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NASA NTRS2001

Use of Soft Computing Technologies for a Qualitative and Reliable Engine Control System for Propulsion Systems

The problem to be addressed in this paper is to explore how the use of Soft Computing Technologies (SCT) could be employed to improve overall vehicle system safety, reliability, and rocket engine performance by development of a qualitative and reliable engine control system (QRECS). Specifically, this will be addressed by enhancing rocket engine control using SCT, innovative data mining tools, and sound software engineering practices used in Marshall's Flight Software Group (FSG). The principle goals for addressing the issue of quality are to improve software management, software development time, software maintenance, processor execution, fault tolerance and mitigation, and nonlinear control in power level transitions. The intent is not to discuss any shortcomings of existing engine control methodologies, but to provide alternative design choices for control, implementation, performance, and sustaining engineering, all relative to addressing the issue of reliability. The approaches outlined in this paper will require knowledge in the fields of rocket engine propulsion (system level), software engineering for embedded flight software systems, and soft computing technologies (i.e., neural networks, fuzzy logic, data mining, and Bayesian belief networks); some of which are briefed in this paper. For this effort, the targeted demonstration rocket engine testbed is the MC-1 engine (formerly FASTRAC) which is simulated with hardware and software in the Marshall Avionics & Software Testbed (MAST) laboratory that currently resides at NASA's Marshall Space Flight Center, building 4476, and is managed by the Avionics Department. A brief plan of action for design, development, implementation, and testing a Phase One effort for QRECS is given, along with expected results. Phase One will focus on development of a Smart Start Engine Module and a Mainstage Engine Module for proper engine start and mainstage engine operations. The overall intent is to demonstrate that by employing soft computing technologies, the quality and reliability of the overall scheme to engine controller development is further improved and vehicle safety is further insured. The final product that this paper proposes is an approach to development of an alternative low cost engine controller that would be capable of performing in unique vision spacecraft vehicles requiring low cost advanced avionics architectures for autonomous operations from engine pre-start to engine shutdown.

Trevino, Luis↗

DOE OSTI2018

Thermomechanical design optimization for low metal footprint in hybrid metal-polymer heat exchanger

Material and maintenance costs of metal-based heat exchangers surpass profits in waste heat recovery (WHR) from ultra-low temperature (<100C) sources [1]. A low-cost alternative like polymer pipes suffer from poor thermal conductivity (~0.2 W/mK), and a low overall heat transfer coefficient. Polymers’ thermal conductivity have previously been enhanced through systematic molecular alignment by stretching [2], chemical vapor deposition of extended polymers [3], surface grating [4], etc. However, these approaches suffer from scalability issues for WHR heat exchangers in terms of cost [3], and thermomechanical considerations [5]. In this work, we propose novel hybrid metal-polymer heat exchangers that are made from polymer-copper strips. Through finite element method (FEM) simulations, we first optimize the placement of copper around polymer strips to enhance the transverse thermal conductivity of the strips. The copper cladded polymer strips are wound helically in a roll-to-roll system to form the pipes for a heat exchanger. We then optimize the design of helically wound pipes to reduce thermomechanical strains to < 0.2 % at 100C and 40 psi working conditions. At 25 % volume fraction of copper in the pipe, we predict up to 20 % enhancement in overall heat transfer from a base polymer with a thermal conductivity of 0.2 W/mK. We also compare and contrast the thermomechanical performance of the optimized metal-polymer strips to random metal matrix composites. Finally, we experimentally verify the thermal conductivity of the optimized strips through bulk thermal conductivity and thermal interface resistance measurement setup. By systematically improving the design through FEM and experimental measurements, we provide an optimized design of hybrid metal-polymer pipes that provides a low metal footprint and cost-effective means for harvesting waste heat from ultra-low temperature sources. Thekdi, Arvind, and Sachin U. Nimbalkar. Oak Ridge National Lab, 2015 Shen, Sheng, et al. Nature nanotechnology 5.4 (2010): 251. Xu, Yanfei, et al. Science advances 4.3 (2018): 3031. Smith, M. K., Singh, V., Kalaitzidou, K., & Cola, B. A. (2015). ACS nano, 9(2), 1080-1088. Aymonier, C., Bortzmeyer, D., Thomann, R., & Mülhaupt, R. (2003). Chemistry of Materials, 15(25), 4874-4878.

C Rajagopal, Manjunath↗

DOE OSTI2019

A modular biogeochemical modeling suite for next-generation ocean models (Final Report)

The Marine Biogeochemistry Library (MARBL) is a self-contained implementation of ocean biogeochemistry suitable for incorporation in Earth system models. The default configuration of MARBL represents multiple nutrient co-limitation (N, P, Si, and Fe), includes three explicit phytoplankton functional groups (diatoms, diazotrophs, and pico/nano phytoplankton), and one implicit group (calcifiers); there is one zooplankton group. MARBL includes fully prognostic carbonate chemistry and simulates sinking particulate organic matter implicitly, subject to ballasting by mineral dust, biogenic mineral carbonate and opal. MARBL represents subgrid-scale variations in light, variable C:P stoichiometry, semi-labile and refractory dissolved organic material pools, prognostic oceanic emission of ammonia, and an explicit ligand tracer that complexes iron. MARBL is fully runtime-configurable, and is flexible enough to accommodate a variable number of plankton functional types and ecosystem configurations. Critically, MARBL is implemented to be independent of any particular ocean general circulation model (OGCM); it is a standalone library that interfaces with an OGCM's via an explicit "driver" layer. MARBL can thus be coupled to multiple OGCM's, enabling efficient maintenance, development, and cross-model inter-comparison. MARBL is the ocean biogeochemistry component for the Community Earth System Model and the DOE’s Energy Exascale Earth System Model.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS2004

New Tool Released for Engine-Airframe Blade-Out Structural Simulations

Researchers at the NASA Glenn Research Center have enhanced a general-purpose finite element code, NASTRAN, for engine-airframe structural simulations during steady-state and transient operating conditions. For steady-state simulations, the code can predict critical operating speeds, natural modes of vibration, and forced response (e.g., cabin noise and component fatigue). The code can be used to perform static analysis to predict engine-airframe response and component stresses due to maneuver loads. For transient response, the simulation code can be used to predict response due to bladeoff events and subsequent engine shutdown and windmilling conditions. In addition, the code can be used as a pretest analysis tool to predict the results of the bladeout test required for FAA certification of new and derivative aircraft engines. Before the present analysis code was developed, all the major aircraft engine and airframe manufacturers in the United States and overseas were performing similar types of analyses to ensure the structural integrity of engine-airframe systems. Although there were many similarities among the analysis procedures, each manufacturer was developing and maintaining its own structural analysis capabilities independently. This situation led to high software development and maintenance costs, complications with manufacturers exchanging models and results, and limitations in predicting the structural response to the desired degree of accuracy. An industry-NASA team was formed to overcome these problems by developing a common analysis tool that would satisfy all the structural analysis needs of the industry and that would be available and supported by a commercial software vendor so that the team members would be relieved of maintenance and development responsibilities. Input from all the team members was used to ensure that everyone's requirements were satisfied and that the best technology was incorporated into the code. Furthermore, because the code would be distributed by a commercial software vendor, it would be more readily available to engine and airframe manufacturers, as well as to nonaircraft companies that did not previously have access to this capability.

Lawrence, Charles↗

NASA NTRS2010

Establishing a Modern Ground Network for Space Geodesy Applications

Ground-based networks of co-located space-geodesy techniques (VLBI, SLR, GLASS, DORIS) are the basis for the development and maintenance of the :International Terrestrial deference Frame (ITRE), which is the basis for our metric measurements of global change. The Global Geodetic Observing System (GGOS) within the International Association of Geodesy has established a task to develop a strategy to design, integrate and maintain the fundamental geodetic network and supporting infrastructure in a sustainable way to satisfy the long-term requirements for the reference frame. The GGOS goal is an origin definition at I mm or better and a temporal stability on the order of 0.1 mm/y, with similar numbers for the scale and orientation components. These goals are based on scientific requirements to address sea level rise with confidence. As a first step, simulations focused on establishing the optimal global SLR and VLBI network, since these two techniques alone are sufficient to define the reference frame. The GLASS constellations will then distribute the reference frame to users anywhere on the Earth. Using simulated data to be collected by the future networks, we investigated various designs and the resulting accuracy in the origin, scale and orientation of the resulting ITRF. We present here the results of extensive simulation studies aimed at designing optimal global geodetic networks to support GGOS science products. Current estimates are the network will require 24 - 32 globally distributed co-location sites. Stations in the near global network will require geologically stable sites witla good weather, established infrastructure, and local support and personnel. EGOS will seek groups that are interested in participation. GGOS intends to issues a Call for Participation of groups that would like to take part in the network implementation and operation_ Some examples of integrated stations currently in operation or under development will be presented. We will examine necessary conditions and challenges in designing a co-location station.

Pearlman, M.↗

DOE OSTI2025

Design and full core fuel performance assessment of high burnup cores for 4-loop PWRs

Increasing the fuel discharge burnup of current light water reactors (LWRs) promises reductions in fuel cycle and/or operations costs. By assuming a constant core power density, the economic gain is enabled by better fuel utilization and/or an increased capacity factor. In this effort to investigate greater than 62 MWd/kgU maximum rod average burnup for 110+ kW/l core power density, two core designs have been developed for a standard 17x17, 193 fuel assemblies pressurized water reactor (PWR). The levelized unit cost methodology is employed to evaluate fuel cycle, operation and maintenance, and capital cost impacts and to examine the economic viability of both core design pathways. Core design and optimization are performed using the commercial STUDSVIK code package. Fuel performance analysis is realized in full core configuration via auditing FRAPCON4.1, FAST1.2, and the high-fidelity code BISON. To provide a realistic assessment, the core design process takes into consideration best practices in current PWR core design. It features acceptable performance in terms of various core design constraints on maximum allowable peaking and boron concentration. Gadolinia (Gd2O3) is used as a burnable poison with a maximum of 9 wt% concentration while feeding 89 or 77 fuel assemblies in a 3-batch refueling scheme. Full core fuel performance simulation, which allows for characterization of relevant fuel temperatures, plenum pressures, stresses, and strains, is performed with respect to two bounding burnup levels. Such performance is potentially licensable for the 18-month high burnup core (<68 MWd/kgU peak pin), while it is more challenging for the 24-month high burnup core design pathway (<75 MWd/kgU peak pin). Maximum rod plenum pressure is identified as the most limiting fuel performance parameter. Here, while the scope of the present study focuses on the steady-state plus overpower conditions, the acceptability of the new discharge burnup has to be further assessed by considering uncertainties and impacts under accident scenarios in the future.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

PHISICS User Manual

PHISICS (Parallel and Highly Innovative Simulation for INL Code System) is a reactor physics package developed at the Idaho National Laboratory. It is composed of several modules: a nodal and semi-structured transport core solver (INSTANT), a depletion module (MRTAU), a time-dependent solver (TimeIntegrator), a cross-section interpolation and manipulation framework (MIXER), a SuperHomogenization scheme (SPH) a criticality search module (CRITICALITY), a fuel management and shuffling component (SHUFFLE) and a coupling API with RELAP5-3D. PHISICS has been built in a highly modular fashion so that different physical models can be activated or deactivated depending on the physics relevant to the particular type of analysis. This approach simplifies development as well as mid- and long-term maintenance of the code. PHISICS is entirely written in FORTRAN 95/2003. Each of its components is fully parallelized and designed to take full advantage of shared-memory computers (multiprocessor desktops and workstations) and middle to large high-performance computing systems (10 to 1000 processors). The aim of this document is to detail the input requirements for PHISICS (and all its modules) focusing on the input structure.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2024

Modernizing the Legacy Fission Wire Measurement System for the Advanced Test Reactor-Critical Facility

Operational lifetime extensions of existing research reactors have emphasized the need for refurbishment, replacements, and upgrades to supporting equipment and instrumentation. The Advanced Test Reactor (ATR) at Idaho National Laboratory (INL), which entered service in 1967, has recently completed the sixth core internals change-out and has scheduled operations until at least 2040. Reactor maintenance and operational risk management is critically important in the research reactor community, however supporting measurement systems sometimes get overlooked when maintenance is planned. The Fission Wire Measurement System (FWMS) is a custom measurement system designed in the 1960s to measure the beta-particle activity of irradiated uranium-aluminum fission wires. This measurement is conducted to determine the fission rate profile of the Advanced Reactor Test Critical (ATR-C) facility. The ATR-C is an open-pool, low-power test reactor that was purpose driven to resemble ATR and is used to qualify experiment configurations and verify core models prior to full-power experiment irradiations in ATR. A power distribution measurement in ATR-C uses uranium-aluminum wires that are distributed throughout the ATR-C core to validate simulation and modeling results. These measurements require 340 to 1500 wires to be irradiated and measured within a 12-hour window. The activity of the wires is measured in the required time with the FWMS, which was put into service in 1965 at the Radiation Measurements Laboratory (RML). The system consists of 4 measurement channels and one reference channel, each with a 2-pi proportional gas flow detector and the measurement channels each have an automated sample changer. This legacy system is crucial to the continued operations of ATR and has undergone some minor hardware upgrades since 1965, however the system presently relies on custom control boards, custom gas ion chambers, analog amplifiers/discriminators, and a user interface (UI) for the system written in outdated code. Much of the equipment and software is custom with no commercial replacements or support and limited documentation. The existing control software requires an operating system that is no longer supported, creating more vulnerabilities to continued operations. A project is underway with a third-party vendor to design, build, and document a new control and data acquisition system (CDAS) for the FWMS. The new upgrade will replace the control system, computer, UI, sample changer motors, and main power supply while maintaining the interface with existing detector hardware. The upgraded system will be operated in parallel with the current hardware and software to conduct validation testing. This equipment upgrade demonstrates the commitment at ATR to ensuring successful operations and potential future research reactors at INL.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗

NASA NTRS1987

Autonomous flight and remote site landing guidance research for helicopters

Automated low-altitude flight and landing in remote areas within a civilian environment are investigated, where initial cost, ongoing maintenance costs, and system productivity are important considerations. An approach has been taken which has: (1) utilized those technologies developed for military applications which are directly transferable to a civilian mission; (2) exploited and developed technology areas where new methods or concepts are required; and (3) undertaken research with the potential to lead to innovative methods or concepts required to achieve a manual and fully automatic remote area low-altitude and landing capability. The project has resulted in a definition of system operational concept that includes a sensor subsystem, a sensor fusion/feature extraction capability, and a guidance and control law concept. These subsystem concepts have been developed to sufficient depth to enable further exploration within the NASA simulation environment, and to support programs leading to the flight test.

Denton, R. V.↗

DOE OSTI2021

Soil organic carbon cycling in response to simulated soil moisture variation under field conditions

The combination of extended dry periods and high intensity rainfall, common in the southeastern US, leads to greater variability in soil moisture and consequently increases uncertainty to microbial processes pertinent to soil carbon (C) mineralization. However, field-based findings on soil moisture sensitivity to soil C cycling are very limited. Therefore, a field experiment was conducted in 2018 and 2019 on a soybean (Glycine max L.) cropland in the southeastern US with three soil moisture treatments: drought (simulated using rainout-shelter from June to October in each year), rainfed (natural precipitation), and irrigated (irrigation and precipitation). Soil respiration was measured weekly from May to November in both years. Soil samples were collected multiple times each year from 0–5, 5–15, and 15–30 cm depths to determine microbial biomass C (MBC), extractable organic C (EOC), hydrolytic enzyme activities, and fungal abundance. The cumulative respiration under drought compared to other treatments was lower by 32% to 33% in 2018 and 38% to 45% in 2019. Increased MBC, EOC, and fungal abundance were observed under drought than other treatments. Specific enzyme activity indicated fewer metabolically active microbes under drought treatment compared to rainfed and irrigated treatments. Also, maintenance of enzyme pool was observed under drought condition. These results provide critical insights on microbial metabolism in response to soil moisture variation and how that influences different pools of soil C under field conditions.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

SOLPS analysis of the necessary conditions for detachment cliff

SOLPS modeling including full cross-filed drifts is used, for the first time, to reproduce the step-like detachment onset observed in the DIII-D tokamak previously simulated with UEDGE [Jaervinen A. E. et al., 2018 Phys. Rev. Lett.121 075001], and to further investigate the underlying physics processes. The SOLPS analysis reveals a strong interplay between the E×B drift-driven flows and carbon radiation in DIII-D. The modeling shows that the high confinement H-mode facilitates the formation of such a detachment cliff due to the narrow SOL width and hence steep radial gradients near the separatrix, which enhances the poloidal E×B drift. Furthermore, the SOLPS modeling indicates that carbon radiation also plays a key role in the formation of the detachment cliff in DIII-D without additional impurity seeding. These findings may have significant implications for the control and maintenance of divertor detachment for the steady-state operation of high-power fusion devices.

Physics - Plasma physics↗

DOE OSTI2025

Micromechanical Surrogate Machine Learning Model for Creep Deformation Modeling

Process variability during the manufacture of gas turbine engine hot section components can significantly affect the material’s resulting microstructure. In casting, for instance, geometric variation within a component (thin sections versus thick sections, radial location) influences cooling rates and the resulting grain size. The high temperature creep response is known to be sensitive to grain size owing to a diffusional creep mechanism which occurs more readily along grain boundaries. Microstructural variation correspondingly drives mechanical behavior which propagates into component scale performance uncertainty. These factors are essential when planning inspection, maintenance, and repair strategies within a reliability framework. These benefits provide opportunities to increase overall energy efficiency through refined margins. Critically, there is an opportunity to bolster existing data-driven reliability models using physics-driven process-structure-property relations. Here we present recent work establishing a framework for evaluating the probabilistic creep performance of high-temperature materials. A novel microstructure-sensitive crystal plasticity finite element model is established that captures both grain boundary and crystallographic deformation effects. The computationally expensive physics model is calibrated using a statistical approach and this high-fidelity model is subsequently used to train a computationally efficient machine learning surrogate model. The surrogate model is essential for sampling a large ensemble of simulated structure-property pair results. The ensemble data are then mined to extract salient trends to be incorporated into a microstructure-sensitive reliability model. The proposed approach represents a novel way to capture microstructure-sensitive trends from physics-based models within a modern reliability framework.

Fernandez-Zelaia, Patxi [ORNL]↗

DOE OSTI2018

Thermomechanical Design Optimization of Roll-to-Roll Manufactured Hybrid Metal Polymer Heat Exchanger

Metal based heat exchangers for ultra-low temperature (<100C) waste heat recovery (WHR) face high maintenance and material costs that surpass profits from recovery[1]. Low-cost polymer pipes suffer from poor thermal conductivity (~0.2 W/mK), and thus a low overall heat transfer coefficient. Thermal conductivity of polymers can be enhanced through systematic molecular alignment by stretching[2], chemical vapor deposition of extended polymers [3], surface grating [4], etc. However, these approaches suffer from scalability issues for WHR heat exchangers in terms of cost [3], and thermomechanical considerations [5]. In this work, we propose novel hybrid metal-polymer strips that are strategically designed to enhance thermal conductivity by cladding copper around polymer strips. The polymer strips with copper-clad edges are wound helically to form the pipes for a heat exchanger. Through finite element simulations, we optimize the design for enhanced thermal performance of the polymer-metal strips. We predict up to 20 % enhancement in overall heat transfer from a base polymer with a thermal conductivity of 0.2 W/mK. We show that the thermomechanical strains induced in the pipes can be reduced to < 0.2 % by strategically stacking and welding multiple polymer-metal strips. We verified the improved thermal performance of the roll-to-roll manufactured strips through a thermal conductivity measurement setup. The optimized design of hybrid metal-polymer pipes provides a scalable and cost-effective means for harvesting waste heat from ultra-low temperature sources. Thekdi, Arvind, and Sachin U. Nimbalkar. Oak Ridge National Lab, 2015 Shen, Sheng, et al. Nature nanotechnology 5.4 (2010): 251. Xu, Yanfei, et al. Science advances 4.3 (2018): 3031. Smith, M. K., Singh, V., Kalaitzidou, K., & Cola, B. A. (2015). ACS nano, 9(2), 1080-1088. Aymonier, C., Bortzmeyer, D., Thomann, R., & Mülhaupt, R. (2003). Chemistry of Materials, 15(25), 4874-4878.

C Rajagopal, Manjunath↗

NASA NTRS1983

A study of the kinetic energy generation with general circulation models

The history data of winter simulation by the GLAS climate model and the NCAR community climate model are used to examine the generation of atmospheric kinetic energy. The contrast between the geographic distributions of the generation of kinetic energy and divergence of kinetic energy flux shows that kinetic energy is generated in the upstream side of jets, transported to the downstream side and destroyed there. The contributions from the time-mean and transient modes to the counterbalance between generation of kinetic energy and divergence of kinetic energy flux are also investigated. It is observed that the kinetic energy generated by the time-mean mode is essentially redistributed by the time-mean flow, while that generated by the transient flow is mainly responsible for the maintenance of the kinetic energy of the entire atmospheric flow.

Chen, T.-C.↗

NASA NTRS2006

NASA Stennis Space Center Integrated System Health Management Test Bed and Development Capabilities

Integrated System Health Management (ISHM) is a capability that focuses on determining the condition (health) of every element in a complex System (detect anomalies, diagnose causes, prognosis of future anomalies), and provide data, information, and knowledge (DIaK)-not just data-to control systems for safe and effective operation. This capability is currently done by large teams of people, primarily from ground, but needs to be embedded on-board systems to a higher degree to enable NASA's new Exploration Mission (long term travel and stay in space), while increasing safety and decreasing life cycle costs of spacecraft (vehicles; platforms; bases or outposts; and ground test, launch, and processing operations). The topics related to this capability include: 1) ISHM Related News Articles; 2) ISHM Vision For Exploration; 3) Layers Representing How ISHM is Currently Performed; 4) ISHM Testbeds & Prototypes at NASA SSC; 5) ISHM Functional Capability Level (FCL); 6) ISHM Functional Capability Level (FCL) and Technology Readiness Level (TRL); 7) Core Elements: Capabilities Needed; 8) Core Elements; 9) Open Systems Architecture for Condition-Based Maintenance (OSA-CBM); 10) Core Elements: Architecture, taxonomy, and ontology (ATO) for DIaK management; 11) Core Elements: ATO for DIaK Management; 12) ISHM Architecture Physical Implementation; 13) Core Elements: Standards; 14) Systematic Implementation; 15) Sketch of Work Phasing; 16) Interrelationship Between Traditional Avionics Systems, Time Critical ISHM and Advanced ISHM; 17) Testbeds and On-Board ISHM; 18) Testbed Requirements: RETS AND ISS; 19) Sustainable Development and Validation Process; 20) Development of on-board ISHM; 21) Taxonomy/Ontology of Object Oriented Implementation; 22) ISHM Capability on the E1 Test Stand Hydraulic System; 23) Define Relationships to Embed Intelligence; 24) Intelligent Elements Physical and Virtual; 25) ISHM Testbeds and Prototypes at SSC Current Implementations; 26) Trailer-Mounted RETS; 27) Modeling and Simulation; 28) Summary ISHM Testbed Environments; 29) Data Mining - ARC; 30) Transitioning ISHM to Support NASA Missions; 31) Feature Detection Routines; 32) Sample Features Detected in SSC Test Stand Data; and 33) Health Assessment Database (DIaK Repository).

Figueroa, Fernando↗

NASA NTRS2012

Piezoelectric Vibration Damping Study for Rotating Composite Fan Blades

Resonant vibrations of aircraft engine blades cause blade fatigue problems in engines, which can lead to thicker and aerodynamically lower performing blade designs, increasing engine weight, fuel burn, and maintenance costs. In order to mitigate undesirable blade vibration levels, active piezoelectric vibration control has been investigated, potentially enabling thinner blade designs for higher performing blades and minimizing blade fatigue problems. While the piezoelectric damping idea has been investigated by other researchers over the years, very little study has been done including rotational effects. The present study attempts to fill this void. The particular objectives of this study were: (a) to develop and analyze a multiphysics piezoelectric finite element composite blade model for harmonic forced vibration response analysis coupled with a tuned RLC circuit for rotating engine blade conditions, (b) to validate a numerical model with experimental test data, and (c) to achieve a cost-effective numerical modeling capability which enables simulation of rotating blades within the NASA Glenn Research Center (GRC) Dynamic Spin Rig Facility. A numerical and experimental study for rotating piezoelectric composite subscale fan blades was performed. It was also proved that the proposed numerical method is feasible and effective when applied to the rotating blade base excitation model. The experimental test and multiphysics finite element modeling technique described in this paper show that piezoelectric vibration damping can significantly reduce vibrations of aircraft engine composite fan blades.

Min, James B.↗

DOE OSTI2019

Design and Characterization of High Thermal Conductivity Pipes from Roll-to- Roll Processed Hybrid Copper-Polymer Strips for Waste Heat Recovery

Metal based heat exchangers targeting low temperature (<150°C) waste heat recovery (WHR) face high maintenance and material costs [1] that result in long payback periods (>1 year). Low-cost polymer pipes suffer from poor thermal conductivity (~0.2 W/m.K), and thus a low overall heat transfer coefficient. Previous reports demonstrated thermal conductivity enhancement in polymers through systematic molecular alignment [2, 3, 4], or by metal micro-particle inclusions [5]. However, these approaches suffer from scalability issues for WHR heat exchangers in terms of cost [1, 3], and thermomechanical considerations [6, 7]. In this work, we propose hybrid metal-polymer strips that are strategically designed to enhance thermal conductivity by cladding copper around polymer strips. The polymer strips with copper-clad edges are wound helically to form the pipes for a heat exchanger. Through numerical simulations, we optimize the copper-polymer strip layouts to achieve high wall thermal conductivity (k > 1 W/m.K) and also have low volume fraction of copper (<70%) for the composite pipes. In copper-polymer composite heat exchangers, the bottlenecks for heat transfer are the thermal interfacial resistances of copper-copper and copper-polymer joints. We experimentally measured interfacial resistances to be ~1x10 -5 K.m 2 /W and ~4x10 -5 K.m 2 /W for copper-copper and copper-polymer joints, respectively. Using the measured interfacial resistances, we further optimized the design of the hybrid pipes to find high thermal conductivity (> 1 W/m.K) designs. We predict up to ~20 % enhancement in overall heat transfer relative to an all polymer (k = 0.2 W/m.K) heat exchanger system. Using a cohesive zone modelling (CZM) for predicting delamination at the weld joints, we find that our hybrid pipes can have operating internal pressures > 200 psi. The optimized designs of hybrid metal-polymer pipes provide a scalable and cost- effective means for harvesting waste heat from low temperature sources. Thekdi, A., and Nimbalkar, S. Oak Ridge National Lab (2014). Shen, Sheng, et al. Nature nanotechnology 5.4 (2010). Xu, Yanfei, et al. Science advances 4.3 (2018). Smith et al. ACS nano, 9(2), (2015). Sofian, N.M., et al., Journal of Thermoplastic Composite Materials (2001). Aymonier et al. Chemistry of Materials, 15(25), (2003). Tavman, I.H., Journal of Applied Polymer Science, 62(12), (1996).

C Rajagopal, Manjunath↗

NASA NTRSDate not supplied

Shoulder Postures in EVA Training in Reduced Gravity Analogues

Shoulder Postures in EVA Training in Reduced Gravity Analogues K. Guhl1, L. Vu2, H. Kim3, S. Rajulu4 1KBR Inc., Houston, TX, 2Aegis Aerospace Inc., Houston, TX, 3Leidos Innovations, Houston, TX, 4NASA Johnson Space Center, Houston, TX. During extravehicular activities (EVAs) and EVA training in both the Neutral Buoyancy Laboratory (NBL) and at the Active Response Gravity Offload System (ARGOS), crewmembers perform a variety of hand-intensive tasks with frequent arm/shoulder repositioning while wearing a pressurized spacesuit. As a result, crewmembers may experience ergonomic stressors such as awkward shoulder postures. The ergonomic shoulder risk is also compounded by limited or restricted shoulder mobility of the spacesuit, extreme work positions such as overhead tasks, and tasks with heavy tools and repetitive motions. Prolonged or frequent shoulder elevation and overhead work, in particular, can lead to excessive stresses and musculoskeletal injuries of the shoulder joints. Future EVA missions, specifically lunar surface EVAs, will also be longer in duration and thus increase the exposure to awkward shoulder postures. In this study, we aimed to assess the ergonomic risk of awkward shoulder postures in simulated lunar surface EVAs by quantifying when and how long the arms are raised above the chest level. We assessed video recordings of pilot lunar EVA simulations (3 lunar trials each in the NBL and at ARGOS and 2 microgravity EVA trials in the NBL). These runs consisted of both training and engineering test objectives. Actual demands for shoulder use varied for different EVA types and analogues, but many EVA runs have common tasks and require similar motion components. A video observation and event logging software was used to document the duration and occurrence of the subject’s arms being raised throughout the video recordings of each EVA run. An arm raised instance was classified as the arm being at 90 degrees or above with relation to gravity for lunar EVA training events and with relation to the body for microgravity EVA training events. Such events included EVA hardware maintenance or heavy geology sampling tool operations. Events where the arm load was partially supported by external objects, like climbing a ladder or leaning against a surface were separately identified and excluded. Statistical analysis was performed to summarize the timing, frequency, and durations of the arm raise events and compared across the different EVA tasks and analogue types. Preliminary observations indicated that the total duration and number of arm raised instances were surprisingly smaller for lunar surface EVA training as compared to microgravity EVA training. The observed difference may be attributed to differing task demands and unique environmental characteristics found in lunar EVAs in comparison to microgravity EVAs. A detailed statistical analysis will be performed between lunar surface EVA training events and microgravity EVA training events in the final submission. Overall, this analysis is expected to provide insight into how ergonomic recommendations can be refined for lunar EVA training with pressurized suits. It may also inform task design and influence suit padding design to better protect crewmembers during future lunar training.

Kaitlyn Lea Guhl↗