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NASA NTRS2003

Enhancement and Extension of Porosity Model in the FDNS-500 Code to Provide Enhanced Simulations of Rocket Engine Components

In the past, the design of rocket engines has primarily relied on the cold flow/hot fire test, and the empirical correlations developed based on the database from previous designs. However, it is very costly to fabricate and test various hardware designs during the design cycle, whereas the empirical model becomes unreliable in designing the advanced rocket engine where its operating conditions exceed the range of the database. The main goal of the 2nd Generation Reusable Launching Vehicle (GEN-II RLV) is to reduce the cost per payload and to extend the life of the hardware, which poses a great challenge to the rocket engine design. Hence, understanding the flow characteristics in each engine components is thus critical to the engine design. In the last few decades, the methodology of computational fluid dynamics (CFD) has been advanced to be a mature tool of analyzing various engine components. Therefore, it is important for the CFD design tool to be able to properly simulate the hot flow environment near the liquid injector, and thus to accurately predict the heat load to the injector faceplate. However, to date it is still not feasible to conduct CFD simulations of the detailed flowfield with very complicated geometries such as fluid flow and heat transfer in an injector assembly and through a porous plate, which requires gigantic computer memories and power to resolve the detailed geometry. The rigimesh (a sintered metal material), utilized to reduce the heat load to the faceplate, is one of the design concepts for the injector faceplate of the GEN-II RLV. In addition, the injector assembly is designed to distribute propellants into the combustion chamber of the liquid rocket engine. A porosity mode thus becomes a necessity for the CFD code in order to efficiently simulate the flow and heat transfer in these porous media, and maintain good accuracy in describing the flow fields. Currently, the FDNS (Finite Difference Navier-Stakes) code is one of the CFD codes which are most widely used by research engineers at NASA Marshall Space Flight Center (MSFC) to simulate various flow problems related to rocket engines. The objective of this research work during the 10-week summer faculty fellowship program was to 1) debug the framework of the porosity model in the current FDNS code, and 2) validate the porosity model by simulating flows through various porous media such as tube banks and porous plate.

Cheng, Gary↗

NASA NTRS2009

Impact Testing on Reinforced Carbon-Carbon Flat Panels with Ice Projectiles for the Space Shuttle Return to Flight Program

Following the tragedy of the Orbiter Columbia (STS-107) on February 1, 2003, a major effort commenced to develop a better understanding of debris impacts and their effect on the space shuttle subsystems. An initiative to develop and validate physics-based computer models to predict damage from such impacts was a fundamental component of this effort. To develop the models it was necessary to physically characterize reinforced carbon-carbon (RCC) along with ice and foam debris materials, which could shed on ascent and impact the orbiter RCC leading edges. The validated models enabled the launch system community to use the impact analysis software LS-DYNA (Livermore Software Technology Corp.) to predict damage by potential and actual impact events on the orbiter leading edge and nose cap thermal protection systems. Validation of the material models was done through a three-level approach: Level 1--fundamental tests to obtain independent static and dynamic constitutive model properties of materials of interest, Level 2--subcomponent impact tests to provide highly controlled impact test data for the correlation and validation of the models, and Level 3--full-scale orbiter leading-edge impact tests to establish the final level of confidence for the analysis methodology. This report discusses the Level 2 test program conducted in the NASA Glenn Research Center (GRC) Ballistic Impact Laboratory with ice projectile impact tests on flat RCC panels, and presents the data observed. The Level 2 testing consisted of 54 impact tests in the NASA GRC Ballistic Impact Laboratory on 6- by 6-in. and 6- by 12-in. flat plates of RCC and evaluated three types of debris projectiles: Single-crystal, polycrystal, and "soft" ice. These impact tests helped determine the level of damage generated in the RCC flat plates by each projectile and validated the use of the ice and RCC models for use in LS-DYNA.

Melis, Matthew E.↗

NASA NTRS2009

Impact Testing on Reinforced Carbon-Carbon Flat Panels With BX-265 and PDL-1034 External Tank Foam for the Space Shuttle Return to Flight Program

Following the tragedy of the Orbiter Columbia (STS-107) on February 1, 2003, a major effort commenced to develop a better understanding of debris impacts and their effect on the space shuttle subsystems. An initiative to develop and validate physics-based computer models to predict damage from such impacts was a fundamental component of this effort. To develop the models it was necessary to physically characterize reinforced carbon-carbon (RCC) along with ice and foam debris materials, which could shed on ascent and impact the orbiter RCC leading edges. The validated models enabled the launch system community to use the impact analysis software LS-DYNA (Livermore Software Technology Corp.) to predict damage by potential and actual impact events on the orbiter leading edge and nose cap thermal protection systems. Validation of the material models was done through a three-level approach: Level 1-fundamental tests to obtain independent static and dynamic constitutive model properties of materials of interest, Level 2-subcomponent impact tests to provide highly controlled impact test data for the correlation and validation of the models, and Level 3-full-scale orbiter leading-edge impact tests to establish the final level of confidence for the analysis methodology. This report discusses the Level 2 test program conducted in the NASA Glenn Research Center (GRC) Ballistic Impact Laboratory with external tank foam impact tests on flat RCC panels, and presents the data observed. The Level 2 testing consisted of 54 impact tests in the NASA GRC Ballistic Impact Laboratory on 6- by 6-in. and 6- by 12-in. flat plates of RCC and evaluated two types of debris projectiles: BX-265 and PDL-1034 external tank foam. These impact tests helped determine the level of damage generated in the RCC flat plates by each projectile and validated the use of the foam and RCC models for use in LS-DYNA.

Melis, Matthew E.↗

NASA NTRS2017

Using Dispersed Modes During Model Correlation

The model correlation process for the modal characteristics of a launch vehicle is well established. After a test, parameters within the nominal model are adjusted to reflect structural dynamics revealed during testing. However, a full model correlation process for a complex structure can take months of man-hours and many computational resources. If the analyst only has weeks, or even days, of time in which to correlate the nominal model to the experimental results, then the traditional correlation process is not suitable. This paper describes using model dispersions to assist the model correlation process and decrease the overall cost of the process. The process creates thousands of model dispersions from the nominal model prior to the test and then compares each of them to the test data. Using mode shape and frequency error metrics, one dispersion is selected as the best match to the test data. This dispersion is further improved by using a commercial model correlation software. In the three examples shown in this paper, this dispersion based model correlation process performs well when compared to models correlated using traditional techniques and saves time in the post-test analysis.

Stewart, Eric C.↗

NASA NTRS1983

The spatial correlation function of rich clusters of galaxies

A series of objective statistical estimators is applied to directly study the three-dimensional distribution of rich clusters, using a recently completed redshift sample of 104 Abell clusters out to distance class four and galactic latitude of 30 deg or more. The sample and the relevant positional and redshift selection effects are discussed, and the two-point angular correlation function and nearest-neighbor distribution of clusters in the sample are determined, as well as in the larger D = 5+6 sample and in several subsamples of different richness classes and latitude zones. The redshift correlation function of clusters for various angular separations on the sky is examined as a test for the reality of the observed angular correlations. The two-point spatial correlation function of clusters in the sample is determined, and the consistency among the three observed correlation functions is tested. A model that describes all the observed correlations is presented.

Bahcall, N. A.↗

DOE OSTI2018

Direct comparison of nanoindentation and tensile test results on reactor-irradiated materials

Nanoindentation testing has been used for decades to assess materials on a local scale and to obtain fundamental mechanical property parameters. Nuclear materials research often faces the challenge of testing rather small samples due to the hazardous nature, limited space in reactors, and shallow ion-irradiated zones, fostering the need for small-scale mechanical testing (SSMT). As such, correlating the results from SSMT to bulk properties is particularly of interest. Here, this study compares macroscopic tensile test data (yield and flow stresses) to nanoindentation data (hardness) obtained on a number of different neutron-irradiated materials in order to understand the scaling behavior on radiation-damaged samples.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Deformation and fracture characteristics of zirconium plate produced via ultrasonic additive manufacturing

Abstract The microstructural evolution, deformation modes, and fracture mechanisms of zirconium plate produced using ultrasonic additive manufacturing (UAM) are presented. In addition to conventional tensile testing techniques, digital image correlation captured highly variable strain accumulation in specimens loaded perpendicular or parallel to the build height (Z). When tested in parallel to Z, delamination at prior foil/foil interfaces creates strain localization noticeable in strain rate maps, whereas specimens loaded perpendicular to Z illustrate conventional strain hardening until necking accelerates delamination. Although bond strengths are statistically and spatially variable, in situ electron backscattering diffraction tests illustrate the ability for grains near interfaces to accommodate strain with twinning and slip modes consistent with conventionally produced zirconium alloys. Finally, mixtures of ductile and delamination-induced fracture highlight the interface-driven failure modes of UAM zirconium plate in the as-built condition. Graphic abstract

36 MATERIALS SCIENCE↗

NASA NTRS2018

Improved Mars Helicopter Aerodynamic Rotor Model for Comprehensive Analyses

The Mars Helicopter is part of the NASA Mars 2020 rover mission scheduled to launch in July of 2020. Its goal is to demonstrate the viability and potential of heavier-than-air vehicles in the Martian atmosphere. Ultimately, it aims to bridge the resolution gap between orbiters and the rover as well as allow access to otherwise inaccessible regions. The low density of the Martian atmosphere and the relatively small-scale rotor result in very low Reynolds number flows. The low density and low Reynolds numbers reduce the lifting force and lifting efficiency, respectively. This paper describes the generation of the improved Mars Helicopter aerodynamic rotor model. The goal is to generate a performance model for the Mars Helicopter rotor using a free wake analysis, since this has a low computational cost for design. The improvements in the analysis are two-fold and are expanded on from two prior publications. First, the fidelity of the simulations is increased by performing higher-order two-dimensional time-accurate OVERFLOW simulations allowing for higher accuracy aerodynamic coefficients and a better understanding of the boundary layer behavior as well as its transient features. Second, a version of the model is generated to duplicate the exact testing conditions in the 25-ft. diameter Space Simulator at the Jet Propulsion Laboratory, which allows for better correlation of rotor performance figures. Previous work correlated performance with that test, but did not consider the higher temperatures in the experiment compared to those of the Martian atmosphere. The higher temperatures in the experiment are expected to give conservative performance estimates, as they give rise to an increase in speed of sound and decrease in observed Reynolds numbers.

Analyses↗

NASA NTRS2018

Improved Mars Helicopter Aerodynamic Rotor Model for Comprehensive Analyses

The Mars Helicopter is part of the NASA Mars 2020 rover mission scheduled to launch in July of 2020. Its goal is to demonstrate the viability and potential of heavier-than-air vehicles in the Martian atmosphere. Ultimately, it aims to bridge the resolution gap between orbiters and the rover as well as allow access to otherwise inaccessible regions. The low density of the Martian atmosphere and the relatively small-scale rotor result in very low Reynolds number flows. The low density and low Reynolds numbers reduce the lifting force and lifting efficiency, respectively. This paper describes the generation of the improved Mars Helicopter aerodynamic rotor model. The goal is to generate a performance model for the Mars Helicopter rotor using a free wake analysis, since this has a low computational cost for design. The improvements in the analysis are two-fold and are expanded on from two prior publications. First, the fidelity of the simulations is increased by performing higher-order two-dimensional time-accurate OVERFLOW simulations allowing for higher accuracy aerodynamic coefficients and a better understanding of the boundary layer behavior as well as its transient features. Second, a version of the model is generated to duplicate the exact testing conditions in the 25–ft. diameter Space Simulator at the Jet Propulsion Laboratory, which allows for better correlation of rotor performance figures. Previous work correlated performance with that test, but did not consider the higher temperatures in the experiment compared to those of the Martian atmosphere. The higher temperatures in the experiment are expected to give conservative performance estimates, as they give rise to an increase in speed of sound and decrease in observed Reynolds numbers.

Grip, Håvard F.↗

DOE OSTI2024

Testing effective field theory with the most general neutron decay correlations

Built on the seminal works by Jackson-Treiman-Wyld and Ebel-Feldman, we derive the most general free neutron differential decay rate where all massive particles (neutron, proton, and electron) are polarized. This introduces 33 new correlations in addition to the 18 existing ones, which overconstrain the coupling constants in the low-energy effective field theory of charged weak interactions, and thus provides stringent tests of the validity of the theory framework itself. We classify the correlation coefficients in terms of their Standard Model limit and discrete symmetries, and study their expansion with respect to the new physics coupling strengths, supplemented by the experiment-independent 𝒪⁡(𝛼) virtual electromagnetic radiative corrections.

Astronomy & Astrophysics↗

DOE OSTI2016

Searches for correlation between UHECR events and high-energy gamma-ray Fermi-LAT data

The astrophysical sources responsible for ultra high-energy cosmic rays (UHECRs) continue to be one of the most intriguing mysteries in astrophysics. Here, we present a comprehensive search for correlations between high-energy (≳ 1 GeV) gamma-ray events from the Fermi Large Area Telescope (LAT) and UHECRs (≳ 60 EeV) detected by the Telescope Array and the Pierre Auger Observatory. We perform two separate searches. First, we conduct a standard cross-correlation analysis between the arrival directions of 148 UHECRs and 360 gamma-ray sources in the Second Catalog of Hard Fermi-LAT sources (2FHL). Second, we search for a possible correlation between UHECR directions and unresolved Fermi-LAT gamma-ray emission. For the latter, we use three different methods: a stacking technique with both a model-dependent and model-independent background estimate, and a cross-correlation function analysis. We also test for statistically significant excesses in gamma rays from signal regions centered on Cen A and the Telescope Array hotspot. There was no significant correlation is found in any of the analyses performed, except a weak (≲ 2σ) hint of signal with the correlation function method on scales ~ 1°. Upper limits on the flux of possible power-law gamma-ray sources of UHECRs are derived.

79 ASTRONOMY AND ASTROPHYSICS↗

NASA NTRS2007

Three-Dimensional Digital Image Correlation of a Composite Overwrapped Pressure Vessel During Hydrostatic Pressure Tests

Ambient temperature hydrostatic pressurization tests were conducted on a composite overwrapped pressure vessel (COPV) to understand the fiber stresses in COPV components. Two three-dimensional digital image correlation systems with high speed cameras were used in the evaluation to provide full field displacement and strain data for each pressurization test. A few of the key findings will be discussed including how the principal strains provided better insight into system behavior than traditional gauges, a high localized strain that was measured where gages were not present and the challenges of measuring curved surfaces with the use of a 1.25 in. thick layered polycarbonate panel that protected the cameras.

Revilock, Duane M., Jr.↗

NASA NTRS1986

Experimental determination of the laminar separation bubble characteristics on an airfoil at low Reynolds numbers

An experimental investigation was conducted in order to document the structure and behavior of laminar separation bubbles at low Reynolds numbers. Data of this type is necessary if the currently insufficient analytical and numerical models are to be improved. The laminar separation bubble which forms on a NACA 66(3)-018 airfoil model was surveyed at chord Reynolds numbers ranging from 50,000 to 200,000 at angles of attack from 8 to 12 degrees. The effects of the various testing conditions on the separation bubble were isolated, and the data was analyzed in relation to existing separation bubble correlations in order to test their low Reynolds number applicability. This analysis indicated that the chord Reynolds number and the disturbance environment strongly influence the experimental pressure distributions. These effects must be included in any analytic prediction technique applied to the low Reynolds number flight regime.

Omeara, M. M.↗

NASA NTRS1991

Open-path tunable diode laser absorption for eddy correlation flux measurements of atmospheric trace gases

Biogenic emissions from and dry deposition to terrestrial surfaces are important processes determining the trace gas composition of the atmosphere. An instrument has been developed for flux measurements of gases such as CH4, N2O, and O3 based on the eddy correlation technique which combines trace gas fluctuation measurements with simultaneous windfield measurements. The instrument combines a tunable diode laser infrared light source with an open-path multipass absorption cell in order to provide the fast time response and short base pathlength required for the eddy correlation method. Initial field tests using the instrument to measure methane emissions from a local wetland demonstrate the capability for high precision eddy correlation flux measurements.

Anderson, Stuart M.↗

DOE OSTI2017

Investigation of Correlation between Field Performance and Indoor Acceleration Measurements of Potential Induced Degradation (PID) for c-Si PV Modules

The correlation between outdoor field testing and indoor chamber measurement for potential-induced degradation in crystalline silicon PV modules is unclear. The motivation of this work is to build up a direct comparison and investigate the correlation between indoor and outdoor performance. First of all, four PID indoor tests were defined from basic to premium, based on the difficulty of the test. Six groups of modules were designed and fabricated in Trina Solar, with different grades of PID resistance from weak to strong. The outdoor field test systems were built in three different climates: tropical, subtropical, and semi-arid climates in Singapore, Changzhou (China) and Golden (CO, USA) respectively, in a collaborative testing campaign involving Trina, SERIS and NREL. The system in Golden has been on-sun for more than 13 months where <4% power loss which includes PID and other reliability losses was detected and power loss of <2% is shown for all six groups of modules after 21 weeks in the field in the subtropical climate in Changzhou. However, PID of 23% was observed after 18 weeks in Singapore for the most PID-susceptible module, while the other PID module types showed degradation of only less than 5%.

14 SOLAR ENERGY↗

DOE OSTI2012

New Density Functional Theory Approaches for Enabling Prediction of Chemical and Physical Properties of Plutonium and Other Actinides

Density Functional Theory (DFT) based Equation of State (EOS) construction is a prominent part of Sandia's capabilities to support engineering sciences. This capability is based on amending experimental data with information gained from computational investigations, in parts of the phase space where experimental data is hard, dangerous, or expensive to obtain. A prominent materials area where such computational investigations are hard to perform today because of limited accuracy is actinide and lanthanide materials. The Science of Extreme Environment Lab Directed Research and Development project described in this Report has had the aim to cure this accuracy problem. We have focused on the two major factors which would allow for accurate computational investigations of actinide and lanthanide materials: (1) The fully relativistic treatment needed for materials containing heavy atoms, and (2) the needed improved performance of DFT exchange-correlation functionals. We have implemented a fully relativistic treatment based on the Dirac Equation into the LANL code RSPt and we have shown that such a treatment is imperative when calculating properties of materials containing actinides and/or lanthanides. The present standard treatment that only includes some of the relativistic terms is not accurate enough and can even give misleading results. Compared to calculations previously considered state of the art, the Dirac treatment gives a substantial change in equilibrium volume predictions for materials with large spin-orbit coupling. For actinide and lanthanide materials, a Dirac treatment is thus a fundamental requirement in any computational investigation, including those for DFT-based EOS construction. For a full capability, a DFT functional capable of describing strongly correlated systems such as actinide materials need to be developed. Using the previously successful subsystem functional scheme developed by Mattsson et.al., we have created such a functional. In this functional the Harmonic Oscillator Gas is providing the necessary reference system for the strong correlation and localization occurring in actinides. Preliminary testing shows that the new Hao-Armiento-Mattsson (HAM) functional gives a trend towards improved results for the crystalline copper oxide test system we have chosen. This test system exhibits the same exchange-correlation physics as the actinide systems do, but without the relativistic effects, giving access to a pure testing ground for functionals. During the work important insights have been gained. An example is that currently available functionals, contrary to common belief, make large errors in so called hybridization regions where electrons from different ions interact and form new states. Together with the new understanding of functional issues, the Dirac implementation into the RSPt code will permit us to gain more fundamental understanding, both quantitatively and qualitatively, of materials of importance for Sandia and the rest of the Nuclear Weapons complex.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2012

A Prolonged Time Interval Between Trauma and Prophylactic Radiation Therapy Significantly Increases the Risk of Heterotopic Ossification

Purpose: To ascertain whether the time from injury to prophylactic radiation therapy (RT) influences the rate of heterotopic ossification (HO) after operative treatment of displaced acetabular fractures. Methods and Materials: This is a single-institution, retrospective analysis of patients referred for RT for the prevention of HO. Between January 2000 and January 2009, 585 patients with displaced acetabular fractures were treated surgically followed by RT for HO prevention. We analyzed the effect of time from injury on prevention of HO by RT. In all patients, 700 cGy was prescribed in a single fraction and delivered within 72 hours postsurgery. The patients were stratified into five groups according to time interval (in days) from the date of their accident to the date of RT: Groups A {<=}3, B {<=}7, C {<=}14, D {<=}21, and E >21days. Results: Of the 585 patients with displaced acetabular fractures treated with RT, (18%) 106 patients developed HO within the irradiated field. The risk of HO after RT increased from 10% for RT delivered {<=}3 days to 92% for treatment delivered >21 days after the initial injury. Wilcoxon test showed a significant correlation between the risk of HO and the length of time from injury to RT (p < 0.0001). Chi-square test and multiple logistic regression analysis showed no significant association between all other factors and the risk of HO (race, gender, cause and type of fracture, surgical approach, or the use of indomethacin). Conclusions: Our data suggest that there is higher incidence and risk of HO if prophylactic RT is significantly delayed after a displaced acetabular fracture. Thus, RT should be administered as early as clinically possible after the trauma. Patients undergoing RT >3 weeks from their displaced acetabular fracture should be informed of the higher risk (>90%) of developing HO despite prophylaxis.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

DOE OSTI2020

Corrosion Control in Carbon Fiber Reinforced Plastic (CFRP) Composite-Aluminum Closure Panel Hem Joints

This project targeted the implementation of CFRP/Al closure panels as a drop-in replacement for all-aluminum closures used in automobile production today. The project focused on the development of corrosion fundamentals involving CFRP materials and the use of those materials in mixed-material joints. Numerous studies were completed to benchmark current materials and test mixed metal joints. Good correlation was found between outdoor exposures and laboratory cyclic corrosion testing. The insights from the corrosion testing fundamentals and benchmarking phases informed the development of low-cure adhesive and electrocoats and conductive primers for the CFRP. Adhesive and electrocoat materials were successfully developed meeting low-cure targets for bake (150C/10min). These materials were scaled-up and used to produce 5 prototype liftgates to further evaluate CFRP/Al joints in a full-scale part. The lower cure materials enabled mitigation of CTE mismatch and reduced the required bake temperature, resulting in reduced part distortion. Corrosion testing of the liftgates revealed unexpected increases in corrosion relative to the standard bake materials. While rigorous evaluation of the parts was not possible due to numerous complexities associated with prototype testing, the results provided significant insights into the material behavior of CFRP/Al joints. Key learnings from the project included a better understanding of the system complexity (interplay of substrate/primer conductivity, production of full-scale prototypes), advances in coating/adhesive design for low-cure applications involving CFRP, and advancement of corrosion test protocols for CFRP.

36 MATERIALS SCIENCE↗