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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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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Development and Application of Weld Track Thermal Analysis for the Exploration Extravehicular Mobility Unit

NASA is studying the next generation of space suit for safe operations in space, from the International Space Station to the lunar surface as part of the Exploration Extravehicular Mobility Unit project. The backplate structure of the portable life support system (PLSS) serves as the attachment point for assembly of the PLSS and contains embedded cooling channels. The thermal loop plumbing assembly and backplate are combined into a single component such that the fluid lines run through the midplane of the backplate. The manufacturing of the Ti-6Al-4V backplate consists of machining channels into a plate, welding cover plates on each channel using an electron beam, and additional machining for excess material removal and final detail. Careful control of the electron beam weld process is necessary to completely seal cover plates, produce consistent weld tracks, and produce channels with uniform cross sections free of debris and defects. The backplate contains multiple weld channels with unique geometries. The weld process parameters include choosing the beam current and focus, accelerating voltage, travel speed, pause times between weld tracks, and sequence of weld tracks. A transient finite element thermal analysis was developed to provide support for choosing and controlling the weld process parameters to maintain a consistent melt pool along each of the weld tracks. A moving distributed heat source is modeled to represent the heat input generated by the electron beam. The heat source model is a critical input to the analysis for accurate temperature predictions during the weld process. A modified conical heat source was developed to account for the change in working distance between the backplate and cover plates. The geometry of the material being welded must be accounted for by the heat source model to define the correct energy input. The weld process control is designed according to the predicted thermal history and melt pool dimensions for each of the weld channels. The analysis model, modified heat source, temperature and melt pool predictions, application of the thermal data to the weld parameters, and comparison with micrograph cross-sections from weld trials will be discussed in this presentation.

Electron Beam Welding↗
NASA NTRS1993

Unit cell geometry of multiaxial preforms for structural composites

The objective of this study is to investigate the yarn geometry of multiaxial preforms. The importance of multiaxial preforms for structural composites is well recognized by the industry but, to exploit their full potential, engineering design rules must be established. This study is a step in that direction. In this work the preform geometry for knitted and braided preforms was studied by making a range of well designed samples and studying them by photo microscopy. The structural geometry of the preforms is related to the processing parameters. Based on solid modeling and B-spline methodology a software package is developed. This computer code enables real time structural representations of complex fiber architecture based on the rule of preform manufacturing. The code has the capability of zooming and section plotting. These capabilities provide a powerful means to study the effect of processing variables on the preform geometry. the code also can be extended to an auto mesh generator for downstream structural analysis using finite element method. This report is organized into six sections. In the first section the scope and background of this work is elaborated. In section two the unit cell geometries of braided and multi-axial warp knitted preforms is discussed. The theoretical frame work of yarn path modeling and solid modeling is presented in section three. The thin section microscopy carried out to observe the structural geometry of the preforms is the subject in section four. The structural geometry is related to the processing parameters in section five. Section six documents the implementation of the modeling techniques into the computer code MP-CAD. A user manual for the software is also presented here. The source codes and published papers are listed in the Appendices.

Ko, Frank↗
NASA NTRS2005

Structural Verification of the Redesigned Space Shuttle Bipod Foam Closeout

This document outlines the structural verification approach for the Space Shuttle External Tank Forward Bipod Foam Closeout. Due to the Space Shuttle Columbia accident, debris has become a major concern. The intent of the structural verification is to ensure that any debris shed from the bipod is within acceptable limits. Since cohesive failure due to internal defects was identified as the most likely cause of the STS-107 bipod ramp foam failure, verification for this failure mode receives particular emphasis. However, all failure modes for TPS are considered and appropriate verification rationale is developed for each failure mode. Figure 1 depicts the structural verification of a production design where analysis and test are the primary methods of verification. It can be seen that the successful completion of structural verification is dependent on three main areas: 1. Production process control and quality assurance must ensure that test articles and/or analytical models are representative of (or conservatively envelope) production hardware in terms of geometry, materials and processing. Variability and defects must be considered. 2. Flight environments must be sufficiently characterized to bound driving environments for all failure modes. Applied environments, either test or analytical, must be representative of flight environments and have a load factor that satisfies design requirements. 3. Structural verification must include all failure modes. A comprehensive list of failure modes and the underlying failure mechanisms has been generated based on flight and test experience. Verification tests and / or analyses must address each failure mode. ET TPS Verification is accomplished by a combination of analysis, test, and similarity.

Poole, Eric L.↗
NASA NTRS1990

Shape design sensitivities using fully automatic 3-D mesh generation

Previous work in three dimensional shape optimization involved specifying design variables by associating parameters directly with mesh points. More recent work has shown the use of fully-automatic mesh generation based upon a parameterized geometric representation. Design variables have been associated with a mathematical model of the part rather than the discretized representation. The mesh generation procedure uses a nonuniform grid intersection technique to place nodal points directly on the surface geometry. Although there exists an associativity between the mesh and the geometrical/topological entities, there is no mathematical functional relationship. This poses a problem during certain steps in the optimization process in which geometry modification is required. For the large geometrical changes which occur at the beginning of each optimization step, a completely new mesh is created. However, for gradient calculations many small changes must be made and it would be too costly to regenerate the mesh for each design variable perturbation. For that reason, a local remeshing procedure has been implemented which operates only on the specific edges and faces associated with the design variable being perturbed. Two realistic design problems are presented which show the efficiency of this process and test the accuracy of the gradient computations.

Botkin, M. E.↗
NASA NTRS1990

External nozzle flap dynamic load measurements on F-15 S/MTD model

Dynamic pressure loads were obtained on 1/12 scale models of the F-15B production aircraft and the F-15 S/MTD experimental aircraft with rectangular nozzles and canards. Flight Mach numbers from 0.51 to 1.20 were studied for aircraft angles of attack from 0 to 10 deg and nozzle pressure ratios from 1.00 to 5.09. The results show that dynamic levels are lower in the internozzle region of twin rectangular nozzles than are levels found with twin axisymmetric nozzles. At other locations, the levels associated with both geometries are of the same order of magnitude when normalized by aircraft dynamic Q. At Mach number of 0.51, the loads spectrum is dominated by plume shock noise processes for both geometries. Above Mach 0.51, this mechanism is associated with either vortex bursting from a forward location or turbulent boundary layer separation over the nozzle external flaps. At supersonic speeds both geometries show significantly decreased load levels.

Seiner, John M.↗
NASA NTRS2019

Uncertainty Analysis of Experimental Discharge Coefficients in Additively Manufactured Liquid Injector Elements

Screening of two additively manufactured liquid injector designs was conducted in the UAH high pressure spray facility. Four variants of each geometry with slightly different dimensions were obtained from eleven separate commercial additive manufacturing services. The devices were manufactured from Inconel 625 using the selective laser melting (SLM) powder bed process. The devices were cold flowed with water over a range of relevant pressure drops (75 psi to 1500 psi) to produce water flow rates from 0.037 to 1.75 lbm/s into ambient back pressure. Discharge coefficients determined from the testing along with the associated uncertainties provide insight into characteristic flow performance variabilities that can be expected from the SLM process for similar geometries.

Venters, James P.↗
NASA NTRS1992

Modeling, design, fabrication, and testing of InP Gunn devices in the D-band (110 GHz - 170 GHz)

The development of fundamental Gunn sources for D-band frequencies requires improvements of doping profiles, processing technology, and circuit design. We have developed a technology for fabricating InP Gunn diodes using an InGaAs etch-stop layer between the InP substrate and the device layers. The epitaxial layers were grown by CBE. During device processing, the substrate is completely removed. Substrateless devices with an n(+) InGaAs cap layer are expected to have reduced contact and series resistances, and skin effect losses. This technology gives better uniformity and control of the device geometry across the processed chip. InP Gunn devices with a 1.7 micron long active region (doping : 9 x 10(exp 15) cm(exp -3)) have been mounted on copper heat sinks. Two tapered leads were then bonded to the diode and to four quartz standoffs. As a preliminary result, an output power of 13 mW at 82 GHz was obtained. Based on these RF measurements, we determine appropriate material parameters to be used in the Ensemble Monte Carlo model. Subsequently, we use this model to design and evaluate the performance of InP Gunn Devices for D-band frequencies. Using the same technology, we are currently processing Gunn devices with a 1 micron long active region for operation at higher frequencies.

Kamoua, R.↗
NASA NTRS1988

Vulnerability-attention analysis for space-related activities

Techniques for representing and analyzing trouble spots in structures and processes are discussed. Identification of vulnerable areas usually depends more on particular and often detailed knowledge than on algorithmic or mathematical procedures. In some cases, machine inference can facilitate the identification. The analysis scheme proposed first establishes the geometry of the process, then marks areas that are conditionally vulnerable. This provides a basis for advice on the kinds of human attention or machine sensing and control that can make the risks tolerable.

Ford, Donnie↗
NASA NTRS1992

Design of fabric preforms for double diaphragm forming

Resin Transfer Molding (RTM) has the potential of becoming one of the most cost effective ways of producing composite structures since the raw materials used, resin and dry fabric, are less costly than prepregs. Unfortunately these low material costs are offset by the high labor costs incurred to layup the dry fabric into 3D shapes. To reduce the layup costs, double diaphragm forming is being investigated as a potential technique for creating a complex 3D preform from a simple flat layup. As part of our effort to develop double diaphragm forming into a production capable process, we have undertaken a series of experiments to investigate the interactions between process parameters, mold geometry, fabric weave, tow size, and the quality of the formed part. The results of these tests will be used to determine the forming geometry limitations of double diaphragm forming and to characterize the formability of fabric configurations. An important part of this work was the development of methods to measure and analyze fiber orientations, deformation angles, tow spreading, and shape conformation of the formed parts. This paper will describe the methods used to mark plies, the double diaphragm forming process, the techniques used to measure the formed parts, and the calculation of the parameters of interest. The results can be displayed as 3D contour plots. These experimental results have also been used to verify and improve a computer model which simulates the draping of fabrics over 3D mold shapes.

Luby, Steven↗
NASA NTRS2019

Bumper: A Tool for Analyzing Spacecraft Micrometeoroid and Orbital Debris Risk

“Bumper” is NASA’s computer program for analyzing spacecraft micrometeoroid and orbital debris (MMOD) risk. Bumper was developed in the late-1980s and has been continuously used and maintained since. The user base has grown from a few government entities to now include numerous commercial entities as well. The NASA Johnson Space Center (JSC) Hypervelocity Impact Technology (HVIT) Team is responsible for all aspects of the Bumper software. Bumper has been used to characterize MMOD risk on hundreds of spacecraft. All of the International Space Station (ISS) modules, visiting vehicles and numerous external components and systems have been analyzed. Bumper was used to analyze each of the Space Shuttle missions since STS-50. The Orion Multi-Purpose Crew Vehicle (MPCV) MMOD shielding is being developed using Bumper as well. Bumper has also been used on numerous telescopes (Hubble, James Webb, and Fermi Gamma-ray Space Telescopes), scientific probes (Stardust, New Horizons, Parker Solar Probe), and Earth observation satellites (Landsat, Joint Polar Satellite System). Bumper is also being used to analyze the micrometeoroid risk and support design of the Deep Space Gateway (DSG) and Mars Sample Return (MSR) missions. The HVIT Bumper Configuration Control Board (CCB) ensures that all changes to the code are approved, reviewed, and documented. Most of the changes are made to add new MMOD damage “ballistic limit equations” (BLEs). BLEs are typically added in response to completion of a hypervelocity impact (HVI) test series and development of an associated BLE. Other less frequent changes include updates of the debris or meteoroid environment models, feature enhancements, and feature retirement. Some BLEs are commercially sensitive and/or proprietary, so the CCB also manages code user-version control and software distribution. The current version – “Bumper 3” – is a FORTRAN executable that utilizes a 64-bit architecture. Bumper 3 has numerous features that make it a powerful tool for analyzing spacecraft MMOD risk. Bumper uses the latest orbital debris and micrometeoroid environment models. Bumper also easily processes large spacecraft geometry models, recognizes hidden surfaces, permits BLE assignment by name or number, and conducts quality checks of the spacecraft geometry model. Bumper 3 can also be used to estimate the effects of particle penetration through thin, high-standoff distance hardware components such as solar arrays and radiators. This is done using a special HVIT-developed technique know as the “3-Part Analysis.” The paper introduces the Bumper 3 MMOD risk analysis code and provides an example MMOD risk assessment showing Bumper’s role in the overall MMOD protection design process.

Lear, Dana M.↗
NASA NTRS1988

Digital image processing for quantification through full flow field tracing (FFFT) in narrow geometries at low Reynolds numbers

This paper introduces a computer based image processing technique to the field of nonintrusive velocity measurements in fluid mechanics. The method is presented with two alternatives: the first is involving intense interaction between the operator and the computer system; the second is a first generation artificial intelligence based system, where a set of initially imputed rules replaces the operator. The methods are applied to flow in narrow gaps.

Braun, M. J.↗
NASA NTRSDate not supplied

Towards Integrated Computational Materials Engineering for Quantifying Performance Impacts of Microstructure and Defect Interactions in Powder Bed Fusion Parts

Powder bed fusion (PBF) additive manufacturing (AM) enables the creation of parts with complexity and functionality levels that were previously impossible with traditional manufacturing methods. By modifying the laser power, hatch spacing, or the numerous other processing parameters, the PBF process supports the production of a wide set of materials and geometries. However, that same process parameter design flexibility causes the process-design space of PBF to be massive and expensive to explore experimentally. Another challenge is quality variation across a build. As a part is being built, geometric variance between locations, such as at a thin-wall section vs. the bulk material, may cause the specified processing parameters to no longer be acceptable for producing defect-free printing. Furthermore, if the processing parameters deviate during the print process, it is difficult to assess if the part will still perform satisfactorily. Integrated Computational Materials Engineering (ICME) provides a way to understand and address these various challenges. This talk will present advancements in process-structure simulations of PBF at NASA Langley Research Center. The ability to simulate grain-scale PBF microstructures using the Physically Based Monte Carlo method will be demonstrated and compared to experimental measurements. Techniques for simulating three-dimensional lack-of-fusion and keyhole porosity defects based on the specific processing conditions and approaches for integrating the two porosity prediction techniques alongside the computational microstructure evolution models will be shown. Finally, the integration of simulated PBF microstructures, embedded process defects, and crystal plasticity finite element models to elucidate the interaction of porosity and microstructure on micromechanical fields will be demonstrated. These integrated techniques demonstrate an example of using ICME to relate processing to performance for PBF AM materials. With continued maturity, it is hoped that such ICME approaches will lead to next-generation computational-materials supported qualification and certification of AM parts.

Additive manufacturing↗
NASA NTRS1989

Detection of edges using local geometry

Researchers described a new representation, the local geometry, for early visual processing which is motivated by results from biological vision. This representation is richer than is often used in image processing. It extracts more of the local structure available at each pixel in the image by using receptive fields that can be continuously rotated and that go to third order spatial variation. Early visual processing algorithms such as edge detectors and ridge detectors can be written in terms of various local geometries and are computationally tractable. For example, Canny's edge detector has been implemented in terms of a local geometry of order two, and a ridge detector in terms of a local geometry of order three. The edge detector in local geometry was applied to synthetic and real images and it was shown using simple interpolation schemes that sufficient information is available to locate edges with sub-pixel accuracy (to a resolution increase of at least a factor of five). This is reasonable even for noisy images because the local geometry fits a smooth surface - the Taylor series - to the discrete image data. Only local processing was used in the implementation so it can readily be implemented on parallel mesh machines such as the MPP. Researchers expect that other early visual algorithms, such as region growing, inflection point detection, and segmentation can also be implemented in terms of the local geometry and will provide sufficiently rich and robust representations for subsequent visual processing.

Gualtieri, J. A.↗
NASA NTRSDate not supplied

Boundary Representation Tolerance Impacts on Mesh Generation and Adaptation

The control of discretization error is critical to obtaining reliable simulation results. Re-cent progress has matured anisotropic mesh adaptation, which automates discretization error control for complex geometries. However, the meshing process can fail when geometric model Boundary REPresentation (BREP) tolerances are larger than boundary layer surface nor-mal and tangential spacing requirements. Geometry sources are often created in Mechanical Computer-Aided Design (MCAD) systems, which are designed to produce models for manufacturing and not the stricter requirements of viscous flow analysis. BREP tolerances are strained by three factors: the inherent complexity of the model (e.g., large range of scales and complex topology), the numerical difficulties arising from surface/surface intersections, and the omission of crucial data during export and translation. Manual preparation of geometry is commonly employed to enable expert-guided mesh generation, which severely inhibits work-flow automation. Accommodation of loose BREP tolerances is required for automated mesh processes, because barrier issues may not be detected until well into the solution process. To raise awareness of this class of geometry issues and their impact on simulation, a survey of these barrier issues is presented with example mitigation techniques. This awareness may also impact geometry creation workflows to prevent the introduction of these artifacts.

CAD↗
NASA NTRS1978

Computational transonic flow about realistic aircraft configurations

A numerical method has been developed to compute transonic flows about realistic wing-fuselage configurations. The finite difference scheme employs an improved small disturbance flow equation. A unique grid embedding technique, which was heretofore applied to airfoils and wings, has been extended to include the treatment of both body and wing-body shapes. The resulting high-density mesh is shown to be a valuable asset in resolving details of the three-dimensional flow. A mathematical modeling system is used to process arbitrary fuselage geometries for body boundary conditions. Correlations with experimental data for simple isolated bodies, an isolated fuselage, and wing-fuselage combinations are included.

Boppe, C. W.↗
NASA NTRS1980

Supersonic wings with significant leading-edge thrust at cruise

Experimental/theoretical correlations are presented which show that significant levels of leading edge thrust are possible at supersonic speeds for certain planforms which match the theoretical thrust distribution potential with the supporting airfoil geometry. The analytical process employed spanwise distribution of both it and/or that component of full theoretical thrust which acts as vortex lift. Significantly improved aerodynamic performance in the moderate supersonic speed regime is indicated.

Robins, A. W.↗
NASA NTRS1984

Optimizing Grid Patterns on Photovoltaic Cells

CELCAL computer program helps in optimizing grid patterns for different photovoltaic cell geometries and metalization processes. Five different powerloss phenomena associated with front-surface metal grid pattern on photovoltaic cells.

Burger, D. R.↗
NASA NTRS1986

Integrated Composite Analyzer (ICAN): Users and programmers manual

The use of and relevant equations programmed in a computer code designed to carry out a comprehensive linear analysis of multilayered fiber composites is described. The analysis contains the essential features required to effectively design structural components made from fiber composites. The inputs to the code are constituent material properties, factors reflecting the fabrication process, and composite geometry. The code performs micromechanics, macromechanics, and laminate analysis, including the hygrothermal response of fiber composites. The code outputs are the various ply and composite properties, composite structural response, and composite stress analysis results with details on failure. The code is in Fortran IV and can be used efficiently as a package in complex structural analysis programs. The input-output format is described extensively through the use of a sample problem. The program listing is also included. The code manual consists of two parts.

Murthy, P. L. N.↗