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At least 433 records · Page 24

Three-Dimensional Reconstruction of Defects and Structures in Additively Manufactured Parts with Automated Serial Sectioning

Metal additive manufacturing (AM) processes have been demonstrated to be effective at reducing costs and lead times associated with complex components for space flight applications. Laser powderbed fusion (L-PBF) is a commonly used AM technology due to the ability to produce complex parts with fine feature resolution in a wide variety of alloys and applications. L-PBF, like many other manufacturing processes, can produce minor flaws in parts when in nominal operation as well as process-escape defects when process abnormalities occur. The effects of the flaws and methods of detecting the flaws are a subject of interest to understand the difficulties in detecting these flaws with current technology and how much risk the flaws or defects pose to potential flight parts. Using a RoboMet.3D automated serial sectioning system, seeded defects as well as minor process flaws can be imaged and reconstructed in three dimensions to compare to non-destructive evaluation (NDE) techniques, such as x-ray computed tomography (CT), neutron CT, and in-situ monitoring. The RoboMet automates the metallography process by automatically grinding, polishing, and imaging samples in a single system and providing the control data for NDE comparisons to know the real size of defects built into coupons. These comparisons provide an understanding behind the technological limitations of the NDE techniques for different alloys. The same serial sectioning methods have also been utilized to characterize the surfaces of parts to reconstruct the surfaces and take measurements of internal features not easily examined with non-destructive methods. Using the RoboMet, fine lattice structures built with L-PBF have been characterized to determine the actual thicknesses of struts and density of the lattice structures. These structures have been used as finer build supports for the L-PBF process, designs for fine catalysts, and other design considerations for small components. The RoboMet data helps to inform the modeling and design efforts around these fine components.

additive manufacturing↗

Progress toward a 30 percent-efficient, monolithic, three-junction, two-terminal concentrator solar cell for space applications

Component efficiencies of 0.2/sq cm cells at approximately 100x AMO light concentration and 80 C temperatures are not at 15.3 percent for a 1.9 eV AlGaAs top cell, 9.9 percent for a 1.4 eV GaAs middle cell under a 1.9 eV AlGaAs filter, and 2.4 percent for a bottom 1.0 eV InGaAs cell under a GaAs substrate. The goal is to continue improvement in these performance levels and to sequentially grow these devices on a single substrate to give 30 percent efficient, monolithic, two-terminal, three-junction space concentrator cells. The broad objective is a 30 percent efficient monolithic two-terminal cell that can operate under 25 to 100x AMO light concentrations and at 75 to 100 C cell temperatures. Detailed modeling predicts that this requires three junctions. Two options are being pursued, and both use a 1.9 eV AlGaAs top junction and a 1.4 eV GaAs middle junction grown by a 1 atm OMVPE on a lattice matched substrate. Option 1 uses a low-doped GaAs substrate with a lattice mismatched 1.0 eV InGaAs cell formed on the back of the substrate. Option 2 uses a Ge substrate to which the AlGaAs and GaAs top junctions are lattice matched, with a bottom 0.7 eV Ge junction formed near the substrate interface with the GaAs growth. The projected efficiency contributions are near 16, 11, and 3 percent, respectively, from the top, middle, and bottom junctions.

Partain, L. D.↗

Anisotropic constitutive modeling for nickel-base single crystal superalloys

An anisotropic constitutive model was developed based on crystallographic slip theory for nickel base single crystal superalloys. The constitutive equations developed utilizes drag stress and back stress state variables to model the local inelastic flow. Specially designed experiments were conducted to evaluate the existence of back stress in single crystal superalloy Rene N4 at 982 C. The results suggest that: (1) the back stress is orientation dependent; and (2) the back stress state variable is required for the current model to predict material anelastic recovery behavior. The model was evaluated for its predictive capability on single crystal material behavior including orientation dependent stress-strain response, tension/compression asymmetry, strain rate sensitivity, anelastic recovery behavior, cyclic hardening and softening, stress relaxation, creep and associated crystal lattice rotation. Limitation and future development needs are discussed.

Sheh, Michael Y.↗

Growth morphology with anisotropic surface kinetics

The morphological evolution of crystals growing from an incongruent vapor phase is studied using a Monte Carlo model, and the full range of growth morphologies is recovered. The diffusion in the bulk nutrient and the anisotropy in the interface kinetics are morphologically destabilizing and stabilizing, respectively. For a given set of simulation parameters and lattice symmetries there is a critical size, which scales linearly with the mean free path in the vapor, beyond which a crystal cannot retain its stable, macroscopically faceted growth shape. Surface diffusion stabilizes faceted growth on the shorter scale of the mean surface diffusion length. In simulations with a uniform drift superimposed on the random walk nutrient transport, crystal faces oriented toward the drift show enhanced morphological stability compared to the purely diffusive situation. Rotational drifts with periodic reversal of direction are morphologically stabilizing for all crystal facets.

Xiao, Rong-Fu↗

Longitudinal Aerodynamic Modeling of the Adaptive Compliant Trailing Edge Flaps on a GIII Airplane and Comparisons to Flight Data

A pair of compliant trailing edge flaps was flown on a modified GIII airplane. Prior to flight test, multiple analysis tools of various levels of complexity were used to predict the aerodynamic effects of the flaps. Vortex lattice, full potential flow, and full Navier-Stokes aerodynamic analysis software programs were used for prediction, in addition to another program that used empirical data. After the flight-test series, lift and pitching moment coefficient increments due to the flaps were estimated from flight data and compared to the results of the predictive tools. The predicted lift increments matched flight data well for all predictive tools for small flap deflections. All tools over-predicted lift increments for large flap deflections. The potential flow and Navier-Stokes programs predicted pitching moment coefficient increments better than the other tools.

aerodynamics↗

Numerical Predictions of Wind Turbine Power and Aerodynamic Loads for the NREL Phase II and IV Combined Experiment Rotor

Accurate, reliable and robust numerical predictions of wind turbine rotor power remain a challenge to the wind energy industry. The literature reports various methods that compare predictions to experiments. The methods vary from Blade Element Momentum Theory (BEM), Vortex Lattice (VL), to variants of Reynolds-averaged Navier-Stokes (RaNS). The BEM and VL methods consistently show discrepancies in predicting rotor power at higher wind speeds mainly due to inadequacies with inboard stall and stall delay models. The RaNS methodologies show promise in predicting blade stall. However, inaccurate rotor vortex wake convection, boundary layer turbulence modeling and grid resolution has limited their accuracy. In addition, the inherently unsteady stalled flow conditions become computationally expensive for even the best endowed research labs. Although numerical power predictions have been compared to experiment. The availability of good wind turbine data sufficient for code validation experimental data that has been extracted from the IEA Annex XIV download site for the NREL Combined Experiment phase II and phase IV rotor. In addition, the comparisons will show data that has been further reduced into steady wind and zero yaw conditions suitable for comparisons to "steady wind" rotor power predictions. In summary, the paper will present and discuss the capabilities and limitations of the three numerical methods and make available a database of experimental data suitable to help other numerical methods practitioners validate their own work.

Duque, Earl P. N.↗

Precision in Assembled Discrete Lattice Space Structures for Next-Generation ISAM Applications

Robust autonomous robotic assembly of large-scale space structures has been a long-term and challenging goal to enable higher quality in-space communication and science instrumentation. For optical observatory support structures and antenna structures, the challenge is the strict dimensional precision requirements (generally RMS surface error) driven by the operational radiation wavelength. Early theoretical work in the area linked RMS surface error of a reflector support truss plate to the natural passive dynamic mode frequencies of the structure, as well as to the error distribution in dimensions of constituent structural elements. Prior robotic truss assembly demonstrations focused on designing ultra-high precision structural elements, joints, and robotic actuators. Recently, an alternative space structure assembly strategy based on a programmable matter approach (NASA ARMADAS) was demonstrated. This approach uses lattice building blocks (voxels) that are reversibly, mechanically joined into a bulk lattice structure by robots that locomote in and on the structure itself. Such a system can achieve high-level autonomy with low computation, robustly assemble utilizing inexpensive and imprecise robots, and efficiently build structures several orders of magnitude larger than the assembly robots. However, for instrumentation support structure applications, the resulting precision of these building block-based lattice structures is not well studied. Since they are demonstrated with many more assembly units than prior art trusses, it is unclear whether the same precision design approaches apply. In this work, we study in simulation the effects of voxel geometry, error in distribution, assembly resolution (module size), and assembly geometry on the error of both beam and plate lattice structures. While average RMS error of a plate increases with plate size, increasing plate thickness quickly collapses RMS error towards a limit that is on the order of the error of the constituent parts. We validate our models against previously published precision measurements of built systems. Results from this study will guide manufacturing precision requirements, as well as designs, for future robotically assembled structural applications and establish feasibility for different applications.

Christine E Gregg↗

A subvortex technique for the close approach to a discretized vortex sheet

The close-approach problem associated with flow calculation methods based on vortex-lattice theory was examined numerically using two-dimensional discretized vortex sheets. The analysis first yields a near-field radius of approximately the distance apart of the vortices in the lattice; only within this distance from the sheet are the errors arising from the discretization significant. Various modifications to the discrete vortices are then considered with the objective of reducing the errors. This leads to a near-field model in which a vortex splits into an increasing number of subvortices as it is approached. The subvortices, whose strengths vary linearly from the vortex position, are evenly distributed along an interpolated curve passing through the basic vortices. This subvortex technique can be extended to the three-dimensional case and is efficient because the number of vortices is effectively increased, but only where and when needed.

Maskew, B.↗

Steady and unsteady incompressible free-wake analysis

The flows around highly sweptback wings and bodies of revolution at high angle of attack are described, and inviscid model approximations and mathematical formulation of the problem are given to steady and unsteady incompressible flows. A general presentation of the methods of solution is given, with emphasis on current computational techniques. Detailed descriptions of the nonlinear vortex-lattice and vortex-panel techniques are presented to show how the boundary conditions are enforced using iteration. Typical numerical results are compared with the available experimental data.

Kandil, O. A.↗

Theoretical estimation of the transonic aerodynamic characteristics of a supercritical-wing transport model with trailing-edge controls

A method for rapidly estimating the overall forces and moments at supercritical speeds, below drag divergence, of transport configurations with supercritical wings is presented. The method was also used for estimating the rolling moments due to the deflection of wing trailing-edge controls. This analysis was based on a vortex-lattice technique modified to approximate the effects of wing thickness and boundary-layer induced camber. Comparisons between the results of this method and experiment indicate reasonably good correlation of the lift, pitching moment, and rolling moment. The method required much less storage and run time to compute solutions over an angle-of-attack range than presently available transonic nonlinear methods require for a single angle-of-attack solution.

Luckring, J. M.↗

The structure of 110 tilt boundaries in large area solar silicon

The models of Hornstra and their connection to the repeating group description of grain boundaries (7-10) are discussed. A model for the Sigma = 27 boundary containing a zig-zag arrangement of dislocations is constructed and it is shown that zig-zag models can account for the contrast features observed in high resolution transmission electron micrographs of second and third order twin boundaries in silicon. The boundaries discussed are symmetric with a 110 tilt axis and a (110) boundary plane in the median lattice (the median plane). The median lattice is identical in structure and halfway in orientation between the crystal lattices either side of the boundary.

Ast, D. G.↗

Simulation-Based Airframe Noise Prediction of a Full-Scale, Full Aircraft

A previously validated computational approach applied to an 18%-scale, semi-span Gulfstream aircraft model was extended to the full-scale, full-span aircraft in the present investigation. The full-scale flap and main landing gear geometries used in the simulations are nearly identical to those flown on the actual aircraft. The lattice Boltzmann solver PowerFLOW® was used to perform time-accurate predictions of the flow field associated with this aircraft. The simulations were performed at a Mach number of 0.2 with the flap deflected 39 deg. and main landing gear deployed (landing configuration). Special attention was paid to the accurate prediction of major sources of flap tip and main landing gear noise. Computed farfield noise spectra for three selected baseline configurations (flap deflected 39 deg. with and without main gear extended, and flap deflected 0 deg. with gear deployed) are presented. The flap brackets are shown to be important contributors to the farfield noise spectra in the mid- to high-frequency range. Simulated farfield noise spectra for the baseline configurations, obtained using a Ffowcs Williams and Hawkings acoustic analogy approach, were found to be in close agreement with acoustic measurements acquired during the 2006 NASA-Gulfstream joint flight test of the same aircraft.

Khorrami, Mehdi R.↗

Environmental fatigue of an Al-Li-Cu alloy. Part 3: Modeling of crack tip hydrogen damage

Environmental fatigue crack propagation rates and microscopic damage modes in Al-Li-Cu alloy 2090 (Parts 1 and 2) are described by a crack tip process zone model based on hydrogen embrittlement. Da/dN sub ENV equates to discontinuous crack advance over a distance, delta a, determined by dislocation transport of dissolved hydrogen at plastic strains above a critical value; and to the number of load cycles, delta N, required to hydrogenate process zone trap sites that fracture according to a local hydrogen concentration-tensile stress criterion. Transgranular (100) cracking occurs for process zones smaller than the subgrain size, and due to lattice decohesion or hydride formation. Intersubgranular cracking dominates when the process zone encompasses one or more subgrains so that dislocation transport provides hydrogen to strong boundary trapping sites. Multi-sloped log da/dN-log delta K behavior is produced by process zone plastic strain-hydrogen-microstructure interactions, and is determined by the DK dependent rates and proportions of each parallel cracking mode. Absolute values of the exponents and the preexponential coefficients are not predictable; however, fractographic measurements theta sub i coupled with fatigue crack propagation data for alloy 2090 established that the process zone model correctly describes fatigue crack propagation kinetics. Crack surface films hinder hydrogen uptake and reduce da/dN and alter the proportions of each fatigue crack propagation mode.

Piascik, Robert S.↗

Determination of a Two-Phase Structure of Nanocrystals: GaN and SiC

The properties of nano-crystalline materials are critically dependent on the structure of the constituent grains. Experimental conditions necessary to perform structural analysis of nanocrystalline materials as a two-phase core-surface shell system are discussed. It is shown, that a standard X-ray diffraction measurements and analysis are insufficient and may lead to incorrect conclusions as to the real structure of the materials. A new method of evaluation of powder diffraction data based on the analysis of the shift of the Bragg reflections from their perfect-lattice positions was developed. "Apparent lattice parameters" quantity, alp, was introduced and calculated from the actual positions of each individual Bragg reflection. The alp values plotted versus diffraction vector (Q) show characteristic features that are used for evaluation of the experimental results. The study was based on modeling of nano-grains and simulations of theoretical intensity profiles using the Debye functions. The method was applied to the analysis of synchrotron X-ray diffraction data of GaN and SiC nanocrystals. A presence of strained surface shell and a considerable internal pressure (GaN) in the nanoparticles was concluded.

Palosz, W.↗

A Model for Backscattering from Quasi Periodic Corn Canopies at L-Band

In this study, a model for backscattering at L-band from a corn canopy is proposed. The canopy consists of a quasi-periodic distribution of stalks and a random distribution of leaves. The Distorted Born Approximation (DBA) is employed to calculate the single scattered return from the corn field. The new feature of the method is that the coherence of the stalks in the row direction is incorporated in the model in a systematic fashion. Since the wavelength is on the order of the distance between corn stalks in a row, grating lobe behavior is observed at certain azimuth angles of incidence. The results are compared with experimental values measured in Huntsville, Alabama in 1998. The mean field and the effective dielectric constant of the canopy are obtained by using the Foldy approximation. The stalks are placed in the effective medium in a two dimensional lattice to simulate the row structure of a corn field. In order to mimic a real corn field, a quasi-periodic stalk distribution is assumed where the stalks are given small random perturbations about their lattice locations. Corn leaves are also embedded in the effective medium and the backscattered field from the stalks and the leaves is computed. The backscattering coefficient is calculated and averaged over successive stalk position perturbations. It is assumed that soil erosion has smoothed the soil sufficiently so that it can be assumed flat. Corn field backscatter data was collected from cornfields during the Huntsville 98 experimental campaign held at Alabama A&M University Research Station, Huntsville, Alabama in 1998 using the NASA/GW truck mounted radar. Extensive ground truth data was collected. This included soil moisture measurements and corn plant architectural data to be used in the model. In particular, the distances between the stalks in a single row have been measured. The L-band radar backscatter data was collected for both H and V polarizations and for look angles of 15o and 45o over a two week period under varying soil moisture conditions. These measured backscattering values will be compared with the model backscattering values and a discussion of the results will be presented.

Lang, R.↗

Some low-speed flutter characteristics of simple low-aspect-ratio delta wing models

Some results from a combined experimental and analytical study of the low-speed flutter characteristics of low-aspect-ratio delta wings are presented. Data are presented which show the effects of sweep angle on the flutter characteristics of some simple plate models of constant planform area. The range of sweep angles studied was from 30 to 72 degrees. In addition, flutter results are presented for two 30 deg-sweep clipped-delta wing models. Further, results are presented that show the effects of root clamping (percentage length of the root chord that is cantilevered) for a 45 deg-sweep delta wing. The experimental data are compared with analytical results obtained by using kernel function and doublet lattice subsonic unsteady lifting surface theories.

Doggett, Robert V., Jr.↗

Some low-speed flutter characteristics of simple low-aspect-ratio delta wing models

Some results from a combined experimental and analytical study of the low-speed flutter characteristics of low-aspect-ratio delta wings are presented. Data are presented which show the effects of sweep angle on the flutter characteristics of some simple plate models of constant planform area. The range of sweep angles studied was from 30 to 72 degrees. In addition, flutter results are presented for two 30 deg-sweep clipped-delta wing models. Further results are presented that show the effects of root clamping (percentage length of the root chord that is cantilevered) for a 45 deg-sweep delta wing. The experimental data are compared with analytical results obtained by using kernel function and doublet lattice subsonic unsteady lifting surface theories.

Doggett, Robert V., Jr.↗

Characterization and Modeling of Indium Gallium Antimonide Avalanche Photodiode and of Indium Gallium Arsenide Two-band Detector

A model of the optical properties of Al(x)Ga(1-x)As(y)Sb(1-y) and In(x)Ga(1-x)As(y)Sb(1-y) is presented, including the refractive, extinction, absorption and reflection coefficients in terms of the optical dielectric function of the materials. Energy levels and model parameters for each binary compound are interpolated to obtain the needed ternaries and quaternaries for various compositions. Bowing parameters are considered in the interpolation scheme to take into account the deviation of the calculated ternary and quaternary values from experimental data due to lattice disorders. The inclusion of temperature effects is currently being considered.

Source record↗