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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 451 records · Page 25

Effects of Notches on the Intermediate Creep-Rupture Life of Alloy 617 Weldment

A Code Case has recently been completed that adds Alloy 617 to Section III, Division 5 of the American Society of Mechanical Engineers Boiler and Pressure Vessel Code, which covers high temperature nuclear components. However, additional information is needed to address concerns raised by the Nuclear Regulatory Commission that are not covered by the Code Case. The effects of notches (geometric discontinuities) and multiaxial stress on the expected creep life of a component are among these concerns. This report covers the current state of testing of Alloy 617 notched specimens at Idaho National Laboratory, with particular focus on intermediate length (8,000 – 20,000 hours) creep tests of Alloy 617 weld metal. While most of this testing is ongoing, the current state of the tests indicate that the multi-axial stress state imposed by the notch geometry does not negatively impact the creep rupture life of the Alloy 617 weld metal. While the weld metal is notch strengthening in short-term (1,000 – 2,000 hours) testing, it is not clear if this characteristic will continue to hold for intermediate and long-term testing. Ongoing tests will provide additional information to address this concern of a crossover from notch strengthening to notch weakening for intermediate and long-term creep lives.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Quantitative ultrasonic evaluation of engineering properties in metals, composites, and ceramics

Ultrasonic techniques that have demonstrated potential for material characterization are reviewed. These techniques rely on physical acoustic properties of materials and the interaction of elastic stress waves with morphological factors in the ultrasonic regime. The speed of wave propagation and energy loss by interaction with material microstructure and geometrical factors underlie ultrasonic determination of material properties. Two categories of ultrasonic measurements are discussed: those related to material strengths (e.g., elastic moduli, tensile strength, and fracture toughness) and those related to morphology and material conditions that govern strength and performance (e.g., microstructure, void content, residual stress, fatigue damage). It is shown that large-scale industrial application of ultrasonic NDE will depend on advancement in such areas as theory development, instrumentation, system automation, standardization, and coordination with design.

Vary, A.↗

Airflow Model Testing to Determine the Distribution of Hot Gas Flow and O/F Ratio Across the Space Shuttle Main Engine Main Injector Assembly

Engine 0209, the certification engine for the new Phase 2+ Hot Gas Manifold (HGM), showed severe deterioration of the Main Combustion Chamber (MCC) liner during hot fire tests. One theory on the cause of the damage held that uneven local distribution of the fuel rich hot gas flow through the main injector assembly was producing regions of high oxidizer/fuel (O/F) ratio near the wall of the MCC liner. Airflow testing was proposed to measure the local hot gas flow rates through individual injector elements. The airflow tests were conducted using full scale, geometrically correct models of both the current Phase 2 and the new Phase 2+ HGMs. Different main injector flow shield configurations were tested for each HGM to ascertain their effect on the pressure levels and distribution of hot gas flow. Instrumentation located on the primary faceplate of the main injector measured hot gas flow through selected injector elements. These data were combined with information from the current space shuttle main engine (SSME) power balances to produce maps of pressure, hot gas flow rate, and O/F ratio near the main injector primary plate. The O/F distributions were compared for the different injector and HGM configurations.

Mahorter, L.↗

Transient creep‐fatigue crack growth in creep‐brittle materials: Application to Alloy 718

Abstract This study presents incremental finite element computations of creep‐fatigue crack growth in Alloy 718 at in air. Alloy 718 is representative of creep‐brittle materials, in which viscoplastic deformation is restricted near the tip of a growing crack. The computations predict crack growth using a unique combination of an irreversible cohesive zone formulation and a strain gradient viscoplastic material model based on the Kocks–Mecking formulation. Cohesive zone damage parameters are estimated using sustained loading and constant‐amplitude cyclic loading experiments. Computations of crack extension under three different waveforms containing overloads all predict post‐overload retardation. The amount of retardation depends strongly on the overload ratio, consistent with experiments in the literature using similar waveforms. Analysis of the crack‐tip fields demonstrates retardation is associated with unloading in the highly deformed material near the advancing crack tip. Dynamic recovery and geometrically necessary dislocations are shown to significantly influence post‐overload crack extension.

36 MATERIALS SCIENCE↗

Preliminary study of supersonic-transport configurations with low values of sonic boom

A parametric study of low-boom supersonic transport airplanes with conventional configurations was made to identify the features of specific configurations that promise relatively low sonic boom overpressures (less than 47.9 N/sq m). The range of values considered was gross weight from 28,300 to 170,000 kg; cruise Mach numbers of 2 to 3.2; and wing loadings of 1436, 2870, and 4309 N/sq m. Fuselage length was varied from 49.1 to 102.4 m and fuselage diameter from 2.75 to 3.98 m. A nominal Mach 2 configuration weighing 56,700 kg and having a wing loading of 2870 N/sq m was selected; and its gross geometric, aerodynamic, and structural features were estimated. At a cruise altitude of 18,300 m, lift-drag ratio was estimated to be 7.35, while sonic boom overpressure was 41.7 N/sq m. Takeoff thrust loading using four afterburning turbojet engines at maximum dry thrust was 0.32. Payload for a 4440-km range was 16.7 percent of gross weight, giving a direct operating cost of 0.82 cent per seat statute mile.

Dugan, J. F., Jr.↗

Scalable Geometric Modeler for Overlap Detection and Resolution (ASC IC L2 Milestone 7181 FY2020 Final Review)

The final review for the FY20 Advanced Simulation and Computing (ASC) Integrated Codes (IC) L2 Milestone #7181 was conducted on August 31, 2020 at Sandia National Laboratories in Albuquerque, New Mexico. The review panel unanimously agreed that the milestone has been successfully completed. Roshan Quadros (1543) led the milestone team and various members from the team presented the results. The review panel was comprised of staff from Sandia National Laboratories Albuquerque and California that are involved with computational engineering modeling and analysis. The panel consisted of experts in the fields of solid modeling, discretization, meshing, simulation workflows, and computational analysis including personnel Brett Clark (1543, Chair); Jay Foulk (8363); Jackie Moore (1553); Ron Kensek (1341); Ed Hoffman (8753); Dan Ibanez (1443). The presentation documented the technical approach of the team and summarized the results with sufficient detail to demonstrate both the value and the completion of the milestone. A separate SAND report was also generated with more detail to supplement the presentation. The purpose of the milestone was to advance capabilities for automatically finding, displaying, and resolving geometric overlaps in CAD models.

97 MATHEMATICS AND COMPUTING↗

Dislocation-induced stop-and-go kinetics of interfacial transformations

Most engineering materials are based on multiphase microstructures produced either through the control of phase equilibria or by the fabrication of different materials as in thin-film processing. In both processes, the microstructure relaxes towards equilibrium by mismatch dislocations (or geometric misfit dislocations) across the heterophase interfaces (1-5) . Despite their ubiquitous presence, directly probing the dynamic action of mismatch dislocations has been unachievable owing to their buried nature. In this work, using the interfacial transformation of copper oxide to copper as an example, we demonstrate the role of mismatch dislocations in modulating oxide-to-metal interfacial transformations in an intermittent manner, by which the lateral flow of interfacial ledges is pinned at the core of mismatch dislocations until the dislocation climbs to the new oxide/metal interface location. Together with atomistic calculations, we identify that the pinning effect is associated with the non-local transport of metal atoms to fill vacancies at the dislocation core. These results provide mechanistic insight into solid-solid interfacial transformations and have substantial implications for utilizing structural defects at buried interfaces to modulate mass transport and transformation kinetics.

25 ENERGY STORAGE↗

Cooperative solutions coupling a geometry engine and adaptive solver codes

Follow-on work has progressed in using Aero Grid and Paneling System (AGPS), a geometry and visualization system, as a dynamic real time geometry monitor, manipulator, and interrogator for other codes. In particular, AGPS has been successfully coupled with adaptive flow solvers which iterate, refining the grid in areas of interest, and continuing on to a solution. With the coupling to the geometry engine, the new grids represent the actual geometry much more accurately since they are derived directly from the geometry and do not use refits to the first-cut grids. Additional work has been done with design runs where the geometric shape is modified to achieve a desired result. Various constraints are used to point the solution in a reasonable direction which also more closely satisfies the desired results. Concepts and techniques are presented, as well as examples of sample case studies. Issues such as distributed operation of the cooperative codes versus running all codes locally and pre-calculation for performance are discussed. Future directions are considered which will build on these techniques in light of changing computer environments.

Dickens, Thomas P.↗

An Accurate and Dynamic Computer Graphics Muscle Model

A computer based musculo-skeletal model was developed at the University in the departments of Mechanical and Biomedical Engineering. This model accurately represents human shoulder kinematics. The result of this model is the graphical display of bones moving through an appropriate range of motion based on inputs of EMGs and external forces. The need existed to incorporate a geometric muscle model in the larger musculo-skeletal model. Previous muscle models did not accurately represent muscle geometries, nor did they account for the kinematics of tendons. This thesis covers the creation of a new muscle model for use in the above musculo-skeletal model. This muscle model was based on anatomical data from the Visible Human Project (VHP) cadaver study. Two-dimensional digital images from the VHP were analyzed and reconstructed to recreate the three-dimensional muscle geometries. The recreated geometries were smoothed, reduced, and sliced to form data files defining the surfaces of each muscle. The muscle modeling function opened these files during run-time and recreated the muscle surface. The modeling function applied constant volume limitations to the muscle and constant geometry limitations to the tendons.

Levine, David Asher↗

Flow Simulation of Supersonic Inlet with Bypass Annular Duct

A relaxed isentropic compression supersonic inlet is a new concept that produces smaller cowl drag than a conventional inlet, but incurs lower total pressure recovery and increased flow distortion in the (radially) outer flowpath. A supersonic inlet comprising a bypass annulus to the relaxed isentropic compression inlet dumps out airflow of low quality through the bypass duct. A reliable computational fluid dynamics solution can provide considerable useful information to ascertain quantitatively relative merits of the concept, and further provide a basis for optimizing the design. For a fast and reliable performance evaluation of the inlet performance, an equivalent axisymmetric model whose area changes accounts for geometric and physical (blockage) effects resulting from the original complex three-dimensional configuration is proposed. In addition, full three-dimensional calculations are conducted for studying flow phenomena and verifying the validity of the equivalent model. The inlet-engine coupling is carried out by embedding numerical propulsion system simulation engine data into the flow solver for interactive boundary conditions at the engine fan face and exhaust plane. It was found that the blockage resulting from complex three-dimensional geometries in the bypass duct causes significant degradation of inlet performance by pushing the terminal normal shock upstream.

Kim, HyoungJin↗

Nonlinear ultrasonic technique for the characterization of microstructure in additive materials

This study employs nonlinear ultrasonic techniques to track microstructural changes in additively manufactured metals. The second harmonic generation technique based on the transmission of Rayleigh surface waves is used to measure the acoustic nonlinearity parameter, β. Stainless steel specimens are made through three procedures: traditional wrought manufacturing, laser-powder bed fusion, and laser engineered net shaping. The β parameter is measured through successive steps of an annealing heat treatment intended to decrease dislocation density. Dislocation density is known to be sensitive to manufacturing variables. In agreement with fundamental material models for the dislocation-acoustic nonlinearity relationship in the second harmonic generation, β drops in each specimen throughout the heat treatment before recrystallization. Geometrically necessary dislocations (GNDs) are measured from electron back-scatter diffraction as a quantitative indicator of dislocations; average GND density and β are found to have a statistical correlation coefficient of 0.852 showing the sensitivity of β to dislocations in additively manufactured metals. Moreover, β shows an excellent correlation with hardness, which is a measure of the macroscopic effect of dislocations.

42 ENGINEERING↗

Interior noise analysis and control for light aircraft

This paper describes experimental and analytical studies of the interior noise of twin-engine, propeller-driven, light aircraft. Experimental results indicate that interior noise levels due to propeller noise can be reduced by reduction of engine rpm at constant airspeed (about 3 dB), by synchronization of the twin engines/propellers (up to 12 dB), and by increasing the distances from propeller tip to fuselage. The analytical model described uses modal methods and incorporates the flat-sided geometrical and skin-stringer structural features of light aircraft. Initial results show good agreement with measured noise transmitted into a rectangular box through a flat panel.

Mixson, J. S.↗

Comparison of NASCAP modelling results with lumped circuit analysis

Engineering design tools that can be used to predict the development of absolute and differential potentials by realistic spacecraft under geomagnetic substorm conditions are described. Two types of analyses are in use: (1) the NASCAP code, which computes quasistatic charging of geometrically complex objects with multiple surface materials in three dimensions; (2) lumped element equivalent circuit models that are used for analyses of particular spacecraft. The equivalent circuit models require very little computation time, however, they cannot account for effects, such as the formation of potential barriers, that are inherently multidimensional. Steady state potentials of structure and insulation are compared with those resulting from the equivalent circuit model.

Stang, D. B.↗

Translators between CADD and section 5 of the ANSI Y14.26M standard

The American National Standard, Engineering Drawing and Related Documentation Practices, Digital Representation for Communication of Product Definition Data (ANSI Y14.26M-1981) comprises an introduction, three sections corresponding to IGES (Initial Graphics Exchange Specification) Version 1.0, and Section 5, a constructive, relational, language-based representation for geometric and topological entities. This presentation discusses the design and development of two-way translators between Section 5 (herein, ANSI5) and CADD (Computer-Aided Design Drafting).

Emnett, R. F.↗

Vibrations of twisted cantilevered plates - Experimental investigation

The experimental portion of a joint government/industry/university research study on the vibrational characteristics of twisted cantilevered plates is presented. The overall purpose of the research study was to assess the capabilities and limitations of existing analytical methods in predicting the vibratory characteristics of twisted plates. Thirty cantilevered plates were precision machined at the Air Force's Aero Propulsion Laboratory. These plates, having five different degrees of twist, two thicknesses, and three aspect ratios representative of turbine engine blade geometries, were tested for their vibration mode shapes and frequencies. The resulting nondimensional frequencies and selected mode shapes are presented as a function of plate tip twist. The trends of the natural frequencies as a function of the governing geometric parameters are discussed. The effect of support compliance on the plate natural frequency and its impact on numerically modeling twisted plates is also presented.

Macbain, J. C.↗

Using NASTRAN To Analyze Vibrations Of Rotor Blades

Report gives information on use of NASTRAN computer program in finite-element analysis of rotating flexible blades like in compressors and on turboprop engines. Predicts steady-state components of deflections and stresses under centrifugal forces, generates data for plots of natural frequency versus rotational speed, and provides vibration-mode data for calculations of flutter. Describes use of NASTRAN solution sequence 64 for geometrical nonlinear analysis and solution sequence 63 for determination of frequencies and vibrational-mode shapes. Includes sample problem with NASTRAN input data. Emphasizes key factors in analysis of rotating blades, such as setting angle and centrifugal softening effects. Combined analyses of solution sequences 64 and 63 reduces computer time and number of output listings, in comparison with separate analyses. In central-processing-unit time cut in half.

Lawrence, Charles↗

The Boeing plastic analysis capability for engines

The current BOPACE program is described as a nonlinear stress analysis program, which is based on a family of isoparametric finite elements. The theoretical, user, programmer, preprocessing aspects are discussed, and example problems are included. New features in the current program version include substructuring, an out-of-core Gauss wavefront equation solver, multipoint constraints, combined material and geometric nonlinearities, automatic calculation of inertia effects, provision for distributed as well as concentrated mechanical loads, follower forces, singular crack-tip elements, the SAIL automatic generation capability, and expanded user control over input quantity definition, output selection, and program execution. BOPACE is written in FORTRAN 4 and is currently available for both the IBM 360/370 and the UNIVAC 1108 machines.

Vos, R. G.↗