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At least 505 records · Page 28

Damage Detection in Rotorcraft Composite Structures Using Thermography and Laser-Based Ultrasound

New rotorcraft structural composite designs incorporate lower structural weight, reduced manufacturing complexity, and improved threat protection. These new structural concepts require nondestructive evaluation inspection technologies that can potentially be field-portable and able to inspect complex geometries for damage or structural defects. Two candidate technologies were considered: Thermography and Laser-Based Ultrasound (Laser UT). Thermography and Laser UT have the advantage of being non-contact inspection methods, with Thermography being a full-field imaging method and Laser UT a point scanning technique. These techniques were used to inspect composite samples that contained both embedded flaws and impact damage of various size and shape. Results showed that the inspection techniques were able to detect both embedded and impact damage with varying degrees of success.

Anastasi, Robert F.↗

Solving Navier-Stokes Equations with Advanced Turbulence Models on Three-Dimensional Unstructured Grids

USM3D is a widely-used unstructured flow solver for simulating inviscid and viscous flows over complex geometries. The current version (version 5.0) of USM3D, however, does not have advanced turbulence models to accurately simulate complicated flows. We have implemented two modified versions of the original Jones and Launder k-epsilon two-equation turbulence model and the Girimaji algebraic Reynolds stress model in USM3D. Tests have been conducted for two flat plate boundary layer cases, a RAE2822 airfoil and an ONERA M6 wing. The results are compared with those of empirical formulae, theoretical results and the existing Spalart-Allmaras one-equation model.

Wang, Qun-Zhen↗

A High-Order Method Using Unstructured Grids for the Aeroacoustic Analysis of Realistic Aircraft Configurations

A method for the prediction of acoustic scatter from complex geometries is presented. The discontinuous Galerkin method provides a framework for the development of a high-order method using unstructured grids. The method's compact form contributes to its accuracy and efficiency, and makes the method well suited for distributed memory parallel computing platforms. Mesh refinement studies are presented to validate the expected convergence properties of the method, and to establish the absolute levels of a error one can expect at a given level of resolution. For a two-dimensional shear layer instability wave and for three-dimensional wave propagation, the method is demonstrated to be insensitive to mesh smoothness. Simulations of scatter from a two-dimensional slat configuration and a three-dimensional blended-wing-body demonstrate the capability of the method to efficiently treat realistic geometries.

Atkins, Harold L.↗

Adjoint Formulation for an Embedded-Boundary Cartesian Method

Many problems in aerodynamic design can be characterized by smooth and convex objective functions. This motivates the use of gradient-based algorithms, particularly for problems with a large number of design variables, to efficiently determine optimal shapes and configurations that maximize aerodynamic performance. Accurate and efficient computation of the gradient, however, remains a challenging task. In optimization problems where the number of design variables dominates the number of objectives and flow- dependent constraints, the cost of gradient computations can be significantly reduced by the use of the adjoint method. The problem of aerodynamic optimization using the adjoint method has been analyzed and validated for both structured and unstructured grids. The method has been applied to design problems governed by the potential, Euler, and Navier-Stokes equations and can be subdivided into the continuous and discrete formulations. Giles and Pierce provide a detailed review of both approaches. Most implementations rely on grid-perturbation or mapping procedures during the gradient computation that explicitly couple changes in the surface shape to the volume grid. The solution of the adjoint equation is usually accomplished using the same scheme that solves the governing flow equations. Examples of such code reuse include multistage Runge-Kutta schemes coupled with multigrid, approximate-factorization, line-implicit Gauss-Seidel, and also preconditioned GMRES. The development of the adjoint method for aerodynamic optimization problems on Cartesian grids has been limited. In contrast to implementations on structured and unstructured grids, Cartesian grid methods decouple the surface discretization from the volume grid. This feature makes Cartesian methods well suited for the automated analysis of complex geometry problems, and consequently a promising approach to aerodynamic optimization. Melvin e t al. developed an adjoint formulation for the TRANAIR code, which is based on the full-potential equation with viscous corrections. More recently, Dadone and Grossman presented an adjoint formulation for the Euler equations. In both approaches, a boundary condition is introduced to approximate the effects of the evolving surface shape that results in accurate gradient computation.

Nemec, Marian↗

A Reduced-frequency Approach for Calculating Dynamic Derivatives

Computational Fluid Dynamics (CFD) is increasingly being used to both augment and create an aerodynamic performance database for aircraft configurations. This aerodynamic database contains the response of the aircraft to varying flight conditions and control surface deflections. The current work presents a novel method for calculating dynamic stability derivatives which reduces the computational cost over traditional unsteady CFD approaches by an order of magnitude, while still being applicable to arbitrarily complex geometries over a wide range of flow regimes. The primary thesis of this work is that the response to a forced motion can often be represented with a small, predictable number of frequency components without loss of accuracy. By resolving only those frequencies of interest, the computational effort is significantly reduced so that the routine calculation of dynamic derivatives becomes practical. The current implementation uses this same non-linear, frequency-domain approach and extends the application to the 3-D Euler equations. The current work uses a Cartesian, embedded-boundary method to automate the generation of dynamic stability derivatives.

Murman, Scott M.↗

Computation of a Single Airfoil Gust Response and Gust-Cascade Interaction Using the CE/SE Method

The problems 1 and 2 in Category 3 are solved using the space-time conservation element and solution element (CE/SE) method. Problem 1 concerns the acoustic field generated by the interaction of a harmonic vertical gust with a single isolated airfoil. Problem 2 models rotor-stator interaction in a 2D cascade. Both problems involve complex geometries and flow physics including vortex shielding and acoustic radiation. An unstructured triangular mesh is used to solve both problems. For problem 2, the Giles approach is incorporated with the CE/SE method to handle non-equal pitches of the rotor and stator. Numerical solution of both near and far fields of problem 1 are presented and compared with a frequency-domain solver GUST3D and a time-domain high-order Discontinuous Spectra Element Method (DSEM) solutions. For problem 2, numerical solutions on the blade surface, inlet and outlet planes are presented.

Wang, Xiao-Yen↗

Finite Element Modeling of the Bulk Magnitization of Railroad Wheels to Improve Test Conditions for Magnetoacoustic Residual Stress Measurements

The magnetoacoustic measurement technique has been used successfully for residual stress measurements in laboratory samples. However, when used to field test samples with complex geometries, such as railroad wheels, the sensitivity of the method declines dramatically. It has been suggested that the decrease in performance may be due, in part, to an insufficient or nonuniform magnetic induction in the test sample. The purpose of this paper is to optimize the test conditions by using finite element modeling to predict the distribution of the induced bulk magnetization of railroad wheels. The results suggest that it is possible to obtain a sufficiently large and uniform bulk magnetization by altering the shape of the electromagnet used in the tests. Consequently, problems associated with bulk magnetization can be overcome, and should not prohibit the magnetoacoustic technique from being used to make residual stress measurements in railroad wheels. We begin by giving a brief overview of the magnetoacoustic technique as it applies to residual stress measurements of railroad wheels. We then define the finite element model used to predict the behavior of the current test configuration along with the nonlinear constitutive relations which we obtained experimentally through measurements on materials typically used to construct both railroad wheels and electromagnets. Finally, we show that by modifying the pole of the electromagnet it is possible to obtain a significantly more uniform bulk magnetization in the region of interest.

Fulton, J. P.↗

A Comparison of Experimental EPMA Data and Monte Carlo Simulations

Monte Carlo (MC) modeling shows excellent prospects for simulating electron scattering and x-ray emission from complex geometries, and can be compared to experimental measurements using electron-probe microanalysis (EPMA) and phi(rho z) correction algorithms. Experimental EPMA measurements made on NIST SRM 481 (AgAu) and 482 (CuAu) alloys, at a range of accelerating potential and instrument take-off angles, represent a formal microanalysis data set that has been used to develop phi(rho z) correction algorithms. The accuracy of MC calculations obtained using the NIST, WinCasino, WinXray, and Penelope MC packages will be evaluated relative to these experimental data. There is additional information contained in the extended abstract.

Carpenter, P. K.↗

Improving the Flow

In early 1995, NASA s Glenn Research Center (then Lewis Research Center) formed an industry-government team with several jet engine companies to develop the National Combustion Code (NCC), which would help aerospace engineers solve complex aerodynamics and combustion problems in gas turbine, rocket, and hypersonic engines. The original development team consisted of Allison Engine Company (now Rolls-Royce Allison), CFD Research Corporation, GE Aircraft Engines, Pratt and Whitney, and NASA. After the baseline beta version was established in July 1998, the team focused its efforts on consolidation, streamlining, and integration, as well as enhancement, evaluation, validation, and application. These activities, mainly conducted at NASA Glenn, led to the completion of NCC version 1.0 in October 2000. NCC version 1.0 features high-fidelity representation of complex geometry, advanced models for two-phase turbulent combustion, and massively parallel computing. Researchers and engineers at Glenn have been using NCC to provide analysis and design support for various aerospace propulsion technology development projects. NASA transfers NCC technology to external customers using non- exclusive Space Act Agreements. Glenn researchers also communicate research and development results derived from NCC's further development through publications and special sessions at technical conferences.

Source record↗

CEMCAN Software Enhanced for Predicting the Properties of Woven Ceramic Matrix Composites

Major advancements are needed in current high-temperature materials to meet the requirements of future space and aeropropulsion structural components. Ceramic matrix composites (CMC's) are one class of materials that are being evaluated as candidate materials for many high-temperature applications. Past efforts to improve the performance of CMC's focused primarily on improving the properties of the fiber, interfacial coatings, and matrix constituents as individual phases. Design and analysis tools must take into consideration the complex geometries, microstructures, and fabrication processes involved in these composites and must allow the composite properties to be tailored for optimum performance. Major accomplishments during the past year include the development and inclusion of woven CMC micromechanics methodology into the CEMCAN (Ceramic Matrix Composites Analyzer) computer code. The code enables one to calibrate a consistent set of constituent properties as a function of temperature with the aid of experimentally measured data.

Murthy, Pappu L. N.↗

Experimental and Analytical Determinations of Spiral Bevel Gear-Tooth Bending Stress Compared

Spiral bevel gears are currently used in all main-rotor drive systems for rotorcraft produced in the United States. Applications such as these need spiral bevel gears to turn the corner from the horizontal gas turbine engine to the vertical rotor shaft. These gears must typically operate at extremely high rotational speeds and carry high power levels. With these difficult operating conditions, an improved analytical capability is paramount to increasing aircraft safety and reliability. Also, literature on the analysis and testing of spiral bevel gears has been very sparse in comparison to that for parallel axis gears. This is due to the complex geometry of this type of gear and to the specialized test equipment necessary to test these components. To develop an analytical model of spiral bevel gears, researchers use differential geometry methods to model the manufacturing kinematics. A three-dimensional spiral bevel gear modeling method was developed that uses finite elements for the structural analysis. This method was used to analyze the three-dimensional contact pattern between the test pinion and gear used in the Spiral Bevel Gear Test Facility at the NASA Glenn Research Center at Lewis Field. Results of this analysis are illustrated in the preceding figure. The development of the analytical method was a joint endeavor between NASA Glenn, the U.S. Army Research Laboratory, and the University of North Dakota.

Handschuh, Robert F.↗

Cooled Ceramic Matrix Composite Panel Successfully Tested in Rocket Exhaust

Actively cooled ceramic matrix composite (CMC) components are enabling or enhancing for a broad range of hypersonic and reusable launch vehicle propulsion systems. Teaming with other NASA centers, the Air Force, and industry, the Glenn Ceramics Branch has successfully tested multiple cooled CMC panel concepts in high-heat-flux, high-pressure, flowing rocket engine combustion gas environments. Sub-element components survived multiple cycles and the severe thermal gradients imposed by combustion gas temperatures in excess of 5500 F and cryogenic hydrogen or ambient temperature water internal coolants. These demonstrations are critical for the continued development of this class of materials, and the research is expected to continue with additional concepts and increasingly larger and more complex geometries being fabricated and tested in a broad range of engine operating conditions.

Eckel, Andrew J.↗

Restraint of Liquid Jets by Surface Tension in Microgravity Modeled

Tension in Microgravity Modeled Microgravity poses many challenges to the designer of spacecraft tanks. Chief among these are the lack of phase separation and the need to supply vapor-free liquid or liquidfree vapor to the spacecraft processes that require fluid. One of the principal problems of phase separation is the creation of liquid jets. A jet can be created by liquid filling, settling of the fluid to one end of the tank, or even closing a valve to stop the liquid flow. Anyone who has seen a fountain knows that jets occur in normal gravity also. However, in normal gravity, the gravity controls and restricts the jet flow. In microgravity, with gravity largely absent, jets must be contained by surface tension forces. Recent NASA experiments in microgravity (Tank Pressure Control Experiment, TPCE, and Vented Tank Pressure Experiment, VTRE) resulted in a wealth of data about jet behavior in microgravity. VTRE was surprising in that, although it contained a complex geometry of baffles and vanes, the limit on liquid inflow was the emergence of a liquid jet from the top of the vane structure. Clearly understanding the restraint of liquid jets by surface tension is key to managing fluids in low gravity. To model this phenomenon, we need a numerical method that can track the fluid motion and the surface tension forces. The fluid motion is modeled with the Navier-Stokes equation formulated for low-speed incompressible flows. The quantities of velocity and pressure are placed on a staggered grid, with velocity being tracked at cell faces and pressure at cell centers. The free surface is tracked via the introduction of a color function that tracks liquid as 1/2 and gas as -1/2. A phase model developed by Jacqmin is used. This model converts the discrete surface tension force into a barrier function that peaks at the free surface and decays rapidly. Previous attempts at this formulation have been criticized for smearing the interface. However, by sharpening the phase function, double gridding the fluid function, and using a higher order solution for the fluid function, interface smearing is avoided. These equations can be rewritten as two coupled Poisson equations that also include the velocity. The method of solution is as follows: first, the phase equations are solved from this solution, a velocity field is generated, then a successive overrelaxation scheme is used to solve for a pressure field consistent with the velocity solution. After the code was implemented in axisymmetric form and verified by several test cases, the drop tower runs of Aydelott were modeled. The model handed the free-surface deformation quite nicely, even to the point of modeling geyser growth in the regime where the free surface was no longer restrained. A representative run is shown.

Chato, David J.↗

Computation of Gust-Cascade Interaction Using the CE/SE Method

The problem 2 in Category 3 of the 4th Computational Aeroacoustic(CAA) Workshop is solved using the space-time conservation element and solution element (CE/SE) method. This problem models rotor-stator interaction in a 2D cascade. It involves complex geometries and flow physics including vortex shedding and acoustic radiation. The parallel version of the 2D nonlinear Euler solver is used with an unstructured triangular mesh to solve this problem. The Giles approach is incorporated with the CE/SE method to handle non-equal pitches of the rotor and stator. Validation on the Giles approach is performed using Problem 3.1 in the 2nd CAA Workshop. The space-time CE/SE method is a finite volume method with second-order accuracy in both space and time. The flux conservation is enforced in both space and time instead of space only. It has low numerical dissipation and dispersion errors. It uses simple non-reflecting boundary conditions and is compatible with unstructured meshes. It is simple, flexible, and generate reasonably accurate solutions. The CE/SE method has been successfully applied to solve numerous practical problems, especially aeroacoustic problems. Some preliminary numerical results of the benchmark problem 3.2 of the 4th CAA Workshop are shown. The steady-state pressure contour is plotted. The mean pressure distribution on the blade surface is compared with Turbo solution showing a good agreement. The sound pressure level versus the rotor harmonic n at the six designated positions on the blade surface, three locations at inlet plane, and three locations at the outlet plane are plotted. It can be seen that the acoustic response exists only at the excitation frequencies (n = 1,2,3). On the blade surface, the acoustic wave at n = 1 is dominant, while at the inlet and outlet planes, the sound pressure level at n = 2 becomes the largest, which is similar to the results presented. The distribution of sound pressure level at different spatial modes along the z- direction is plotted for n = 1,2,3, respectively. It shows that the spatial modes m = -32 and 22 at n = 1 exponentially decay, and the spatial modes m = 10 at n = 2, m = -42 and 12 at n = 3 propagate both upstream and downstream, which agrees with the prediction based on the linearized theory. Some oscillations are observed, which needs to be investigated further. In the final paper, the numerical results will be compared with a frequency-domain solver LINFLUX solution if it is available.

Wang, X.-Y.↗

Chapter 19B - Antenna Radiation Patterns

Modern civil and military aircraft are equipped with a variety of communication devices, radio navigation equipment, and air traffic control systems. For all of these devices appropriate antennas must be available to transmit and receive the signals. As a result, as many as 30 antennas, and sometimes even more, are mounted around today's aircraft. For this reason, it is necessary to know the capabilities of the receiving/transmitting equipment on board. These capabilities are driven by the antenna characteristics. Therefore, coverage, shading, and beam pointing pattern data are necessary for optimum electronic coverage. The aircraft antenna has to convert the available power density of the electromagnetic field to an electric voltage at its connector. This voltage level must be sufficiently high to operate the connected equipment. The reciprocity principle states that it makes no difference if the antenna is receiving or transmitting. For the certification of the aircraft antennas it must be proven that the antennas are at least generating the minimum receiver input voltage which is required for each radio service. The prime condition is, of course, that the specified field power densities of the different radio navigation and communication services are available. An important property of a radio frequency link is the electro-magnetic field intensity at every point in space for a given output power of the antenna. As the propagation of radio frequency waves in free space is well known, the spatial distribution of the field intensity needs only be measured at one spatial sphere around the antenna. The information is usually given as distributions along the circumference of flat sections through this sphere: each of these is called an ARP. Several ARPs are usually required to describe the complete spatial antenna pattern of an antenna. In addition to mathematical modeling, measurements on sub-scale models, and static measurements on full size models or aircraft on the ground, dynamic measurements on aircraft in flight play the most important role in the aircraft antenna testing and certification. [19B-1] The shape of an ARP, for one given frequency, is determined by the shape of the antenna and the shape and material of the surface it is mounted on. As the directly transmitted waves interfere with waves reflected by the aircraft skin with its complex geometry, and the surface material parameters are only roughly known, it is not possible to predict the ARP with the required accuracy. In ground measurements the earth's surface also acts as a reflector thereby causing the ground ARP to be different from the in-flight ARP. As the in-flight ARP is the ARP we are actually interested in it becomes clear that it is necessary to conduct in-flight ARP measurements. The Flight Test Engineer must be aware of the needs of the specialists who are establishing the test program for measuring antenna patterns and radar cross sections. These tests will require special test equipment and dedicated flights to obtain the data that they require. This Section provides an introduction to the principles of determining antenna patterns and the flight techniques for determining both antenna patterns and radar cross section. Reference 19B-1 provides detailed information.

Helmut Bothe↗

Vibration Characteristics Determined for Stainless Steel Sandwich Panels With a Metal Foam Core for Lightweight Fan Blade Design

The goal of this project at the NASA Glenn Research Center is to provide fan materials that are safer, weigh less, and cost less than the currently used titanium alloy or polymer matrix composite fans. The proposed material system is a sandwich fan construction made up of thin solid face sheets and a lightweight metal foam core. The stiffness of the sandwich structure is increased by separating the two face sheets by the foam layer. The resulting structure has a high stiffness and lighter weight in comparison to the solid facesheet material alone. The face sheets carry the applied in-plane and bending loads (ref. 1). The metal foam core must resist the transverse shear and transverse normal loads, as well as keep the facings supported and working as a single unit. Metal foams have ranges of mechanical properties, such as light weight, impact resistance, and vibration suppression (ref. 2), which makes them more suitable for use in lightweight fan structures. Metal foams have been available for decades (refs. 3 and 4), but the difficulties in the original processes and high costs have prevented their widespread use. However, advances in production techniques and cost reduction have created a new interest in this class of materials (ref. 5). The material chosen for the face sheet and the metal foam for this study was the aerospace-grade stainless steel 17-4PH. This steel was chosen because of its attractive mechanical properties and the ease with which it can be made through the powder metallurgy process (ref. 6). The advantages of a metal foam core, in comparison to a typical honeycomb core, are material isotropy and the ease of forming complex geometries, such as fan blades. A section of a 17-4PH sandwich structure is shown in the following photograph. Part of process of designing any blade is to determine the natural frequencies of the particular blade shape. A designer needs to predict the resonance frequencies of a new blade design to properly identify a useful operating range. Operating a blade at or near the resonance frequencies leads to high-cycle fatigue, which ultimately limits the blade's durability and life. So the aim of this study is to determine the variation of the resonance frequencies for an idealized sandwich blade as a function of its face-sheet thickness, core thickness, and foam density. The finite element method is used to determine the natural frequencies for an idealized rectangular sandwich blade. The proven Lanczos method (ref. 7) is used in the study to extract the natural frequency.

Ghosn, Louis J.↗

Calculated X-ray Intensities Using Monte Carlo Algorithms: A Comparison to Experimental EPMA Data

Monte Carlo (MC) modeling has been used extensively to simulate electron scattering and x-ray emission from complex geometries. Here are presented comparisons between MC results and experimental electron-probe microanalysis (EPMA) measurements as well as phi(rhoz) correction algorithms. Experimental EPMA measurements made on NIST SRM 481 (AgAu) and 482 (CuAu) alloys, at a range of accelerating potential and instrument take-off angles, represent a formal microanalysis data set that has been widely used to develop phi(rhoz) correction algorithms. X-ray intensity data produced by MC simulations represents an independent test of both experimental and phi(rhoz) correction algorithms. The alpha-factor method has previously been used to evaluate systematic errors in the analysis of semiconductor and silicate minerals, and is used here to compare the accuracy of experimental and MC-calculated x-ray data. X-ray intensities calculated by MC are used to generate a-factors using the certificated compositions in the CuAu binary relative to pure Cu and Au standards. MC simulations are obtained using the NIST, WinCasino, and WinXray algorithms; derived x-ray intensities have a built-in atomic number correction, and are further corrected for absorption and characteristic fluorescence using the PAP phi(rhoz) correction algorithm. The Penelope code additionally simulates both characteristic and continuum x-ray fluorescence and thus requires no further correction for use in calculating alpha-factors.

Carpenter, P. K.↗

Solid State Digital Propulsion "Cluster Thrusters" For Small Satellites Using High Performance Electrically Controlled Extinguishable Solid Propellants (ECESP)

Electrically controlled extinguishable solid propellants (ESCSP) are capable of multiple ignitions, extinguishments and throttle control by the application of electrical power. Both core and end burning no moving parts ECESP grains/motors to three inches in diameter have now been tested. Ongoing research has led to a newer family of even higher performance ECESP providing up to 10% higher performance, manufacturing ease, and significantly higher electrical conduction. The high conductivity was not found to be desirable for larger motors; however it is ideal for downward scaling to micro and pico- propulsion applications with a web thickness of less than 0.125 inch/ diameter. As a solid solution propellant, this ECESP is molecularly uniform, having no granular structure. Because of this homogeneity and workable viscosity it can be directly cast into thin layers or vacuum cast into complex geometries. Both coaxial and grain stacks have been demonstrated. Combining individual propellant coaxial grains and/or grain stacks together form three-dimensional arrays yield modular cluster thrusters. Adoption of fabless manufacturing methods and standards from the electronics industry will provide custom, highly reproducible micro-propulsion arrays and clusters at low costs. These stack and cluster thruster designs provide a small footprint saving spacecraft surface area for solar panels and/or experiments. The simplicity of these thrusters will enable their broad use on micro-pico satellites for primary propulsion, ACS and formation flying applications. Larger spacecraft may find uses for ECESP thrusters on extended booms, on-orbit refueling, pneumatic actuators, and gas generators.

Sawka, Wayne N.↗