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DOE OSTI2024

Development of a Method for Shape Optimization for a Gas Turbine Fuel Injector Design Using Metal-Additive Manufacturing

Adjoint shape optimization has enabled physics-based optimal designs for aerodynamic surfaces. Additive manufacturing (AM) makes it possible to manufacture complex shapes. However, there has been a gap between optimal and manufacturable surfaces due to the inherent limitations of commercial computational fluid dynamics (CFD) codes to implement geometric constraints during adjoint computation. In such cases, the design sensitivities are exported and used to perform constrained shape modifications using parametric information stored in computer aided design (CAD) files to satisfy manufacturability constraints. However, modifying the design using adjoint methods in CFD solvers and performing constrained shape modification in CAD can lead to inconsistencies due to different shape parameterization schemes. This paper describes a method to enable the simultaneous optimization of the fluid domain and impose AM manufacturability constraints, resolving one of the key issues of geometry definition for isogeometric analysis. Similar to a grid convergence study, the proposed method verifies the consistencies between shape parameterization techniques present within commercial CAD and CFD software during mesh movement as a part of the adjoint shape optimization routine. By identifying the appropriate parameters essential to a shape optimization study, the error metric between the different parameterization techniques converges to demonstrate sufficient consistencies for justifiable exchange of data between CAD and CFD. For the identified shape optimization parameters, the error metric to measure the deviation between the two parameterization schemes lies within the AM laser-powder bed fusion (L-PBF) process tolerance. Additionally, comparison for subsequent objective function calculations between iterations of the optimization loop showed acceptable differences within 1% variation between the modified geometries obtained using the two parameterization schemes. This method provides justification for the use of multiphysics guided adjoint design sensitivities computed in CFD software to perform shape modifications in CAD to incorporate AM manufacturability constraints during the shape optimization loop such that optimal designs are also additively manufacturable.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2004

High Energy Boundary Conditions for a Cartesian Mesh Euler Solver

Inlets and exhaust nozzles are often omitted or fared over in aerodynamic simulations of aircraft due to the complexities involving in the modeling of engine details such as complex geometry and flow physics. However, the assumption is often improper as inlet or plume flows have a substantial effect on vehicle aerodynamics. A tool for specifying inlet and exhaust plume conditions through the use of high-energy boundary conditions in an established inviscid flow solver is presented. The effects of the plume on the flow fields near the inlet and plume are discussed.

Pandya, Shishir A.↗

NASA NTRS1991

A fast implicit upwind solution algorithm for three-dimensional unstructured dynamic meshes

A fast implicit upwind algorithm for the solution of the time-dependent Euler equations is presented for aerodynamic analysis involving unstructured dynamic meshes. The spatial discretization of the scheme is based on the upwind approach of Roe, referred to as flux-difference splitting (FDS). The FDS approach is naturally dissipative and captures shock waves and contact discontinuities sharply. The temporal discretization of the scheme involves an implicit time-integration using a two-sweep Gauss-Seidel relaxation procedure. The procedure is computationally efficient for either steady or unsteady flow problems. A detailed description is given of the implicit upwind solution algorithm along with results which assess the capability. The results are presented for the NACA 0012 airfoil and for the Boeing 747 aircraft. The 747 geometry includes the fuselage, wing, horizontal and vertical tails, under-wing pylons, and flow-through engine nacelles. Euler solutions for the 747 aircraft on an unstructured tetrahedral mesh containing approximately 100,000 cells were obtained to engineering accuracy in less than one hour CPU time on a Cray-2 computer.

Batina, John T.↗

NASA NTRS1992

A fast implicit upwind solution algorithm for three-dimensional unstructured dynamic meshes

Batina, John T.↗

NASA NTRS1984

A linear aerodynamic analysis for unsteady transonic cascades

A potential flow analysis to predict unsteady airloads produced by the vibrations of turbomachinery blades operating at transonic Mach numbers is presented. The unsteady aerodynamic model includes the effects of blade geometry, finite mean pressure variation across the blade row, high frequency blade motion, and shock motion within the framework of a linearized, frequency domain formulation. The unsteady equations are solved implicit, least squares, finite difference approximation which is applicable on arbitrary grids. A numerical solution for the entire unsteady field is determined by matching a solution determined on a rectilinear type cascade mesh, which covers an extended blade passage region, to a solution determined on a detailed polar type local mesh, which covers and extends well beyond the supersonic region(s) adjacent to a blade surface. Cascades of double circular arc and flat plate blades demonstrate the unsteady analysis, and partially illustrate the effects of blade geometry, inlet Mach number, blade vibration frequency and shock motion on unsteady response.

Verdon, J. M.↗

NASA NTRS2013

A Floating Node Method for the Modelling of Discontinuities Within a Finite Element

This paper focuses on the accurate numerical representation of complex networks of evolving discontinuities in solids, with particular emphasis on cracks. The limitation of the standard finite element method (FEM) in approximating discontinuous solutions has motivated the development of re-meshing, smeared crack models, the eXtended Finite Element Method (XFEM) and the Phantom Node Method (PNM). We propose a new method which has some similarities to the PNM, but crucially: (i) does not introduce an error on the crack geometry when mapping to natural coordinates; (ii) does not require numerical integration over only part of a domain; (iii) can incorporate weak discontinuities and cohesive cracks more readily; (iv) is ideally suited for the representation of multiple and complex networks of (weak, strong and cohesive) discontinuities; (v) leads to the same solution as a finite element mesh where the discontinuity is represented explicitly; and (vi) is conceptually simpler than the PNM.

Pinho, Silvestre T.↗

DOE OSTI2026

Final Technical Report - Center for Simulation of Fusion Relevant RF Actuators

We have developed a suite of 3D electromagnetic field solvers, both FEM and FDTD based, that account for the RF antenna and vacuum vessel geometries with unprecedented accuracy. Workflows were developed that make it possible to translate CAD models for the antenna and vacuum vessel to physics meshes for RF wave simulation. Nonlinear RF sheath formation has been incorporated self-consistently as a boundary condition in these solvers. We have also carried out extensive studies of the impact of RF sheaths on the ion energy angle distribution at plasma-material interfaces, using high fidelity particle-in-cell codes. Comprehensive simulation models were developed to assess the impact of blob-like edge turbulence on RF wave propagation and the impact of the RF ponderomotive force on the plasma scrape-off layer (SOL). A fluid transport solver for the far-SOL was also developed which accounts for the high parallel to perpendicular heat anisotropy on an unstructured mesh, thus making it possible to precisely represent an antenna structure in the presence of edge transport. Finally we have developed a hierarchy of core wave propagation and absorption models that self-consistently combine continuum Fokker Planck and Monte Carlo treatments of fast ion evolution with ICRF full-wave field solvers and continuum Fokker Planck treatments of fast electron evolution with both full-wave and ray tracing models.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1988

Generation of a crowned pinion tooth surface by a plane

The topology of a crowned spur pinion tooth surface that reduces the level of transmission errors due to misalignment is described. The geometry of the modified pinion tooth surface and of the regular involute gear tooth surface is discussed. The tooth contact analysis between the meshing surfaces is also described. Generating a modified pinion tooth surface by a plane whose motion is controlled by a 5-degree-of-freedom system is investigated. The numerical results included indicate that the transmission error remains low as the gears are misaligned.

Litvin, F. L.↗

NASA NTRS1995

Euler technology assessment for preliminary aircraft design employing OVERFLOW code with multiblock structured-grid method

The viability of applying a state-of-the-art Euler code to calculate the aerodynamic forces and moments through maximum lift coefficient for a generic sharp-edge configuration is assessed. The OVERFLOW code, a method employing overset (Chimera) grids, was used to conduct mesh refinement studies, a wind-tunnel wall sensitivity study, and a 22-run computational matrix of flow conditions, including sideslip runs and geometry variations. The subject configuration was a generic wing-body-tail geometry with chined forebody, swept wing leading-edge, and deflected part-span leading-edge flap. The analysis showed that the Euler method is adequate for capturing some of the non-linear aerodynamic effects resulting from leading-edge and forebody vortices produced at high angle-of-attack through C(sub Lmax). Computed forces and moments, as well as surface pressures, match well enough useful preliminary design information to be extracted. Vortex burst effects and vortex interactions with the configuration are also investigated.

Treiber, David A.↗

NASA NTRS1998

User Manual for Beta Version of TURBO-GRD: A Software System for Interactive Two-Dimensional Boundary/ Field Grid Generation, Modification, and Refinement

TURBO-GRD is a software system for interactive two-dimensional boundary/field grid generation. modification, and refinement. Its features allow users to explicitly control grid quality locally and globally. The grid control can be achieved interactively by using control points that the user picks and moves on the workstation monitor or by direct stretching and refining. The techniques used in the code are the control point form of algebraic grid generation, a damped cubic spline for edge meshing and parametric mapping between physical and computational domains. It also performs elliptic grid smoothing and free-form boundary control for boundary geometry manipulation. Internal block boundaries are constructed and shaped by using Bezier curve. Because TURBO-GRD is a highly interactive code, users can read in an initial solution, display its solution contour in the background of the grid and control net, and exercise grid modification using the solution contour as a guide. This process can be called an interactive solution-adaptive grid generation.

Choo, Yung K.↗

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 NTRSDate not supplied

Investigation of Physical Mechanisms for Jet Noise Reduction by Plug Nozzle Porosity

This paper presents the results of a computational study on porous-plug nozzles for their eventual application in reducing takeoff noise levels for supersonic civil transport. The study explores a wide range of porous-plug geometries, encompassing variations in hole size, plug length and porosity. Computational fluid dynamics (CFD) analyses are employed in concert with an advanced automated mesh refinement (AMR) scheme, Sketch-to-Solution (S2S), to investigate porous plug nozzle design strategies that may diminish shock strength, broad-band shock noise (BBSN), flow separation, and other undesirable characteristics associated with high takeoff noise levels. A selected subset of the porous-plug nozzles that were analyzed computationally were manufactured at subscale using stereolithography 3D printing. These nozzles were tested experimentally, obtaining far-field noise spectral data and schlieren flow visualization pictures. Detailed comparisons between CFD predictions and experimental results were conducted. These comparisons focus on gaining a better understanding of the underlying physical mechanisms responsible for noise reduction with the porous plugs relative to corresponding solid plugs.

computational fluid dynamics↗

NASA NTRSDate not supplied

Investigation of Physical Mechanisms for Jet Noise Reduction by Plug Nozzle Porosity

Nozzles↗

DOE OSTI2025

Q3 Report for FY25 Theory and Simulation Performance Target: Development of an integrated modeling framework for fusion reactor design and assessment

This report describes the work and activities carried out towards the completion of each of the following milestones in FY25 Q3: 1. Demonstrate workflow for generating self-consistent CESOL plasma profiles + first wall and divertor loading prediction and generate the CAT plasma and neutron loading needed for further engineering analysis. • Benchmark between two first wall heat flux mapping methods, identify importance of various heat flux sources and physics impact of using fully coupled CESOL vs post-analysis evaluation. 2. Generate medium fidelity parametrized CAD. • Generate parametrized CAD components for the CAT example case via either user-defined modules called within the geometry generation or by defeatured/parametrized CAD, including DCLL blanket matched to divertor boundary and magnets. Define materials, labels, and boundary conditions for passing the mesh to CFD tools. 3. Demonstrate multiphysics magnet analysis. • Demonstrate magnet analysis workflow called from the FREDA workflow, and 4. Demonstrate nuclear analysis. • Add model to OpenFOAM and/or other codes possibly including Diablo to account for tritium diffusion in solids.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1997

RIACS

Topics considered include: high-performance computing; cognitive and perceptual prostheses (computational aids designed to leverage human abilities); autonomous systems. Also included: development of a 3D unstructured grid code based on a finite volume formulation and applied to the Navier-stokes equations; Cartesian grid methods for complex geometry; multigrid methods for solving elliptic problems on unstructured grids; algebraic non-overlapping domain decomposition methods for compressible fluid flow problems on unstructured meshes; numerical methods for the compressible navier-stokes equations with application to aerodynamic flows; research in aerodynamic shape optimization; S-HARP: a parallel dynamic spectral partitioner; numerical schemes for the Hamilton-Jacobi and level set equations on triangulated domains; application of high-order shock capturing schemes to direct simulation of turbulence; multicast technology; network testbeds; supercomputer consolidation project.

Oliger, Joseph↗

NASA NTRS1985

Embedded mesh solutions of the Euler equation using a multiple-grid method

New developments make it now possible to obtain solutions to Euler equations for many problems on the basis of acceptable computing times. The possibility of an extension of these methods to more difficult flows and increasingly complex geometries can depend on obtaining suitable grid structures. Thus, an attractive approach to complex geometries involves the recasting of the problem into the framework of a multiple-grid structure. The discrete equations represented on the grid are solved as a simultaneous system. In the present investigation, this is accomplished with the aid of Ni's multiple-grid algorithm. The multiple-grid structure provided in this study represents the first step towards a completely general modular approach to the solution of the complete compressible flow problem. In the presented cases, a fine mesh resolution is obtained within the embedded mesh regions, while preserving the global coarse mesh convergence rates.

Usab, W. J., Jr.↗

NASA NTRS2001

Thermal Analysis of a High-Speed Aircraft Wing Using p-Version Finite Elements

This paper presents the results of conceptual level thermal analyses of a High Speed Civil Transport (HSCT) wing using p-version finite elements. The work was motivated by a thermal analysis of a HSCT wing structure which showed the importance of radiation heat transfer throughout the structure. The analysis also showed that refining a traditional finite element mesh to accurately capture the temperature distribution on the internal structure led to very large meshes with unacceptably long execution times. Further study indicated using p-version finite elements might improve computation performance for this class of problem. Methods for determining internal radiation heat transfer were then developed and demonstrated on test problems representative of the geometry found in an aircraft wing structure. This paper presents the results of the application of these new methods to the analysis of a high speed aircraft wing. Results for both a wing box model as well as a full wing model are presented. 'Me reduced wing box model allows for a comparison of the traditional finite element method with mesh refinement (h-refinement) to the new p-version finite elements while the full wing model demonstrates the applicability and efficiency of p-version finite elements for large models.

Gould, Dana C.↗

NASA NTRS1995

Simulation of patch and slot antennas using FEM with prismatic elements and investigations of artificial absorber mesh termination schemes

Year 1 progress can be characterized with four major achievements which are crucial toward the development of robust, easy to use antenna analysis code on doubly conformal platforms. (1) A new FEM code was developed using prismatic meshes. This code is based on a new edge based distorted prism and is particularly attractive for growing meshes associated with printed slot and patch antennas on doubly conformal platforms. It is anticipated that this technology will lead to interactive, simple to use codes for a large class of antenna geometries. Moreover, the codes can be expanded to include modeling of the circuit characteristics. An attached report describes the theory and validation of the new prismatic code using reference calculations and measured data collected at the NASA Langley facilities. The agreement between the measured and calculated data is impressive even for the coated patch configuration. (2) A scheme was developed for improved feed modeling in the context of FEM. A new approach based on the voltage continuity condition was devised and successfully tested in modeling coax cables and aperture fed antennas. An important aspect of this new feed modeling approach is the ability to completely separate the feed and antenna mesh regions. In this manner, different elements can be used in each of the regions leading to substantially improved accuracy and meshing simplicity. (3) A most important development this year has been the introduction of the perfectly matched interface (PMI) layer for truncating finite element meshes. So far the robust boundary integral method has been used for truncating the finite element meshes. However, this approach is not suitable for antennas on nonplanar platforms. The PMI layer is a lossy anisotropic absorber with zero reflection at its interface. (4) We were able to interface our antenna code FEMA_CYL (for antennas on cylindrical platforms) with a standard high frequency code. This interface was achieved by first generating equivalent magnetic currents across the antenna aperture using the FEM code. These currents were employed as the sources in the high frequency code.

Gong, J.↗