Results for “Complex Geometry” — Page 27

NASA NTRS2021

The Effect of Composition on Microstructure and Properties for Additively Manufactured Superalloy 718

Additive manufacturing (AM) represents an exciting new approach towards producing metallic aerospace components. The ability to make complex geometries that were impossible to create using conventional manufacturing methods has sparked interest from the aerospace community, including NASA. The use of AM components for crucial and human rated space missions necessitates a full characterization of the differences between AM and more conventional wrought and cast processes. For this study, sixteen different commercially available superalloy 718 powder feedstocks were obtained, built using laser powder bed fusion(L-PBF), and microstructurally and mechanically analyzed. These measurements revealed a wide range of build qualities and microstructures despite all powder lots falling within the 718chemical specification and being processed using the same prescribed build and heat treatment parameters. Statistical analysis found a strong correlation of the amount of carbon in the powder with the final grain size and strength of the heat-treated 718 part. Ultimately, this study highlights the need of a refined superalloy 718 chemical specification for powder lots to be used in AM.

Timothy M Smith↗

NASA NTRSDate not supplied

Development of Acoustic Mufflers for Cabin Noise Reduction in Orion Spacecraft

Controlling cabin acoustic noise levels in the Crew Module (CM) of the Orion spacecraft is critical to ensure adequate speech intelligibility, to avoid fatigue, and prevent any possibility of temporary and permanent hearing loss to the crew. The primary source of cabin noise for the on-orbit phase of the mission is from the Environmental Control and Life Support System (ECLSS) which recycles and conditions breathing air and maintains cabin pressurization through its duct network and components. Unfortunately, as a side effect, noise from the ECLSS fans propagates through theses ducts and emanate into the cabin habitable volume via the ECLSS inlet and outlets. To mitigate excessive duct-borne noise, two ECLSS mufflers have been designed to provide significant acoustic transmission loss (TL) so that the cabin noise requirements can be met. Each muffler is meant to be installed in the ducting of the ECLSS air inlet and outlet sides, respectively. Packaging constraints and tight volume requirements necessitated the mufflers to be of complex geometry and compatible with the bends of the ECLSS duct layout. To design and characterize the acoustic performance of the inlet and outlet mufflers, computational acoustic models were developed using the Finite Element Method (FEM) with 𝑤𝑎𝑣𝑒଺ vibroacoustic software. Characterization of the acoustic material and perforations in the mufflers were addressed with poroelastic theory. Once the mufflers were designed on paper and its TL predicted, prototypes of these mufflers were created using additive manufacturing. The muffler prototypes were subsequently tested for acoustic TL in the laboratory with various con-figurations of acoustic materials. Comparing the analytical predictions to the test performance yielded excellent correlation for acoustic TL and demonstrated significant broadband noise attenuation. The ECLSS mufflers are currently scheduled to be installed on the Artemis II Crew Module (CM) of the Orion spacecraft and will provide significant cabin comfort to crew during the mission.

Indranil Dandaroy↗

NASA NTRSDate not supplied

Effect of Boundary Conditions on Process-Induced Stresses in a Plain Weave Unit Cell

Woven polymer matrix composites (PMCs) are leveraged in aerospace applications for their desirable specific properties, yet they are vulnerable to high residual stresses during manufacturing and their complex geometry makes experimental results difficult to observe. Process modeling is needed to characterize the effects of the curing and predict end stress states. Finite element software can be used to model woven architectures, however accurate representation of processing conditions remains a challenge when it comes to selecting boundary conditions. The effect of BCs on process-induced stress within woven PMCs is studied. The commercial Finite Element Analysis (FEA) software Abaqus is coupled with user-written subroutines in a process modeling framework. A two-dimensionally (2D) woven PMC repeating unit cell (RUC) is modeled with TexGen and Abaqus. Virtual curing is imposed on the bulk matrix. The BC study is conducted with Free, Periodic, Flat, and Flat-Free configurations. Results show that the end stress state is sensitive to the boundary condition assumptions. Flat BC results show great agreement with Periodic BCs. Residual stress results from process modeling are then compared with a linear-elastic thermal cooldown analysis in Abaqus. Cooldown results indicate an overestimation in matrix stresses compared with process modeling.

micromechanics↗

NASA NTRS2020

Thermal system and environmental testing of the Mars Helicopter

The Mars Helicopter will be a technology demonstration conducted during the Mars 2020 mission. The primary mission objective is to achieve several 90-second flights demonstrating the feasibility of heavier than air flight on Mars and capture visible light images via forward and nadir mounted cameras. These flights could possibly provide reconnaissance data for sampling site selection for other Mars surface missions. A solar array and batteries for flight operations, imaging, communications, and survival heating power the Helicopter. The thermal design is driven by minimizing survival heater energy while maintaining compliance with allowable flight temperatures in a variable thermal environment. Due to the small size of the Helicopter and its complex geometries, along with the fact that it operates with very low power and small margins in the extreme Mars environment, additional care had to be paid while planning thermal tests and designing the thermal system. The first section of the paper describes the evolution of the thermal system of the Mars Helicopter. After the first thermal vacuum test of the engineering model, the thermal team has conducted a partial effect analysis on the thermal design components that had a major impact on the system performance. Several design choices derived by analysis and test have been made to meet the energy allocation and the temperature requirements. These changes included increased gas gaps to reduce gas conduction, low emissivity coatings for internal components, blanket implementation, optimization of wire routing and fine-tuning of surface operations to optimize waste heat recovery. The second part of the paper describes the flight model thermal vacuum test and the subsequent thermal model correlation necessary to confirm the fidelity of the analysis results.

Pauken, Michael↗

NASA NTRSDate not supplied

Rapid Hypersonic Simulations using US3D and Pointwise

For hypersonic simulations, unstructured flow solvers typically have problems predicting surface heat fluxes when strong shocks are present. To address these issues, this paper outlines a workflow that applies best practices developed for structured grids to unstructured meshes. In addition, unstructured grid generation can significantly reduce the time required to create quality grids for complex geometries. Several examples are computed using DPLR, a structured grid flow solver, and US3D flow, an unstructured mesh solver. Results from the two codes are compared, and they show excellent agreement. Overall, the unstructured grid workflow offers a viable and attractive alternative for hypersonic simulations.

C. Tang↗

NASA NTRSDate not supplied

Rapid Hypersonic Simulations using US3D and Pointwise

For hypersonic simulations, unstructured flow solvers typically have problems predicting surface heat fluxes when strong shocks are present. To address these issues, this paper outlines a workflow that applies best practices developed for structured grids to unstructured meshes. In addition, unstructured grid generation can significantly reduce the time required to create quality grids for complex geometries. Several examples are computed using DPLR, a structured grid flow solver, and US3D flow, an unstructured mesh solver. Results from the two codes are compared, and they show excellent agreement. Overall, the unstructured grid workflow offers a viable and attractive alternative for hypersonic simulations.

Chun Tang↗

NASA NTRS2022

Quantifying Errors in 3D CME Parameters Derived from Synthetic Data Using White-Light Reconstruction Techniques

Current efforts in space weather forecasting of CMEs have been focused on predicting their arrival time and magnetic structure. To make these predictions, methods have been developed to derive the true CME speed, size, position, and mass, among others. Difficulties in determining the input parameters for CME forecasting models arise from the lack of direct measurements of the coronal magnetic fields and uncertainties in estimating the CME 3D geometric and kinematic parameters after eruption. White-light coronagraph images are usually employed by a variety of CME reconstruction techniques that assume more or less complex geometries. This is the first study from our International Space Science Institute (ISSI) team “Understanding Our Capabilities in Observing and Modeling Coronal Mass Ejections”, in which we explore how subjectivity affects the 3D CME parameters that are obtained from the Graduated Cylindrical Shell (GCS) reconstruction technique, which is widely used in CME research. To be able to quantify such uncertainties, the “true” values that are being fitted should be known, which are impossible to derive from observational data. We have designed two different synthetic scenarios where the “true” geometric parameters are known in order to quantify such uncertainties for the first time. We explore this by using two sets of synthetic data: 1) Using the ray-tracing option from the GCS model software itself, and 2) Using 3D magnetohydrodynamic (MHD) simulation data from the Magnetohydrodynamic Algorithm outside a Sphere code. Our experiment includes different viewing configurations using single and multiple viewpoints. CME reconstructions using a single viewpoint had the largest errors and error ranges overall for both synthetic GCS and simulated MHD white-light data. As the number of viewpoints increased from one to two, the errors decreased by approximately 4° in latitude, 22° in longitude, 14° in tilt, and 10° in half-angle. Our results quantitatively show the critical need for at least two viewpoints to be able to reduce the uncertainty in deriving CME parameters. We did not find a significant decrease in errors when going from two to three viewpoints for our specific hypothetical three spacecraft scenario using synthetic GCS white-light data. As we expected, considering all configurations and numbers of viewpoints, the mean absolute errors in the measured CME parameters are generally significantly higher in the case of the simulated MHD white-light data compared to those from the synthetic white-light images generated by the GCS model. We found the following CME parameter error bars as a starting point for quantifying the minimum error in CME parameters from white-light reconstructions: Δθ (latitude)=6° +2° -3° , Δϕ (longitude)=11° +18° -6° , Δγ (tilt)=25° +8° -7° , Δx (half-angle)=10° +12° -6° , Δh (height)=0.6 +1.2 -0.4 R ⨀ , and Δκ (ratio)=0.1 +0.03 -0.02 .

Coronal mass ejections↗

NASA NTRSDate not supplied

Recent BOLT Discrete-Roughness Trip Results from the 20-Inch Mach 6 Tunnel

- Air Force Office of Scientific Research (AFOSR) primary sponsor of BOLT (for Boundary Layer Transition) sounding rocket flight project as continuation of previous HIFiRE flights (1 & 5) - Sounding rockets provide cost-effective flight research tool - Study hypersonic BoLT on increasingly complex geometries - BOLT shape includes concave surfaces and swept leading edges - Two missions, two flights: - BOLT mission at Esrange, Sweden - Johns Hopkins University Applied Physics Laboratory as lead - Focus on transition onset measurements - Flew June 2021 (staging anomaly) - BOLT II mission at Wallops Flight Facility, Virginia - Texas A&M and CUBRC provide primary leadership - Focus on turbulence measurements - Flew March 2022 - Flight named in memory of Mike Holden - NASA’s support to both BOLT missions provided through the Hypersonic Technologies Project (HTP)

Hypersonic↗

NASA NTRS2022

Hypersonic Simulations with US3D using Unstructured Grids from Fidelity Pointwise

For hypersonic simulations, unstructured flow solvers typically have problems predicting surface heat fluxes when strong shocks are present. This article outlines a workflow that applies best practices for structured and unstructured grids. In addition, unstructured grid generation can significantly reduce the time required to create quality grids for complex geometries. Several examples are computed using DPLR, a structured grid flow solver, and US3D flow, an unstructured flow solver. Results from the two codes are compared and they show excellent agreement. The unstructured grid workflow offers a viable and attractive alternative for hypersonic simulations.

C. Tang↗

NASA NTRSDate not supplied

Additive Manufacturing of Electronics for Space Applications

Additive manufacturing techniques for electronics will enable new detector and electronic assemblies that were not previously possible with traditional assembly processes. This technology has the potential to reduce mass and volume for fabrication and assembly of detector, instrument, and electronics concepts by printing fine feature sizes, printing on complex geometries, and allowing new concept production. This presentation summarizes efforts developing printing techniques to manufacture detectors and circuitry for two different space applications.

Additive Manufacturing↗

NASA NTRS2022

Quantifying Errors in 3D CME Parameters Derived From Synthetic Data Using White-Light Reconstruction Techniques

Current efforts in space weather forecasting of CMEs have been focused on predicting their arrival time and magnetic structure. To make these predictions, methods have been developed to derive the true CME speed, size, position, and mass, among others. Difficulties in determining the input parameters for CME forecasting models arise from the lack of direct measurements of the coronal magnetic fields and uncertainties in estimating the CME 3D geometric and kinematic parameters after eruption. White-light coronagraph images are usually employed by a variety of CME reconstruction techniques that assume more or less complex geometries. This is the first study from our International Space Science Institute (ISSI) team “Understanding Our Capabilities in Observing and Modeling Coronal Mass Ejections”, in which we explore how subjectivity affects the 3D CME parameters that are obtained from the Graduated Cylindrical Shell (GCS) reconstruction technique, which is widely used in CME research. To be able to quantify such uncertainties, the “true” values that are being fitted should be known, which are impossible to derive from observational data. We have designed two different synthetic scenarios where the “true” geometric parameters are known in order to quantify such uncertainties for the first time. We explore this by using two sets of synthetic data: 1) Using the ray-tracing option from the GCS model software itself, and 2) Using 3D magnetohydrodynamic (MHD) simulation data from the Magnetohydrodynamic Algorithm outside a Sphere code. Our experiment includes different viewing configurations using single and multiple viewpoints. CME reconstructions using a single viewpoint had the largest errors and error ranges overall for both synthetic GCS and simulated MHD white-light data. As the number of viewpoints increased from one to two, the errors decreased by approximately 4° in latitude, 22° in longitude, 14° in tilt, and 10° in half-angle. Our results quantitatively show the critical need for at least two viewpoints to be able to reduce the uncertainty in deriving CME parameters. We did not find a significant decrease in errors when going from two to three viewpoints for our specific hypothetical three spacecraft scenario using synthetic GCS white-light data. As we expected, considering all configurations and numbers of viewpoints, the mean absolute errors in the measured CME parameters are generally significantly higher in the case of the simulated MHD white-light data compared to those from the synthetic white-light images generated by the GCS model. We found the following CME parameter error bars as a starting point for quantifying the minimum error in CME parameters from white-light reconstructions: Δθ (latitude)=6° +2° -3° , Δϕ (longitude)=11° +18° -6° , Δγ (tilt)=25° +8° -7° , Δx (half-angle)=10° +12° -6° , Δh (height)=0.6 +1.2 -0.4 R ⨀ , and Δκ (ratio)=0.1 +0.03 -0.02 .

Coronal mass ejections↗

NASA NTRS2020

Implicit Large-Eddy Simulations of Hot and Cold Supersonic Jets in Loci-CHEM

Turbulence is a critical factor in most aero- and propulsion-related flows. For many years, the industry-standard approach to incorporating the effect of turbulence in computational fluid dynamics (CFD)calculations has been the Reynolds Averaged Navier Stokes (RANS) modeling approach. RANS implicitly time-averages turbulent motion, and models its effect on the mixing of species, momentum, and energy in a flow field. The approach is economical and often allows a CFD calculation to proceed to steady-state. However, it makes several simplifying assumptions, and the results will only be as good as the RANS turbulence model. Meanwhile, the last two decades have witnessed rapid and explosive growth in computational power, the development of CFD codes which scale well over thousands of processors, and the refinement of unstructured grid-generation tools which facilitate rapid surface and volume gridding of complex geometries. CFD engineering calculations of 108– 109 finite-volume cells have become routine. Thus, large eddy simulation (LES), which attempts to directly resolve the unsteady motion of the largest scales of turbulence, is increasingly of interest for many fluids engineering problems. Additionally, hybrid RANS-LES approaches such as Spalart’s Detached Eddy Simulation (DES), which attempt to marry the best strengths of both methods, are in active use and development. Because it seeks to accurately resolve the unsteady motion of the largest scales of turbulence, LES places certain requirements on the numerical method used to discretize and advance the Navier Stokes equations. In particular, LES requires high time accuracy and minimal intrinsic numerical dispersion and dissipation over a wide range of length scales.

C I Morris↗

NASA NTRSDate not supplied

Separation and Transition on the ROTEX-T Cone-Flare

As part of NATO STO AVT-346 “Predicting Hypersonic Boundary-Layer Transition on Complex Geometries,” coordinated experimental and computational studies were conducted on the ROTEX-T, a cone-flare geometry used in a successful flight-test experiment. At the as-flown conditions, a separation bubble existed at the compression corner. Separation, reattachment, and the multifaceted linear instability paths leading this bubble to transition to turbulence are challenging to predict, but have significant impact on surface pressure and heat flux. High-resolution background-oriented schlieren and infrared thermography measurements were made in the AFOSR–Notre Dame Large Mach-6 Quiet Tunnel at freestream unit Reynolds numbers from 5.8×10(exp 6) to 12.2×10(exp 6) m-1and nominally zero angle of attack. High-speed self-aligned focusing schlieren, infrared thermography, and focused laser differential interferometry measurements were made in the AFRL Mach-6 Ludwieg Tube from 2.2×10(exp 6) to 24.7×10(exp 6) m-1and nominally zero degrees angle of attack. The surface heat-flux and Stanton number distributions were computed. Separation and reattachment locations, as well as the flow state at each, were determined from the combination of surface and off-wall measurements. The convective and global boundary-layer instabilities of the axisymmetric laminar flow at the experimental conditions were investigated computationally. Amplification of Mack’s first and second modes were observed to have logarithmic amplification factors between 5 to 7.5 at the separation location, depending on conditions. The flow was found to be globally unstable to stationary three-dimensional disturbances concentrated in the reattachment region. Previous analysis of the ROTEX-T flight data had not assessed reattachment location or the flow state upon reattachment. Thanks to the insights gained from the coordinated, on- and off-wall ground-test measurements, these evaluations have now been made. The separation location indicated by laminar simulations is consistently numerically predicted to be upstream of the experimentally observed location for a transitional separation bubble. The cause of this difference is understood to lie in the steady-state and axisymmetric assumptions made by both solvers employed to compute the basic states analyzed, as flow topology considerations assert that unsteady two-dimensional or axisymmetric separation bubbles are structurally unstable and will become three-dimensional. Computed laminar heating rates prior to separation agreed well with experiment; transitional heating rates after reattachment were between laminar and turbulent computations.

CFD Validation↗

NASA NTRSDate not supplied

Separation and Transition on the ROTEX-T Cone-Flare

As part of NATO STO AVT-346 “Predicting Hypersonic Boundary-Layer Transition on Complex Geometries,” coordinated experimental and computational studies were conducted on the ROTEX-T, a cone-flare geometry used in a successful flight-test experiment. At the as-flown conditions, a separation bubble existed at the compression corner. Separation, reattachment, and the multifaceted linear instability paths leading this bubble to transition to turbulence are challenging to predict, but have significant impact on surface pressure and heat flux. High-resolution background-oriented schlieren and infrared thermography measurements were made in the AFOSR–Notre Dame Large Mach-6 Quiet Tunnel at freestream unit Reynolds numbers from 5.8×10(exp 6) to 12.2×10(exp 6) m-1and nominally zero angle of attack. High-speed self-aligned focusing schlieren, infrared thermography, and focused laser differential interferometry measurements were made in the AFRL Mach-6 Ludwieg Tube from 2.2×10(exp 6) to 24.7×10(exp 6) m-1and nominally zero degrees angle of attack. The surface heat-flux and Stanton number distributions were computed. Separation and reattachment locations, as well as the flow state at each, were determined from the combination of surface and off-wall measurements. The convective and global boundary-layer instabilities of the axisymmetric laminar flow at the experimental conditions were investigated computationally. Amplification of Mack’s first and second modes were observed to have logarithmic amplification factors between 5 to 7.5 at the separation location, depending on conditions. The flow was found to be globally unstable to stationary three-dimensional disturbances concentrated in the reattachment region. Previous analysis of the ROTEX-T flight data had not assessed reattachment location or the flow state upon reattachment. Thanks to the insights gained from the coordinated, on- and off-wall ground-test measurements, these evaluations have now been made. The separation location indicated by laminar simulations is consistently numerically predicted to be upstream of the experimentally observed location for a transitional separation bubble. The cause of this difference is understood to lie in the steady-state and axisymmetric assumptions made by both solvers employed to compute the basic states analyzed, as flow topology considerations assert that unsteady two-dimensional or axisymmetric separation bubbles are structurally unstable and will become three-dimensional. Computed laminar heating rates prior to separation agreed well with experiment; transitional heating rates after reattachment were between laminar and turbulent computations.

CFD Validation↗

NASA NTRSDate not supplied

Near Infrared In-situ Measurements for the Detection of Keyhole Porosity in Autogenous Ti-6AL-4V Welds

Certification of additive manufactured metal parts requires nondestructive evaluation (NDE) to ensure build quality. NDE can be performed during the build process or post build. For large parts with complex geometries, post build NDE can be challenging. In-situ NDE potentially provides a way to perform the inspection layer by layer. This work explores the use of a high speed near infrared (NIR) camera that is focused in-line with a laser to obtain high spatial and temporal resolution thermal imagery of the melt pool and associated cooling areas. The thermal data is obtained during a laser melting process using Ti-6AL-4V plate and of particular interest is the detection of keyhole porosity. Keyhole porosity can result from non-optimal build conditions, such as excessive laser power at a given laser scanning speed, that creates an entrapped bubble. The NIR measured melt pool and cooling areas are processed to detect keyhole porosity. The results are compared to X-ray CT results for validation.

additive manufacturing↗

NASA NTRSDate not supplied

Near Infrared In-situ Measurements for the Detection of Keyhole Porosity in Autogenous Ti-6AL-4V Welds

Certification of additive manufactured metal parts requires nondestructive evaluation (NDE) to ensure build quality. NDE can be performed during the build process or post build. For large parts with complex geometries, post build NDE can be challenging. In-situ NDE potentially provides a way to perform the inspection layer by layer. This work explores the use of a high speed near infrared (NIR) camera that is focused in-line with a laser to obtain high spatial and temporal resolution thermal imagery of the melt pool and associated cooling areas. The thermal data is obtained during a laser melting process using a Ti-6Al-4V plate and of particular interest is the detection of keyhole porosity. Keyhole porosity can result from non-optimal build conditions, such as excessive laser power at a given laser scanning speed, that creates an entrapped bubble. The NIR measured melt pool and cooling areas are processed to detect keyhole porosity. The results are compared to X-ray CT results for validation. Small keyhole pores buried deep were not detectable with this technique, however, some larger subsurface elongated pores along with some open surface pores did show some promise for detectability.

additive manufacturing↗

NASA NTRS2026

Impact Testing of 410 Stainless Steel for Material Impact Model Development

A project is underway to develop a consistent set of material properties, impact test data, and failure analysis for a variety of metallic aircraft materials that can be used to develop improved impact failure and deformation models. This project is jointly funded by the NASA Glenn Research Center and the Federal Aviation Administration William J. Hughes Technical Center. Particular features of this set of data are that all material property and impact test data are obtained using traceable material, the test methods and procedures are extensively documented, and all the raw data are available. Four parallel efforts are currently underway: measurement of material deformation and failure response over a wide range of strain rates and temperatures, failure analysis of material property specimens and impact test articles, development of improved numerical modeling techniques for deformation and failure, and impact testing of flat panels and substructures for model validation. This report describes impact testing performed on 410 stainless steel sheet and plate samples of different thicknesses with two different types of projectiles, one a regular cylinder and one with a more complex geometry incorporating features representative of a jet engine fan blade. Data from this testing will be used in validating material models developed under this program. The material tests and the material models developed in this program will be published in separate reports.

410 Stainless Steel↗

NASA NTRS2026

Radiation-Conditioned Ti–hBN Coatings for Space Mechanisms: Bridging Tribology and Irradiation Effects from Laboratory to Low-Earth Orbit

The longevity of tribological components in extraterrestrial environments is challenged by abrasive regolith, extreme temperatures, and ionizing radiation. This study evaluates the performance of vacuum plasma sprayed (VPS) Ti-2vol.% hexagonal boron nitride (hBN) coatings applied to joint mechanisms such as rod and slot, ball and socket, and hinge assemblies, fabricated from Al6061 and Ti6Al4V for planetary structures. Coated and uncoated samples were tested under vacuum with lunar regolith simulant (JSC-1A), followed by environmental exposures including electron radiation and thermal cycling. Results show that coated samples consistently outperformed uncoated counterparts across all configurations. Wear depth in coated components was reduced by over 80%, as confirmed by 3D profilometry and surface imaging. SEM analysis revealed severe abrasion and localized plastic deformation in uncoated surfaces, while coated samples retained structural integrity due to synergy of hard protective phases formed during deposition and retained hBN providing solid lubrication in the sliding surface. Coated and exposed samples exhibited smoother actuation profiles and reduced friction, indicating a beneficial "conditioning" effect from environmental exposure. The coatings-maintained performance even on complex geometries with minimal delamination. These findings demonstrate the potential of VPS Ti-hBN coatings to extend the operational life of lunar mechanisms, bridging laboratory-scale tribology with flight-relevant mechanical applications.

tribology↗