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NASA NTRSDate not supplied

An Approach to Shape Parameterization Using Laboratory Hypervelocity Impact Experiments

NASA’s Orbital Debris Program Office relies on laboratory-based impact tests to supplement the measurement data of on-orbit events that defines the orbital debris environment. These experiments provide information that is essential to interpreting the radar and optical measurements of orbital fragmentation events into useful metrics, such as characteristic size of the debris, and to providing a better understanding of the distributions of fragment populations in terms of their masses, material constituents, fragment densities, cross-sectional areas, area-to-mass ratios, shapes, etc. The Satellite Orbital Debris Characterization Impact Test (SOCIT) was a notable laboratory impact experiment conducted in 1992 using a surplus U.S. Navy Transit navigation satellite of the 1960s. The data from this ground-based experiment were combined with on-orbit measurements to develop the NASA Standard Satellite Breakup Model (SSBM). To account for advancements in satellite design and construction since, a new impact test series – DebriSat – was conducted in 2014. This test utilized a high-fidelity mock-up spacecraft that better represents the materials and construction techniques used to design and manufacture modern spacecraft. Together, these tests offer valuable data to model an orbital debris environment composed of legacy and modern spacecraft. This paper presents an overview of the two laboratory impact tests, comparing their fragment parameter distributions with each other and with relevant distributions from the NASA SSBM. The categorization and descriptions of fragment shapes are of significant interest for future work, yet there are marked differences in the definitions of shape categories between each dataset. The categorizations of constituent materials, and the measurement techniques employed to populate these two datasets, are also different. New rubrics simplify and equate the categorizations between datasets to aid comparative analyses and to facilitate the potential use of both datasets in tandem with future environmental debris models. A preferred approach to classifying shape across disparate datasets uses the characteristic-length dimensions, and a simplified shape classification based on physical, solid-body dimensions, to mathematically construct an encapsulating right-circular cylinder that represents the fragment. The ratio of cylinder length-to-diameter (L:D) then provides a single continuum value for shape that is strongly correlated with its designated shape and size. This metric can then be used to further assess the distribution of shape with populations of other fragment characteristics within these datasets. The shape parameterization using the L:D ratios of right-circular cylinders is discussed.

John H. Seago↗
NASA NTRSDate not supplied

An Approach to Shape Parameterization Using Laboratory Hypervelocity Impact Experiments

NASA’s Orbital Debris Program Office relies on laboratory-based impact tests to supplement the measurement data of on-orbit events that defines the orbital debris environment. These experiments provide information that is essential to interpreting the radar and optical measurements of orbital fragmentation events into useful metrics, such as characteristic size of the debris, and to providing a better understanding of the distributions of fragment populations in terms of their masses, material constituents, fragment densities, cross-sectional areas, area-to-mass ratios, shapes, etc. The Satellite Orbital Debris Characterization Impact Test (SOCIT) was a notable laboratory impact experiment conducted in 1992 using a surplus U.S. Navy Transit navigation satellite of the 1960s. The data from this ground-based experiment were combined with on-orbit measurements to develop the NASA Standard Satellite Breakup Model (SSBM). To account for advancements in satellite design and construction since, a new impact test series – DebriSat – was conducted in 2014. This test utilized a high-fidelity mock-up spacecraft that better represents the materials and construction techniques used to design and manufacture modern spacecraft. Together, these tests offer valuable data to model an orbital debris environment composed of legacy and modern spacecraft. This paper presents an overview of the two laboratory impact tests, comparing their fragment parameter distributions with each other and with relevant distributions from the NASA SSBM. The categorization and descriptions of fragment shapes are of significant interest for future work, yet there are marked differences in the definitions of shape categories between each dataset. The categorizations of constituent materials, and the measurement techniques employed to populate these two datasets, are also different. New rubrics simplify and equate the categorizations between datasets to aid comparative analyses and to facilitate the potential use of both datasets in tandem with future environmental debris models. A preferred approach to classifying shape across disparate datasets uses the characteristic-length dimensions, and a simplified shape classification based on physical, solid-body dimensions, to mathematically construct an encapsulating right-circular cylinder that represents the fragment. The ratio of cylinder length-to-diameter (L:D) then provides a single continuum value for shape that is strongly correlated with its designated shape and size. This metric can then be used to further assess the distribution of shape with populations of other fragment characteristics within these datasets. The shape parameterization using the L:D ratios of right-circular cylinders is discussed.

John H Seago↗
DOE OSTI2025

Revealing mechanisms of processing defect mitigation in laser powder bed fusion via shaped beams using high-speed X-ray imaging

The laser powder bed fusion (LPBF) process utilizing a focused Gaussian-shaped beam faces challenges, including pore formation, melt pool fluctuation and liquid spattering. While beam shaping technology has been explored as a potential approach for defect mitigation, the beam-matter interaction dynamics during melting with shaped beams remain unclear. Here, we report the direct observation of ring-shaped beam-matter interaction dynamics, including pore formation, melt pool fluctuation and liquid spattering, and unveil defect mitigation mechanisms in ring-shaped beam laser powder bed fusion process. Here, we find that, by spatially manipulating incident laser rays, the ring-shaped beam controls keyhole morphology, thereby managing the distribution of the reflected rays. This manipulation can effectively eliminate the formation of an unstable cavity at the keyhole tip, stabilizing the keyhole and mitigating keyhole pores. This enhanced keyhole stability effectively reduces the melt pool fluctuation, the formation of liquid breakup induced spatters and liquid droplet colliding induced large spatters in the laser powder bed fusion process. Additionally, the high-energy forefront of the ring-shaped beam effectively melts the powder bed, reducing agglomeration liquid spatter in the laser powder bed fusion process. The discovered defect mitigation mechanisms may guide the design of beam shaping strategies for simultaneously increasing the quality and productivity of metal additive manufacturing.

Beam shaping↗
DOE OSTI2026

Shape evolution in neutron-rich odd-even 105–109 Nb isotopes

Background: Neutron-rich nuclei around 𝑍 ≈ 40 are well known for exhibiting multiple shape transitions. Here, this region shows one of the sharpest shape transitions in the nuclear chart, evolving from a spherical vibrator at 𝑁 = 58 to a strongly deformed prolate shape at 𝑁 = 60. The largest deformations are observed for 38 Sr and 40 Zr . This abrupt shape transition disappears at 𝑍 = 36 and below, where a shape transition from spherical to oblate nuclei is predicted. On the other hand, for 𝑍 ≥ 42 and 𝑁 ≥ 60, the shape is known to evolve from axial to triaxial. While the even-𝑍 nuclei in this region have already been extensively studied, new insights can be gained from the studies of odd-𝑍 isotopes for a better understanding of the underlying mechanisms driving these phenomena. Purpose: The 41 Nb nuclei lie at the boundary between axially deformed Zr and triaxially deformed Mo nuclei. This work investigates the nuclear structure of very neutron-rich Nb nuclei up to 𝑁 = 68. The goal is to understand how the nuclear shape evolves as a function of isospin in this isotopic chain and provide new insights into the emergence of triaxial deformation. Methods: The structure of the neutron-rich Nb isotopes was investigated using state-of-the-art high-resolution 𝛾-ray spectroscopy of fission fragments produced via two different fission reactions. The use of 9 Be ⁢( 238 U, 𝑓) inverse kinematics, with a detection system comprising AGATA, EXOGAM, and VAMOS++, enabled the measurement of prompt and delayed 𝛾 rays from isotopically identified fission fragments, and 𝛾−𝛾−𝛾−𝛾 highfold data were obtained from a spontaneous fission source of 252 Cf using the Gammasphere array. Results: The level scheme of 105 Nb has been significantly extended, with the addition of two negative-parity bands observed for the first time. A new level scheme is proposed for 107 Nb, which is not in agreement with an earlier measurement, and new levels and transitions have been added to the very neutron-rich 109 Nb. The degree of triaxiality of the new bands is discussed on the basis of signature splitting analysis. The recently reported level scheme of 99 Nb has been revised. Conclusions: This systematic study on the Nb isotopic chain, compared to Zr and Mo, indicates that while the ground-state band exhibits a triaxial deformation, attributed to a proton hole coupled to a triaxially deformed Mo core, the negative-parity bands, based on isomeric bandheads, display an axially symmetric deformed structure, similar to that observed in the Zr isotopes, revealing the existence of a shape coexistence in the neutron-rich Nb nuclei.

Abushawish, M. [Université Claude-Bernard Lyon 1 (↗
NASA NTRS1998

Input Shaping to Reduce Solar Array Structural Vibrations

Structural vibrations induced by actuators can be minimized using input shaping. Input shaping is a feedforward method in which actuator commands are convolved with shaping functions to yield a shaped set of commands. These commands are designed to perform the maneuver while minimizing the residual structural vibration. In this report, input shaping is extended to stepper motor actuators. As a demonstration, an input-shaping technique based on pole-zero cancellation was used to modify the Solar Array Drive Assembly (SADA) actuator commands for the Lewis satellite. A series of impulses were calculated as the ideal SADA output for vibration control. These impulses were then discretized for use by the SADA stepper motor actuator and simulated actuator outputs were used to calculate the structural response. The effectiveness of input shaping is limited by the accuracy of the knowledge of the modal frequencies. Assuming perfect knowledge resulted in significant vibration reduction. Errors of 10% in the modal frequencies caused notably higher levels of vibration. Controller robustness was improved by incorporating additional zeros in the shaping function. The additional zeros did not require increased performance from the actuator. Despite the identification errors, the resulting feedforward controller reduced residual vibrations to the level of the exactly modeled input shaper and well below the baseline cases. These results could be easily applied to many other vibration-sensitive applications involving stepper motor actuators.

Doherty, Michael J.↗
NASA NTRS2001

Suppression of Soot Formation and Shapes of Laminar Jet Diffusion Flames

Laminar nonpremixed (diffusion) flames are of interest because they provide model flame systems that are far more tractable for analysis and experiments than practical turbulent flames. In addition, many properties of laminar diffusion flames are directly relevant to turbulent diffusion flames using laminar flamelet concepts. Finally, laminar diffusion flame shapes have been of interest since the classical study of Burke and Schumann because they involve a simple nonintrusive measurement that is convenient for evaluating flame shape predictions. Motivated by these observations, the shapes of round hydrocarbon-fueled laminar jet diffusion flames were considered, emphasizing conditions where effects of buoyancy are small because most practical flames are not buoyant. Earlier studies of shapes of hydrocarbon-fueled nonbuoyant laminar jet diffusion flames considered combustion in still air and have shown that flames at the laminar smoke point are roughly twice as long as corresponding soot-free (blue) flames and have developed simple ways to estimate their shapes. Corresponding studies of hydrocarbon-fueled weakly-buoyant laminar jet diffusion flames in coflowing air have also been reported. These studies were limited to soot-containing flames at laminar smoke point conditions and also developed simple ways to estimate their shapes but the behavior of corresponding soot-free flames has not been addressed. This is unfortunate because ways of selecting flame flow properties to reduce soot concentrations are of great interest; in addition, soot-free flames are fundamentally important because they are much more computationally tractable than corresponding soot-containing flames. Thus, the objectives of the present investigation were to observe the shapes of weakly-buoyant laminar jet diffusion flames at both soot-free and smoke point conditions and to use the results to evaluate simplified flame shape models. The present discussion is brief.

Xu, F.↗
NASA NTRS2006

Reentry-Vehicle Shape Optimization Using a Cartesian Adjoint Method and CAD Geometry

A DJOINT solutions of the governing flow equations are becoming increasingly important for the development of efficient analysis and optimization algorithms. A well-known use of the adjoint method is gradient-based shape. Given an objective function that defines some measure of performance, such as the lift and drag functionals, its gradient is computed at a cost that is essentially independent of the number of design variables (e.g., geometric parameters that control the shape). Classic aerodynamic applications of gradient-based optimization include the design of cruise configurations for transonic and supersonic flow, as well as the design of high-lift systems. are perhaps the most promising approach for addressing the issues of flow solution automation for aerodynamic design problems. In these methods, the discretization of the wetted surface is decoupled from that of the volume mesh. This not only enables fast and robust mesh generation for geometry of arbitrary complexity, but also facilitates access to geometry modeling and manipulation using parametric computer-aided design (CAD). In previous work on Cartesian adjoint solvers, Melvin et 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 two-dimensional Euler equations using a ghost-cell method to enforce the wall boundary conditions. In Refs. 18 and 19, we presented an accurate and efficient algorithm for the solution of the adjoint Euler equations discretized on Cartesian meshes with embedded, cut-cell boundaries. Novel aspects of the algorithm were the computation of surface shape sensitivities for triangulations based on parametric-CAD models and the linearization of the coupling between the surface triangulation and the cut-cells. The accuracy of the gradient computation was verified using several three-dimensional test cases, which included design variables such as the free stream parameters and the planform shape of an isolated wing. The objective of the present work is to extend our adjoint formulation to problems involving general shape changes. Factors under consideration include the computation of mesh sensitivities that provide a reliable approximation of the objective function gradient, as well as the computation of surface shape sensitivities based on a direct-CAD interface. We present detailed gradient verification studies and then focus on a shape optimization problem for an Apollo-like reentry vehicle. The goal of the optimization is to enhance the lift-to-drag ratio of the capsule by modifying the shape of its heat-shield in conjunction with a center-of-gravity (c.g.) offset. This multipoint and multi-objective optimization problem is used to demonstrate the overall effectiveness of the Cartesian adjoint method for addressing the issues of complex aerodynamic design.

Nemec, Marian↗
NASA NTRS1991

Shape-memory alloy micro-actuator

A method of producing an integral piece of thermo-sensitive material, which is responsive to a shift in temperature from below to above a phase transformation temperature range to alter the material's condition to a shape-memory condition and move from one position to another. The method is characterized by depositing a thin film of shape-memory material, such as Nickel titanium (Ni-Ti) onto a substrate by vacuum deposition process such that the alloy exhibits an amorphous non-crystalline structure. The coated substrate is then annealed in a vacuum or in the presence of an inert atmosphere at a selected temperature, time and cool down rate to produce an ordered, partially disordered or fully disordered BCC structure such that the alloy undergoes thermoelastic, martinsetic phase transformation in response to alteration in temperature to pass from a martinsetic phase when at a temperature below a phase transformation range and capable of a high level of recoverable strain to a parent austenitic phase in a memory shape when at a temperature above the phase transformation range. Also disclosed are actuator devices employing shape-memory material actuators that deform from a set shape toward an original shape when subjected to a critical temperature level after having been initially deformed from the original shape into the set shape while at a lower temperature. The actuators are mechanically coupled to one or more movable elements such that the temperature-induce deformation of the actuators exerts a force or generates a motion of the mechanical element(s).

Busch, John D.↗
NASA NTRS2010

A Review of Discrete Element Method (DEM) Particle Shapes and Size Distributions for Lunar Soil

As part of ongoing efforts to develop models of lunar soil mechanics, this report reviews two topics that are important to discrete element method (DEM) modeling the behavior of soils (such as lunar soils): (1) methods of modeling particle shapes and (2) analytical representations of particle size distribution. The choice of particle shape complexity is driven primarily by opposing tradeoffs with total number of particles, computer memory, and total simulation computer processing time. The choice is also dependent on available DEM software capabilities. For example, PFC2D/PFC3D and EDEM support clustering of spheres; MIMES incorporates superquadric particle shapes; and BLOKS3D provides polyhedra shapes. Most commercial and custom DEM software supports some type of complex particle shape beyond the standard sphere. Convex polyhedra, clusters of spheres and single parametric particle shapes such as the ellipsoid, polyellipsoid, and superquadric, are all motivated by the desire to introduce asymmetry into the particle shape, as well as edges and corners, in order to better simulate actual granular particle shapes and behavior. An empirical particle size distribution (PSD) formula is shown to fit desert sand data from Bagnold. Particle size data of JSC-1a obtained from a fine particle analyzer at the NASA Kennedy Space Center is also fitted to a similar empirical PSD function.

Lane, John E.↗
NASA NTRS2011

Extension of Ko Straight-Beam Displacement Theory to Deformed Shape Predictions of Slender Curved Structures

The Ko displacement theory originally developed for shape predictions of straight beams is extended to shape predictions of curved beams. The surface strains needed for shape predictions were analytically generated from finite-element nodal stress outputs. With the aid of finite-element displacement outputs, mathematical functional forms for curvature-effect correction terms are established and incorporated into straight-beam deflection equations for shape predictions of both cantilever and two-point supported curved beams. The newly established deflection equations for cantilever curved beams could provide quite accurate shape predictions for different cantilever curved beams, including the quarter-circle cantilever beam. Furthermore, the newly formulated deflection equations for two-point supported curved beams could provide accurate shape predictions for a range of two-point supported curved beams, including the full-circular ring. Accuracy of the newly developed curved-beam deflection equations is validated through shape prediction analysis of curved beams embedded in the windward shallow spherical shell of a generic crew exploration vehicle. A single-point collocation method for optimization of shape predictions is discussed in detail

Ko, William L.↗
NASA NTRS2011

Ice Shape Characterization Using Self-Organizing Maps

A method for characterizing ice shapes using a self-organizing map (SOM) technique is presented. Self-organizing maps are neural-network techniques for representing noisy, multi-dimensional data aligned along a lower-dimensional and possibly nonlinear manifold. For a large set of noisy data, each element of a finite set of codebook vectors is iteratively moved in the direction of the data closest to the winner codebook vector. Through successive iterations, the codebook vectors begin to align with the trends of the higher-dimensional data. In information processing, the intent of SOM methods is to transmit the codebook vectors, which contains far fewer elements and requires much less memory or bandwidth, than the original noisy data set. When applied to airfoil ice accretion shapes, the properties of the codebook vectors and the statistical nature of the SOM methods allows for a quantitative comparison of experimentally measured mean or average ice shapes to ice shapes predicted using computer codes such as LEWICE. The nature of the codebook vectors also enables grid generation and surface roughness descriptions for use with the discrete-element roughness approach. In the present study, SOM characterizations are applied to a rime ice shape, a glaze ice shape at an angle of attack, a bi-modal glaze ice shape, and a multi-horn glaze ice shape. Improvements and future explorations will be discussed.

McClain, Stephen T.↗
NASA NTRS2011

AC Electric Field Activated Shape Memory Polymer Composite

Shape memory materials have drawn interest for applications like intelligent medical devices, deployable space structures and morphing structures. Compared to other shape memory materials like shape memory alloys (SMAs) or shape memory ceramics (SMCs), shape memory polymers (SMPs) have high elastic deformation that is amenable to tailored of mechanical properties, have lower density, and are easily processed. However, SMPs have low recovery stress and long response times. A new shape memory thermosetting polymer nanocomposite (LaRC-SMPC) was synthesized with conductive fillers to enhance its thermo-mechanical characteristics. A new composition of shape memory thermosetting polymer nanocomposite (LaRC-SMPC) was synthesized with conductive functionalized graphene sheets (FGS) to enhance its thermo-mechanical characteristics. The elastic modulus of LaRC-SMPC is approximately 2.7 GPa at room temperature and 4.3 MPa above its glass transition temperature. Conductive FGSs-doped LaRC-SMPC exhibited higher conductivity compared to pristine LaRC SMP. Applying an electric field at between 0.1 Hz and 1 kHz induced faster heating to activate the LaRC-SMPC s shape memory effect relative to applying DC electric field or AC electric field at frequencies exceeding1 kHz.

Kang, Jin Ho↗
NASA NTRS2012

Low-Gain Circularly Polarized Antenna with Torus-Shaped Pattern

The Juno mission to Jupiter requires an antenna with a torus-shaped antenna pattern with approximately 6 dBic gain and circular polarization over the Deep Space Network (DSN) 7-GHz transmit frequency and the 8-GHz receive frequency. Given the large distances that accumulate en-route to Jupiter and the limited power afforded by the solar-powered vehicle, this toroidal low-gain antenna requires as much gain as possible while maintaining a beam width that could facilitate a +/-10deg edge of coverage. The natural antenna that produces a toroidal antenna pattern is the dipole, but the limited approx. = 2.2 dB peak gain would be insufficient. Here a shaped variation of the standard bicone antenna is proposed that could achieve the required gains and bandwidths while maintaining a size that was not excessive. The final geometry that was settled on consisted of a corrugated, shaped bicone, which is fed by a WR112 waveguide-to-coaxial- waveguide transition. This toroidal low-gain antenna (TLGA) geometry produced the requisite gain, moderate sidelobes, and the torus-shaped antenna pattern while maintaining a very good match over the entire required frequency range. Its "horn" geometry is also low-loss and capable of handling higher powers with large margins against multipactor breakdown. The final requirement for the antenna was to link with the DSN with circular polarization. A four-layer meander-line array polarizer was implemented; an approach that was fairly well suited to the TLGA geometry. The principal development of this work was to adapt the standard linear bicone such that its aperture could be increased in order to increase the available gain of the antenna. As one increases the aperture of a standard bicone, the phase variation across the aperture begins to increase, so the larger the aperture becomes, the greater the phase variation. In order to maximize the gain from any aperture antenna, the phase should be kept as uniform as possible. Thus, as the standard bicone fs aperture increases, the gain increase becomes less until one reaches a point of diminishing returns. In order to overcome this problem, a shaped aperture is used. Rather than the standard linear bicone, a parabolic bicone was found to reduce the amount of phase variation as the aperture increases. In fact, the phase variation is half of the standard linear bicone, which leads to higher gain with smaller aperture sizes. The antenna pattern radiated from this parabolic-shaped bicone antenna has fairly high side lobes. The Juno project requested that these sidelobes be minimized. This was accomplished by adding corrugations to the parabolic shape. This corrugated-shaped bicone antenna had reasonably low sidelobes, and the appropriate gain and beamwidth to meet project requirements.

Amaro, Luis R.↗
NASA NTRS2013

Elastically Shaped Wing Optimization and Aircraft Concept for Improved Cruise Efficiency

This paper presents the findings of a study conducted tn 2010 by the NASA Innovation Fund Award project entitled "Elastically Shaped Future Air Vehicle Concept". The study presents three themes in support of meeting national and global aviation challenges of reducing fuel burn for present and future aviation systems. The first theme addresses the drag reduction goal through innovative vehicle configurations via non-planar wing optimization. Two wing candidate concepts have been identified from the wing optimization: a drooped wing shape and an inflected wing shape. The drooped wing shape is a truly biologically inspired wing concept that mimics a seagull wing and could achieve about 5% to 6% drag reduction, which is aerodynamically significant. From a practical perspective, this concept would require new radical changes to the current aircraft development capabilities for new vehicles with futuristic-looking wings such as this concept. The inflected wing concepts could achieve between 3% to 4% drag reduction. While the drag reduction benefit may be less, the inflected-wing concept could have a near-term impact since this concept could be developed within the current aircraft development capabilities. The second theme addresses the drag reduction goal through a new concept of elastic wing shaping control. By aeroelastically tailoring the wing shape with active control to maintain optimal aerodynamics, a significant drag reduction benefit could be realized. A significant reduction in fuel burn for long-range cruise from elastic wing shaping control could be realized. To realize the potential of the elastic wing shaping control concept, the third theme emerges that addresses the drag reduction goal through a new aerodynamic control effector called a variable camber continuous trailing edge flap. Conventional aerodynamic control surfaces are discrete independent surfaces that cause geometric discontinuities at the trailing edge region. These discontinuities promote vorticities which result in drag rises as well as noise sources. The variable camber trailing edge flap concept could provide a substantial drag reduction benefit over a conventional discrete flap system. Aerodynamic simulations show a drag reduction of over 50% could be achieved with the flap concept over a conventional discrete flap system.

Nguyen, Nhan↗
NASA NTRS2014

Arbitrary Shape Deformation in CFD Design

Sculptor(R) is a commercially available software tool, based on an Arbitrary Shape Design (ASD), which allows the user to perform shape optimization for computational fluid dynamics (CFD) design. The developed software tool provides important advances in the state-of-the-art of automatic CFD shape deformations and optimization software. CFD is an analysis tool that is used by engineering designers to help gain a greater understanding of the fluid flow phenomena involved in the components being designed. The next step in the engineering design process is to then modify, the design to improve the components' performance. This step has traditionally been performed manually via trial and error. Two major problems that have, in the past, hindered the development of an automated CFD shape optimization are (1) inadequate shape parameterization algorithms, and (2) inadequate algorithms for CFD grid modification. The ASD that has been developed as part of the Sculptor(R) software tool is a major advancement in solving these two issues. First, the ASD allows the CFD designer to freely create his own shape parameters, thereby eliminating the restriction of only being able to use the CAD model parameters. Then, the software performs a smooth volumetric deformation, which eliminates the extremely costly process of having to remesh the grid for every shape change (which is how this process had previously been achieved). Sculptor(R) can be used to optimize shapes for aerodynamic and structural design of spacecraft, aircraft, watercraft, ducts, and other objects that affect and are affected by flows of fluids and heat. Sculptor(R) makes it possible to perform, in real time, a design change that would manually take hours or days if remeshing were needed.

Landon, Mark↗
NASA NTRS2017

Shaped Recess Flow Control

One or more embodiments of techniques or systems for shaped recess flow control are provided herein. A shaped recess or cavity can be formed on a surface associated with fluid flow. The shaped recess can be configured to create or induce fluid effects, temperature effects, or shedding effects that interact with a free stream or other structures. The shaped recess can be formed at an angle to a free stream flow and may be substantially "V" shaped. The shaped recess can be coupled with a cooling channel, for example. The shaped recess can be upstream or downstream from a cooling channel and aligned in a variety of manners. Due to the fluid effects, shedding effects, and temperature effects created by a shaped recess, lift-off or separation of cooling jets of cooling channels can be mitigated, thereby enhancing film cooling effectiveness.

Shyam, Vikram↗
NASA NTRS2022

Structural Shape Sensing from Strain Data Using the Basis Function Method

An aircraft shape must be measured during flight to implement an active trim shape control, such as an active dihedral control for a highly flexible aircraft with a high-aspect-ratio wing, and an active sonic boom control for a supersonic transport aircraft. A basis function method for linear as well as geometrically nonlinear structural shape sensing is proposed in this study. Basis functions can be mode shapes, linear static deformation shapes, or geometrically nonlinear static deformation shapes. The proposed basis function method is validated using a high-aspect-ratio wing, a swept test plate, and the National Aeronautics and Space Administration Low Boom Flight Demonstration mission X-59 Quiet Supersonic Technology (QueSST) aircraft (Lockheed Martin, Bethesda, Maryland). A large structural deformation of a high-aspect-ratio wing is successfully captured using the proposed basis function method with less than 0.3-percentprediction error at the wing-tip section. The basis function method gives excellent deformation prediction, even with stress concentration. Performance of the basis functions is compared using the X-59 stabilator sample case. In most of the sample load cases, static deformations give a better correlation with the target deformation than do mode shapes. Wing shape sensing with sparse strain data is also demonstrated in this study using the X-59 QueSST aircraft. Predicted structural deformations match reasonably with the target deformations even without strain gauges on some structural components. The predicted deformations have a good match with the target deformations.

Chan-gi Pak↗
DOE OSTI2025

X-Ray Microtomography Measurements of Coevolving Particle Size and Shape

This study measures simultaneous changes in particle size and shape during grain crushing and proposes quantitative metrics to track their coevolving statistical distribution. Idealized granular materials with widely different initial particle shapes (i.e., spheres, quasi-ellipsoids, plates, and rods) are compressed oedometrically at vertical stress levels sufficient to induce particle breakage. X-ray microtomography and digital image analysis are then used to track changes in particle-scale characteristics. The observations indicate that more irregular particles tend to exhibit a higher degree of breakage compared to more spherical grains subjected to an equivalent stress level. Despite these differences, the measurements also indicate that all the tested particle sets approach a common attractor (expressed in terms of aspect ratio, flatness, and elongation), regardless of their initial morphology. A new shape evolution index is proposed to quantify such trends. With this new metric, it is shown that in all the tested materials, the particle shape evolves faster than size, especially for the more regular morphologies, thus implying that the shape tends to reach its attractor point before the grading reaches its ultimate particle size distribution. Furthermore, this finding underpins an ultimate stage of crushing-driven compression that occurs with particle size reduction but minimal shape changes (i.e., self-replicating shapes due to fractures).

Oedometric compression↗