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Computer codes developed and under development at Lewis

The objective of this summary is to provide a brief description of: (1) codes developed or under development at LeRC; and (2) the development status of IPACS with some typical early results. The computer codes that have been developed and/or are under development at LeRC are listed in the accompanying charts. This list includes: (1) the code acronym; (2) select physics descriptors; (3) current enhancements; and (4) present (9/91) code status with respect to its availability and documentation. The computer codes list is grouped by related functions such as: (1) composite mechanics; (2) composite structures; (3) integrated and 3-D analysis; (4) structural tailoring; and (5) probabilistic structural analysis. These codes provide a broad computational simulation infrastructure (technology base-readiness) for assessing the structural integrity/durability/reliability of propulsion systems. These codes serve two other very important functions: they provide an effective means of technology transfer; and they constitute a depository of corporate memory.

Chamis, Christos C.↗

A Concept for the Use and Integration of Super-Conducting Magnets in Structural Systems in General and Maglev Guideway Mega-Structures in Particular

Recent breakthroughs in several different fields now make it possible to incorporate the use of superconducting magnets in structures in ways which enhance the performance of structural members or components of structural systems in general and Maglev guideway mega-structures in particular. The building of structural systems which connect appropriately scaled superconducting magnets with the post-tensioned tensile components of beams, girders, or columns would, if coupled with 'state of the art' structure monitoring, feedback and control systems, and advanced computer software, constitute a distinct new generation of structures that would possess the unique characteristic of being heuristic and demand or live-load responsive. The holistic integration of powerful superconducting magnets in structures so that they do actual structural work, creates a class of 'technologically endowed' structures that, in part - literally substitute superconductive electric power and magnetism for concrete and steel. The research and development engineering, and architectural design issues associated with such 'technologically endowed' structural system can now be conceptualized, designed, computer simulates built and tested. The Maglev guideway mega-structure delineated herein incorporates these concepts, and is designed for operation in the median strip of U.S. Interstate Highway 5 from San Diego to Seattle an Vancouver, and possibly on to Fairbanks, Alaska. This system also fits in the median strip of U.S. Interstate Highway 55 and 95 North-South, and 80 and 10, East-West. As a Western Region 'Peace Dividend' project, it could become a National or Bi-National research, design and build, super turnkey project that would create thousands of jobs by applying superconducting, material science, electronic aerospace and other defense industry technologies to a multi-vehicle, multi-use Maglev guideway megastructure that integrates urban mass transit Lower Speed (0-100 mph), High Speed (100-200 mph), Super Speed (200-400 mph), and Hypersonic evacuated tube (400-10,000 mph) Maglev systems.

Ussery, Wilfred T.↗

Modeling and Design Analysis Methodology for Tailoring of Aircraft Structures with Composites

Composite materials provide design flexibility in that fiber placement and orientation can be specified and a variety of material forms and manufacturing processes are available. It is possible, therefore, to 'tailor' the structure to a high degree in order to meet specific design requirements in an optimum manner. Common industrial practices, however, have limited the choices designers make. One of the reasons for this is that there is a dearth of conceptual/preliminary design analysis tools specifically devoted to identifying structural concepts for composite airframe structures. Large scale finite element simulations are not suitable for such purposes. The present project has been devoted to creating modeling and design analysis methodology for use in the tailoring process of aircraft structures. Emphasis has been given to creating bend-twist elastic coupling in high aspect ratio wings or other lifting surfaces. The direction of our work was in concert with the overall NASA effort Twenty- First Century Aircraft Technology (TCAT). A multi-disciplinary team was assembled by Dr. Damodar Ambur to work on wing technology, which included our project.

Rehfield, Lawrence W.↗

Scale resolving simulations of the NASA Juncture Flow Model using the LAVA solver

Two distinct simulation methodologies: Delayed Detached Eddy Simulation (DDES) and stress based Wall-modelled Large Eddy Simulation (WMLES) are evaluated using structured overset curvilinear grids for the NASA juncture flow model. While both methodologies are shown to mitigate the primary shortcomings of steady state Reynolds Averaged Navier Stokes(RANS) simulations, several unresolved aspects are identified. Strong sensitivity to RANS-typegrid refinement is observed in the DDES with a substantial deterioration of the solution quality with increasing spatial resolution associated with deficiencies in the shielding function. Mean profiles for attached boundary layers on the fuselage show spurious inflections suggesting modelled stress depletion on finer grids. Lower numerical dissipation in terms of spatial discretization and time step size is seen to improve the solution quality, and the advantage of using RC and QCR2000 corrections in the underlying RANS closure is demonstrated for DDES on RANS-type meshes. Equilibrium Wall-Modelled LES used grids that resolved the tripping dots over the fuselage nose and the wing leading edge, consistent with the experiment setup. These simulations resulted in a cost-competitive approach compared to DDES on RANS-type grids. Although the agreement between WMLES predictions of first and second order single point statistics with experimental measurements is promising, a fundamental shortcoming is noted in terms of an overshoot in streamwise momentum in corner regions of the wing-fuselage juncture. This excess momentum subsequently delays the onset of separation,thereby resulting in an underprediction in length of the separation bubble. Some quantitative sensitivity to numerical discretization is observed; lowering of numerical dissipation shows better agreement with the experiment.

T^3↗

Computational Investigation of Oxidative Etch Pitting in FiberForm and Its Impact on Material Properties

Oxidation-driven carbon erosion does not occur uniformly but rather through the development of localized etch pits at active surface sites. These active sites form due to atomic defects on the carbon surface, making them significantly more reactive than the surrounding, non-defective areas. As a result, these sites are the first to react during ablation, leading to their removal. This process creates new defects in neighboring atoms, increasing their reactivity and causing localized carbon removal around these active sites. In this way, the highly reactive defective areas serve as nucleation points for the formation and growth of etch pits, which can have adverse effects on structural integrity of FiberForm. To better understand how these etch pits impact the material properties of carbon fiber microstructures, we have developed a new capability within the direct simulation Monte Carlo (DSMC) framework to capture the etch pit formation process. This capability, integrated into the DSMC code SPARTA (Stochastic Parallel Rarefied-gas Time-accurate Analyzer), models material removal in the presence of active sites, leading to the formation of etch pits. The current work focuses on studying the effects of these etch pits on the material properties of FiberForm, a widely used base material in thermal protection systems (TPS). The microstructure of virgin FiberForm, obtained via X-ray microtomography, is imported into SPARTA to generate the ablated geometries with etch pits. These modified microstructures are then analyzed using the Porous Microstructure Analysis (PuMA) software to compute various material properties, including elasticity, thermal conductivity, and permeability. We investigate the variation of these properties due to the complex surface topology changes caused by etch pit formation. Additionally, we compare the effects of pitting with the conventional model of shrinking fibers, traditionally used to simulate the ablation of carbon structures. Significant differences emerge between the two approaches. Consequently, this physically realistic model of material removal through etch pit formation offers improved accuracy in predicting the degradation of carbon-based TPS during oxidation. It also provides insights into other mechanisms, such as spallation, where chunks of material are removed into the flow due to etch pit growth. Ultimately, this model enhances our understanding of failure modes in these materials during ablation.

PuMA↗

Gravitational collapse of small-scale structure as the origin of the Lyman-alpha forest

If gravitational clustering is a hierarchical process, the present large-scale structure of the galaxy distribution implies that structures on smaller scales must have formed at high redshift. We simulate the formation of small-scale structure (average cell mass: (delta) bar m(sub b) = 10(sup 4.2) solar mass) and the evolution of photoionized gas, in the specific case of the CDM + Lambda model. The photoionized gas has a natural minimal scale of collapse, the Jeans scale (m(sub b,J) is approximately equal to 10(exp 9) solar mass). We find that low column density (N(sub HI) is less than or equal to 10(exp 14)/sq cm) lines originate in regions resembling Zel'dovich pancakes, where gas with overdensities in the range 3-30 is enclosed by two shocks but is typically reexpanding at approximately the Hubble velocity. However, higher column density lines stem from more overdense regions where the shocked gas is cooling. We show that this model can probably account for the observed number of lines, their distribution in column density and b-parameters, as well as the cloud physical sizes as observed in gravitationally lensed quasars. We find a redshift evolution that is too steep; however, this may be due to insufficient dynamical range in the simulation or because the specific model is incorrect. The model predicts that high signal-to-noise observations should find systematic deviations from Voigt profiles, mainly in the form of broad wings in the line profiles, and that a fluctuating Gunn-Peterson effect will be detected, which can be modeled as a superposition of weak lines with a wide range of b-parameters.

Cen, Renyue↗

Testing the gravitational instability hypothesis?

We challenge a widely accepted assumption of observational cosmology: that successful reconstruction of observed galaxy density fields from measured galaxy velocity fields (or vice versa), using the methods of gravitational instability theory, implies that the observed large-scale structures and large-scale flows were produced by the action of gravity. This assumption is false, in that there exist nongravitational theories that pass the reconstruction tests and gravitational theories with certain forms of biased galaxy formation that fail them. Gravitational instability theory predicts specific correlations between large-scale velocity and mass density fields, but the same correlations arise in any model where (a) structures in the galaxy distribution grow from homogeneous initial conditions in a way that satisfies the continuity equation, and (b) the present-day velocity field is irrotational and proportional to the time-averaged velocity field. We demonstrate these assertions using analytical arguments and N-body simulations. If large-scale structure is formed by gravitational instability, then the ratio of the galaxy density contrast to the divergence of the velocity field yields an estimate of the density parameter Omega (or, more generally, an estimate of beta identically equal to Omega(exp 0.6)/b, where b is an assumed constant of proportionality between galaxy and mass density fluctuations. In nongravitational scenarios, the values of Omega or beta estimated in this way may fail to represent the true cosmological values. However, even if nongravitational forces initiate and shape the growth of structure, gravitationally induced accelerations can dominate the velocity field at late times, long after the action of any nongravitational impulses. The estimated beta approaches the true value in such cases, and in our numerical simulations the estimated beta values are reasonably accurate for both gravitational and nongravitational models. Reconstruction tests that show correlations between galaxy density and velocity fields can rule out some physically interesting models of large-scale structure. In particular, successful reconstructions constrain the nature of any bias between the galaxy and mass distributions, since processes that modulate the efficiency of galaxy formation on large scales in a way that violates the continuity equation also produce a mismatch between the observed galaxy density and the density inferred from the peculiar velocity field. We obtain successful reconstructions for a gravitational model with peaks biasing, but we also show examples of gravitational and nongravitational models that fail reconstruction tests because of more complicated modulations of galaxy formation.

Babul, Arif↗

Analytic Modeling of the Hydrodynamic, Thermal, and Structural Behavior of Foil Thrust Bearings

A simulation and modeling effort is conducted on gas foil thrust bearings. A foil bearing is a self acting hydrodynamic device capable of separating stationary and rotating components of rotating machinery by a film of air or other gaseous lubricant. Although simple in appearance these bearings have proven to be complicated devices in analysis. They are sensitive to fluid structure interaction, use a compressible gas as a lubricant, may not be in the fully continuum range of fluid mechanics, and operate in the range where viscous heat generation is significant. These factors provide a challenge to the simulation and modeling task. The Reynolds equation with the addition of Knudsen number effects due to thin film thicknesses is used to simulate the hydrodynamics. The energy equation is manipulated to simulate the temperature field of the lubricant film and combined with the ideal gas relationship, provides density field input to the Reynolds equation. Heat transfer between the lubricant and the surroundings is also modeled. The structural deformations of the bearing are modeled with a single partial differential equation. The equation models the top foil as a thin, bending dominated membrane whose deflections are governed by the biharmonic equation. A linear superposition of hydrodynamic load and compliant foundation reaction is included. The stiffness of the compliant foundation is modeled as a distributed stiffness that supports the top foil. The system of governing equations is solved numerically by a computer program written in the Mathematica computing environment. Representative calculations and comparisons with experimental results are included for a generation I gas foil thrust bearing.

Bruckner, Robert J.↗

Progress in the Modeling of NiAl-Based Alloys Using the BFS Method

The BFS method has been applied to the study of NiAl-based materials to assess the effect of alloying additions on structure. Ternary, quaternary and even pent-alloys based on Ni-rich NiAl with additions of Ti, Cr and Cu were studied. Two approaches were used, Monte Carlo simulations to determine ground state structures and analytical calculations of high symmetry configurations which give physical insight into preferred bonding. Site occupancy energetics for ternary and the more complicated case of quaternary additions were determined, and solubility limits and precipitate formation with corresponding information concerning structure and lattice parameter were also 'observed' computationally. The method was also applied to determine the composition of alloy surfaces and interfaces. Overall, the results demonstrate that the BFS method for alloys is a powerful tool for alloy design and with its simplicity and obvious advantages can be used to complement any experimental alloy design program.

Bozzolo, Guillermo↗

Dynamic Finite Element Predictions for Mars Sample Return Cellular Impact Test #4

The nonlinear finite element program MSC.Dytran was used to predict the impact pulse for (he drop test of an energy absorbing cellular structure. This pre-test simulation was performed to aid in the design of an energy absorbing concept for a highly reliable passive Earth Entry Vehicle (EEV) that will directly impact the Earth without a parachute. In addition, a goal of the simulation was to bound the acceleration pulse produced and delivered to the simulated space cargo container. EEV's are designed to return materials from asteroids, comets, or planets for laboratory analysis on Earth. The EEV concept uses an energy absorbing cellular structure designed to contain and limit the acceleration of space exploration samples during Earth impact. The spherical shaped cellular structure is composed of solid hexagonal and pentagonal foam-filled cells with hybrid graphite-epoxy/Kevlar cell walls. Space samples fit inside a smaller sphere at the enter of the EEV's cellular structure. The material models and failure criteria were varied to determine their effect on the resulting acceleration pulse. Pre-test analytical predictions using MSC.Dytran were compared with the test results obtained from impact test #4 using bungee accelerator located at the NASA Langley Research Center Impact Dynamics Research Facility. The material model used to represent the foam and the proper failure criteria for the cell walls were critical in predicting the impact loads of the cellular structure. It was determined that a FOAMI model for the foam and a 20% failure strain criteria for the cell walls gave an accurate prediction of the acceleration pulse for drop test #4.

Fasanella, Edwin L.↗

A Database of CFD-Based Buffet Forcing Functions for Artemis I Structural Response Evaluation

Time-accurate FUN3D simulations are utilized to estimate buffet-induced unsteady forces experienced by the Space Launch System during the Artemis I (AR01) flight. A set of FUN3D simulations was developed that employed time-accurate mesh translations to simulate the changing velocity and attitude based on the AR01 best estimated trajectory. In these simulations, referred to as accelerating-flow simulations, the freestream Mach number increased from 0.80 to 1.92. Additional time-accurate simulations were obtained at constant freestream Mach number equal to 0.95, 1.18, 1.70, thereby simulating stationary conditions experienced by the flow in a wind-tunnel. On the grounds of favorable comparisons between simulated and flight-measured environments, the FUN3D-based surface pressures were utilized to develop a buffet forcing function (BFF) database. This BFF database was analyzed to characterize the spatial distribution and frequency content of the buffet forces during transonic and supersonic portions of the AR01 flight. The region of interest is located downstream of the forward attachment (FA) hardware between the core stage and the solid rocket boosters where vortex shedding off the FA protuberance produces significant unsteadiness. The analysis reveals that, at transonic and supersonic conditions, buffet forces that are based on constant freestream Mach number data are a good approximation of those based on accelerating-flow simulations.

FUN3D↗

Simulations of Multidimensional Burner-stabilized Flames

Detailed numerical simulations have been performed to study the structure and dynamics of downward propagating burner-stabilized flames in lean hydrogen-air mixtures. These simulations include the effects of fluid convection, detailed hydrogen-oxygen chemistry, multispecies diffusion, thermal conduction, viscosity, and heat losses to the burner. One-dimensional calculations have been carried out to investigate burner boundary conditions. Well known features of a burner-stabilized flame have been reproduced. Two-dimensional calculations show the presence of cellular structures at the burner surface. At low inlet velocities, these cellular structures are suppressed by the increased heat loss to the burner. These simulations have been examined in detail to gain understanding of the similarities and differences in structure and stability of freely propagating and burner-stabilized flames.

Patnaik, G.↗

Simulating the interaction of the heliosphere with the local interstellar medium: MHD results from a finite volume approach, first bidimensional results

We have designed a full compressible MHD code working on unstructured meshes in order to be able to compute accurately sharp structures embedded in large scale simulations. The code is based on a finite volume method making use of a kinetic flux splitting. A bidimensional version of the code has been used to simulate the interaction of a moving interstellar medium, magnetized or unmagnetized with a rotating and magnetized heliopspheric plasma source. Being aware that these computations are not realistic due to the restriction to two dimensions, we present it to demonstrate the ability of this new code to handle this problem. An axisymetric version, now under development, will be operational in a few months. Ultimately we plan to run a full 3d version.

Chanteur, G.↗

Scale Model Experiments on Sound Propagation From a Mach 2.5 Cold Nitrogen Jet Flowing Through a Rigid-Walled Duct With a J-Deflector

The Launch Systems Testbed (LST) represents the evolution of vibroacoustics research and development work performed at NASA John F. Kennedy Space Center (KSC) over the last 15 years. The LST is located at the Launch Equipment Test Facility (LETF) in the KSC industrial complex. The LETF is operated by Sierra Lobo, Inc., as a member of University-Affiliated Technology Development Contract (USTDC) to KSC Spaceport and Engineering and Technology Directorate (YA), with ASRC Aerospace Corporation as a the prime contractor. Trajectory Simulation Mechanism (TSM) is a major component of the LST, developed specifically to simulate nonstationary acoustic loads on launch pad structures, vehicles, and payloads. TSM enhances the capabilities within LST for simulating launch environments of future vehicles. The scaled launch environments will be used to predict the full-scale launch environment via an appropriate scaling procedure. Air Force Research Laboratory (AFRL) has tasked NASA KSC to perform a basic technology test program in support of developing a low-cost clean pad (incorporating passive mitigation techniques) for future launch vehicles. The overall goal of the program is to develop innovative launch exhaust management systems, which effectively reduce launch acoustic environment with innovative duct designs, while eliminating traditional sound suppression water systems. Passive techniques, such as nontraditional duct geometries, resonators, and diffusers, etc., will be investigated. The overall goals are to advance innovative concepts for a clean pad while developing ideas to reduce transmitted sound via investigation and modeling of jet exhaust acoustic and flow field characteristics. The series of tests outlined in this report represent baseline tests and are geared towards defining the acoustic load environment on the TSM pad for open and closed duct configurations. This report summarizes the cold jet acoustic testing for Mach 2.5 supersonic nitrogen jet issuing from a nozzle with 1-inch exit diameter. Acoustic data, including spectral sound power and Overall Sound Pressure Level (OASPL), are obtained both for a free jet and with the jet flowing through a rigid-walled duct with a J-deflector. The relative performance of closed duct and open duct is evaluated. The results show that the closed duct is superior to the partially open duct, and results in about 3-decibel (dB) noise reduction (near the duct axis) relative to the free jet. The location of the nozzle exit plane (NEP) relative to the duct inlet plane (DIP) has a significant effect on the acoustic field. The results suggest that the location of NEP at 10 inches above the DIP results in reduced acoustic loads relative to 5 inches above the duct inlet and 1 inch into the duct inlet.

Kandula, Max↗

Active Members to Establish On-Orbit Modal Data for Modal Correlation

The paper presents an approach to experimentally determine the modal sensitivity derivitives with respect to physical parameters of a structure in space or on the ground. The information experimentally validates the Jacobian used to update the analytical model to correlate with the experimental modal data. The approach is applicable to Adaptive Structures and utilizes active members. For verification of the approach, numerical simulations of a 4.5 meter diameter truss structure and experimental verification plan and progress are presented.

space structures modal analysis dynamic models ada↗

Thermomechanical Property Prediction of Amorphous and Crystal PEKK via Molecular Dynamics

Traditionally, advanced aerospace composites have been manufactured using thermoset resins. However, recently, thermoplastics have been investigated for use in the manufacturing of composite materials due to their unique manufacturing characteristics. Thermoplastic resins can be reshaped and formed, along with the added benefit of being recyclable, which thermoset resin cannot. Thermoplastic materials undergo a crystallization process during manufacturing which affects the percent crystallinity of the material. The crystallization needs to be understood better to maximize the potential of thermoplastic resins. PEKK is a thermoplastic material with good chemical, thermal, and mechanical loading resistance. PEKK is also a material NASA is interested in for developing new bonded joint technology. The crystalline microstructure of PEKK is at the micrometer length scale, and it is of interest to model the effects of the crystallinity structure on PEKK’s bulk properties. Molecular dynamics (MD) is a simulation tool that allows for property-structure relationships between atomistic structure and nanometer-length portions of a material. This makes MD a useful tool for developing the structure-property relationship of PEKK. However, the micrometer length scale of PEKK’s crystal structure is too large for MD. Thus, a hybrid approach to modeling PEKK’s microstructure is proposed in this work where MD models are built of both the amorphous and crystalline phases of PEKK. The engineering material properties can be obtained using MD at the nanometer length scale. A micromechanics approach can then generate the micrometer length scale of the crystallinity and the effective properties can be homogenized. The objective of this paper is to show the MD model workflow and the MD-predicted properties of PEKK. The properties can then be homogenized with different crystalline percentages to build design graphs that can be used to tailor PEKK for specific composite applications.

poly ether ketone ketone↗

Relevant Environment Additive Construction Technology (REACT)

Project Overview This project is focused on developing technologies that enable construction of a Lunar Safe Haven type structure on the moon. A full scale architectural and structural design will be completed based on lunar conditions and Artemis mission needs. A scaled structure will be 3D printed in simulated lunar environments. Technical Approach Polymer bound regolith composite materials will be developed and characterized for lunar additive construction applications. A full scale architectural and structural design will be completed based on the latest scientific data on lunar environments including radiation, meteoroids, thermal conditions, reduced gravity, and moonquakes. The project will culminate with a demonstration of additive construction in simulated lunar vacuum, thermal, regolith, and UV conditions. Results/Summary Preliminary material specifications have been developed and an initial batch has been produced. A first iteration of the architectural and structural designs have been completed. Hardware for 3D printing in simulated lunar conditions is under development. Contributing Partners AI Space Factory – Winner of the NASA 3D Printed Habitat Centennial Challenge Infusion and Transition Plan On-surface construction of infrastructure is a critical capability of the sustainable phase of the Artemis Program and eventual sustainable human presence on Mars. It provides the ability to create protective shelters on-demand using local resources. The 3D-printing technology will achieve TRL 6 in 1g/vacuum tests with thermal/UV exposure in this project. CLPS missions will be pursued for infusion to demonstrate vertical construction with lunar regolith and conditions. Modeling and simulation will be used to define the pilot-scale shelter construction mission for long-term exposure on the lunar surface to validate the system for Artemis operational deployment.

Lunar Construction↗

Verification of Loop Diagnostics

Many different techniques have been used to characterize the plasma in the solar corona: density-sensitive spectral line ratios are used to infer the density, the evolution of coronal structures in different passbands is used to infer the temperature evolution, and the simultaneous intensities measured in multiple passbands are used to determine the emission measure. All these analysis techniques assume that the intensity of the structures can be isolated through background subtraction. In this paper, we use simulated observations from a 3D hydrodynamic simulation of a coronal active region to verify these diagnostics. The density and temperature from the simulation are used to generate images in several passbands and spectral lines. We identify loop structures in the simulated images and calculate the loop background. We then determine the density, temperature and emission measure distribution as a function of time from the observations and compare with the true temperature and density of the loop. We find that the overall characteristics of the temperature, density, and emission measure are recovered by the analysis methods, but the details of the true temperature and density are not. For instance, the emission measure curves calculated from the simulated observations are much broader than the true emission measure distribution, though the average temperature evolution is similar. These differences are due, in part, to inadequate background subtraction, but also indicate a limitation of the analysis methods.

Winebarger, A.↗