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DOE OSTI2024

Report on use of Inoculants in Missile Application Alloys

This report documents the status of current inoculant research relevant to missile application alloys and MTCR control language. The information is intended to provide data on current inoculants for us determining the current state of development and identifying potential research directions. Although there has been significant scientific research into the development and synthesis of inoculants, their current availability is limited is traditional powder inoculants employed during casting processes. However, research continues the development of complex oxides, ribbon materials, high entropy alloys, and other inoculant product forms, including the use of inoculants in the melt pools produced during additive manufacturing. Research to date has focused primarily on aluminum and steel alloys with emphasis on refining grain structures and evolving equiaxed morphologies while increasing strength and castability. The primary inoculants in steel and cast irons include TiN, SiC, FeSi75, and Ce which have increased strength properties. Chief inoculants for Al alloys often include TiC, SiC, Al3Sc(x) and TiB2 to aid in precipitation and refinement. Ti and Ni alloys have fewer research activities involving inoculants, although TiN, TiB, ZrN and LaB6 (for Ti alloys) and WC, Co3FeNb2, and CrFeNb (for Ni alloys) have been used. Sic, Al2O3, Mg and Ti are key inoculants for Mg alloys. Multiple cast alloys from each of the material classes demonstrated increased strength and performance properties using inoculants, with several approaching requirements applicable to missile service environments. The continued evolution of advanced manufacturing capabilities is making it easier to produce high temperature near net shape structural materials using inoculant powders. These shapes may include the geometric shapes addressed within the MTCR (tubes and limited wall thicknesses). The use of inoculants may enable further development of high temperature alloys into near net shapes traditionally produced via casting processes due to limited ductility. This may decrease material and manufacturing costs. In addition, inoculation provides controlled kinetics and achievable chemical segregation that enables potential for far-from equilibrium thermodynamic microstructures and chemistries that could provide new metastable alloy states and subsequent properties to address co-design engineering constraints, including needs for increased strength and ductility. It is recommended that specific material combinations within these alloy classes be carefully watched as the materials evolve, with controls aimed at those having material properties above current MTCR levels. This specifically includes the use of refractory inoculants in alloys, and the application of inoculants in high strength and high temperature alloys via additive manufacturing processes, with care to link capabilities to product forms similar to the current requirements on tube geometries and material feed stocks. The continued development of nanoparticle inoculants will increase strength and ductility of high strength castings and additive manufactured metallic components. For example, adding inoculants into the casting of maraging steels and other precipitation strengthened alloys may drastically elevate mechanical properties above the control limit of current regulations.

36 MATERIALS SCIENCE↗

NASA NTRS1974

Geometry considerations for jet noise shielding with CTOL engine-over-the-wing concept

Jet noise shielding benefits for CTOL engine-over-the-wing installations were obtained with various model-scale circular nozzles and wing chord geometries. Chord-to-nozzle diameter ratios were varied from 3 to 20, while ratios of nozzle height above the wing to the diameter were varied from near zero to 3. Spectral noise data were obtained with jet velocities from 640 to 1110 ft/sec. Characteristics of low frequency noise sources are discussed. Jet-noise shielding is correlated in terms of acoustic and geometric parameters. Implications of extending the model-scale data to full-scale are discussed.

Vonglahn, U.↗

NASA NTRS1974

Geometry considerations for jet noise shielding with CTOL engine-over-the-wing concept

Von Glahn, U.↗

NASA NTRS1983

Production and analysis of output data products for Landsat-4 in the engineering check-out phase

The Landsat-D (now Landsat-4) program was initiated by NASA in the mid-1970's. The spacecraft was launched on July 16, 1982. Instruments on the satellite include the fourth Multispectral Scanner (MSS) and the new higher-resolution Thematic Mapper (TM). In order to achieve the planned engineering and scientific objectives, attention has to be given to the validation of spacecraft and instrument performance, the adjustment of ground processing procedures, and the definition of the measures of the TU utility. To satisfy these requirements, a Landsat Assessment System (LAS) was conceived, and the Applications Developmental Data System (ADDS) was instituted. The set of component systems collectively became known as the 'Scrounge' system. The present investigation is concerned with the Scrounge system and the results of radiometric and geometric data evaluations. Attention is given to the TM geometric correction, TM data resampling, a radiometric correction functional description, and the results of the TM geometric and radiometric correction.

Lyon, J. C.↗

NASA NTRS1990

A3I visibility modeling project

The Army-NASA Aircrew Aircraft Integration program is supporting a joint project to build a visibility computer-aided design (CAD) tool. CAD has become an essential tool in modern engineering applications. CAD tools are used to create engineering drawings and to evaluate potential designs before they are physically realized. The visibility CAD tool will provide the design engineer with a tool to aid in the location and specification of windows, displays, and control in crewstations. In an aircraft cockpit the location of instruments and the emissive and reflective characteristics of the surfaces must be determined to assure adequate aircrew performance. The visibility CAD tool will allow the designer to ask and answer many of these questions in the context of a three-dimensional graphical representation of the cockpit. The graphic representation of the cockpit is a geometrically valid model of the cockpit design. A graphic model of a pilot, called the pilot manikin, can be placed naturalistically in the cockpit model. The visibility tool has the capability of mapping the cockpit surfaces and other objects modeled in this graphic design space onto the simulated pilot's retinas for a given visual fixation.

Larimer, James↗

NASA NTRS1993

Numerical simulation using vorticity-vector potential formulation

An accurate and efficient computational method is needed for three-dimensional incompressible viscous flows in engineering applications. On solving the turbulent shear flows directly or using the subgrid scale model, it is indispensable to resolve the small scale fluid motions as well as the large scale motions. From this point of view, the pseudo-spectral method is used so far as the computational method. However, the finite difference or the finite element methods are widely applied for computing the flow with practical importance since these methods are easily applied to the flows with complex geometric configurations. However, there exist several problems in applying the finite difference method to direct and large eddy simulations. Accuracy is one of most important problems. This point was already addressed by the present author on the direct simulations on the instability of the plane Poiseuille flow and also on the transition to turbulence. In order to obtain high efficiency, the multi-grid Poisson solver is combined with the higher-order, accurate finite difference method. The formulation method is also one of the most important problems in applying the finite difference method to the incompressible turbulent flows. The three-dimensional Navier-Stokes equations have been solved so far in the primitive variables formulation. One of the major difficulties of this method is the rigorous satisfaction of the equation of continuity. In general, the staggered grid is used for the satisfaction of the solenoidal condition for the velocity field at the wall boundary. However, the velocity field satisfies the equation of continuity automatically in the vorticity-vector potential formulation. From this point of view, the vorticity-vector potential method was extended to the generalized coordinate system. In the present article, we adopt the vorticity-vector potential formulation, the generalized coordinate system, and the 4th-order accurate difference method as the computational method. We present the computational method and apply the present method to computations of flows in a square cavity at large Reynolds number in order to investigate its effectiveness.

Tokunaga, Hiroshi↗

NASA NTRS2011

Network Flow Simulation of Fluid Transients in Rocket Propulsion Systems

Fluid transients, also known as water hammer, can have a significant impact on the design and operation of both spacecraft and launch vehicle propulsion systems. These transients often occur at system activation and shutdown. The pressure rise due to sudden opening and closing of valves of propulsion feed lines can cause serious damage during activation and shutdown of propulsion systems. During activation (valve opening) and shutdown (valve closing), pressure surges must be predicted accurately to ensure structural integrity of the propulsion system fluid network. In the current work, a network flow simulation software (Generalized Fluid System Simulation Program) based on Finite Volume Method has been used to predict the pressure surges in the feed line due to both valve closing and valve opening using two separate geometrical configurations. The valve opening pressure surge results are compared with experimental data available in the literature and the numerical results compared very well within reasonable accuracy (< 5%) for a wide range of inlet-to-initial pressure ratios. A Fast Fourier Transform is preformed on the pressure oscillations to predict the various modal frequencies of the pressure wave. The shutdown problem, i.e. valve closing problem, the simulation results are compared with the results of Method of Characteristics. Most rocket engines experience a longitudinal acceleration, known as "pogo" during the later stage of engine burn. In the shutdown example problem, an accumulator has been used in the feed system to demonstrate the "pogo" mitigation effects in the feed system of propellant. The simulation results using GFSSP compared very well with the results of Method of Characteristics.

Bandyopadhyay, Alak↗

DOE OSTI2024

Versatile TRISO fuel particle modeling in Bison

Tri-structural isotropic (TRISO) fuel particles are a key component in several previous and current reactors as well as in a variety of novel nuclear reactor designs. Interest in TRISO fuel is on the rise, necessitating considerable computer modeling of TRISO fuel behavior in order to support related design and licensing activities. The Bison nuclear fuel performance code, which offers a full set of capabilities for modeling TRISO fuels, makes it easier to explore the various important aspects of TRISO fuel behavior. One key advantage of Bison is its ability to create meshes in 1D, 2D, and 3D. Users can customize these meshes for specific geometries, mesh densities, and use cases. This enables a wide variety of analyses, including thermal, structural, mass diffusion, homogenization, and statistical failure analyses. Furthermore, the meshing capability simplifies analysts’ workflows. The inherent mesh generation capability eliminates the need for separate mesh-generating software and mesh file management. Also, the fact that the meshes are customizable makes it straightforward to automate an investigation over a range of geometric parameters or mesh densities. Here, the present paper highlights the ease with which Bison may be used to create meshes for both simple and relatively complex TRISO fuel particles, and it explores the types of analyses enabled by these meshes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Thermal Image Processing for Feature Extraction from Encapsulated Phase Change Materials

Encapsulated inorganic particles with high melting points (>300 °C) are desired as high-temperature Phase Change Materials (PCMs) for next-generation Latent Heat Thermal Energy Storage (LHTES) systems. One of the many challenges during the development of PCMs is to achieve a high throughput that in turn depends on accurately modeling the relation between process parameters and geometric & thermal properties of the PCMs particle. During the production of the PCMs, a high-speed infrared camera is used to acquire images of the encapsulated material under controlled illumination conditions. This research article focuses on the development of image processing techniques for both geometric and thermal feature extraction during the development of the PCMs. A user-friendly GUI has been designed in MATLAB and preliminary experimental results have demonstrated that the method is fast, accurate and reliable for a high throughput production. The extracted features will be used to develop Machine Learning (ML) models to predict the geometric and thermal properties of the PCM based on the process parameter settings. The ML model will accelerate the search for the optimized process settings to boost the throughput of the production.

25 ENERGY STORAGE↗

NASA NTRS1988

Considerations in development and implementation of elasto-viscoplastic constitutive model for high temperature applications

The prediction of inelastic behavior of metallic materials at elevated temperatures has increased in importance in recent years. The operating conditions within the hot section of a rocket motor or a modern gas turbine engine present an extremely harsh thermomechanical environment. Large thermal transients are induced each time the engine is started or shut down. Additional thermal transients from an elevated ambient occur whenever the engine power level is adjusted to meet flight requirements. The structural elements employed in such hot sections, as well as any engine components located therein, must be capable of withstanding such extreme conditions. Failure of a component would, due to the critical nature of the hot section, lead to an immediate and catastrophic loss in power. Consequently, assuring satisfactory long term performance for such components is a major concern. Nonisothermal loading of structures often causes excursion of stress well into the inelastic range. Moreover, the influence of geometry changes on the response is also significant in most cases. Therefore, both material and geometric nonlinear effects are considered.

Riff, Richard↗

NASA NTRS1993

Single element injector cold flow testing for STME swirl coaxial injector element design

An oxidizer-swirled coaxial element injector is being investigated for application in the Space Transportation Main Engine (STME). Single element cold flow experiments were conducted to provide characterization of the STME injector element for future analysis, design, and optimization. All tests were conducted to quiescent, ambient backpressure conditions. Spray angle, circumferential spray uniformity, dropsize, and dropsize distribution were measured in water-only and water/nitrogen flows. Rupe mixing efficiency was measured using water/sucrose solution flows with a large grid patternator for simple comparative evaluation of mixing. Factorial designs of experiment were used for statistical evaluation of injector geometrical design features and propellant flow conditions on mixing and atomization. Increasing the free swirl angle of the liquid oxidizer had the greatest influence on increasing the mixing efficiency. The addition of gas assistance had the most significant effect on reducing oxidizer droplet size parameters and increasing droplet size distribution. Increasing the oxidizer injection velocity had the greatest influence for reducing oxidizer droplet size parameters and increasing size distribution for non-gas assisted flows. Single element and multi-element subscale hot fire testing are recommended to verify optimized designs before committing to the STME design.

Hulka, J.↗

NASA NTRS1999

Crack Growth Simulation and Residual Strength Prediction in Airplane Fuselages

This is the final report for the NASA funded project entitled "Crack Growth Prediction Methodology for Multi-Site Damage." The primary objective of the project was to create a capability to simulate curvilinear fatigue crack growth and ductile tearing in aircraft fuselages subjected to widespread fatigue damage. The second objective was to validate the capability by way of comparisons to experimental results. Both objectives have been achieved and the results are detailed herein. In the first part of the report, the crack tip opening angle (CTOA) fracture criterion, obtained and correlated from coupon tests to predict fracture behavior and residual strength of built-up aircraft fuselages, is discussed. Geometrically nonlinear, elastic-plastic, thin shell finite element analyses are used to simulate stable crack growth and to predict residual strength. Both measured and predicted results of laboratory flat panel tests and full-scale fuselage panel tests show substantial reduction of residual strength due to the occurrence of multi-site damage (MSD). Detailed comparisons of n stable crack growth history, and residual strength between the predicted and experimental results are used to assess the validity of the analysis methodology. In the second part of the report, issues related to crack trajectory prediction in thin shells; an evolving methodology uses the crack turning phenomenon to improve the structural integrity of aircraft structures are discussed, A directional criterion is developed based on the maximum tangential stress theory, but taking into account the effect of T-stress and fracture toughness orthotropy. Possible extensions of the current crack growth directional criterion to handle geometrically and materially nonlinear problems are discussed. The path independent contour integral method for T-stress evaluation is derived and its accuracy is assessed using a p- and hp-version adaptive finite element method. Curvilinear crack growth is simulated in coupon tests and in full-scale fuselage panel tests. Both T-stress and fracture toughness orthotropy are found to be essential to predict the observed crack paths. The analysis methodology and software program (FRANC3D/STAGS) developed herein allows engineers to maintain aging aircraft economically while insuring continuous airworthiness. Consequently, it will improve the technology to support the safe operation of the current aircraft fleet as well as the design of more damage-tolerant aircraft for the next generation fleet.

Chen, Chuin-Shan↗

NASA NTRS1983

Integration of Landsat data into the Saginaw River Basin geographic information system

One of the objectives of the Saginaw River Basin study is related to the development of a computer model to predict flood damages. The computer model is to be operational in June 1985. In order to achieve this objective, the input of land-use data into a data base consisting of 198,000 grid cells will be required. A planning technique using Spatial Analysis Methodology (SAM) was developed by the Corps of Engineers Hydrologic Engineering Center (HEC) to systematically handle these data. The HEC-SAM system uses the spatially oriented map data in a series of data management and analysis software programs for input to the Corps hydrologic and environmental models. Attention is given to data base development, Landsat digital data, the placement of the Landsat data into the grid cell data base, and the development of the land cover classification. The Landsat-2 MSS scene covering 85 percent of the Saginaw River Basin was geometrically corrected to a UTM coordinate system.

Mckim, H. L.↗

DOE OSTI2024

Endowing low fatigue for elastocaloric effect by refined hierarchical microcomposite in additive manufactured NiTiCuCo alloy

Abstract NiTiCu-based shape memory alloys have been considered as ideal materials for solid-state refrigeration due to their superb cycling stability for elastocaloric effect. However, the embrittlement and deterioration caused by secondary phase and coarse grains restrict their applications, and it is still challenging since the geometric components are required. Here, bulk NiTiCuCo parts with excellent forming quality were fabricated by laser powder bed fusion (LPBF) technique. The as-fabricated alloy exhibits refined three-phases hierarchical microcomposite formed based on the rapid cooling mode of LPBF, composed of intricate dendritic Ti 2 Ni–NiTi composite and nano Ti 2 Cu embedded inside the NiTi-matrix. This configuration endows far superior elastocaloric stability compared to the as-cast counterpart. The low fatigue stems from the strong elastic coupling between the interphases with reversible martensite transformation, revealed byin-situsynchrotron high-energy x-ray diffraction. The fabrication of NiTiCuCo alloy via LPBF fills the bill of complex geometric structures for elastocaloric NiTiCu alloys. The understanding of interphase micro-coupling could provide the guide for designing LPBF fabricated shape memory-based composites, enabling their applications for special demands on other functionalities.

Engineering↗

DOE OSTI2026

Nonlocal Metasurface with Resonance-Selective Nonlinear Wavefront Shaping

We demonstrate a nonlinear nonlocal metasurface supporting quasi-trapped modes that enable helicity-dependent wavefront shaping at third-harmonic wavelengths. The geometric phase is selectively modified near resonance, revealing a mechanism for polarization-dependent nonlinear phase control.

Sedeh, Hooman [Duke University]↗

DOE OSTI2021

Machine learning assisted prediction of the Young’s modulus of compositionally complex alloys

We identify compositionally complex alloys (CCAs) that offer exceptional mechanical properties for elevated temperature applications by employing machine learning (ML) in conjunction with rapid synthesis and testing of alloys for validation to accelerate alloy design. The advantages of this approach are scalability, rapidity, and reasonably accurate predictions. ML tools were implemented to predict Young’s modulus of refractory-based CCAs by employing different ML models. Our results, in conjunction with experimental validation, suggest that average valence electron concentration, the difference in atomic radius, a geometrical parameter λ and melting temperature of the alloys are the key features that determine the Young’s modulus of CCAs and refractory-based CCAs. The Gradient Boosting model provided the best predictive capabilities (mean absolute error of 6.15 GPa) among the models studied. Our approach integrates high-quality validation data from experiments, literature data for training machine-learning models, and feature selection based on physical insights. It opens a new avenue to optimize the desired materials property for different engineering applications.

36 MATERIALS SCIENCE↗

NASA NTRS1989

Turbomachinery aeroelasticity at NASA Lewis Research Center

The turbomachinery aeroelastic effort is focused on unstalled and stalled flutter, forced response, and whirl flutter of both single rotation and counter rotation propfans. It also includes forced response of the Space Shuttle Main Engine (SSME) turbopump blades. Because of certain unique features of propfans and the SSME turbopump blades, it is not possible to directly use the existing aeroelastic technology of conventional propellers, turbofans or helicopters. Therefore, reliable aeroelastic stability and response analysis methods for these propulsion systems must be developed. The development of these methods for propfans requires specific basic technology disciplines, such as 2-D and 3-D steady and unsteady aerodynamic theories in subsonic, transonic and supersonic flow regimes; modeling of composite blades; geometric nonlinear effects; and passive and active control of flutter and response. These methods are incorporated in a computer program, ASTROP. The program has flexibility such that new and future models in basic disciplines can be easily implemented.

Kaza, Krishna Rao V.↗

DOE OSTI2023

Aerodynamic-whistles-based ultrasonic tone generators for bat deterrence

Novel ultrasonic bat deterrents based on aerodynamic whistles are proposed and investigated experimentally and numerically for their ability to generate ultrasound. The baseline deterrent, a single-whistle design inspired by Beeken [“Fluid ultrasonic generator,” U.S. patent 3,432,804 (1969)], is examined first. It consists of two resonating cavities/chambers. The whistle is “powered” by a regulated high-pressure air supply, and the performance of the whistle is examined for a range of supply pressures. Far-field acoustic measurements in the 20 Hz–50 kHz frequency range are made in an anechoic chamber. The noise measurements are supplemented with two- and three-dimensional unsteady Reynolds-averaged Navier–Stokes (uRANS) simulations to investigate the mechanisms of ultrasound generation. The Ffowcs Williams–Hawkings acoustic analogy is used with the three-dimensional uRANS results to predict the far-field radiation. The far-field acoustic predictions are in good agreement with the measurements in the anechoic chamber. The peak frequency (fundamental) of the radiated ultrasound of the baseline deterrent is approximately 23 kHz. Harmonics and a sub-harmonic of the fundamental tone are also observed. The numerical simulations show that the two resonating chambers of the baseline deterrent operate out-of-phase and Helmholtz resonance determines the whistling frequency over the range of supply air pressure considered. A six-whistle deterrent targeting a broad spectral coverage in the 20–50 kHz frequency range is designed, fabricated, and tested in the anechoic chamber. Each whistle in the deterrent is obtained by geometrically scaling the baseline whistle. Measurements show that the six-whistle ultrasound deterrent generates ultrasound with six dominant peaks in the designed frequency range when the supply air pressure exceeds 5 psig. The proposed ultrasound devices can be used for a variety of purposes including bat deterrence at wind turbines.

42 ENGINEERING↗