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At least 721 records · Page 40

Smart Process Planning for Automated Fiber Placement

Many industries, including aerospace, automotive, wind energy, maritime, and sporting goods, rely on strong, lightweight materials called composites. These materials are made by layering fibers, which can come in the form of narrow strips or wider sheets, and setting them in a polymer matrix. One of the most advanced ways to make these parts is through automated fiber placement, where a machine lays down the fibers in precise patterns. This method can create very efficient and strong designs, but it is complex, expensive, and often depends heavily on the experience of skilled engineers. Today, the design, manufacturing, and inspection stages of composite production are usually handled separately. This separation means that important information, such as how a part will be built or what defects might occur, is not always shared between stages. As a result, parts may not be as lightweight, strong, or defect-free as possible, and the process can take longer and cost more. This research develops a smart process planning system that connects design, manufacturing, and inspection into one continuous process. Built as software that works with existing tools, the system can automatically plan how the fibers are placed, predicting and reducing defects while improving both manufacturability and strength. The system optimizes not only individual layers but also how defects are distributed across all layers, preventing them from stacking up in ways that weaken the final part. It also uses inspection results from completed parts to improve future designs, creating a feedback loop where each stage informs the others. The system was tested by designing a composite panel using this new approach and comparing it to a panel made with state-of-the-art manual planning methods. The results showed that the system could intentionally control where defects appeared and increase the efficiency of the planning process. By unifying design, manufacturing, and inspection, this research shows a way to make advanced composite manufacturing more efficient, consistent, and cost-effective. This approach lowers the barrier to using automated fiber placement and opens the door for its wider adoption not only in aerospace but also in industries such as automotive, wind energy, maritime, and sporting goods, where strong and lightweight structures are essential.

Computer-Aided Process Planning↗

Development and Validation of MALAMUTE model for Electric Field Assisted Sintering of Structural Materials

Fusion power plant designs feature extreme material performance requirements for structural material candidates. In addition to conventional alloys, more advanced composites and oxide dispersion strengthened (ODS) alloys are being explored, however, achieving the desired microstructures to maximize performance using traditional manufacturing methods can be challenging. The advanced manufacturing (AM) electric field-assisted sintering (EFAS) technique offers improved control over the final microstructure through higher heating and cooling rates and moderate pressures. Modeling and simulation tools show promise in elucidating the process-structure-property-performance (PSPP) correlation for AM-produced parts, including the EFAS process. An inherently multiscale process, the EFAS technique aligns well with the multiscale modeling capability of the open-source Multiphysics Object-Oriented Simulation Environment (MOOSE)[cite]. We present here an electro-thermo-mechanical approach to modeling the EFAS process using the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) code. Prediction of the field and gradient distributions across the EFAS tooling is required to accurately describe the conditions for the lower-scale microstructural evolution models. In this work we present the MALAMUTE model developed to predict the electrical potential, temperature, and mechanical stress distribution across the EFAS graphite tooling and part at the larger engineering-scale. Validation of the MALAMUTE engineering-scale model is completed using data from experimental densification and pre-densified runs of iron powder via EFAS at 1000oC. These runs were conducted using a Thermal Technology DCS-5 EFAS system. Data collected during the experiment runs include the direct current (DC) supplied to the graphite tooling, the temperature of the graphite tooling as measured with a pyrometer, and the force applied to the top of the graphite tooling stack, and the data were recorded every 10 seconds. Our validation approach used the current and force data from the EFAS run as boundary condition inputs to the MAMALUTE simulation; the temperature data were used to evaluate the MALAMUTE EFAS model prediction. Results of the MALAMUTE simulations are employed to connect the external pyrometer temperature measurement to the temperature profile across the part undergoing consolidation. We investigate the impact of material property variation and mesh deformation on the temperature profile as predicted by MALAMUTE. We conclude by highlighting projects where the MALAMUTE EFAS modeling and simulation capabilities will be used to assist experimental design.

36 - MATERIALS SCIENCE↗

The impact of circulation control on rotary aircraft controls systems

Application of circulation to rotary wing systems is a new development. Efforts to determine the near and far field flow patterns and to analytically predict those flow patterns have been underway for some years. Rotary wing applications present a new set of challenges in circulation control technology. Rotary wing sections must accommodate substantial Mach number, free stream dynamic pressure and section angle of attack variation at each flight condition within the design envelope. They must also be capable of short term circulation blowing modulation to produce control moments and vibration alleviation in addition to a lift augmentation function. Control system design must provide this primary control moment, vibration alleviation and lift augmentation function. To accomplish this, one must simultaneously control the compressed air source and its distribution. The control law algorithm must therefore address the compressor as the air source, the plenum as the air pressure storage and the pneumatic flow gates or valves that distribute and meter the stored pressure to the rotating blades. Also, mechanical collective blade pitch, rotor shaft angle of attack and engine power control must be maintained.

Kingloff, R. F.↗

NASA Tech Briefs, November 2005

Topics covered include: Laser System for Precise, Unambiguous Range Measurements; Flexible Cryogenic Temperature and Liquid-Level Probes; Precision Cryogenic Dilatometer; Stroboscopic Interferometer for Measuring Mirror Vibrations; Some Improvements in H-PDLCs; Multiple-Bit Differential Detection of OQPSK; Absolute Position Encoders With Vertical Image Binning; Flexible, Carbon-Based Ohmic Contacts for Organic Transistors; GaAs QWIP Array Containing More Than a Million Pixels; AutoChem; Virtual Machine Language; Two-Dimensional Ffowcs Williams/Hawkings Equation Solver; Full Multigrid Flow Solver; Doclet To Synthesize UML; Computing Thermal Effects of Cavitation in Cryogenic Liquids; GUI for Computational Simulation of a Propellant Mixer; Control Program for an Optical-Calibration Robot; SQL-RAMS; Distributing Data from Desktop to Hand-Held Computers; Best-Fit Conic Approximation of Spacecraft Trajectory; Improved Charge-Transfer Fluorescent Dyes; Stability-Augmentation Devices for Miniature Aircraft; Tool Measures Depths of Defects on a Case Tang Joint; Two Heat-Transfer Improvements for Gas Liquefiers; Controlling Force and Depth in Friction Stir Welding; Spill-Resistant Alkali-Metal-Vapor Dispenser; A Methodology for Quantifying Certain Design Requirements During the Design Phase; Measuring Two Key Parameters of H3 Color Centers in Diamond; Improved Compression of Wavelet-Transformed Images; NASA Interactive Forms Type Interface - NIFTI; Predicting Numbers of Problems in Development of Software; Hot-Electron Photon Counters for Detecting Terahertz Photons; Magnetic Variations Associated With Solar Flares; and Artificial Intelligence for Controlling Robotic Aircraft.

Source record↗

Computational Analysis of the X-57 Maxwell Airplane, the Landing Configuration with High-Lift Blowing and Aileron Deflections (Preliminary Fuselage)

The X-57 Maxwell is an all-electric airplane with a distributed electric propulsion system used for a high-lift system at takeoff and landing conditions. The Kestrel and USM3D flow solvers were used at NASA Langley to investigate the performance of the X-57 Maxwell in the development of an aerodynamic database. The configuration investigated in this paper had a 30° flap deflection, and in addition the pilot’s right aileron were deflected and undeflected in different cases. The solutions were computed at an airspeed of 58 KEAS, for an altitude of 6000 feet, and a flight Reynolds number of 0.588e+06 per foot. To evaluate the high-lift distributed electric propulsion system without aileron deflections, the solutions were computed for an angle-of-attack sweep from −2° to 20°, with the high-lift propellers blowing and the cruise propellers excluded from the simulation. To investigate the aileron effectiveness, the solutions were computed at angles of attack of −2° and 14°, for aileron deflections from −25° to 18° with the high-lift propellers blowing and the cruise propellers windmilling at idle-power. The high-lift propellers and the idle-power cruise propellers were modeled with an actuator disk. Results show negligible differences in lift, drag and pitching moment whether the idle-powered cruise propellers were included or excluded from the simulation. In general, the Kestrel and USM3D codes compared well for lift, drag and pitching moment for the landing configuration with no aileron control. The Kestrel code, using the Spalart-Allmaras turbulence model with the rotation corrections terms, predicted an increasing lift coefficient up to maximum lift coefficient of 4.65 at a 15° angle of attack. The USM3D code, using the Spalart-Allmaras turbulence model turbulence model with the Quadratic Constitutive Relation predicted an increasing lift coefficient up to maximum lift coefficient of 4.5 at a 12° angle of attack, with the lift remaining constant through a 14◦ angle of attack. A possible difference in lift coefficient between the codes for high angles of attack may result from the different available options used with the standard Spalart-Allmaras turbulence model. The Kestrel code predicted more drag across the range of angle of attack than the USM3D code. The codes compared well for pitching moment coefficient across the range of angle of attack. The Kestrel and USM3D codes compared well for aileron effectiveness at a 2° angle of attack. The Kestrel code predicts better aileron effectiveness than USM3D at a 14° angle of attack. There is more flow separation in the region outboard of the last high-lift nacelle for the USM3D solutions at a 14° angle of attack, which diminishes the ability of the aileron to be effective.

X-57 Maxwell Airplane↗

Predicted Impacts of Pt and Ionomer Distributions on Low-Pt-Loaded PEMFC Performance

Low-cost, high performance proton exchange membrane fuel cells (PEMFCs) have been difficult to develop due to limited understanding of coupled processes in the cathode catalyst layer (CCL). Low-Pt-loaded PEMFCs suffer losses beyond those predicted solely due to reduced catalyst area. Although consensus links these losses to thin ionomer films in the CCL, a precise mechanistic explanation remains elusive. In this publication, we present a physically based PEMFC model with novel structure-property relationships for thin-film Nafion, validated against PEMFC data with low Pt loading. Results suggest that flooding exacerbates kinetic limitations in low-loaded PEMFCs, shifting the Faradaic current distribution. As current density increases, protons travel further into the CCL, resulting in higher Ohmic overpotentials. We also present a parametric study of CCL design parameters. We find that graded Pt and ionomer loadings reduce Ohmic losses and flooding, but individually do not provide significant improvements. However, a dual-graded CCL (i.e., graded Pt and ionomer) is predicted to significantly improve the maximum power density and limiting current compared to uniformly loaded CCLs. This work highlights the importance of accurate transport parameters for thin-film Nafion and provides a pathway to low-cost PEMFCs via precise control of CCL microstructures.

08 HYDROGEN↗

Computational Models of the Cardiovascular System and Its Response to Microgravity

Computational models of the cardiovascular system are powerful adjuncts to ground-based and in-flight experiments. We will provide NSBRI with a model capable of simulating the short-term effects of gravity on cardiovascular function. The model from this project will: (1) provide a rational framework which quantitatively defines interactions among complex cardiovascular parameters and which supports the critical interpretation of experimental results and testing of hypotheses. (2) permit predictions of the impact of specific countermeasures in the context of various hypothetical cardiovascular abnormalities induced by microgravity. Major progress has been made during the first 18 months of the program: (1) We have developed an operational first-order computer model capable of simulating the cardiovascular response to orthostatic stress. The model consists of a lumped parameter hemodynamic model and a complete reflex control system. The latter includes cardiopulmonary and carotid sinus reflex limbs and interactions between the two. (2) We have modeled the physiologic stress of tilt table experiments and lower body negative pressure procedures (LBNP). We have verified our model's predictions by comparing them with experimental findings from the literature. (3) We have established collaborative efforts with leading investigators interested in experimental studies of orthostatic intolerance, cardiovascular control, and physiologic responses to space flight. (4) We have established a standardized method of transferring data to our laboratory from the ongoing NSBRI bedrest studies. We use this data to estimate input parameters to our model and compare our model predictions to actual data to further verify our model. (5) We are in the process of systematically simulating current hypotheses concerning the mechanism underlying orthostatic intolerance by matching our simulations to stand test data from astronauts pre- and post-flight. (6) We are in the process of developing a JAVA version of the simulator which will be distributed amongst the cardiovascular team members. Future work on this project involves modifications of the model to represent a rodent (rat) model, further evaluation of the bedrest astronaut and animal data, and systematic investigation of specific countermeasures.

Kamm, Roger D.↗

Substrate Effects on Electronic Properties of Atomic Chains

When the device size is reduced down to 0.07 micrometers, the number of dopant atoms in the channel will no longer be macroscopic, typically less than a hundred. A spatial distribution of these dopant atoms will fluctuate statistically from device to device even in identically designed devices, and this places a serious limitation for integration. It is, however, impractical to control dopant positions within atomic dimension. One fundamental solution to this problem is to create electronics with atomically precise, but preferably simple structures. Atomic chains, precise structures of adatoms created on an atomically regulated surface, are candidates for constituent components in future electronics. All the adatoms will be placed at designated positions on the substrate, and all the device structures will be precise, free from any deviations. It was predicted using the tight-binding calculation with universal parameters that silicon chains were metallic and magnesium chains were semiconducting regardless of the lattice spacing, and a possible doping method was also proposed. In these treatments, the substrate was assumed to serve as a non-interacting template holding the adatoms without a formation of chemical bonding with substrate atoms. However, this scheme may not be easy to implement experimentally. Adatoms will have to be fixed with a van der Waals force on the substrate, but the force is generally weak and an extremely low temperature environment has to be prepared to suppress their unwanted thermal displacement. It may be logical to seek a scheme to allow the adatoms to form chemical bonding with the substrate atoms and secure their positions. The substrate effects are studied in detail.

Yamada, Toshishige↗

Creation of Synthetic Electric Grids (SPP/MISO) Supporting PERFORM (Final Report)

Over the course of the project, two “realistic but not real” synthetic transmission-level grid models over the SPP-MISO and ERCOT footprints were created to provide more realistic data and increase the reliability and resiliency of the grids under a variety of scenarios. The synthetic ERCOT transmission grid is compatible with the distribution grid developed in collaboration with NREL. All generators are based on the EIA 860 data and a column with EIA plant code and Gen ID is added to generators of both grids so that they can be easily mapped. The improvements are also made to electric grids including N-1 contingencies with some remedial actions, improving the transmission lines to avoid lines in lakes, including an HVDC line to the SPP-MISO case, providing several generator parameters and their temporal constraints that were not included in EIA 860 form, generators’ cost curves, load offer curves, adding phase shifters and tap changers with impedance correction tables, adding reactive power control and partitioning the grids into active and reactive reserve zones and determine different types of the required reserve for each zone. Hourly load time series at the bus level were generated to create scenarios for solving power flow in different loading conditions. Weather measurement information and the models of renewable generators are used to directly include the impact of weather on the grids. Based on a variety of load and weather conditions the grids are improved to accommodate different conditions. The ERCOT 7k-bus grids were also modeled for the year 2030 with predicted improvements in renewable resources. The renewable generation model was also improved with historic weather data included. The impact of electric vehicles on the ERCOT grid is also modeled.

24 POWER TRANSMISSION AND DISTRIBUTION↗

4D Observations of the initiation of abnormal grain growth in commercially pure Ni

Abnormal grain growth (AGG), where a small fraction of grains grow faster than others, is critical to predict because it can significantly impact material properties. However, the mechanism behind AGG remains unclear. In this study, laboratory-based x-ray diffraction contrast tomography (LabDCT) is employed to non-destructively track the 3D microstructural evolution of high-purity nickel during the onset of AGG at 800 °C. The initial microstructure state is used to test hypothesized microstructure predictors of the initiation of AGG. The change in grain size was not related to the initial grain size or normalized integral mean curvature. Additionally, the grain boundary energy distributions of abnormal grains were indistinguishable from those of control groups exhibiting normal grain growth. However, the grains that later became abnormal exhibit large areas of asymmetric tilt boundaries that were previously found to be fast. This 3D microstructure dataset is useful to investigate new hypotheses for the initiation of AGG.

36 MATERIALS SCIENCE↗

Spatial-frequency response of the Limb Infrared Monitor of the Stratosphere /LIMS/ radiometer

The Limb Infrared Monitor of the Stratosphere (LIMS), an experiment on the Nimbus-7 satellite, is designed to scan the earth's limb vertically and measure spectral emission profiles of trace atmospheric gases believed to be important in processes controlling the stratospheric ozone distribution. Experiment objectives are reviewed and several analyses and measurements are described which were performed to determine the adequacy of the system for satisfying these objectives. Adequate spatial-frequency response for all the spectral channels is required to provide, through inversion of the measured limb-radiance profiles, important information about the temperature, structure, and composition of the atmosphere. From the LIMS design-model data, the MTF was calculated for the optical system, the detector field mask, the electronics, and the overall system, for each channel. The signal output performance of the instrument was predicted from the system MTF data model input radiance data for each channel. MTF measurements made on the flight sensor confirmed the analytical results. The predictions indicate that the instrument can satisfy the basic measurement objectives of the experiment.

Wilson, R. G.↗

An Advanced Buffet Load Alleviation System

This paper describes the development of an advanced buffet load alleviation (BLA) system that utilizes distributed piezoelectric actuators in conjunction with an active rudder to reduce the structural dynamic response of the F/A-18 aircraft vertical tails to buffet loads. The BLA system was defined analytically with a detailed finite-element-model of the tail structure and piezoelectric actuators. Oscillatory aerodynamics were included along with a buffet forcing function to complete the aeroservoelastic model of the tail with rudder control surface. Two single-input-single-output (SISO) controllers were designed, one for the active rudder and one for the active piezoelectric actuators. The results from the analytical open and closed loop simulations were used to predict the system performance. The objective of this BLA system is to extend the life of vertical tail structures and decrease their life-cycle costs. This system can be applied to other aircraft designs to address suppression of structural vibrations on military and commercial aircraft.

Burnham, Jay K.↗

The Effect of Drive Signal Limiting on High Cycle Fatigue Life Analysis

It is common practice to assume a Gaussian distribution of both the input acceleration and the response when modeling random vibration tests. In the laboratory, however, shaker controllers often limit the drive signal to prevent high amplitude peaks. The high amplitudes may either be truncated at a given level (socalled brick wall limiting or abrupt clipping), or compressed (soft limiting), resulting in drive signals which are no longer Gaussian. The paper first introduces several methods for limiting a drive signal, including brick wall limiting and compression. The limited signal is then passed through a linear time-invariant system representing a device under test. High cycle fatigue life predictions are subsequently made using spectral fatigue and rainflow cycle counting schemes. The life predictions are compared with those obtained from unclipped input signals. Some guidelines are provided to help the test engineer decide how clipping should be applied under different test scenarios.

Kihm, Frederic↗

Dynamic Model Agnostic Reliability Evaluation of Machine-Learning Models Integrated in Instrumentation & Control Systems

In recent years, the field of data-driven neural network-based machine learning (ML) algorithms has grown significantly and spurred research in its applicability to instrumentation and control systems. While they are promising in operational contexts, the trustworthiness of such algorithms is not adequately assessed. Failures of ML-integrated systems are poorly understood; the lack of comprehensive risk modeling can degrade the trustworthiness of these systems. In recent reports by the National Institute for Standards and Technology, trustworthiness in ML is a critical barrier to adoption and will play a vital role in intelligent systems' safe and accountable operation. Thus, in this work, we demonstrate a real-time model-agnostic method to evaluate the relative reliability of ML predictions by incorporating out-of-distribution detection on the training dataset. It is well documented that ML algorithms excel at interpolation (or near-interpolation) tasks but significantly degrade at extrapolation. This occurs when new samples are "far" from training samples. The method, referred to as the Laplacian distributed decay for reliability (LADDR), determines the difference between the operational and training datasets, which is used to calculate a prediction's relative reliability. LADDR is demonstrated on a feedforward neural network-based model used to predict safety significant factors during different loss-of-flow transients. LADDR is intended as a "data supervisor" and determines the appropriateness of well-trained ML models in the context of operational conditions. Ultimately, LADDR illustrates how training data can be used as evidence to support the trustworthiness of ML predictions when utilized for conventional interpolation tasks.

97 MATHEMATICS AND COMPUTING↗

Spacecraft particulate contaminant redistribution

This paper describes analyses that were performed in support of the Hubble Space Telescope (HST)) particulate contamination control effort. The specific problems addressed include extension of available particle removal data to launch acoustic and random vibration conditions, development of an engineering model for transport of suspended particulates by airflow and in the presence of vehicle acceleration, turbulent diffusion, and migration of particulates over vibrating surfaces, and integration of the various models into a code that could be used to generate contamination level estimates for the HST primary mirror and other critical surfaces for the HST mission phases. The overall redistribution calculations were made assuming a specified initial contaminant distribution in terms of MIL STD 1246A levels, and using predicted vibration data for the various HST surfaces and mission phases. As expected, the effects of airflow were found to be significant, particularly for the larger particles. Particles smaller than about 20 microns did not participate appreciably in the redistribution.

Klavins, A.↗

A design procedure for the phase-controlled parallel-loaded resonant inverter

High-frequency-link power conversion and distribution based on a resonant inverter (RI) has been recently proposed. The design of several topologies is reviewed, and a simple approximate design procedure is developed for the phase-controlled parallel-loaded RI. This design procedure seeks to ensure the benefits of resonant conversion and is verified by data from a laboratory 2.5 kVA, 20-kHz converter. A simple phasor analysis is introduced as a useful approximation for design purposes. The load is considered to be a linear impedance (or an ac current sink). The design procedure is verified using a 2.5-kVA 20-kHz RI. Also obtained are predictable worst-case ratings for each component of the resonant tank circuit and the inverter switches. For a given load VA requirement, below-resonance operation is found to result in a significantly lower tank VA requirement. Under transient conditions such as load short-circuit, a reversal of the expected commutation sequence is possible.

King, Roger J.↗

Partitioning the LIS/OTD Lightning Climatological Dataset into Separate Ground and Cloud Flash Distributions

Presently, it is not well understood how to best model nitrogen oxides (NOx) emissions from lightning because lightning is highly variable. Peak current, channel length, channel altitude, stroke multiplicity, and the number of flashes that occur in a particular region (i.e., flash density) all influence the amount of lightning NOx produced. Moreover, these 5 variables are not the same for ground and cloud flashes; e.g., cloud flashes normally have lower peak currents, higher altitudes, and higher flash densities than ground flashes [see (Koshak, 2009) for additional details]. Because the existing satellite observations of lightning (Fig. 1) from the Lightning Imaging Sensor/Optical Transient Detector (LIS/OTD) do not distinguish between ground and cloud fashes, which produce different amounts of NOx, it is very difficult to accurately account for the regional/global production of lightning NOx. Hence, the ability to partition the LIS/OTD lightning climatology into separate ground and cloud flash distributions would substantially benefit the atmospheric chemistry modeling community. NOx indirectly influences climate because it controls the concentration of ozone and hydroxyl radicals in the atmosphere. The importance of lightning-produced NOx is empasized throughout the scientific literature (see for example, Huntrieser et al. 1998). In fact, lightning is the most important NOx source in the upper troposphere with a global production rate estimated to vary between 2 and 20 Tg (N)yr(sup -1) (Lee et al., 1997), with more recent estimates of about 6 Tg(N)yr(sup -1) (Martin et al., 2007). In order to make accurate predictions, global chemistry/climate models (as well as regional air quality modells) must more accurately account for the effects of lightning NOx. In particular, the NASA Goddard Institute for Space Studies (GISS) Model E (Schmidt et al., 2005) and the GEOS-CHEM global chemical transport model (Bey et al., 2001) would each benefit from a partitioning of the LIS/OTD lightning climatology. In this study, we introduce a new technique for retrieving the ground flash fraction in a set of N lightning observed from space and that occur within a specific latitude/longitude bin. The method is briefly described and applied to CONUS lightning that have already been partitioned into ground and cloud flashes using independent ground-based observations, in order to assess the accuracy of the retrieval method. The retrieval errors are encouragingly small.

Koshak, W. J.↗

Urban Air Mobility: A Control-Centric Approach to Addressing Technical Challenges

Urban Air Mobility (UAM) is an emerging aviation sector and is playing an integral part in the on-demand mobility revolution. UAM is powered by the convergence of advances in distributed electrical propulsion (DEP) and vehicle autonomy. The complexity of operations in the urban environment and the unconventional vehicle configurations designed to take advantage of new propulsion technologies, result in numerous challenges that benefit from a control-centric approach. In this talk we outline some of these challenges and present our current approach to addressing them. For example, in order to achieve full market potential and access to UAM, vehicle autonomous flight is required. A key barrier to autonomous flight in a large multi-agent system is dealing with off-nominal situations and contingencies in a safe and predictable manner. We present our approach to intelligent contingency management, and share recent results and open problems. Additionally, we discuss another major barrier to ubiquitous UAM – the noise signature produced by vehicles with multiple rotors. We present our approach to minimizing such noise within the framework of the acoustically-aware vehicle.

UAM↗