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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS1989

Vector algorithms for geometrically nonlinear 3D finite element analysis

Algorithms for geometrically nonlinear finite element analysis are presented which exploit the vector processing capability of the VPS-32, which is closely related to the CYBER 205. By manipulating vectors (which are long lists of numbers) rather than individual numbers, very high processing speeds are obtained. Long vector lengths are obtained without extensive replication or reordering by storage of intermediate results in strategic patterns at all stages of the computations. Comparisons of execution times with those from programs using either scalar or other vector programming techniques indicate that the algorithms presented are quite efficient.

Whitcomb, John D.↗
NASA NTRS2015

Probabilistic Fatigue Damage Prognosis Using a Surrogate Model Trained Via 3D Finite Element Analysis

Utilizing inverse uncertainty quantification techniques, structural health monitoring can be integrated with damage progression models to form probabilistic predictions of a structure's remaining useful life. However, damage evolution in realistic structures is physically complex. Accurately representing this behavior requires high-fidelity models which are typically computationally prohibitive. In the present work, a high-fidelity finite element model is represented by a surrogate model, reducing computation times. The new approach is used with damage diagnosis data to form a probabilistic prediction of remaining useful life for a test specimen under mixed-mode conditions.

Leser, Patrick E.↗
NASA NTRS2017

3D Material Response Analysis of PICA Pyrolysis Experiments

Primarily interested in improving ablation modeling for use in inverse reconstruction of flight environments on ablative heat shields. Ablation model is essentially a component of the heat flux sensor, so model uncertainties lead to measurement uncertainties. Non-equilibrium processes have been known to be significant in low density ablators for a long time, but increased accuracy requirements of the reconstruction process necessitates incorporating this physical effect. Attempting to develop a pyrolysis model for implementation in material response based on the PICA data produced by Bessire and Minton. Pyrolysis gas species molar yields as a function of temperature and heating rate. Several problems encountered while trying to fit Arrhenius models to the data led to further investigation of the experimental setup.

Oliver, Brandon A.↗
NASA NTRS2003

Colossal Tooling Design: 3D Simulation for Ergonomic Analysis

The application of high-level 3D simulation software to the design phase of colossal mandrel tooling for composite aerospace fuel tanks was accomplished to discover and resolve safety and human engineering problems. The analyses were conducted to determine safety, ergonomic and human engineering aspects of the disassembly process of the fuel tank composite shell mandrel. Three-dimensional graphics high-level software, incorporating various ergonomic analysis algorithms, was utilized to determine if the process was within safety and health boundaries for the workers carrying out these tasks. In addition, the graphical software was extremely helpful in the identification of material handling equipment and devices for the mandrel tooling assembly/disassembly process.

Hunter, Steve L.↗
NASA NTRS1997

Parallel ALLSPD-3D: Speeding Up Combustor Analysis Via Parallel Processing

The ALLSPD-3D Computational Fluid Dynamics code for reacting flow simulation was run on a set of benchmark test cases to determine its parallel efficiency. These test cases included non-reacting and reacting flow simulations with varying numbers of processors. Also, the tests explored the effects of scaling the simulation with the number of processors in addition to distributing a constant size problem over an increasing number of processors. The test cases were run on a cluster of IBM RS/6000 Model 590 workstations with ethernet and ATM networking plus a shared memory SGI Power Challenge L workstation. The results indicate that the network capabilities significantly influence the parallel efficiency, i.e., a shared memory machine is fastest and ATM networking provides acceptable performance. The limitations of ethernet greatly hamper the rapid calculation of flows using ALLSPD-3D.

Fricker, David M.↗
DOE OSTI2025

RELAP5-3D Capabilities for High-Temperature Gas-Cooled Reactor Analysis

RELAP5-3D is the premier systems thermal-hydraulic code in the world. The code has been used significantly for high-temperature gas-cooled reactor (HTGR) analyses over the last 10 years, but there has not been a comprehensive summary of RELAP5-3D capabilities and methods for HTGR modeling. In this paper, we provide a guide for how novice users can build models for prismatic HTGRs. This guide includes best practices for developing heat structures and setting up radiation and conduction heat transfer. We also provide a summary of relevant validation studies. These studies are divided into three categories: separate effects tests, integral effects tests, and nuclear reactor studies. We present a comprehensive review of RELAP5-3D HTGR applications for reactor modeling over the last 10 years. These applications include work for the Modular High-Temperature Gas-Cooled Reactor benchmark, design activities for a prismatic HTGR as part of the U.S. Department of Energy’s Advanced Demonstration and Test Reactor Options Study, and studies performed to design gas-cooled microreactors. Following the comprehensive literature review, we present a gap analysis highlighting capabilities of RELAP5-3D that are available and missing for a complete analysis of HTGR thermal hydraulics. We also discuss the limitations of existing code capabilities and potential improvements that could improve analyses. Current research efforts have yet to fully validate RELAP5-3D for a prismatic HTGR analysis; however, some of this is attributable to confounding factors in the available experimental data as opposed to code capabilities. In conclusion, this paper presents the most comprehensive review to date on RELAP5-3D capabilities, limitations, and applications for HTGR analysis.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Parametric Finite Element Analysis of Naturally Corroded Steel Specimens Using 3D Surface Laser Scans

Corrosion is considered a uniform thickness reduction design guideline of the maritime industry. However, additionally, the corroded and irregular morphology of the surface affects the steel's load-bearing capacity and its impact on the strength and elongation behaviour of the steel is not yet fully understood. These effects on the local behaviour of steel structures under tensile loading were investigated with tensile tests on naturally corroded steel specimens and nonlinear finite element simulations including the corroded surface morphology with a uniform surface idealation. The models also include the deformed specimen shape. The developed approach led to highly accurate parametric finite element models predicting the ultimate tensile strength and longitudinal position of fracture. The results show that all included aspects are essential for accurate simulations, while solely the maximum available surface resolution was not as decisive.

corrosion↗
NASA NTRS2013

3D Guided Wave Motion Analysis on Laminated Composites

Ultrasonic guided waves have proved useful for structural health monitoring (SHM) and nondestructive evaluation (NDE) due to their ability to propagate long distances with less energy loss compared to bulk waves and due to their sensitivity to small defects in the structure. Analysis of actively transmitted ultrasonic signals has long been used to detect and assess damage. However, there remain many challenging tasks for guided wave based SHM due to the complexity involved with propagating guided waves, especially in the case of composite materials. The multimodal nature of the ultrasonic guided waves complicates the related damage analysis. This paper presents results from parallel 3D elastodynamic finite integration technique (EFIT) simulations used to acquire 3D wave motion in the subject laminated carbon fiber reinforced polymer composites. The acquired 3D wave motion is then analyzed by frequency-wavenumber analysis to study the wave propagation and interaction in the composite laminate. The frequency-wavenumber analysis enables the study of individual modes and visualization of mode conversion. Delamination damage has been incorporated into the EFIT model to generate "damaged" data. The potential for damage detection in laminated composites is discussed in the end.

Tian, Zhenhua↗
DOE OSTI2026

Validation Studies of RELAP5-3D for High-Temperature Gas-Cooled Reactor Analysis Using a Refined RELAP5-3D Model of the High Temperature Test Facility

RELAP5-3D has been used extensively for high-temperature gas-cooled reactor (HTGR) analysis, but such analysis lies outside the validation basis for the code. Oregon State University (OSU) and the United States Department of Energy’s (DOE) Advanced Reactor Technologies (ART) – Gas-cooled reactor campaign worked together to design and operate the High Temperature Test Facility (HTTF) at OSU to provide validation data for prismatic HTGR thermal hydraulics analysis. Work using a previous RELAP5-3D model of HTTF demonstrated the ability to reproduce trends in HTTF data but an inability to reproduce the values measured in multiple experiments within the uncertainty. It was hypothesized that a new model with a finer radial nodalization would perform better for HTTF analysis. In this paper, we present the development of that more refined model and analyze HTTF experiments PG-27 and PG-29, a pressurized (PCC) and depressurized conduction cooldown (DCC) transient. Comparing PG-27 results to experimental data shows a better prediction of steady state and transient temperatures; however, a deeper dive reveals that better transient temperature predictions are a result of better initial conditions. The transient temperature rise in the core is comparable between the two models, but the legacy model predicts temperatures in the reflectors better. The new model demonstrates the ability to predict unique temperatures in each sector of the core during PG-29, capturing the azimuthal asymmetry; however, the temperature predictions still differ from measured temperatures. One hypothesis is that differences between the assumed and actual power distribution leads to the underprediction of the individual block temperatures. These results suggest that gaps and uncertainties in the measured boundary conditions for the HTTF tests do not allow to fully validate RELAP5-3D for prismatic HTGR analyses. The authors suspect that some of the differences between predicted and measured temperatures may be a result of uncertainties associated with HTTF itself rather than RELAP5-3D. We demonstrated improved validation for steady-state analysis, but significantly improved transient performance has yet to be recognized.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Quantitatively accounting for the effects of surface topography on the oxidation kinetics of additive manufactured Hastelloy X processed by electron beam melting

In this work, the effects of surface roughness on the high-temperature corrosion of nickel-based superalloy X produced through electron-beam melting (EBM) additive manufacturing were studied. Surface area of samples in the rough, as-fabricated condition was measured using a 2D cross-section image analysis technique and a 3D image analysis technique. To verify the accuracy of surface area measurements, oxidation testing of samples in the as-fabricated and polished conditions was performed; polished sample oxidation curves were then compared to the as-fabricated sample oxidation curves before and after being adjusted using obtained surface area measurements. It was found that the 2D technique accurately measured surface area and accounted for the overlapping features present on EBM sample surfaces, whereas the 3D technique did not. Further, it was also observed that oxidation kinetics were moderately faster on the alloy X samples in the as-fabricated condition than for the polished condition.

36 MATERIALS SCIENCE↗
NASA NTRS2018

Implementation of J-A Methodology Elastic-Plastic Crack Instability Analysis Capability into the WARP-3D Code

Characterization of the near crack-tip stress/strain fields is the foundation of fracture mechanics. The description of the near tip stress field and the prediction of when fracture occurs is well established for brittle materials that exhibit linear elastic behavior. However, in ductile materials or conditions that violate linear elastic assumptions (Aluminum alloys, Al 2024-T3, Al 2024- T351 etc.), the elastic-plastic crack-tip stress fields are characterized by the Hutchison-Rice-Rosengren (HRR) field. The J-integral is commonly used to characterize amplitude of the HRR field under elastic-plastic conditions. The J-integral has been demonstrated for crack-tip fields that are under high constraint conditions (i.e., small-scale plasticity where the J-dominance is maintained). However, as the external load increases, yielding changes from small- to largescale plasticity and usually a loss of constraint (i.e., reduction in the triaxial stress field along the crack front). The loss of constraint leads to the deviation of the crack-tip stress fields from that given by the HRR field. Hence, the J-dominance will be gradually lost and additional parameter(s) are required to quantify the crack-tip stress fields and predict fracture behavior. The assessment objectives were to: 1) implement a two-parameter (i.e., J-A) fracture criterion into an elastic-plastic three-dimensional (3D) finite element analysis (FEA), 2) validate the implementation by comparison with the A parameter from literature data, 3) conduct material characterization tests to quantify the material behavior and provide fracture data for validation of the J-A fracture criteria, and (4) perform evaluations to establish if the J-A criteria can be used to predict fracture in a ductile metallic material (e.g., aluminum alloys). The A parameter in these criteria is the second parameter in a three-term elastic-plastic asymptotic expansion of the neartip stress behavior. A series of extensive FEAs were performed using WARP3D software package to obtain solutions for the A parameter for different specimen configurations. The methodology needed for the estimation of the A parameter in the asymptotic expansion was developed and implemented using Matlab®. A user material (UMAT) routine was used to model the material stress-strain response using a Ramberg-Osgood power law with a hardening exponent (n) and a material coefficient (alpha). This UMAT routine was successfully implemented in WARP3D software and validated through comparison with the experimental data. Three configurations were extracted from published results: 1) center cracked plate (CCP), 2) single edge-cracked plate (SECP), and 3) double edge-cracked plate (DECP). These configurations and four other configurations (three-hole tension (THT)), three-point bend (3PTB), three-hole compact tension (3PCT), and compact tension (CT)) were analyzed to verify the methodology that was developed and implemented into WARP3D. Solutions of the A parameter were obtained for remote tension loading conditions that started with small-scale yielding and continued into the large-scale plasticity regime. The results indicate that the methodology developed can be used to calculate the elastic-plastic J-A parameters for test specimens with a range of crack geometries, material strain hardening behaviors, and loading conditions. The J-A parameters were implemented as fracture criteria and used to predict the test results. For comparison, other fracture criteria were used to predict the same test results. Major findings include: The A constraint parameter A varies with specimen type and applied load thus accurate determination is crucial in predicting the failure load, and the A parameter is asymptotic as the failure load is approached, making an accurate determination difficult (i.e., small differences in the A parameter can cause large variations in failure load) for materials exhibiting elastic-plastic behavior. The failure predictions from J-A methodology were more accurate than the traditionally used KC and J methods, and have comparable scatter to that observed when using the crack-tip opening angle (CTOA) method. However, the J-A methodology requires considerable effort (expertise level and labor) to implement and to evaluate the A parameter for different specimen types and materials, or to apply this methodology to part-through crack (e.g., 3D problems) structural applications.

Hamm, Kenneth R., Jr.↗
NASA NTRS2017

Liquefaction Study of Gaseous Oxygen Inside Mars Ascent Vehicle Propellant Tank

The in-situ production of propellants for Mars missions will utilize carbon dioxide (CO2) in the Mars atmosphere to produce oxygen. The oxygen then needs to be cooled, liquefied, and stored to be available for Mars ascent propulsion, which could be up to 2 years after liquefaction starts. Recent investigations have demonstrated the feasibility of both achieving zero boiloff and controlling the pressure of oxygen within a tank using high-efficiency reverse turbo-Brayton-cycle cryocoolers. A tube-on-tank configuration is being studied in this work. The cooling fluid circulating in the cryocooler system is routed through a network of cooling tubes on the oxygen tank. The oxygen gas produced from the in-situ production process is introduced into the chilled tank. A series of analysis of this configuration has been performed to investigate the liquefaction rate inside the tank, the thermal gradient near the top of the tank where the oxygen gas feeding tubing is located. The analyses include 2D axisymmetric CFD analysis using ANSYS Fluent, 1D thermal analysis using Matlab, and 3D thermal analysis using MSC Patran/pthermal. These three models correlate and validate each other.

Liquefaction↗
DOE OSTI2022

Implementing Spatio-Temporal 3D-Convolution Neural Networks and UAV Time Series Imagery to Better Predict Lodging Damage in Sorghum

Unmanned aerial vehicle (UAV)-based remote sensing is gaining momentum in a variety of agricultural and environmental applications. Very-high-resolution remote sensing image sets collected repeatedly throughout a crop growing season are becoming increasingly common. Analytical methods able to learn from both spatial and time dimensions of the data may allow for an improved estimation of crop traits, as well as the effects of genetics and the environment on these traits. Multispectral and geometric time series imagery was collected by UAV on 11 dates, along with ground-truth data, in a field trial of 866 genetically diverse biomass sorghum accessions. We compared the performance of Convolution Neural Network (CNN) architectures that used image data from single dates (two spatial dimensions, 2D) versus multiple dates (two spatial dimensions + temporal dimension, 3D) to estimate lodging detection and severity. Lodging was detected with 3D-CNN analysis of time series imagery with 0.88 accuracy, 0.92 Precision, and 0.83 Recall. This outperformed the best 2D-CNN on a single date with 0.85 accuracy, 0.84 Precision, and 0.76 Recall. The variation in lodging severity was estimated by the best 3D-CNN analysis with 9.4% mean absolute error (MAE), 11.9% root mean square error (RMSE), and goodness-of-fit (R2) of 0.76. This was a significant improvement over the best 2D-CNN analysis with 11.84% MAE, 14.91% RMSE, and 0.63 R2. The success of the improved 3D-CNN analysis approach depended on the inclusion of “before and after” data, i.e., images collected on dates before and after the lodging event. The integration of geometric and spectral features with 3D-CNN architecture was also key to the improved assessment of lodging severity, which is an important and difficult-to-assess phenomenon in bioenergy feedstocks such as biomass sorghum. This demonstrates that spatio-temporal CNN architectures based on UAV time series imagery have significant potential to enhance plant phenotyping capabilities in crop breeding and Precision agriculture applications.

3D-convolution neural networks↗
DOE OSTI2022

3013 Inner Container Closure Weld Region (ICCWR) Characterization by Wide Area 3D Measurement System (WAMS) Analysis (FY21 Progress Report)

As part of the 3013 Surveillance Program, through-wall penetration from stress corrosion cracking (SCC) of the 3013 inner containers has been identified as the most credible condition for failure withing the 50- years lifetime. Chlorides contained in Pu-bearing material, together with intra-canister humidity levels, metallurgical conditions, and internal stresses have been found to produce corrosion in the Inner Container Closure Weld Region (ICCWR) of the 3013 canister system. A Laser Confocal Microscope (LCM) is used as part of the 3013 Surveillance Program protocol to identify the prevalence of corrosion and corrosionrelated cracking in the ICCWR2. With the LCM, a close visual examination is made of the ICCWR surface along with measurements of corrosion-related features. LCM inspections produce immense amounts of image data that is time intensive to analyze. There is also a 9-year backlog of images, with approximately 49 canisters that must be evaluated. To expedite data analysis and reduce the amount of generated data, a Wide Area 3D Measurement System (WAMS) microscope has been added to the examination protocol. Although WAMS is a lower resolution microscope, small features of interest can be still identified. The advantage of collecting data for the full circumference using the WAMS is that it can take about 1/16 of the time needed with the LCM. Both systems offer capabilities that combined can be utilized to expedite the examination of the ICCWR. The WAMS is an efficient system for screening and identification of corrosion features while the LCM can be utilized to obtain higher resolution images areas identified by the WAMS. This report explains and justifies the data collection methods used with the WAMS. It includes a summary of the data generated by WAMS in FY21. The goals set for data collection in FY21 were met. A total of twenty-two DE’s were imaged, and analysis was carried out on eleven samples. The analyzed samples showed large numbers of potential cracks and pits distributed throughout the surfaces. Lastly, to explain the advantages of the WAMS, its capabilities were compared to those of a simpler microscope. Micrographs of the samples imaged in FY21 and those analyzed are included in the appendices.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRSDate not supplied

Global 3D Data Visualization and Analysis Platform with Advanced Machine Learning Capabilities in Support of Lunar Exploration

Introduction: The science goals for NASA’s Artemis program include: a) Understanding the character and origin of lunar polar volatiles, b) Conducting experimental science in the lunar environment and c) Investigating and mitigating exploration risks. The permanently shadowed regions (PSRs) on the Lunar south pole are expected to host large quantities of water-ice and volatiles that are important for sustainable Lunar exploration. There are several missions such as onboard Korea Pathfinder Lunar Orbiter (KPLO: Korean name Danuri) with onboard ShadowCam camera, Astrobotic Peregrine Mission One [4], and other efforts underway to obtain high resolution topographic, minerals, volatiles and other information on the moon. We envision a need in immediate future for platforms to integrate these data sets, provide rendering and visualization capabilities in the context of a 3D Lunar globe for easier information access and analysis. NASA's Celestial Mapping System (CMS) is developed to address the need for 3D tools for planetary science investigations, mission planning, in-situ operations, in a 3D-first design constructed around a unified view of a planetary globe. At present CMS provides many critical functionalities that include: 1) equipment planning and optimized placement on Lunar surface 2) line-of-sight (LOS) analysis 3) powerful measurement tools based on 3D terrain with realistic 3D models to represent rovers, astronauts and equipment 4) visualization of derived mapping products (e.g. resource maps), and 5) a data engine for hosting new observations that are not available in other contemporary lunar data tools. Planetary Data Ingestion: CMS can consume and analyze data from locally hosted and external third party sources. It is compatible with Open Geospatial Consortium (OGC) data and file standards and currently integrates datasets from the Astrogeology Science Center of USGS. This includes global and local data acquired from NASA (LRO, Clementine, Lunar Orbiter) and JAXA (SELENE/Kaguya), with capability of integrating more datasets. In addition, users can specify other WMS-hosted data endpoints, which CMS can then query and stream data from automatically. To set-up an automated process for ingestion and accurate rendering, visualization and analysis of external 3rd party planetary datasets within CMS, we initiated the process of ingesting unique dataset of super-enhanced images of the permanently shadowed regions (PSRs) at the lunar poles which were produced by the Hyper-effective nOise Removal U-net Software (HORUS) tool. This tool was developed to enhance the extremely low-light images of the interior of PSRs and provide the ability to see within these regions at and discern surface features (i.e. boulders and craters) down to 3 meters in size. We focused on the Nobile region on the Lunar south pole, selected site for VIPER mission and stitched several images to create a high-resolution map within one of the PSR of Nobile crater. Figure 1 shows the dark PSR zone form the original NAC layer of LRO as the base layer (left image) and the illuminated areas within that crater (center) which was created by ingesting and merging several of HORUS generated images. At present we employ a semi-automated process to ensure spatial accuracy and merger of several overlapping zones. However, we are in the process of completely automating this process by employing AI based techniques that would rank, sort, and stack the images based on their information density. The georectification of the images would employ selected features. Analysis on Ingested Planetary Datasets: Once an external planetary data-set is successfully ingested, georectified and merged seamlessly as a data-layer; CMS’ numerous analysis tools can be used on this data. A Line of Sight (LOS) tool has been developed for CMS which analyzes terrain profiles and obstructions to determine visibility for remote observers. Figure 1 (right image) shows the viewshed analysis on the same PSR in the Nobile region. The yellow pin shows the observer location outside the PSR. The yellow area shows the visible part of PSR. The obstructed area with no visibility for the observer is shown in red. The Measurements tool allows the user to take area and distance measurements of features on the terrain using various shapes. Measurement type can be specified in a number of ways: Line, Path, Polygon, Circle, Ellipse, Square, Rectangle or Freehand. Once the shape is specified, elevation information can then be extracted along each of these shapes. Figure 2 (left) shows the measurements performed on a crater n illuminated PSR in Nobile region. The equipment placement tool allows the user to place a 3D equipment model at a desired location and analyze its coverage area. The equipment placement tool is coupled with LOS to determine the coverage. Figure 2 (right) shows an equipment placed on the Lunar terrain and it’s coverage area. The red rays are blocked sight lines and the green rays are non-obstructed sight lines with the cyan lines showing the point of intersection with the terrain. More details are provided in the video demonstrations in Reference 5. Overcoming Polar Distortions: 3D geospatial applications exhibit significant distortions in polar imagery due to several reasons: 1) distortions in the source imagery, 2) incompatible tessellation algorithms at the poles, and 3) map projections. We are leveraging new tessellation algorithms and reprojecting data using projections that are better suited for Lunar poles. The goal is to seamlessly switch to polar projections while maintaining 3D view and navigation.

Maps↗