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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 NTRS2000

Thermographic Analysis of Composite Cobonds on the X-33

During the manufacture of the X-33 liquid hydrogen (LH2) Tank 2, a total of thirty-six reinforcing caps were inspected thermographically. The cured reinforcing sheets of graphite/epoxy were bonded to the tank using a wet cobond process with vacuum bagging and low temperature curing. A foam filler material wedge separated the reinforcing caps from the outer skin of the tank. Manufacturing difficulties caused by a combination of the size of the reinforcing caps and their complex geometry lead to a potential for trapping air in the bond line. An inspection process was desired to ensure that the bond line was free of voids before it had cured so that measures could be taken to rub out the entrapped air or remove the cap and perform additional surface matching. Infrared thermography was used to perform the precure "wet bond" inspection as well as to document the final "cured" condition of the caps. The thermal map of the bond line was acquired by heating the cap with either a flash lamp or a set of high intensity quartz lamps and then viewing it during cool down. The inspections were performed through the vacuum bag and voids were characterized by localized hot spots. In order to ensure that the cap had bonded to the tank properly, a post cure "flash heating" thermographic investigation was performed with the vacuum bag removed. Any regions that had opened up after the preliminary inspection or that were hidden during the bagging operation were marked and filled by drilling small holes in the cap and injecting resin. This process was repeated until all critical sized voids were filled.

Russell, Samuel S.↗
NASA NTRS2000

Annual Research Briefs - 2000: Center for Turbulence Research

This report contains the 2000 annual progress reports of the postdoctoral Fellows and visiting scholars of the Center for Turbulence Research (CTR). It summarizes the research efforts undertaken under the core CTR program. Last year, CTR sponsored sixteen resident Postdoctoral Fellows, nine Research Associates, and two Senior Research Fellows, hosted seven short term visitors, and supported four doctoral students. The Research Associates are supported by the Departments of Defense and Energy. The reports in this volume are divided into five groups. The first group largely consists of the new areas of interest at CTR. It includes efficient algorithms for molecular dynamics, stability in protoplanetary disks, and experimental and numerical applications of evolutionary optimization algorithms for jet flow control. The next group of reports is in experimental, theoretical, and numerical modeling efforts in turbulent combustion. As more challenging computations are attempted, the need for additional theoretical and experimental studies in combustion has emerged. A pacing item for computation of nonpremixed combustion is the prediction of extinction and re-ignition phenomena, which is currently being addressed at CTR. The third group of reports is in the development of accurate and efficient numerical methods, which has always been an important part of CTR's work. This is the tool development part of the program which supports our high fidelity numerical simulations in such areas as turbulence in complex geometries, hypersonics, and acoustics. The final two groups of reports are concerned with LES and RANS prediction methods. There has been significant progress in wall modeling for LES of high Reynolds number turbulence and in validation of the v(exp 2) - f model for industrial applications.

Source record↗
NASA NTRS2001

Unic Unstructured CFD Methodology Development

Base heating characteristics is crucial to the success and the overall performance of the X-33 engine. Base heating is important throughout the entire flight trajectory due to the aerospike engine design of X-33. The base region is surrounded by the hot-gas plume, which expands, circulates and impinges on the base. An advanced computation fluid dynamics method is employed in an effort to develop a robust, accurate and efficient tool for the X-33 base heating performance predictions. This computational tool is developed based on a Navier-Stokes flow solver, which is suitable for general complex geometry and includes turbulence, finite-rate chemistry, and radiation models. To fulfill the fast turnaround requirement as a design analysis tool, adaptive mesh refinement method and parallel-computing algorithm are also incorporated in the present model. Case study for the X-33 base-region fluid dynamics and heat transfer characteristics are presented.

Chen, Y. S.↗
NASA NTRS2001

Coarse Grid Modeling of Turbine Film Cooling Flows Using Volumetric Source Terms

The recent trend in numerical modeling of turbine film cooling flows has been toward higher fidelity grids and more complex geometries. This trend has been enabled by the rapid increase in computing power available to researchers. However, the turbine design community requires fast turnaround time in its design computations, rendering these comprehensive simulations ineffective in the design cycle. The present study describes a methodology for implementing a volumetric source term distribution in a coarse grid calculation that can model the small-scale and three-dimensional effects present in turbine film cooling flows. This model could be implemented in turbine design codes or in multistage turbomachinery codes such as APNASA, where the computational grid size may be larger than the film hole size. Detailed computations of a single row of 35 deg round holes on a flat plate have been obtained for blowing ratios of 0.5, 0.8, and 1.0, and density ratios of 1.0 and 2.0 using a multiblock grid system to resolve the flows on both sides of the plate as well as inside the hole itself. These detailed flow fields were spatially averaged to generate a field of volumetric source terms for each conservative flow variable. Solutions were also obtained using three coarse grids having streamwise and spanwise grid spacings of 3d, 1d, and d/3. These coarse grid solutions used the integrated hole exit mass, momentum, energy, and turbulence quantities from the detailed solutions as volumetric source terms. It is shown that a uniform source term addition over a distance from the wall on the order of the hole diameter is able to predict adiabatic film effectiveness better than a near-wall source term model, while strictly enforcing correct values of integrated boundary layer quantities.

Heidmann, James D.↗
NASA NTRS2000

An Application of the Quadrature-Free Discontinuous Galerkin Method

The process of generating a block-structured mesh with the smoothness required for high-accuracy schemes is still a time-consuming process often measured in weeks or months. Unstructured grids about complex geometries are more easily generated, and for this reason, methods using unstructured grids have gained favor for aerodynamic analyses. The discontinuous Galerkin (DG) method is a compact finite-element projection method that provides a practical framework for the development of a high-order method using unstructured grids. Higher-order accuracy is obtained by representing the solution as a high-degree polynomial whose time evolution is governed by a local Galerkin projection. The traditional implementation of the discontinuous Galerkin uses quadrature for the evaluation of the integral projections and is prohibitively expensive. Atkins and Shu introduced the quadrature-free formulation in which the integrals are evaluated a-priori and exactly for a similarity element. The approach has been demonstrated to possess the accuracy required for acoustics even in cases where the grid is not smooth. Other issues such as boundary conditions and the treatment of non-linear fluxes have also been studied in earlier work This paper describes the application of the quadrature-free discontinuous Galerkin method to a two-dimensional shear layer problem. First, a brief description of the method is given. Next, the problem is described and the solution is presented. Finally, the resources required to perform the calculations are given.

Lockard, David P.↗
NASA NTRS2001

Textbook Multigrid Efficiency for Computational Fluid Dynamics Simulations

Considerable progress over the past thirty years has been made in the development of large-scale computational fluid dynamics (CFD) solvers for the Euler and Navier-Stokes equations. Computations are used routinely to design the cruise shapes of transport aircraft through complex-geometry simulations involving the solution of 25-100 million equations; in this arena the number of wind-tunnel tests for a new design has been substantially reduced. However, simulations of the entire flight envelope of the vehicle, including maximum lift, buffet onset, flutter, and control effectiveness have not been as successful in eliminating the reliance on wind-tunnel testing. These simulations involve unsteady flows with more separation and stronger shock waves than at cruise. The main reasons limiting further inroads of CFD into the design process are: (1) the reliability of turbulence models; and (2) the time and expense of the numerical simulation. Because of the prohibitive resolution requirements of direct simulations at high Reynolds numbers, transition and turbulence modeling is expected to remain an issue for the near term. The focus of this paper addresses the latter problem by attempting to attain optimal efficiencies in solving the governing equations. Typically current CFD codes based on the use of multigrid acceleration techniques and multistage Runge-Kutta time-stepping schemes are able to converge lift and drag values for cruise configurations within approximately 1000 residual evaluations. An optimally convergent method is defined as having textbook multigrid efficiency (TME), meaning the solutions to the governing system of equations are attained in a computational work which is a small (less than 10) multiple of the operation count in the discretized system of equations (residual equations). In this paper, a distributed relaxation approach to achieving TME for Reynolds-averaged Navier-Stokes (RNAS) equations are discussed along with the foundations that form the basis of this approach. Because the governing equations are a set of coupled nonlinear conservation equations with discontinuities (shocks, slip lines, etc.) and singularities (flow- or grid-induced), the difficulties are many. This paper summarizes recent progress towards the attainment of TME in basic CFD simulations.

Brandt, Achi↗
NASA NTRS2001

Thermographic Analysis of Composite Cobonds on the X-33

During the manufacture of the X-33 liquid hydrogen (LH2) Tank 2, a total of 36 reinforcing caps were inspected thermographically. The cured reinforcing sheets of graphite/epoxy were bonded to the tank using a wet cobond process with vacuum bagging and low temperature curing. A foam filler material wedge separated the reinforcing caps from the outer skin of the tank. Manufacturing difficulties caused by a combination of the size of the reinforcing caps and their complex geometry lead to a potential for trapping air in the bond line. An inspection process was desired to ensure that the bond line was free of voids before it had cured so that measures could be taken to rub out the entrapped air or remove the cap and perform additional surface matching. Infrared thermography was used to perform the procure 'wet bond' inspection as well a to document the final 'cured' condition of the caps. The thermal map of the bond line was acquired by heating the cap with either a flash lamp or a set of high intensity quartz lamps and then viewing it during cool down. The inspections were performed through the vacuum bag and voids were characterized by localized hot spots. In order to ensure that the cap had bonded to the tank properly, a post cure 'flash heating' thermographic investigation was performed with the vacuum bag removed. Any regions that had opened up after the preliminary inspection or that were hidden during the bagging operation were marked and filled by drilling small holes in the cap and injecting resin. This process was repeated until all critical sized voids were filled.

Russell, S. S.↗
NASA NTRS2001

Spherical Ethylene/Air Diffusion Flames Subject to Concentric DC Electric Field in Microgravity

It is well known that microgravity conditions, by eliminating buoyant flow, enable many combustion phenomena to be observed that are not possible to observe at normal gravity. One example is the spherical diffusion flame surrounding a porous spherical burner. The present paper demonstrates that by superimposing a spherical electrical field on such a flame, the flame remains spherical so that we can study the interaction between the electric field and flame in a one-dimensional fashion. Flames are susceptible to electric fields that are much weaker than the breakdown field of the flame gases owing to the presence of ions generated in the high temperature flame reaction zone. These ions and the electric current of the moving ions, in turn, significantly change the distribution of the electric field. Thus, to understand the interplay between the electric field and the flame is challenging. Numerous experimental studies of the effect of electric fields on flames have been reported. Unfortunately, they were all involved in complex geometries of both the flow field and the electric field, which hinders detailed study of the phenomena. In a one-dimensional domain, however, the electric field, the flow field, the thermal field and the chemical species field are all co-linear. Thus the problem is greatly simplified and becomes more tractable.

Yuan, Z. -G.↗
NASA NTRS2001

B-spline Method in Fluid Dynamics

B-spline functions are bases for piecewise polynomials that possess attractive properties for complex flow simulations : they have compact support, provide a straightforward handling of boundary conditions and grid nonuniformities, and yield numerical schemes with high resolving power, where the order of accuracy is a mere input parameter. This paper reviews the progress made on the development and application of B-spline numerical methods to computational fluid dynamics problems. Basic B-spline approximation properties is investigated, and their relationship with conventional numerical methods is reviewed. Some fundamental developments towards efficient complex geometry spline methods are covered, such as local interpolation methods, fast solution algorithms on cartesian grid, non-conformal block-structured discretization, formulation of spline bases of higher continuity over triangulation, and treatment of pressure oscillations in Navier-Stokes equations. Application of some of these techniques to the computation of viscous incompressible flows is presented.

Botella, Olivier↗
NASA NTRS1997

Dynamic Electrothermal Model of a Sputtered Thermopile Thermal Radiation Detector for Earth Radiation Budget Applications

The Clouds and the Earth's Radiant Energy System (CERES) is a program sponsored by the National Aeronautics and Space Administration (NASA) aimed at evaluating the global energy balance. Current scanning radiometers used for CERES consist of thin-film thermistor bolometers viewing the Earth through a Cassegrain telescope. The Thermal Radiation Group, a laboratory in the Department of Mechanical Engineering at Virginia Polytechnic Institute and State University, is currently studying a new sensor concept to replace the current bolometer: a thermopile thermal radiation detector. This next-generation detector would consist of a thermal sensor array made of thermocouple junction pairs, or thermopiles. The objective of the current research is to perform a thermal analysis of the thermopile. Numerical thermal models are particularly suited to solve problems for which temperature is the dominant mechanism of the operation of the device (through the thermoelectric effect), as well as for complex geometries composed of numerous different materials. Feasibility and design specifications are studied by developing a dynamic electrothermal model of the thermopile using the finite element method. A commercial finite element-modeling package, ALGOR, is used.

Weckmann, Stephanie↗
NASA NTRS2001

Automatic Overset Grid Generation with Heuristic Feedback Control

An advancing front grid generation system for structured Overset grids is presented which automatically modifies Overset structured surface grids and control lines until user-specified grid qualities are achieved. The system is demonstrated on two examples: the first refines a space shuttle fuselage control line until global truncation error is achieved; the second advances, from control lines, the space shuttle orbiter fuselage top and fuselage side surface grids until proper overlap is achieved. Surface grids are generated in minutes for complex geometries. The system is implemented as a heuristic feedback control (HFC) expert system which iteratively modifies the input specifications for Overset control line and surface grids. It is developed as an extension of modern control theory, production rules systems and subsumption architectures. The methodology provides benefits over the full knowledge lifecycle of an expert system for knowledge acquisition, knowledge representation, and knowledge execution. The vector/matrix framework of modern control theory systematically acquires and represents expert system knowledge. Missing matrix elements imply missing expert knowledge. The execution of the expert system knowledge is performed through symbolic execution of the matrix algebra equations of modern control theory. The dot product operation of matrix algebra is generalized for heuristic symbolic terms. Constant time execution is guaranteed.

Robinson, Peter I.↗
NASA NTRS1996

Challenges and Accomplishments of Viscous Incompressible Flow Computations in Aerospace and Beyond

Recent progress in incompressible Navier-Stokes solution methods will be presented. Discussions are focused on the methods designed for complex geometry applications in three dimensions, and thus are limited to primitive variable formulation. Both steady- and unsteady-solution algorithms and their salient features are discussed. A summary of our recent progress in flow solver development is given followed by numerical studies of a few example problems of our current interest. Solvers discussed here are based on structured-grid approach using finite-difference or finite-volume frame work. This short course will be delivered in three one-our lectures. The material in the course are collected from the work performed by the Incompressible Navier-Stokes group at NASA Ames Research Center over the past several years, and can be found in our publications widely disseminated in the US and abroad. This short course is sponsored by AGARD Consultant and Exchange Program under Support Project P-110.

Kwak, Dochan↗
NASA NTRS1997

Direct Simulations of Transition and Turbulence Using High-Order Accurate Finite-Difference Schemes

In recent years the techniques of computational fluid dynamics (CFD) have been used to compute flows associated with geometrically complex configurations. However, success in terms of accuracy and reliability has been limited to cases where the effects of turbulence and transition could be modeled in a straightforward manner. Even in simple flows, the accurate computation of skin friction and heat transfer using existing turbulence models has proved to be a difficult task, one that has required extensive fine-tuning of the turbulence models used. In more complex flows (for example, in turbomachinery flows in which vortices and wakes impinge on airfoil surfaces causing periodic transitions from laminar to turbulent flow) the development of a model that accounts for all scales of turbulence and predicts the onset of transition may prove to be impractical. Fortunately, current trends in computing suggest that it may be possible to perform direct simulations of turbulence and transition at moderate Reynolds numbers in some complex cases in the near future. This seminar will focus on direct simulations of transition and turbulence using high-order accurate finite-difference methods. The advantage of the finite-difference approach over spectral methods is that complex geometries can be treated in a straightforward manner. Additionally, finite-difference techniques are the prevailing methods in existing application codes. In this seminar high-order-accurate finite-difference methods for the compressible and incompressible formulations of the unsteady Navier-Stokes equations and their applications to direct simulations of turbulence and transition will be presented.

Rai, Man Mohan↗
NASA NTRS2002

Progress in the Simulation of Steady and Time-Dependent Flows with 3D Parallel Unstructured Cartesian Methods

The proposed paper will present recent extensions in the development of an efficient Euler solver for adaptively-refined Cartesian meshes with embedded boundaries. The paper will focus on extensions of the basic method to include solution adaptation, time-dependent flow simulation, and arbitrary rigid domain motion. The parallel multilevel method makes use of on-the-fly parallel domain decomposition to achieve extremely good scalability on large numbers of processors, and is coupled with an automatic coarse mesh generation algorithm for efficient processing by a multigrid smoother. Numerical results are presented demonstrating parallel speed-ups of up to 435 on 512 processors. Solution-based adaptation may be keyed off truncation error estimates using tau-extrapolation or a variety of feature detection based refinement parameters. The multigrid method is extended to for time-dependent flows through the use of a dual-time approach. The extension to rigid domain motion uses an Arbitrary Lagrangian-Eulerlarian (ALE) formulation, and results will be presented for a variety of two- and three-dimensional example problems with both simple and complex geometry.

Aftosmis, M. J.↗
NASA NTRS2001

Method Improvements in Thermal Analysis of Mach 10 Leading Edges

Several improvements have recently been made in the thermal analysis methods for leading edges of a hypersonic vehicle. The leading edges of this vehicle undergo exceptionally high heat loads that incorporate extreme spatial gradients as well as severe transients. Due to the varying flight conditions, complex geometry, and need for thermal loads at many points along the trajectory, full computational fluid dynamics (CFD) analysis of the aeroheating; loads is not feasible. Thus, engineering methods must be used to determine the aeroheating on the vehicle surfaces, and that must be utilized in the thermal analysis. Over the last year, the thermal analysis of a hypersonic vehicle has been enhanced in several ways. Two different engineering codes are used to predict aeroheating loads: one over the curve near the stagnation point, and the other on flat surfaces downstream of the leading edge. These two are matched together at the intersection point using a method that allows closer approximation of CFD results. User-developed FORTRAN, which is part of the thermal solver PATRAN Thermal, is used to accomplish this. The customizable FORTRAN code also allows use of many different time- and space-dependent factors, interpolation of the heat load in time and space, and inclusion of both highly swept and unswept grid structures. This FORTRAN is available to other PATRAN users who may want to accomplish a similar objective in analysis. Flux, rather than convective coefficient, is used to define heat loads, which allows more accurate analysis as well as better application of margins. Improvements have also been made in more efficient utilization of imported CAD geometry, by creating faces on solids to facilitate load application.

Amundsen, Ruth M.↗
NASA NTRS2002

A Flow Solver for Three-Dimensional DRAGON Grids

DRAGONFLOW code has been developed to solve three-dimensional Navier-Stokes equations over a complex geometry whose flow domain is discretized with the DRAGON grid-a combination of Chimera grid and a collection of unstructured grids. In the DRAGONFLOW suite, both OVERFLOW and USM3D are presented in form of module libraries, and a master module controls the invoking of these individual modules. This report includes essential aspects, programming structures, benchmark tests and numerical simulations.

Liou, Meng-Sing↗
NASA NTRS2002

Parametric Study of a YAV-8B Harrier in Ground Effect using Time-Dependent Navier-Stokes Computations

A process is described which enables the generation of 35 time-dependent viscous solutions for a YAV-8B Harrier in ground effect in one week. Overset grids are used to model the complex geometry of the Harrier aircraft and the interaction of its jets with the ground plane and low-speed ambient flow. The time required to complete this parametric study is drastically reduced through the use of process automation, modern computational platforms, and parallel computing. Moreover, a dual-time-stepping algorithm is described which improves solution robustness. Unsteady flow visualization and a frequency domain analysis are also used to identify and correlated key flow structures with the time variation of lift.

Pandya, Shishir↗
NASA NTRS2002

A Unified Overset Grid Generation Graphical Interface and New Concepts on Automatic Gridding Around Surface Discontinuities

For many years, generation of overset grids for complex configurations has required the use of a number of different independently developed software utilities. Results created by each step were then visualized using a separate visualization tool before moving on to the next. A new software tool called OVERGRID was developed which allows the user to perform all the grid generation steps and visualization under one environment. OVERGRID provides grid diagnostic functions such as surface tangent and normal checks as well as grid manipulation functions such as extraction, extrapolation, concatenation, redistribution, smoothing, and projection. Moreover, it also contains hyperbolic surface and volume grid generation modules that are specifically suited for overset grid generation. It is the first time that such a unified interface existed for the creation of overset grids for complex geometries. New concepts on automatic overset surface grid generation around surface discontinuities will also be briefly presented. Special control curves on the surface such as intersection curves, sharp edges, open boundaries, are called seam curves. The seam curves are first automatically extracted from a multiple panel network description of the surface. Points where three or more seam curves meet are automatically identified and are called seam corners. Seam corner surface grids are automatically generated using a singular axis topology. Hyperbolic surface grids are then grown from the seam curves that are automatically trimmed away from the seam corners.

Chan, William M.↗