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NASA NTRS2017

Micromechanics of Composite Materials Governed by Vector Constitutive Laws

The high-fidelity generalized method of cells micromechanics theory has been extended for the prediction of the effective property tensor and the corresponding local field distributions for composites whose constituents are governed by vector constitutive laws. As shown, the shear analogy, which can predict effective transverse properties, is not valid in the general three-dimensional case. Consequently, a general derivation is presented that is applicable to both continuously and discontinuously reinforced composites with arbitrary vector constitutive laws and periodic microstructures. Results are given for thermal and electric problems, effective properties and local field distributions, ordered and random microstructures, as well as complex geometries including woven composites. Comparisons of the theory's predictions are made to test data, numerical analysis, and classical expressions from the literature. Further, classical methods cannot provide the local field distributions in the composite, and it is demonstrated that, as the percolation threshold is approached, their predictions are increasingly unreliable. XXXX It has been observed that the bonding between the fibers and matrix in composite materials can be imperfect. In the context of thermal conductivity, such imperfect interfaces have been investigated in micromechanical models by Dunn and Taya (1993), Duan and Karihaloo (2007), Nan et al. (1997) and Hashin (2001). The present HFGMC micromechanical method, derived for perfectly bonded composite materials governed by vector constitutive laws, can be easily generalized to include the effects of weak bonding between the constituents. Such generalizations, in the context of the mechanical micromechanics problem, involve introduction of a traction-separation law at the fiber/matrix interface and have been presented by Aboudi (1987), Bednarcyk and Arnold (2002), Bednarcyk et al. (2004) and Aboudi et al. (2013) and will be addressed in the future.

micromechanics↗

NASA NTRS2017

Verification of a Finite Element Model for Pyrolyzing Ablative Materials

Ablating thermal protection system (TPS) materials have been used in many reentering spacecraft and in other applications such as rocket nozzle linings, fire protection materials, and as countermeasures for directed energy weapons. The introduction of the finite element model to the analysis of ablation has arguably resulted in improved computational capabilities due the flexibility and extended applicability of the method, especially to complex geometries. Commercial finite element codes often provide enhanced capability compared to custom, specially written programs based on versatility, usability, pre- and post-processing, grid generation, total life-cycle costs, and speed.

ablating materials↗

NASA NTRS2017

Cause and Cure - Deterioration in Accuracy of CFD Simulations with Use of High-Aspect-Ratio Triangular/Tetrahedral Grids

Traditionally high-aspect ratio triangular/tetrahedral meshes are avoided by CFD researchers in the vicinity of a solid wall, as it is known to reduce the accuracy of gradient computations in those regions. Although for certain complex geometries, the use of high-aspect ratio triangular/tetrahedral elements in the vicinity of a solid wall can be replaced by quadrilateral/prismatic elements, ability to use triangular/tetrahedral elements in such regions without any degradation in accuracy can be beneficial from a mesh generation point of view. The benefits also carry over to numerical frameworks such as the space-time conservation element and solution element (CESE), where simplex elements are the mandatory building blocks. With the requirement of the CESE method in mind, a rigorous mathematical framework that clearly identifies the reason behind the difficulties in use of such high-aspect ratio simplex elements is formulated using two different approaches and presented here. Drawing insights from the analysis, a potential solution to avoid that pitfall is also provided as part of this work. Furthermore, through the use of numerical simulations of practical viscous problems involving high-Reynolds number flows, how the gradient evaluation procedures of the CESE framework can be effectively used to produce accurate and stable results on such high-aspect ratio simplex meshes is also showcased.

CESE Method↗

NASA NTRS2017

Cause and Cure - Deterioration in Accuracy of CFD Simulations With Use of High-Aspect-Ratio Triangular Tetrahedral Grids

Traditionally high-aspect ratio triangular/tetrahedral meshes are avoided by CFD re-searchers in the vicinity of a solid wall, as it is known to reduce the accuracy of gradient computations in those regions and also cause numerical instability. Although for certain complex geometries, the use of high-aspect ratio triangular/tetrahedral elements in the vicinity of a solid wall can be replaced by quadrilateral/prismatic elements, ability to use triangular/tetrahedral elements in such regions without any degradation in accuracy can be beneficial from a mesh generation point of view. The benefits also carry over to numerical frameworks such as the space-time conservation element and solution element (CESE), where triangular/tetrahedral elements are the mandatory building blocks. With the requirement of the CESE method in mind, a rigorous mathematical framework that clearly identities the reason behind the difficulties in use of such high-aspect ratio triangular/tetrahedral elements is presented here. As will be shown, it turns out that the degree of accuracy deterioration of gradient computation involving a triangular element is hinged on the value of its shape factor Gamma def = sq sin Alpha1 + sq sin Alpha2 + sq sin Alpha3, where Alpha1; Alpha2 and Alpha3 are the internal angles of the element. In fact, it is shown that the degree of accuracy deterioration increases monotonically as the value of Gamma decreases monotonically from its maximal value 9/4 (attained by an equilateral triangle only) to a value much less than 1 (associated with a highly obtuse triangle). By taking advantage of the fact that a high-aspect ratio triangle is not necessarily highly obtuse, and in fact it can have a shape factor whose value is close to the maximal value 9/4, a potential solution to avoid accuracy deterioration of gradient computation associated with a high-aspect ratio triangular grid is given. Also a brief discussion on the extension of the current mathematical framework to the tetrahedral-grid case along with some of the practical results of this extension is also provided. Furthermore, through the use of numerical simulations of practical viscous problems involving high-Reynolds number flows, the effectiveness of the gradient evaluation procedures within the CESE framework (that have their basis on the analysis presented here) to produce accurate and stable results on such high-aspect ratio meshes is also showcased.

CESE Method↗

NASA NTRS2017

Cause and Cure-Deterioration in Accuracy of CFD Simulations with Use of High-Aspect-Ratio Triangular/Tetrahedral Grids

In the multi-dimensional space-time conservation element and solution element16 (CESE) method, triangles and tetrahedral mesh elements turn out to be the most natural building blocks for 2D and 3D spatial grids, respectively. As such, the CESE method is naturally compatible with the simplest 2D and 3D unstructured grids and thus can be easily applied to solve problems with complex geometries. However, because (a) accurate solution of a high-Reynolds number flow field near a solid wall requires that the grid intervals along the direction normal to the wall be much finer than those in a direction parallel to the wall and, as such, the use of grid cells with extremely high aspect ratio (103 to 106) may become mandatory, and (b) unlike quadrilateral hexahedral grids, it is well-known that accuracy of gradient computations involving triangular tetrahedral grids tends to deteriorate rapidly as cell aspect ratio increases. As a result, the use of triangular tetrahedral grid cells near a solid wall has long been deemed impractical by CFD researchers. In view of (a) the critical role played by triangular tetrahedral grids in the CESE development, and (b) the importance of accurate resolution of high-Reynolds number flow field near a solid wall, as will be presented in the main paper, a comprehensive and rigorous mathematical framework that clearly identifies the reasons behind the accuracy deterioration as described above has been developed for the 2D case involving triangular cells. By avoiding the pitfalls identified by the 2D framework, and its 3D extension, it has been shown numerically.

CFD↗

NASA NTRS2017

Strategies Toward Automation of Overset Structured Surface Grid Generation

An outline of a strategy for automation of overset structured surface grid generation on complex geometries is described. The starting point of the process consists of an unstructured surface triangulation representation of the geometry derived from a native CAD, STEP, or IGES definition, and a set of discretized surface curves that captures all geometric features of interest. The procedure for surface grid generation is decomposed into an algebraic meshing step, a hyperbolic meshing step, and a gap-filling step. This paper will focus primarily on the high-level plan with details on the algebraic step. The algorithmic procedure for the algebraic step involves analyzing the topology of the network of surface curves, distributing grid points appropriately on these curves, identifying domains bounded by four curves that can be meshed algebraically, concatenating the resulting grids into fewer patches, and extending appropriate boundaries of the concatenated grids to provide proper overlap. Results are presented for grids created on various aerospace vehicle components.

overset↗

NASA NTRS2017

Computed Tomography Inspection and Analysis for Additive Manufacturing Components

Computed tomography (CT) inspection was performed on test articles additively manufactured from metallic materials. Metallic AM and machined wrought alloy test articles with programmed flaws and geometric features were inspected using a 2-megavolt linear accelerator based CT system. Performance of CT inspection on identically configured wrought and AM components and programmed flaws was assessed to determine the impact of additive manufacturing on inspectability of objects with complex geometries.

Beshears, Ronald D.↗

NASA NTRS2015

Parallel Adaptive High-Order CFD Simulations Characterizing SOFIA Cavitiy Acoustics

This paper presents large-scale MPI-parallel computational uid dynamics simulations for the Stratospheric Observatory for Infrared Astronomy (SOFIA). SOFIA is an airborne, 2.5-meter infrared telescope mounted in an open cavity in the aft fuselage of a Boeing 747SP. These simulations focus on how the unsteady ow eld inside and over the cavity interferes with the optical path and mounting structure of the telescope. A tempo- rally fourth-order accurate Runge-Kutta, and a spatially fth-order accurate WENO-5Z scheme were used to perform implicit large eddy simulations. An immersed boundary method provides automated gridding for complex geometries and natural coupling to a block-structured Cartesian adaptive mesh re nement framework. Strong scaling studies using NASA's Pleiades supercomputer with up to 32k CPU cores and 4 billion compu- tational cells shows excellent scaling. Dynamic load balancing based on execution time on individual AMR blocks addresses irregular numerical cost associated with blocks con- taining boundaries. Limits to scaling beyond 32k cores are identi ed, and targeted code optimizations are discussed.

Parallell↗

NASA NTRS2017

Development of a Three-Dimensional, Unstructured Material Response Design Tool

A preliminary verification and validation of a new material response model is presented. This model, Icarus, is intended to serve as a design tool for the thermal protection systems of re-entry vehicles. Currently, the capability of the model is limited to simulating the pyrolysis of a material as a result of the radiative and convective surface heating imposed on the material from the surrounding high enthalpy gas. Since the major focus behind the development of Icarus has been model extensibility, the hope is that additional physics can be quickly added. This extensibility is critical since thermal protection systems are becoming increasing complex, e.g. woven carbon polymers. Additionally, as a three-dimensional, unstructured, finite-volume model, Icarus is capable of modeling complex geometries. In this paper, the mathematical and numerical formulation is presented followed by a discussion of the software architecture and some preliminary verification and validation studies.

Thermal Protection System↗

NASA NTRS2018

Additively Manufactured Oxidizer Turbopump

Additive Manufacturing, or 3D printing, is a key technology for enhancing rocket engine designs and making them more affordable for future exploration missions. The Oxidzer Turbopump (OTP) offers the ability to demonstrate additively manufactured rotating, vaned, and critical pressure vessel components in relevant oxygen turbopump environments. The additively manufactured components of the OTP include the main housings, impeller, and turbine components. A key technology development goal is to understand the benefits and limitations of additive manufacturing as it applies to the complex geometries needed for a rocket engine turbopump.

Manufacturing↗

NASA NTRS2019

Aerosol Jet Printing on Rigid and Flexible Substrates for Space Applications

Aerosol Jet Printing (AJP) will enable new detector 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 reducing trace widths down to 10 microns, printing on complex geometries, and allowing new concept production. This presentation summarizes efforts developing AJP for detectors and circuitry for space applications.

Aerosol Jet Printing↗

NASA NTRS2019

Aerodynamic and Aerothermal Simulations of Mars Concept Vehicles Using Overset DPLR

NASA's Descent System Studies (DSS) Program is studying various concept vehicles to enable landing of heavy payloads on the surface of Mars. While it is desirable to run high-fidelity CFD simulations to accurately assess the aerodynamic and aerothermal effects of various design changes during EDL, it is usually difficult to quickly generate high-quality grids suitable for such analyses. One approach to address this bottleneck in mesh generation is through the use oversetting grids. Although the overset approach is efficient and powerful in solving partial differential equations on complex geometries, new users often find it challenging to apply overset concepts for their simulations. For example, generating hyperbolic grids with sufficient overlap; priority in hole-cutting on multiple overlapping grids; and fixes to assemble overlapping viscous grids at the body surface. The objective of this presentation is to introduce a simple process that combines the advantages of near-body, point-matched, structured grids with oversetting background grids suitable for grid alignment. This approach allows for grids that can be sequenced, reclustering of mesh spacing at the wall, and grid alignment with the bow shock. The current methodology is tested on a Mid-L/D configuration using the overset DPLR code.

Overset Grids↗

NASA NTRS2019

Materials and Processes for New Propulsion Systems with Reduced Environmental Impact

Aeronautics research at NASA Glenn Research Center includes development, characterization and modeling of high temperature, lightweight materials and fabrication processes for aircraft propulsion systems with increased efficiency and reduced emissions, fuel burn and noise. Current propulsion materials research includes Ceramic Matrix Composites and Environmental Barrier Coatings, Polymer Matrix Composites and Additive Manufacturing processes. This presentation will summarize recent progress and plans in these areas. Ceramic Matrix Composites for Turbine Components: As part of NASA's Aeronautics research, Glenn Research Center has developed Ceramic Matrix Composites for 2700 degrees Fahrenheit turbine engine applications in the next generation of ultra-efficient aircraft. In this presentation, the development of advanced fiber and matrix constituents that enabled this advancement will be reviewed, and characterization of the resulting improvements in mechanical properties and durability will be summarized. Progress toward the development and validation of models predicting the effects of the engine environment on durability of Ceramic Matrix Composites and Environmental Barrier Coatings will be summarized. Progress and plans for collaborative research with industry and other government agencies will be reviewed. Polymer Matrix Composites for Powertrain and Impact Protection: A lightweight, hybrid polymer matrix composite/steel gear concept for rotorcraft power transmission applications was evaluated at realistic speed, torque, and power conditions. Dynamic testing was performed at 5000 horsepower and 5400 revolutions per minute with no performance degradation. Test results demonstrated the potential of hybrid composite / metal gears to reduce gear weight by approximately 15 percent, enabling the implementation of multi-speed drive systems, which would otherwise have a weight penalty, for increased speed and efficiency. Results of post-test inspection and endurance tests will be presented. Separately, ballistic impact tests demonstrated improved damage tolerance in polymer matrix composites by incorporating lightweight, thermoplastic veil materials between selected composite plies during the composite fabrication process. Results of impact tests and post-test inspection will be presented. Additive Manufacturing for Electric Propulsion: Additive Manufacturing processes offer the potential to fabricate new, high power density electric motor designs with complex geometries, multi-material components and optimally designed components that would not be feasible with traditional manufacturing processes. High performance stator components using advanced 3-phase conductive coils were fabricated using direct printing with optimized silver pastes. Additional additive manufacturing methods are being used to fabricate rotors and motor housing components. Systems studies show that the higher performance and lower weight motors offer improved energy efficiency and reduced emissions. Improvements to motor performance resulting from optimized materials and component designs will be presented.

Additive Manufacturing↗

NASA NTRS2019

Additive Manufacturing Circuitry on Rigid and Flexible Substrates for Space Applications

Additive manufacturing techniques for electronics, including Aerosol Jet Printing (AJP), Syringe Printing, and Ink Jet Printing, will enable new detector 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 reducing trace widths down to 10 microns, printing on complex geometries, and allowing new concept production. This presentation summarizes efforts developing printing techniques to manufacture detectors and circuitry for space applications.

Detectors↗

NASA NTRSDate not supplied

Wall-modeled LES of the NASA Juncture Flow Experiment

We perform wall-modeled large eddy simulation (WMLES) of the NASA Juncture Flow experiment (Kegerise & Neuhart, NASA/TM–2019–20286) using an equilibrium wall model and unstructured finite volume solver, to assess its predictive ability for complex geometries. The flow condition simulated corresponds to 5 degrees angle of attack with a freestream Mach number of 0.189, and a Reynolds number based on the mean crank chord of 2.4 million. All simulations neglect the effects of wind tunnel walls, sting and mast present in the experiment. To assess the performance of WMLES on simpler flows with very coarse grids, we simulate flow in a turbulent channel at a friction Reynolds number, Reτ≈2000, and flow through a square duct at anReτ≈1000. The duct flow results using the equilibrium wall model indicate that the skin friction is inaccurate near the corner for grid topologies and resolutions typically used in WMLES, having implications for more complicated flows such as the juncture flow. For the juncture flow simulation, two different approaches are investigated. The first approach consists of a truncated-domain simulation wherein the inflow plane of the computational domain is placed at≈0.2chord length of the wing, and we prescribe the mean flow from a separate Reynolds-averaged Navier-Stokes (RANS) solution along with synthetic turbulence to initiate realistic unsteadiness in the domain. The second approach involves simulating the entire geometry with trips to trigger transition to turbulence. The truncated- and full-domain simulations contain about 62 and 90 million cells, respectively; with 8-10 points per boundary layer thickness in the wall-parallel directions, 14-20 points in the wall-normal direction and a near-wall viscous spacing (∆n+1) of≈100. Preliminary results are encouraging overall in terms of the prediction of wall pressure, wall skin friction, velocity and stresses; but indicate that further work is required to improve the predictions in the separation bubble and wing-fuselage corner regions. The grid resolution used in this study is still fairly coarse, and the results should be interpreted as work in progress.

Prahladh S Iyer↗

NASA NTRS2020

Impact Testing of Inconel 718 for Material Impact Model Development

One of the difficulties with developing and verifying accurate impact models is that parameters such as high strain-rate material properties, failure modes, static properties, and impact test measurements are often obtained from a variety of different sources using different materials, with little control over consistency among the different sources. In addition, there is often a lack of quantitative measurements in impact tests to which the models can be compared. To alleviate some of these problems, a project is underway to develop a consistent set of material property, impact test data, and failure analysis for a variety of 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 (FAA) William J. Hughes Technical Center. Unique 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 of the raw data is available. Four parallel efforts are currently underway. The Ohio State University conducts both measurement of material deformation and failure response over a wide range of strain rates and temperatures and failure analysis of material property specimens and impact test articles. The George Mason University conducts the development of improved numerical modeling techniques for deformation and failure. Glenn conducts the impact testing of flat panels and substructures. This report describes impact testing performed on Inconel 718 sheet and plate samples of different thicknesses with 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.

J Michael Pereira↗

NASA NTRS2010

TPSAS-NF1676L-10669-DND

Thermography is excellent at rapid detection of delaminations in composite sandwich structure. Interpretation of the results can be difficult – Especially for complex geometries. The use of complementary techniques such as X-ray CT or ultrasound may be necessary to get the complete picture.

K Elliott Cramer↗

NASA NTRSDate not supplied

Feasibility Study of a Carbon Dioxide Breathing, Solid-Fueled Ramjet for Martian Descent and Landing of Human Class Payloads

This study analyzes the cross-range capabilities of solid-fueled ramjets in a Martian atmosphere for applications in entry, descent, and landing. Trajectories and engine operability are characterized using Mach and dynamic pressure operational points. It is predicted that use of atmosphere-breathing propulsion will enable access to additional surface latitudes without the need for orbital plane changes. Development of an integrated design environment facilitates preliminary ramjet design and analysis, and enables sensitivity studies to identify high impact areas of technology development. In addition, additive manufacturing supports prototyping, rapid ground testing, and allows for utilization of complex geometries.

Shi Broadwell↗