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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 127 records · Page 7

Characterization and manufacture of braided composites for large commercial aircraft structures

Braided composite materials, one of the advanced material forms which is under investigation in Boeing's ATCAS program, have been recognized as a potential cost-effective material form for fuselage structural elements. Consequently, there is a strong need for more knowledge in the design, manufacture, test, and analysis of textile structural composites. The overall objective of this work is to advance braided composite technology towards applications to a large commercial transport fuselage. This paper summarizes the mechanics of materials and manufacturing demonstration results which have been obtained in order to acquire an understanding of how braided composites can be applied to a commercial fuselage. Textile composites consisting of 1D, 2D triaxial, and 3D braid patterns with thermoplastic and two RTM resin systems were investigated. The structural performance of braided composites was evaluated through an extensive mechanical test program. Analytical methods were also developed and applied to predict the following: internal fiber architectures, stiffnesses, fiber stresses, failure mechanisms, notch effects, and the entire history of failure of the braided composites specimens. The applicability of braided composites to a commercial transport fuselage was further assessed through a manufacturing demonstration. Three foot fuselage circumferential hoop frames were manufactured to demonstrate the feasibility of consistently producing high quality braided/RTM composite primary structures. The manufacturing issues (tooling requirements, processing requirements, and process/quality control) addressed during the demonstration are summarized. The manufacturing demonstration in conjunction with the mechanical test results and developed analytical methods increased the confidence in the ATCAS approach to the design, manufacture, test, and analysis of braided composites.

Fedro, Mark J.↗

Combined buoyancy-thermocapillary convection

Combined buoyancy-thermocapillary convection was studied in 2D and 3D. Fluid motion caused by thermally induced tension gradients on the free surface of a fluid is termed thermocapillary convection. It is well-known that in containerless processing of materials in space, thermocapillary convection is a dominant mechanism of fluid flow. Welding and crystal growth processes are terrestrial applications where thermocapillary convection has direct relevance.

Homsy, G. M.↗

Modeling Creep Effects in Advanced SiC/SiC Composites

Because advanced SiC/SiC composites are projected to be used for aerospace components with large thermal gradients at high temperatures, efforts are on-going at NASA Glenn to develop approaches for modeling the anticipated creep behavior of these materials and its subsequent effects on such key composite properties as internal residual stress, proportional limit stress, ultimate tensile strength, and rupture life. Based primarily on in-plane creep data for 2D panels, this presentation describes initial modeling progress at applied composite stresses below matrix cracking for some high performance SiC/SiC composite systems recently developed at NASA. Studies are described to develop creep and rupture models using empirical, mechanical analog, and mechanistic approaches, and to implement them into finite element codes for improved component design and life modeling

Lang, Jerry↗

A New Method of Absorption-Phase Nanotomography for 3D Observation of Mineral-Organic-Water Textiles and its Application to Pristine Carbonaceous Chondrites

Pristine carbonaceous chondrites contain fine-grained matrix, which is composed largely of amorphous silicates, sub-micron silicate and sulfide crystals, and organic materials. They are regarded as primitive dust in the early Solar System that have suffered minimal alteration in their parent bodies. The matrix generally has different lithologies; some of them are unaltered but some are more or less aqueously altered. Their textures have been examined in 2D usually by FE-SEM/EDS, TEM/EDS, nano-SIMS and micro-XRD. Observation of their complex fine textures, such as spatial relation between different lithologies in 3D, is important for understanding aggregation and alteration processes. Synchrotron radiation (SR)-based X-ray tomography reveals 3D structures nondestructively with high spatial resolution of approximately greater than 100 nm. We have developed a new technique using absorption contrasts called "dual-energy tomography" (DET) to obtain 3D distribution of minerals at SPring-8, SR facility in Japan, and applied successfully to Itokawa particles. Phase and absorption contrast images can be simultaneously obtained in 3D by using "scanning-imaging x-ray microscopy" (SIXM) at SPring-8, which can discriminate between void, water and organic materials. We applied this technique combined with FIB micro-sampling to carbonaceous chondrites to search for primitive liquid water. In this study, we combined the DET and SIXM to obtain three dimensional submicron-scale association between minerals, organic materials and water and applied this to pristine carbonaceous chondrites.

Tsuchiyama, A.↗

A Convolutional Neural Network for Multiscale Modeling of Composite Materials

An artificial convolutional neural network was created to efficiently mimic a micromechanics model, the High Fidelity Generalized Method of Cells, for use in multi-scale structural finite element analysis. The network was found to quickly and accurately replicate the stiffness predicted by the micromechanics model using a 2D image of an idealized representative volume element of a fiber/matrix microstructure. The long-term goal of this work is to efficiently apply multi-scale methods for predicting the damage progression of a composite structure.

Composites↗

Acoustic, Flow Related, and Performance Related Experimental Results for Generation 1.5 High Speed Civil Transport (HSCT) 2-Dimensional Exhaust Nozzles

The principle objectives of the current program were to experimentally investigate the repeatability of acoustic and aerodynamic characteristics of 2D-CD mixer-ejector nozzles and the effects on the acoustic and aerodynamic characteristics of 2D mixer-ejectors due to (1) the configurational variations, which include mixers with aligned CD chutes, aligned convergent chutes, and staggered CD chutes and aerodynamic cycle variables, (2) treatment variations by using different treatment materials, treating the ejector with varying area, location, and treatment thickness for a mixer-ejector configuration, and (3) secondary inlet shape (i.e., a more realistic inlet) and the blockage across the inlet (a possible fin-like structure needed for installation purpose) by modifying one of the inlet of a mixer-ejector configuration. The objectives also included the measurement dynamic pressures internal to the ejector for a few selected configuration to examine the internal noise characteristics.

Salikuddin, M.↗

Preparations for Tomographic Background-Oriented Schlieren Measurements in the 11-by 11-Foot Transonic Wind Tunnel

Efforts from a collaboration involving NASA’s Langley, Glenn, and Ames Research Centers to construct and test a tomographic background-oriented schlieren system in preparation for testing at the Ames 11-by 11-foot Transonic Wind Tunnel are discussed. To prepare for the test and to evaluate the probability of success, a mock-up of the tunnel test section was constructed at Langley. Schematics and renderings of the tunnel were used to place eight gigabit Ethernet CMOS cameras circumferentially around approximately 180° of the mock-up. Camera modules designed in-house were used to provide on-axis lighting to get maximum intensity return from the retroreflective backgrounds. A data acquisition system was designed to control the eight cameras and light sources with an acquisition rate of 4 Hz. A novel method for creation of the speckled background was developed for the test, enabling simple application and removal of the material on the tunnel walls. A tea light candle and a heat gun with two different nozzle shape attachments were used to provide an index of refraction gradient field to assess the quality of the 2D and tomographic results from the system. The heat gun was again used as an initial test article after the camera system had been set up at the Ames tunnel, giving similar results to those seen at the mock-up, and indicating a high probability of success for the testing campaign.

Joshua M. Weisberger↗

An Unbiased CO Survey toward the Northern Region of the Small Magellanic Cloud with the Atacama Compact Array. I. Overview: CO Cloud Distributions

We have analyzed the data from a large-scale CO survey toward the northern region of the Small Magellanic Cloud (SMC) obtained with the Atacama Compact Array (ACA) stand-alone mode of ALMA. The primary aim of this study is to comprehensively understand the behavior of CO as an H2 tracer in a low-metallicity environment (Z ∼ 0.2 Zꙩ). The total number of mosaic fields is ∼8000, which results in a field coverage of 0.26 sq.deg (∼2.9 ×10^(5) sq.pc), corresponding to ∼10% of the area of the galaxy. The sensitive ∼2 pc resolution observations reveal the detailed structure of the molecular clouds previously detected in the single-dish NANTEN survey. We have detected a number of compact CO clouds within lower H2 column density (∼10^(20) per sq.cm) regions whose angular scale is similar to the ACA beam size. Most of the clouds in this survey also show peak brightness temperature as low as <1 K, which for optically thick CO emission implies an emission size much smaller than the beam size, leading to beam dilution. The comparison between an available estimation of the total molecular material traced by thermal dust emission and the present CO survey demonstrates that more than ∼90% of H(2) gas cannot be traced by the low-J CO emission. Our processed data cubes and 2D images are publicly available.

Kazuki Tokuda↗

Bolt cutter functional evaluation

The Aerospace Corporation has been implementing finite difference and finite element codes for the analysis of a variety of explosive ordnance devices. Both MESA-2D and DYNA3D have been used to evaluate the role of several design parameters on the performance of a satellite separation system bolt cutter. Due to a lack of high strain rate response data for the materials involved, the properties for the bolt cutter and the bolt were selected to achieve agreement between computer simulation and observed characteristics of the recovered test hardware. The calculations provided insight into design parameters such as the cutter blade kinetic energy, the preload on the bolt, the relative position of the anvil, and the anvil shape. Modeling of the cutting process clarifies metallographic observation of both cut and uncut bolts obtained from several tests. Understanding the physical processes involved in bolt cutter operation may suggest certain design modifications that could improve performance margin without increasing environmental shock response levels.

S. Goldstein↗

Further Developments in Modeling Creep Effects Within Structural SiC/SiC Components

Anticipating the implementation of advanced SiC/SiC composites into turbine section components of future aero-propulsion engines, the primary objective of this on-going study is to develop physics-based analytical and finite-element modeling tools to predict the effects of constituent creep on SiC/SiC component service life. A second objective is to understand how to possibly manipulate constituent materials and processes in order to minimize these effects. Focusing on SiC/SiC components experiencing through-thickness stress gradients (e.g., airfoil leading edge), prior NASA creep modeling studies showed that detrimental residual stress effects can develop globally within the component walls which can increase the risk of matrix cracking. These studies assumed that the SiC/SiC composites behaved as isotropic viscoelastic continuum materials with creep behavior that was linear and symmetric with stress and that the creep parameters could be obtained from creep data as experimentally measured in-plane in the fiber direction of advanced thin-walled 2D SiC/SiC panels. The present study expands on those prior efforts by including constituent behavior with non-linear stress dependencies in order to predict such key creep-related SiC/SiC properties as time-dependent matrix stress, constituent creep and content effects on composite creep rates and rupture times, and stresses on fiber and matrix during and after creep.

Lang, Jerry↗

Experimental Characterization and Simulation of Slip Transfer at Grain Boundaries and Microstructurally-Sensitive Crack Propagation

A systematic study of crack tip interaction with grain boundaries is critical for improvement of multiscale modeling of microstructurally-sensitive fatigue crack propagation and for the computationally-assisted design of more durable materials. In this study, single, bi- and large-grain multi-crystal specimens of an aluminum-copper alloy are fabricated, characterized using electron backscattered diffraction (EBSD), and deformed under tensile loading and nano-indentation. 2D image correlation (IC) in an environmental scanning electron microscope (ESEM) is used to measure displacements near crack tips, grain boundaries and within grain interiors. The role of grain boundaries on slip transfer is examined using nano-indentation in combination with high-resolution EBSD. The use of detailed IC and EBSD-based experiments are discussed as they relate to crystal-plasticity finite element (CPFE) model calibration and validation.

Gupta, Vipul↗

Recent progress in NASA Langley textile reinforced composites program

The NASA LaRC is conducting and sponsoring research to explore the benefits of textile reinforced composites for civil transport aircraft primary structures. The objective of this program is to develop and demonstrate the potential of affordable textile reinforced composite materials to meet design properties and damage tolerance requirements of advanced aircraft structural concepts. In addition to in-house research, the program was recently expanded to include major participation by the aircraft industry and aerospace textile companies. The major program elements include development of textile preforms, processing science, mechanics of materials, experimental characterization of materials, and development and evaluation of textile reinforced composite structural elements and subcomponents. The NASA Langley in-house focus is as follows: development of a science-based understanding of resin transfer molding (RTM), development of powder-coated towpreg processes, analysis methodology, and development of a performance database on textile reinforced composites. The focus of the textile industry participation is on development of multidirectional, damage-tolerant preforms, and the aircraft industry participation is in the areas of design, fabrication and testing of textile reinforced composite structural elements and subcomponents. Textile processes such as 3D weaving, 2D and 3D braiding, and knitting/stitching are being compared with conventional laminated tape processes for improved damage tolerance. Through-the-thickness reinforcements offer significant damage tolerance improvements. However, these gains must be weighed against potential loss in in-plane properties such as strength and stiffness. Analytical trade studies are underway to establish design guidelines for the application of textile material forms to meet specific loading requirements. Fabrication and testing of large structural components are required to establish the full potential of textile reinforced composite materials.

Dexter, H. Benson↗

Steady-state thermal-solutal convection and diffusion in a simulated float zone

Models describing the steady-state thermal diffusion in a pure system, the thermal-solutal diffusion in a binary system, and heat and momentum transverse in a pure system are presented. The geometry of the model is described by a 2D Cartesian coordinate system that is applicable for crystal sheets. The melting, solidifying, and melt/gas interfacial shapes as well as the thermal, flow, and solutal profiles are analytically evaluated as functions of the heat and ambient temperature profiles and material properties. The solution procedure involves a coupled asymptotic/numerical approach which reduces the coupled set of partial differential equations to ordinary type. The results should be applicable in situations where melt flows are not intense enough to change the thermal field in pure systems, or where the physical properties of the melt are such that the convective field is decoupled from the thermal field, the latter being established primarily by diffusion.

Young, G. W.↗

NESC GN&C TDT Workshop on 2D Image Motion Optical Transfer Functions, Pointing Performance Analysis, and Requirements

This course was prepared by the author in support of the NASA GN&C Technical Discipline Team (TDT). The purpose of this two-day course is to inform practicing GN&C engineers, and other system and subsystem engineers, including payload engineers and mission analysts, of methodologies to analyze the pointing performance of spacecraft and to write unambiguous pointing requirements that are relevant to optical payload performance. It is hoped that the seminar will contribute to a best-practices manual and contribute to accepted and uniform means of requirements definition, validation, and verification. The course material is designed to address the needs of not only practicing GN&C engineers, but also system and subsystem engineers of other disciplines, payload engineers, mission analysts, and even astronomers who need to understand how they interface to a GN&C subsystem. Much revision is the direct result of active student participation during the presentations and from feedback obtained through course evaluation forms.

2D Image↗

Analysis of Arc Welding Process in Space

This work is motivated by NASA plans to conduct welding experiments on the ISS. It is expected that deployment of welding and additive manufacturing technologies in the space environment has the potential to revolutionise how orbiting platforms are designed, manufactured, and assembled. However, the structure, composition and quality of a weld is extremely dependent on the environment and can be difficult to control in space. Shielding gases would also be tough to manage as gases behave differently in zero gravity and airless environments. Additional points of concern are related to the spatter and sparks dynamics in space. Therefore, there is a need for a more basic understanding of welding processes by computational modelling. To provide such an insight we developed state of art models of the ARC torch, droplet detachment and transfer, and the melt pool build up using magnetohydrodynamics approximation and level set method for two-phase liquid metal/-gas flow modelling. Two finite element models were built using 2D axisymmetric geometry in COMSOL Multiphysics®: (i) stationary model of the ARC torch and (ii) dynamical model of droplet detachment and transfer. Both models demonstrate reasonable agreement with earlier experimental observations and high sensitivity to the temperature dependence of the thermophysical parameters on the system materials. The models were used to provide physical insight into ARC welding in various environments and geometries. It was shown, in particular, that there is a significant probability of gas bubbles trapping in the meltpool and a possibility of unbounded wondering of sparks in the welding chamber in zero gravity. In addition, we estimated metal evaporation rate that may be hazardous in the confined environment of the ISS. These issues raise concern of quality of the weld and safety for ISS applications.

ARC welding↗

Towards Autonomous Lunar Resource Excavation via Reinforcement Learning

To continue on a sustainable and flexible path, NASA needs to address the challenge of collecting and moving large amounts of regolith at the destination. NASA’s Regolith Advanced Surface Systems Operations Robot (RASSOR) is principally designed to mine and deliver regolith for In-Situ Resource Utilization (ISRU) processing. RASSOR’s design enables it to efficiently collect and deposit regolith, return collected material for processing, and myriad related ISRU activities. To reliably perform these operations on the lunar surface, RASSOR software and sensory systems need to be robust and maximize the information extracted from a reduced sensor payload. Herein, we present preliminary findings from the Intelligent Capabilities Enhanced RASSOR project. We created reduced-order simulation environments to develop autonomous trenching controllers via reinforcement learning and prototype state estimation architectures. The goal of reinforcement learning is for an agent to learn a policy (task strategy) through interactions with an environment. When the agent performs an action, a change occurs in environment state and a numerical reward is received which informs the agent whether the action performed was good or not. Since reinforcement learning algorithms learn through trial-and-error, a simulation is a desirable first environment for development and learning. We developed two simulations, the first is a 2D excavation simulation developed to facilitate parameter selection, and a 3D simulation developed using a game physics engine, to simulate simplified soil interactions and increase the fidelity of the dynamic models of the robotic agents. The development of this 3D simulation has enabled the training of additional sensing capabilities and research both at the granular mechanics and operations levels. We experimented with various virtual sensor payloads to identify a combination that enabled efficient excavation operation and learning. Our reward function is based on how much material is excavated per step. A penalty is also received for leaving the dig site and to smooth the acceleration of the drum arms. We implemented pseudo time-of-flight sensors to report distance from each drum to ground and the height above ground which was found to be more efficient than existing solutions. Our findings suggest that reinforcement learning for autonomous operations has learned viable trenching strategies within 3000 training episodes in our simplified 2D environment and helped identify desirable sensing capabilities, arrangements, and considerations such as the positioning of time-of-flight sensors. Future work includes expanding our simulation to more complex environments and scenarios, and transfer learning from simulation to RASSOR 2.0 hardware for deployment in the Regolith Test Bin at NASA's Kennedy Space Center.

rassor↗

Users manual for AUTOMESH-2D: A program of automatic mesh generation for two-dimensional scattering analysis by the finite element method

AUTOMESH-2D is a computer program specifically designed as a preprocessor for the scattering analysis of two dimensional bodies by the finite element method. This program was developed due to a need for reproducing the effort required to define and check the geometry data, element topology, and material properties. There are six modules in the program: (1) Parameter Specification; (2) Data Input; (3) Node Generation; (4) Element Generation; (5) Mesh Smoothing; and (5) Data File Generation.

Hua, Chongyu↗

An Immersed Boundary Method for Solving the Compressible Navier-Stokes Equations with Fluid Structure Interaction

An immersed boundary method for the compressible Navier-Stokes equation and the additional infrastructure that is needed to solve moving boundary problems and fully coupled fluid-structure interaction is described. All the methods described in this paper were implemented in NASA's LAVA solver framework. The underlying immersed boundary method is based on the locally stabilized immersed boundary method that was previously introduced by the authors. In the present paper this method is extended to account for all aspects that are involved for fluid structure interaction simulations, such as fast geometry queries and stencil computations, the treatment of freshly cleared cells, and the coupling of the computational fluid dynamics solver with a linear structural finite element method. The current approach is validated for moving boundary problems with prescribed body motion and fully coupled fluid structure interaction problems in 2D and 3D. As part of the validation procedure, results from the second AIAA aeroelastic prediction workshop are also presented. The current paper is regarded as a proof of concept study, while more advanced methods for fluid structure interaction are currently being investigated, such as geometric and material nonlinearities, and advanced coupling approaches.

Equations↗