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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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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Validation of process simulation workflow for thermosetting prepreg platelet molding compounds

Continuous carbon fiber prepreg slit and cut into rectangular platelets has proven to be a useful material for net shape molding of semi-structural and structural components in the aerospace and automotive industries. Furthermore, to assist the designer in use of these prepreg platelet molding compounds, sometimes called carbon fiber sheet molding compounds, simulation tools are required that can predict the as-manufactured fiber orientation state which has a significant impact on the resulting performance. Herein, an analysis workflow for design-enabling predictions is demonstrated for a double dome geometry with two different initial charge configurations. Here, the workflow is validated through comparison with experimental short shots, orientation state, and stiffness trends. Significantly, to complete the validation, a method is proposed for determining the confidence bounds on measured orientation state enhancing the results of optical microscopy which can only produce a small sample of platelet orientations.

36 MATERIALS SCIENCE↗
NASA NTRS1991

A general software reliability process simulation technique

The structure and rationale of the generalized software reliability process, together with the design and implementation of a computer program that simulates this process are described. Given assumed parameters of a particular project, the users of this program are able to generate simulated status timelines of work products, numbers of injected anomalies, and the progress of testing, fault isolation, repair, validation, and retest. Such timelines are useful in comparison with actual timeline data, for validating the project input parameters, and for providing data for researchers in reliability prediction modeling.

Tausworthe, Robert C.↗
DOE OSTI2024

Adsorption Thermodynamics for Process Simulation

Adsorption has rapidly evolved in recent decades and is an established separation technology extensively practiced in gas separation industries and others. However, rigorous thermodynamic modeling of multicomponent adsorption equilibrium remains elusive, and industrial practitioners rely heavily on expensive and time-consuming trial-and-error pilot studies to develop adsorption units. Here, this article highlights the need for rigorous adsorption thermodynamic models and the limitations and deficiencies of existing models such as the extended Langmuir isotherm, dual-process Langmuir isotherm, and adsorbed solution theory. It further presents a series of recent advances in the generalization of the classical Langmuir isotherm of single-component adsorption by deriving an activity coefficient model to account for the adsorbed phase adsorbate–adsorbent interactions, substituting adsorbed phase adsorbate and vacant site concentrations with activities, and extending to multicomponent competitive adsorption equilibrium, both monolayer and multilayer. Requiring a minimum set of physically meaningful model parameters, the generalized Langmuir isotherm for monolayer adsorption and the generalized Brunauer–Emmett–Teller isotherm for multilayer adsorption address various thermodynamic modeling challenges including adsorbent surface heterogeneity, isosteric enthalpies of adsorption, BET surface areas, adsorbed phase nonideality, adsorption azeotrope formation, and multilayer adsorption. Also discussed is the importance of quality adsorption data that cover sufficient temperature, pressure, and composition ranges for reliable determination of the model parameters to support adsorption process simulation, design, and optimization.

09 BIOMASS FUELS↗
DOE OSTI2021

Kraft black liquor concentration with graphene oxide membranes: Process simulations and technoeconomic analysis

Abstract Black liquor (BL) dewatering by multi‐effect evaporation in the kraft papermaking process is highly energy‐intensive. It was previously shown that graphene oxide (GO) nanofiltration membranes can remove lignin, other organics, and inorganic salts from BL while exhibiting stability in caustic BL conditions. Here, we design and simulate several candidate dewatering processes and evaluate their technoeconomic characteristics. All processes concentrate BL from 15 to 30 wt% solutes while producing aqueous permeate. Two process options were analyzed—option A including “last‐mile” permeate treatment to reduce solutes to 0.2 wt%, and option B excluding this treatment and producing a 3–4 wt% solutes stream. These processes were simulated in custom‐built ASPEN Plus flowsheets interfaced with Microsoft Excel and MATLAB. All processes deliver large (>40%) energy savings. Detailed technoeconomic analysis showed that option A processes are profitable in mills equipped with condensing turbines, but unprofitable with only purchased fuel savings. Option B processes are profitable in both situations, but require the caustic permeate to be utilized in other kraft process units. They are also profitable with electricity generation when operated at smaller scales matching the requirements of other process units. Monte‐Carlo sensitivity analysis shows that Option A can yield median 20‐year NPVs up to ~$10MM and Option B up to ~$25MM. Overall, GO membrane‐based BL dewatering is economically promising, assuming successful slipstream piloting and scale‐up campaigns. It would have immediate sustainability benefits from large energy savings, and broader implications for biorefinery processes due to the ability to fractionate biomass feedstock components under harsh conditions.

Wang, Zhongzhen↗
DOE OSTI2021

Large-Scale Welding Process Simulation by GPU Parallelized Computing

The computational design of industrially relevant welded structures is extremely time consuming due to coupled physics and high nonlinearity. Previously, most welding distortion and residual stress simulations have been limited to small coupons and reduced order (from three-dimensional [3D] to two-dimensional [2D]), or inherent strain approximations were used for large structures. In this current study, an explicit finite element code based on a graphics processing unit was utilized to perform 3D transient thermomechanical simulation of structural components during welding. Laser brazing of aluminum alloy panels as representative of automotive manufacturing scenarios was simulated to predict out-of-plane distortion under different clamping conditions. The predicted deformation pattern and magnitude were validated by laser scanning data of physical assemblies. In addition, the code was used to investigate residual stresses developed during multipass arc welding of a nuclear industry pressurizer surge nozzle and subsequent welding repair where a 3D simulation was necessary. Taking the experimental data as reference, the 3D model predicted better residual stress distribution than a typical 2D asymmetrical model. Stress evolution in welding repair was also presented and discussed in this study. Furthermore, the efficient numerical model made it feasible to use integrated computational welding engineering to simulate welding processes for large-scale structures.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1988

Random Process Simulation for stochastic fatigue analysis

A simulation technique is described which directly synthesizes the extrema of a random process and is more efficient than the Gaussian simulation method. Such a technique is particularly useful in stochastic fatigue analysis because the required stress range moment E(R sup m), is a function only of the extrema of the random stress process. The family of autoregressive moving average (ARMA) models is reviewed and an autoregressive model is presented for modeling the extrema of any random process which has a unimodal power spectral density (psd). The proposed autoregressive technique is found to produce rainflow stress range moments which compare favorably with those computed by the Gaussian technique and to average 11.7 times faster than the Gaussian technique. The autoregressive technique is also adapted for processes having bimodal psd's. The adaptation involves using two autoregressive processes to simulate the extrema due to each mode and the superposition of these two extrema sequences. The proposed autoregressive superposition technique is 9 to 13 times faster than the Gaussian technique and produces comparable values for E(R sup m) for bimodal psd's having the frequency of one mode at least 2.5 times that of the other mode.

Larsen, Curtis E.↗
NASA NTRS1989

Explicit modeling and computational load distribution for concurrent processing simulation of the space station

Two important aspects of concurrent processing under development at TRW are discussed. These are: (1) the derivation of explicit mathematical models of multibody dynamic systems, and (2) a balanced computational load distribution (BCLD) among loosely coupled computational units (processors) of a concurrent processing system. The developed methodologies are demonstrated by way of an application to the Phase 1 of the Space Station - a task being performed by TRW under NASA/JSC contract NAS9-17778. The mathematical model of the Space Station consists of three interconnected flexible bodies capable of undergoing large, rigid-body motion with respect to each other. Body 1 is the main central body and contains the pressurized modules inboard of the two Alpha gimbals. Bodies 2 and 3 are the starboard and port bodies connected to Body 1 at the Alpha gimbals and include all components on the transverse booms outboard of the Alpha gimbals (including the solar arrays). The control systems in the model maintain Body 1 in a prescribed 3-axis attitude control mode, while producing large-angle rotations of the flexible solar arrays to position them normal to the sun-line.

Gluck, R.↗
NASA NTRS1987

Integration of communications and tracking data processing simulation for space station

A simplified model of the communications network for the Communications and Tracking Data Processing System (CTDP) was developed. It was simulated by use of programs running on several on-site computers. These programs communicate with one another by means of both local area networks and direct serial connections. The domain of the model and its simulation is from Orbital Replaceable Unit (ORU) interface to Data Management Systems (DMS). The simulation was designed to allow status queries from remote entities across the DMS networks to be propagated through the model to several simulated ORU's. The ORU response is then propagated back to the remote entity which originated the request. Response times at the various levels were investigated in a multi-tasking, multi-user operating system environment. Results indicate that the effective bandwidth of the system may be too low to support expected data volume requirements under conventional operating systems. Instead, some form of embedded process control program may be required on the node computers.

Lacovara, Robert C.↗
DOE OSTI2022

Simulation process and data flow for a large system dynamics model

This paper documents the workflow and supporting technologies that a large system dynamics model, the biomass scenario model, employs to streamline the data preparation, simulation, quality control, and analysis process at the National Renewable Energy Laboratory. The workflow centers on automation of routine aspects of the flow of data between data stores, simulations, and visualizations. It enforces quality checks on data, reproducibility of computations, and traceability of results, while maintaining complete archives of modeling and analysis artifacts. The resulting frictionless simulation/analysis environment supports large-scale sensitivity analysis, interactive creation of ensembles of simulations, and rapid visualization-based exploration of simulation results.

09 BIOMASS FUELS↗
NASA NTRS2017

Cyclotron Resonant Scattering Feature Simulations II. Description of the CRSF Simulation Process

Context. Cyclotron resonant scattering features (CRSFs) are formed by scattering of X-ray photons o_ quantized plasma electrons in the strong magnetic field (of the order 1012 G) close to the surface of an accreting X-ray pulsar. Due to the complex scattering cross-sections, the line profiles of CRSFs cannot be described by an analytic expression. Numerical methods, such as Monte Carlo (MC) simulations of the scattering processes, are required in order to predict precise line shapes for a given physical setup, which can be compared to observations to gain information about the underlying physics in these systems.Aims. A versatile simulation code is needed for the generation of synthetic cyclotron lines. Sophisticated geometries should be investigatable by making their simulation possible for the first time.Methods. The simulation utilizes the mean free path tables described in the first paper of this series for the fast interpolation of propagation lengths. The code is parallelized to make the very time-consuming simulations possible on convenient time scales. Furthermore, it can generate responses to monoenergetic photon injections, producing Green's functions, which can be used later to generate spectra for arbitrary continua.Results. We develop a new simulation code to generate synthetic cyclotron lines for complex scenarios, allowing for unprecedented physical interpretation of the observed data. An associated XSPEC model implementation is used to fit synthetic line profiles to NuSTAR data of Cep X-4. The code has been developed with the main goal of overcoming previous geometrical constraints in MC simulations of CRSFs. By applying this code also to more simple, classic geometries used in previous works, we furthermore address issues of code verification and cross-comparison of various models. The XSPEC model and the Green's function tables are available online (see link in footnote, page 1).

Schwarm, F.-W.↗
NASA NTRS1989

Concurrent processing simulation of the space station

The development of a new capability for the time-domain simulation of multibody dynamic systems and its application to the study of a large angle rotational maneuvers of the Space Station is described. The effort was divided into three sequential tasks, which required significant advancements of the state-of-the art to accomplish. These were: (1) the development of an explicit mathematical model via symbol manipulation of a flexible, multibody dynamic system; (2) the development of a methodology for balancing the computational load of an explicit mathematical model for concurrent processing; and (3) the implementation and successful simulation of the above on a prototype Custom Architectured Parallel Processing System (CAPPS) containing eight processors. The throughput rate achieved by the CAPPS operating at only 70 percent efficiency, was 3.9 times greater than that obtained sequentially by the IBM 3090 supercomputer simulating the same problem. More significantly, analysis of the results leads to the conclusion that the relative cost effectiveness of concurrent vs. sequential digital computation will grow substantially as the computational load is increased. This is a welcomed development in an era when very complex and cumbersome mathematical models of large space vehicles must be used as substitutes for full scale testing which has become impractical.

Gluck, R.↗
DOE OSTI2025

Simulation Process Automation for Window Attachments Rating

WINDOW (LBNL 2022) and AERCalc (LBNL 2018) software developed by Lawrence Berkely National Laboratory are needed for running the tool. The database that in installed along with WINDOW software is utilized and modified to develop database for AERCalc simulation in generic case. However, any other custom WINDOW database created by users can be utilized as well. Another requirement for use of the tool is the availability of the shading fabric in the complex glazing database (CGDB). The CGDB id of the fabric was used for database generation discussed in next section.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Validation Data for Benchmarking Wire Arc Additive Manufacturing Process Simulations

Residual stresses cause geometric distortion and affect mechanical performance of additively manufactured structures, yet they are notoriously difficult to assess and predict. Distortion (warpage) can drive parts outside dimensional tolerance limits, leading to part rejection or rework. For parts that meet tolerance, locked-in residual stress fields can affect structural integrity during operation, particularly subcritical cracking by fatigue, creep, or corrosion. This work develops benchmark data for a common additive manufacturing process (Wire Arc Additive Manufacturing) that can be applied for calibration and validation of physical process models that predict residual stress fields. The work includes design of two different samples of differing geometry, detailed manufacturing records for a set of physical samples, and an extensive set of residual stress measurement data developed using two diverse techniques (the contour method and neutron diffraction). An initial application of the work is also reported, where a modeling challenge was issued to secure residual stress model predictions from two independent laboratories that were blind to residual stress measurement data. These initial blind residual stress predictions show significant discrepancies relative to the measurement data, illustrating the potential value of the underlying validation data. An open repository for this work, including the sample designs, manufacturing process records, and the residual stress data, is also provided for future application in non-blind validation efforts.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Covariant density functional theory input for r-process simulations in actinides and superheavy nuclei: The ground state and fission properties

A systematic investigation of the ground-state and fission properties of even-even actinides and superheavy nuclei with Z = 90–120 from the two-proton up to two-neutron drip lines with proper assessment of systematic theoretical uncertainties has been performed for the first time in the framework of covariant density functional theory (CDFT). Furthermore, these results provide a necessary theoretical input for the r-process modeling in heavy nuclei and, in particular, for the study of fission cycling. Four state-of-the-art globally tested covariant energy density functionals (CEDFs), namely, DD-PC1, DD-ME2, NL3*, and PC-PK1, representing the major classes of the CDFT models are employed in the present paper. Ground-state deformations, binding energies, two-neutron separation energies, α-decay Q α values and half-lives, and the heights of fission barriers have been calculated for all these nuclei. Theoretical uncertainties in these physical observables and their evolution as a function of proton and neutron numbers have been quantified and their major sources have been identified. Spherical shell closures at Z = 120, N = 184, and N = 258 and the structure of the single-particle (especially, high-j) states in their vicinities as well as nuclear matter properties of employed CEDFs are two major factors contributing to theoretical uncertainties. However, different physical observables are affected in a different way by these two factors. For example, theoretical uncertainties in calculated ground-state deformations are affected mostly by the former factor, while theoretical uncertainties in fission barriers depend on both of these factors.

190 ≤ A ≤ 219↗
NASA NTRS1995

Verification of a three-dimensional resin transfer molding process simulation model

Experimental evidence was obtained to complete the verification of the parameters needed for input to a three-dimensional finite element model simulating the resin flow and cure through an orthotropic fabric preform. The material characterizations completed include resin kinetics and viscosity models, as well as preform permeability and compaction models. The steady-state and advancing front permeability measurement methods are compared. The results indicate that both methods yield similar permeabilities for a plain weave, bi-axial fiberglass fabric. Also, a method to determine principal directions and permeabilities is discussed and results are shown for a multi-axial warp knit preform. The flow of resin through a blade-stiffened preform was modeled and experiments were completed to verify the results. The predicted inlet pressure was approximately 65% of the measured value. A parametric study was performed to explain differences in measured and predicted flow front advancement and inlet pressures. Furthermore, PR-500 epoxy resin/IM7 8HS carbon fabric flat panels were fabricated by the Resin Transfer Molding process. Tests were completed utilizing both perimeter injection and center-port injection as resin inlet boundary conditions. The mold was instrumented with FDEMS sensors, pressure transducers, and thermocouples to monitor the process conditions. Results include a comparison of predicted and measured inlet pressures and flow front position. For the perimeter injection case, the measured inlet pressure and flow front results compared well to the predicted results. The results of the center-port injection case showed that the predicted inlet pressure was approximately 50% of the measured inlet pressure. Also, measured flow front position data did not agree well with the predicted results. Possible reasons for error include fiber deformation at the resin inlet and a lag in FDEMS sensor wet-out due to low mold pressures.

Fingerson, John C.↗