonstrate that the proposed methodology can achieve remarkably high accuracy for limited training data, and outperformed other neural network strategies we compared against.

42 ENGINEERING↗

NASA NTRS1991

Multidisciplinary optimization in aircraft design using analytic technology models

An approach to multidisciplinary optimization is presented which combines the Global Sensitivity Equation method, parametric optimization, and analytic technology models. The result is a powerful yet simple procedure for identifying key design issues. It can be used both to investigate technology integration issues very early in the design cycle, and to establish the information flow framework between disciplines for use in multidisciplinary optimization projects using much more computational intense representations of each technology. To illustrate the approach, an examination of the optimization of a short takeoff heavy transport aircraft is presented for numerous combinations of performance and technology constraints.

Malone, Brett↗

NASA NTRS1974

Optimal rocket thrust profile shaping using third degree spline function interpolation

Optimal solid-rocket thrust profiles for the parallel-burn, solid-rocket-assisted space shuttle are investigated. Solid-rocket thrust profiles are simulated by using third-degree spline functions, with the values of the thrust ordinates defined as parameters. The profiles are optimized parametrically, using the Davidon-Fletcher-Powell penalty function method, by minimizing propellant weight subject to state and control inequality constraints and to terminal boundary conditions. This study shows that optimizing a control variable parametrically by using third-degree spline function interpolation allows the control to be shaped so that inequality constraints are strictly adhered to and all corners are eliminated. The absence of corners, which is realistic in nature, makes this method attractive from the viewpoint of solid rocket grain design.

Johnson, I. L.↗

NASA NTRS1999

Further Development, Support and Enhancement of CONDUIT

From the first airplanes steered by handles, wheels, and pedals to today's advanced aircraft, there has been a century of revolutionary inventions, all of them contributing to flight quality. The stability and controllability of aircraft as they appear to a pilot are called flying or handling qualities. Many years after the first airplanes flew, flying qualities were identified and ranked from desirable to unsatisfactory. Later on engineers developed design methods to satisfy these practical criteria. CONDUIT, which stands for Control Designer's Unified Interface, is a modern software package that provides a methodology for optimization of flight control systems in order to improve the flying qualities. CONDUIT is dependent on an the optimization engine called CONSOL-OPTCAD (C-O). C-O performs multicriterion parametric optimization. C-O was successfully tested on a variety of control problems. The optimization-based computational system, C-O, requires a particular control system description as a MATLAB file and possesses the ability to modify the vector of design parameters in an attempt to satisfy performance objectives and constraints specified by the designer, in a C-type file. After the first optimization attempts on the UH-60A control system, an early interface system, named GIFCORCODE (Graphical Interface for CONSOL-OPTCAD for Rotorcraft Controller Design) was created.

Veronica, Moldoveanu↗

NASA NTRS1979

Optimization of space manufacturing systems

Four separate analyses are detailed: transportation to low earth orbit, orbit-to-orbit optimization, parametric analysis of SPS logistics based on earth and lunar source locations, and an overall program option optimization implemented with linear programming. It is found that smaller vehicles are favored for earth launch, with the current Space Shuttle being right at optimum payload size. Fully reusable launch vehicles represent a savings of 50% over the Space Shuttle; increased reliability with less maintenance could further double the savings. An optimization of orbit-to-orbit propulsion systems using lunar oxygen for propellants shows that ion propulsion is preferable by a 3:1 cost margin over a mass driver reaction engine at optimum values; however, ion engines cannot yet operate in the lower exhaust velocity range where the optimum lies, and total program costs between the two systems are ambiguous. Heavier payloads favor the use of a MDRE. A parametric model of a space manufacturing facility is proposed, and used to analyze recurring costs, total costs, and net present value discounted cash flows. Parameters studied include productivity, effects of discounting, materials source tradeoffs, economic viability of closed-cycle habitats, and effects of varying degrees of nonterrestrial SPS materials needed from earth. Finally, candidate optimal scenarios are chosen, and implemented in a linear program with external constraints in order to arrive at an optimum blend of SPS production strategies in order to maximize returns.

Akin, D. L.↗

NASA NTRS2013

Control of Future Air Traffic Systems via Complexity Bound Management

The complexity of the present system for managing air traffic has led to "discreteness" in approaches to creating new concepts: new concepts are created as point designs, based on experience, expertise, and creativity of the proposer. Discrete point designs may be highly successful but they are difficult to substantiate in the face of equally strong substantiation of competing concepts, as well as the state of the art in concept evaluation via simulations. Hybrid concepts may present a compromise - the golden middle. Yet a hybrid of sometimes in principle incompatible concepts forms another point design that faces the challenge of substantiation and validation. We are faced with the need to re-design the air transportation system ab initio. This is a daunting task, especially considering the problem of transitioning from the present system to any fundamentally new system. However, design from scratch is also an opportunity to reconsider approaches to new concept development. In this position paper we propose an approach, Optimized Parametric Functional Design, for systematic development of concepts for management and control of airspace systems, based on optimization formulations in terms of required system functions and states. This reasoning framework, realizable in the context of ab initio system design, offers an approach to deriving substantiated airspace management and control concepts. With growing computational power, we hope that the approach will also yield a methodology for actual dynamic control of airspace

Alexandrov, Natalia↗

NASA NTRS1993

Techniques for designing rotorcraft control systems

This report summarizes the work that was done on the project from 1 Apr. 1992 to 31 Mar. 1993. The main goal of this research is to develop a practical tool for rotorcraft control system design based on interactive optimization tools (CONSOL-OPTCAD) and classical rotorcraft design considerations (ADOCS). This approach enables the designer to combine engineering intuition and experience with parametric optimization. The combination should make it possible to produce a better design faster than would be possible using either pure optimization or pure intuition and experience. We emphasize that the goal of this project is not to develop an algorithm. It is to develop a tool. We want to keep the human designer in the design process to take advantage of his or her experience and creativity. The role of the computer is to perform the calculation necessary to improve and to display the performance of the nominal design. Briefly, during the first year we have connected CONSOL-OPTCAD, an existing software package for optimizing parameters with respect to multiple performance criteria, to a simplified nonlinear simulation of the UH-60 rotorcraft. We have also created mathematical approximations to the Mil-specs for rotorcraft handling qualities and input them into CONSOL-OPTCAD. Finally, we have developed the additional software necessary to use CONSOL-OPTCAD for the design of rotorcraft controllers.

Levine, William S.↗