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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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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Surface smoothing for laser powder-bed Ti-6Al-4V by a transient liquid phase

Surface roughness is the primary driver of fatigue for additively manufactured metals. To address surface roughness, this work introduces a new method to smooth features beyond line-of-sight without material removal. The method applies a coating that triggers local surface remelting by activating a eutectic reaction during heat treatment. The associated liquid phase then wets and isothermally solidifies into a smoother surface. For Ti-6Al-4V fabricated with laser powder bed fusion, samples with and without TLP smoothing (using a Cu coating) were characterized with a suite of techniques, including mechanical testing, electron backscatter diffraction, synchrotron X-ray tomography, and fractography. TLP smoothing reduced surface roughness by 80% and amplified compressive residual stress at the surface by about 50%. With statistically equivalent virtual microstructures, crystal plasticity scrutinized the roles of phases, porosity, and surface roughness. Although the tensile strain-to-failure was reduced to 1% strain, the TLP smoothing process increased high-cycle fatigue strength by about 20% compared to control samples, pointing to future opportunities to optimize the new process through various coating compositions and heat treatment schedules. Overall, this work establishes a new paradigm for treating surfaces of materials for smoothness and compressive residual stress.

Additive manufacturing↗
DOE OSTI2025

Optimal Polynomial Smoothers and One‐Sided V‐Cycles for Poisson Problems

The solution to the Poisson equation arising from the spectral element discretization of the incompressible Navier‐Stokes equations needs robust preconditioning strategies. One such strategy is multigrid. To realize the potential of multigrid methods, effective smoothing strategies are needed. Chebyshev polynomial smoothers, in conjunction with pointwise Jacobi or additive Schwarz methods (ASMs), prove to be an effective smoother. Other polynomial smoothers, however, may provide superior convergence to the multigrid preconditioner. The authors compare the standard Chebyshev polynomial smoothers to both the novel fourth‐kind Chebyshev polynomial smoothers proposed by Lottes as well as smoothers based on the polynomial of best uniform approximation to as proposed by Kraus, Vassilevski, and Zikatanov. At the cost of symmetry, further improvements may be made. For example, a order polynomial smoother on both sides of the V‐cycle may be substituted with an order polynomial smoother on one side at no additional cost. The choice of omitting the postsmoother in favor of higher‐order polynomial presmoothing is advantageous in cases where the multigrid approximation property constant is large. The authors consider a 2D model problem based on finite differences to motivate the choice of polynomial smoother, order, and whether to apply postsmoothing for the target application of high‐order ‐geometric multigrid methods for GPU architectures. Results from both domains demonstrate the substantial improvement of these approaches over the standard Chebyshev polynomial smoother with a symmetric V‐cycle.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

COUPLING SMOOTHED PARTICLE HYDRODYNAMICS WITH FINITE ELEMENT METHOD TO SIMULATE RESIDUAL STRESSES FROM FRICTION STIR PROCESSING

Friction stir processing (FSP) is a solid-state material processing technique that locally modifies the microstructure but also induces undesirable residual stresses. A robust numerical model for the FSP can help in mitigating these residual stresses. Heat source models within a finite element method (FEM) framework suffer from inaccuracies. In contrast, smoothed particle hydrodynamics (SPH) model that explicitly captures the material flow near the tool and the associated heat generation are accurate. However, the computational expense of SPH simulations can be prohibitive. In this work, we propose a coupled SPH-FEM framework. SPH is used to model the heat generation accurately near the tool and which is then inserted into to the FEM model as a heat source. To verify this proposed coupling approach, a test case is set up with typical FSP conditions and it is modeled in both SPH and SPH-FEM. The temperatures profiles were compared after the simulations have reached steady-state temperatures. The similarity of the temperature profiles from SPH-FEA and SPH validated the proposed coupling approach. This proposed approach achieves the accuracy of the SPH method while potentially retaining the low computational expense of FEM.

smoothed particle hydrodynamics, Finite Element Me↗
DOE OSTI2019

Derivative-free optimization methods

In many optimization problems arising from scientific, engineering and artificial intelligence applications, objective and constraint functions are available only as the output of a black-box or simulation oracle that does not provide derivative information. Such settings necessitate the use of methods for derivative-free, or zeroth-order, optimization. We provide a review and perspectives on developments in these methods, with an emphasis on highlighting recent developments and on unifying treatment of such problems in the non-linear optimization and machine learning literature. We categorize methods based on assumed properties of the black-box functions, as well as features of the methods. We first overview the primary setting of deterministic methods applied to unconstrained, non-convex optimization problems where the objective function is defined by a deterministic black-box oracle. We then discuss developments in randomized methods, methods that assume some additional structure about the objective (including convexity, separability and general non-smooth compositions), methods for problems where the output of the black-box oracle is stochastic, and methods for handling different types of constraints.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1978

Solution of axisymmetric and two-dimensional inviscid flow over blunt bodies by the method of lines

Comparisons with experimental data and the results of other computational methods demonstrated that very accurate solutions can be obtained by using relatively few lines with the method of lines approach. This method is semidiscrete and has relatively low core storage requirements as compared with fully discrete methods since very little data were stored across the shock layer. This feature is very attractive for three dimensional problems because it enables computer storage requirements to be reduced by approximately an order of magnitude. In the present study it was found that nine lines was a practical upper limit for two dimensional and axisymmetric problems. This condition limits application of the method to smooth body geometries where relatively few lines would be adequate to describe changes in the flow variables around the body. Extension of the method to three dimensions was conceptually straightforward; however, three dimensional applications would also be limited to smooth body geometries although not necessarily to total of nine lines.

Hamilton, H. H., II↗
NASA NTRS1990

Surface definition and grid generation about an Assured Crew Return Vehicle (ACRV) for Space Station Freedom

The surface definition and grid generation about an Assured Crew Return Vehicle (ACRV) for the Space Station Freedom are described. The purpose of the surface definition and grid generation is to provide the necessary geometry information for CFD calculations about the vehicle. There are two salient features in this description. The first is that the numerical model representing the ACRV configuration is obtained from the measurement of an existing wind tunnel model. The method for smoothing the measured data and obtaining the numerical model is described. The second feature is the description of the algebraic grid generation method and software to compute volume grids about the ACRV. The methods and software allow rapid computation of volume grids for a wide range of flow conditions.

Smith, R. E.↗
NASA NTRS1959

Sampled-Data Techniques Applied to a Digital Controller for an Altitude Autopilot

Sampled-data theory, using the Z transformation, is applied to the design of a digital controller for an aircraft-altitude autopilot. Particular attention is focused on the sensitivity of the design to parameter variations and the abruptness of the response, that is, the normal acceleration required to carry out a transient maneuver. Consideration of these two characteristics of the system has shown that the finite settling time design method produces an unacceptable system, primarily because of the high sensitivity of the response to parameter variations, although abruptness can be controlled by increasing the sampling period. Also demonstrated is the importance of having well-damped poles or zeros if cancellation is attempted in the design methods. A different method of smoothing the response and obtaining a design which is not excessively sensitive is proposed, and examples are carried through to demonstrate the validity of the procedure. This method is based on design concepts of continuous systems, and it is shown that if no pole-zero cancellations are allowed in the design, one can obtain a response which is not too abrupt, is relatively insensitive to parameter variations, and is not sensitive to practical limits on control-surface rate. This particular design also has the simplest possible pulse transfer function for the digital controller. Simulation techniques and root loci are used for the verification of the design philosophy.

Schmidt, Stanley F.↗
DOE OSTI2019

Dot tracking methodology for background-oriented schlieren (BOS)

We propose here a dot tracking methodology for processing background-oriented schlieren (BOS) images. The technique improves the accuracy, precision and spatial resolution compared to conventional cross-correlation algorithms. Our methodology utilizes the prior information about the dot pattern such as the location, size and number of dots to provide near 100% yield even for high dot densities (20 dots/32 × 32 pixels) and is robust to image noise. Furthermore, we propose an improvement to the displacement estimation step in the tracking process, especially for noisy images, using a “correlation correction”, whereby we combine the spatial resolution benefit of the tracking method and the smoothing property of the correlation method to increase the dynamic range of the overall measurement process. We evaluate the performance of the method with synthetic BOS images of buoyancy-driven turbulence rendered using ray-tracing simulations, and experimental images of flow in the exit plane of a converging–diverging nozzle. The results show that the improved spatial resolution results in a better accuracy of the tracking method compared to correlation-based methods in regions with sharp displacement gradients, and the correlation correction step reduces the noise floor of the measurement, resulting in a fourfold improvement in the dynamic range.

42 ENGINEERING↗
NASA NTRS1975

Solutions to Kuessner's integral equation in unsteady flow using local basis functions

The computational procedure and numerical results are presented for a new method to solve Kuessner's integral equation in the case of subsonic compressible flow about harmonically oscillating planar surfaces with controls. Kuessner's equation is a linear transformation from pressure to normalwash. The unknown pressure is expanded in terms of prescribed basis functions and the unknown basis function coefficients are determined in the usual manner by satisfying the given normalwash distribution either collocationally or in the complex least squares sense. The present method of solution differs from previous ones in that the basis functions are defined in a continuous fashion over a relatively small portion of the aerodynamic surface and are zero elsewhere. This method, termed the local basis function method, combines the smoothness and accuracy of distribution methods with the simplicity and versatility of panel methods. Predictions by the local basis function method for unsteady flow are shown to be in excellent agreement with other methods. Also, potential improvements to the present method and extensions to more general classes of solutions are discussed.

Fromme, J. A.↗
DOE OSTI2020

Three-dimensional phase field sintering simulations accounting for the rigid-body motion of individual grains

Sintering is a widely used powder processing technique in industrial applications. During sintering, atoms migrate to decrease the energy of the system via two main mechanisms: coarsening and densification, both of which lead to significant morphological variation of the sintered microstructure. When simulating sintering dynamics, the phase-field method has been broadly utilized because of its convenience in tracking morphology evolution. When a large number of grains is involved, it is common to use the same order parameter to describe multiple grains that are not in direct contact with one another (in order to reduce the computational memory demands). However, with this treatment it is difficult to handle the rigid-body motion of individual grains during densification. In this work, an implementation scheme is introduced to overcome the challenge of calculating individual particle motion based on existing equations. It uses a grouping algorithm and sets a cutoff radius on each grain for calculating the particle velocity during densification. This method allows for the incorporation of the densification mechanism, which has been commonly ignored in previous work, into phase-field sintering models in three-dimensional simulations with a large number of particles/grains. Moreover, through combination with the smoothed boundary method, material properties of sintered microstructures, such as the effective diffusivity and Young’s modulus, can be calculated during the sintering processes.

36 MATERIALS SCIENCE↗
NASA NTRS2001

A Highly Accurate Technique for the Treatment of Flow Equations at the Polar Axis in Cylindrical Coordinates using Series Expansions

Numerical methods for solving the flow equations in cylindrical or spherical coordinates should be able to capture the behavior of the exact solution near the regions where the particular form of the governing equations is singular. In this work we focus on the treatment of these numerical singularities for finite-differences methods by reinterpreting the regularity conditions developed in the context of pseudo-spectral methods. A generally applicable numerical method for treating the singularities present at the polar axis, when nonaxisymmetric flows are solved in cylindrical, coordinates using highly accurate finite differences schemes (e.g., Pade schemes) on non-staggered grids, is presented. Governing equations for the flow at the polar axis are derived using series expansions near r=0. The only information needed to calculate the coefficients in these equations are the values of the flow variables and their radial derivatives at the previous iteration (or time) level. These derivatives, which are multi-valued at the polar axis, are calculated without dropping the accuracy of the numerical method using a mapping of the flow domain from (0,R)*(0,2pi) to (-R,R)*(0,pi), where R is the radius of the computational domain. This allows the radial derivatives to be evaluated using high-order differencing schemes (e.g., compact schemes) at points located on the polar axis. The proposed technique is illustrated by results from simulations of laminar-forced jets and turbulent compressible jets using large eddy simulation (LES) methods. In term of the general robustness of the numerical method and smoothness of the solution close to the polar axis, the present results compare very favorably to similar calculations in which the equations are solved in Cartesian coordinates at the polar axis, or in which the singularity is removed by employing a staggered mesh in the radial direction without a mesh point at r=0, following the method proposed recently by Mohseni and Colonius (1). Extension of the method described here for incompressible flows or for any other set of equations that are solved on a non-staggered mesh in cylindrical or spherical coordinates with finite-differences schemes of various level of accuracy is immediate.

Constantinescu, George S.↗
DOE OSTI2024

Wet-Etching of Acoustically Spalled GaAs for Substrate Reuse

Acoustic spalling is a promising technique for substrate reuse in the fabrication of gallium arsenide (GaAs) photovoltaic cells. However, the acoustic spalling process can leave the substrate with areas of rough surface morphology that can interfere with subsequent cell growth and processing. In this work, we investigate the use of wet etchants to smooth the surface of acoustically spalled GaAs substrates. We evaluated six different etchants. Of those tested, an 8:1:1 mixture of sulfuric acid, hydrogen peroxide, and water at 30 degrees C and a moderate stirring rate showed the greatest roughness reduction per mass loss while producing the desired morphology. This etchant was then applied to an acoustically spalled 2-inch GaAs wafer. A single-junction GaAs cell was then grown via metalorganic vapor-phase epitaxy on this substrate, an acoustic spalled substrate without a smoothing etch, and an epi-ready substrate. Use of the 8:1:1 H2SO4:H2O2:H2O etchant produced cells an average efficiency of 12.8% as compared to that of 2.0% grown on the unetched acoustically spalled substrate and 16.3% grown on the epi-ready substrate. The results of this work demonstrate that wet etching is a viable method for smoothing the surface of spalled GaAs substrates, paving the way for substrate reuse via acoustic spalling at efficiencies that approach growth on epi-ready substrates.

etching↗
DOE OSTI2025

Toward Higher-order Accuracy in Self-gravitating Hydrodynamics

High-order algorithms have emerged in numerical astrophysics as a promising avenue to reduce truncation error (proportional to a power of the linear resolution Δ x ) with only a moderate increase to computational expense. Significant effort has been placed in the development of finite-volume algorithms for (magneto)hydrodynamics; however, state-of-the-art astrophysical simulations tightly couple a plenitude of physics, additionally including gravity, photon transport, cosmic-ray transport, chemistry, and/or diffusion, to name a few. Algorithms frequently operator-split this additional physics (often a first-order error in time) and/or adopt a model wherein their evaluation is limited to second-order accuracy in space. In this work, we present a fourth-order-accurate finite-volume scheme for self-gravitating hydrodynamics on a uniform Cartesian grid. The method supplies source terms for the gravitational acceleration ( ρ g ) and gravitational energy release ( ρ v · g ) associated with fourth-order-accurate solutions to the Poisson equation. Our scheme (1) guarantees the conservation of total linear momentum while (2) decreasing (in proportion to Δ x 4 ) the effects of spurious heating and/or cooling associated with truncation error in the gravity. We demonstrate expected convergence rates for the algorithm by measuring errors in test problems evolving self-gravity modified linear waves and 3D polytropic equilibria. We test robustness of the algorithm by integrating an induced “inside-out” adiabatic collapse. We also discuss a method to smoothly downgrade the solution to second-order spatial accuracy to avoid spurious overshoots near steep density and/or pressure gradients.

79 ASTRONOMY AND ASTROPHYSICS↗
NASA NTRSDate not supplied

A Method for Obtaining Surface Flow Vectors and Its Implementation in Interferometric Skin Friction Measurement

A new method was developed to extract surface flow vectors from an oilflow visualization image that has oil streaklines. The method is analogous to the PIV processing where the image is divided into interrogation windows. A representative flow direction is obtained for each interrogation window using image processing with a line-detection algorithm. Repeating the process for the entire image, one can find the surface vector field. The Hough transformation, Radon transformation and Machine Learning were used as line-detection algorithms. The obtained vector field is then postprocessed to filter spurious vectors and to apply smoothing. The method was tested on 2D and 3D models with different flow complexities. The method was able to predict surface flow vectors for all cases tested. The predicted surface flow vectors were used in obtaining the surface skin friction. The successful implementation of the surface flow vectors enables interferometric skin friction measurements on surfaces beneath 3D complex flows. In addition, the surface flow vectors can be superimposed on the oilflow visualization images to better explain the surface flow topology.

Surface flow vectors↗
NASA NTRSDate not supplied

A Method for Obtaining Surface Flow Vectors and Its Implementation in Interferometric Skin Friction Measurement

A new method was developed to extract surface flow vectors from an oilflow visualization image that has oil streaklines. The method is analogous to the PIV processing where the image is divided into interrogation windows. A representative flow direction is obtained for each interrogation window using image processing with a line-detection algorithm. Repeating the process for the entire image, one can find the surface vector field. The Hough transformation, Radon transformation and Machine Learning were used as line-detection algorithms. The obtained vector field is then postprocessed to filter spurious vectors and to apply smoothing. The method was tested on 2D and 3D models with different flow complexities. The method was able to predict surface flow vectors for all cases tested. The predicted surface flow vectors were used in obtaining the surface skin friction. The successful implementation of the surface flow vectors enables interferometric skin friction measurements on surfaces beneath 3D complex flows. In addition, the surface flow vectors can be superimposed on the oilflow visualization images to better explain the surface flow topology.

Surface flow vectors↗
DOE OSTI2020

A Two-Stage Decomposition Approach for AC Optimal Power Flow

The alternating current optimal power flow (AC-OPF) problem is critical to power system operations and planning, but it is generally hard to solve due to its nonconvex and large-scale nature. Furthermore, this paper proposes a scalable decomposition approach in which the power network is decomposed into a master network and a number of subnetworks, where each network has its own AC-OPF subproblem. This formulates a two-stage optimization problem and requires only a small amount of communication between the master and subnetworks. The key contribution is a smoothing technique that renders the response of a subnetwork differentiable with respect to the input from the master problem, utilizing properties of the barrier problem formulation that naturally arises when subproblems are solved by a primal-dual interior-point algorithm. Consequently, existing efficient nonlinear programming solvers can be used for both the master problem and the subproblems. The advantage of this framework is that speedup can be obtained by processing the subnetworks in parallel, and it has convergence guarantees under reasonable assumptions. The formulation is readily extended to instances with stochastic subnetwork loads. Numerical results show favorable performance and illustrate the scalability of the algorithm which is able to solve instances with more than 11 million buses.

24 POWER TRANSMISSION AND DISTRIBUTION↗