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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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NASA NTRS2005

Structural Verification of the Redesigned Space Shuttle Bipod Foam Closeout

This document outlines the structural verification approach for the Space Shuttle External Tank Forward Bipod Foam Closeout. Due to the Space Shuttle Columbia accident, debris has become a major concern. The intent of the structural verification is to ensure that any debris shed from the bipod is within acceptable limits. Since cohesive failure due to internal defects was identified as the most likely cause of the STS-107 bipod ramp foam failure, verification for this failure mode receives particular emphasis. However, all failure modes for TPS are considered and appropriate verification rationale is developed for each failure mode. Figure 1 depicts the structural verification of a production design where analysis and test are the primary methods of verification. It can be seen that the successful completion of structural verification is dependent on three main areas: 1. Production process control and quality assurance must ensure that test articles and/or analytical models are representative of (or conservatively envelope) production hardware in terms of geometry, materials and processing. Variability and defects must be considered. 2. Flight environments must be sufficiently characterized to bound driving environments for all failure modes. Applied environments, either test or analytical, must be representative of flight environments and have a load factor that satisfies design requirements. 3. Structural verification must include all failure modes. A comprehensive list of failure modes and the underlying failure mechanisms has been generated based on flight and test experience. Verification tests and / or analyses must address each failure mode. ET TPS Verification is accomplished by a combination of analysis, test, and similarity.

Poole, Eric L.↗

DOE OSTI2025

Predictive dynamic wetting, fluid–structure interaction simulations for braze run-out

Brazing and soldering are metallurgical joining techniques that use a wetting molten metal to create a joint between two faying surfaces. Here, the quality of the brazing process depends strongly on the wetting properties of the molten filler metal, namely the surface tension and contact angle, and the resulting joint can be susceptible to various defects, such as run-out and underfill, if the material properties or joining conditions are not suitable. In this work, we implement a finite element simulation to predict the formation of such defects in braze processes. This model incorporates both fluid–structure interaction through an arbitrary Eulerian–Lagrangian technique and free surface wetting through conformal decomposition finite element modeling. Upon validating our numerical simulations against experimental run-out studies on a silver-Kovar system, we then use the model to predict run-out and underfill in systems with variable surface tension, contact angles, and applied pressure. Finally, we consider variable joint/surface geometries and show how different geometrical configurations can help to mitigate run-out. This work aims to understand how brazing defects arise and validate a coupled wetting and fluid–structure interaction simulation that can be used for other industrial problems.

36 MATERIALS SCIENCE↗

NASA NTRS1999

Variable Complexity Optimization of Composite Structures

The use of several levels of modeling in design has been dubbed variable complexity modeling. The work under the grant focused on developing variable complexity modeling strategies with emphasis on response surface techniques. Applications included design of plates with discontinuities subject to uncertainty in material properties and geometry, design of stiffened composite plates for improved damage tolerance, and the use of response surfaces for fitting weights obtained by structural optimization.

Haftka, Raphael T.↗

NASA NTRS1972

Fastening on the F-14A for cost effective fatigue resistance

Cost effectiveness airframe considerations dictated a variable geometry wing design that requires weight optimization, maximum working stress resistance and minimum fatigue concentration factors. The extensive use of titanium structural materials employed electron beam welding methods and interference fit fastening techniques as principle mechanical joining means for economic F-14A production and reliability engineering.

Beal, B. H.↗

NASA NTRS1993

High-Temperature, Flexible, Pressure-Assisted Brush Seal

Ceramic-fibers brush and integral spring clip block hot, engine flows. High-temperature, pressure-assisted brush seal installed in movable panel in advanced hypersonic engine. Seal prevents flow of hot engine gas from penetrating gap between movable panel and adjacent stationary panel. Potential applications include sealing gaps in variable-geometry two-dimensional turbojet exhaust nozzles or sealing control surface gaps of hypersonic vehicles. Ceramic brush seals also used as structural seals in high-temperature furnaces or advanced ceramic heat exchangers.

Steinetz, Bruce M.↗

NASA NTRS1991

Commercialization of NESSUS: Status

A plan was initiated in 1988 to commercialize the Numerical Evaluation of Stochastic Structures Under Stress (NESSUS) probabilistic structural analysis software. The goal of the on-going commercialization effort is to begin the transfer of Probabilistic Structural Analysis Method (PSAM) developed technology into industry and to develop additional funding resources in the general area of structural reliability. The commercialization effort is summarized. The SwRI NESSUS Software System is a general purpose probabilistic finite element computer program using state of the art methods for predicting stochastic structural response due to random loads, material properties, part geometry, and boundary conditions. NESSUS can be used to assess structural reliability, to compute probability of failure, to rank the input random variables by importance, and to provide a more cost effective design than traditional methods. The goal is to develop a general probabilistic structural analysis methodology to assist in the certification of critical components in the next generation Space Shuttle Main Engine.

Thacker, Ben H.↗

DOE OSTI2026

First-Principles Evaluation of Proton Hopping in Tetrahedral Oxide Motifs

Proton-conducting oxides (PCOs) are important materials used as ionic conductors for energy conversion technologies. Existing research efforts on PCO optimization and discovery generally focus on complex perovskite-based oxides that require doping and alloying to engineer oxygen deficiency and high proton conductivity. However, the variety of chemical compositions and coordination environments in oxides poses challenges for efficient materials design. In this computational study, we construct a database of simplified motifs to elucidate the relationship between fundamental materials chemistry and proton kinetics. Specifically, we focus on the zincblende crystal structure as a proxy for tetrahedral metal–oxide (M–O) coordination environments. We systematically quantified the effects of cation type, oxidation states, and M–O bond lengths on the proton hopping barrier, and found that strong M–O bonds and metal cations with large and variable oxidation states (e.g., Mo 6+ , V 5+ ) lead to smaller proton hopping barriers. By mapping the candidate cations and their preferred bond geometries onto materials databases such as the Inorganic Crystal Structure Database (ICSD) and Materials Project, we identified real materials containing the corresponding metal–oxide units. In general, we observed good agreement between the calculated proton hopping barriers obtained in real crystal structures and those predicted by our motif database. We also discuss the limitations of our model and possible future extensions to improve its predictive capabilities. Overall, our model provides a first step for the rational design and quick screening of energy-efficient PCOs.

organic↗

NASA NTRS2003

Thermal Response of Cooled Silicon Nitride Plate Due to Thermal Conductivity Effects Analyzed

Lightweight, strong, tough high-temperature materials are required to complement efficiency improvements for next-generation gas turbine engines that can operate with minimum cooling. Because of their low density, high-temperature strength, and high thermal conductivity, ceramics are being investigated as materials to replace the nickelbase superalloys that are currently used for engine hot-section components. Ceramic structures can withstand higher operating temperatures and a harsh combustion environment. In addition, their low densities relative to metals help reduce component mass (ref. 1). To complement the effectiveness of the ceramics and their applicability for turbine engine applications, a parametric study using the finite element method is being carried out. The NASA Glenn Research Center remains very active in conducting and supporting a variety of research activities related to ceramic matrix composites through both experimental and analytical efforts (ref. 1). The objectives of this work are to develop manufacturing technology, develop a thermal and environmental barrier coating (TBC/EBC), develop an analytical modeling capability to predict thermomechanical stresses, and perform a minimal burner rig test on silicon nitride (Si3N4) and SiC/SiC turbine nozzle vanes under simulated engine conditions. Moreover, we intend to generate a detailed database of the material s property characteristics and their effects on structural response. We expect to offer a wide range of data since the modeling will account for other variables, such as cooling channel geometry and spacing. Comprehensive analyses have begun on a plate specimen with Si3N4 cooling holes.

Baaklini, George Y.↗

NASA NTRS1981

Cooled variable nozzle radial turbine for rotor craft applications

An advanced, small 2.27 kb/sec (5 lbs/sec), high temperature, variable area radial turbine was studied for a rotor craft application. Variable capacity cycles including single-shaft and free-turbine engine configurations were analyzed to define an optimum engine design configuration. Parametric optimizations were made on cooled and uncooled rotor configurations. A detailed structural and heat transfer analysis was conducted to provide a 4000-hour life HP turbine with material properties of the 1988 time frame. A pivoted vane and a moveable sidewall geometry were analyzed. Cooling and variable geometry penalties were included in the cycle analysis. A variable geometry free-turbine engine configuration with a design 1477K (2200 F) inlet temperature and a compressor pressure ratio of 16:1 was selected. An uncooled HP radial turbine rotor with a moveable sidewall nozzle showed the highest performance potential for a time weighted duty cycle.

Rogo, C.↗

DOE OSTI2025

Variable X-Ray Reverberation in the Rapidly Accreting Active Galactic Nucleus Ark 564: The Response of the Soft Excess to the Changing Geometry of the Inner Accretion Flow

X-ray reverberation, which exploits the time delays between variability in different energy bands as a function of Fourier frequency, probes the structure of the inner accretion disks and X-ray coronae of active galactic nuclei. We present a systematic X-ray spectroscopic and reverberation study of the high-Eddington-ratio narrow-line Seyfert 1 galaxy Ark 564, using over 900 ks of XMM-Newton and NuSTAR observations spanning 13 yr. The time-averaged spectra can be well described by a model consisting of a coronal continuum, relativistic disk reflection, warm Comptonization, and three warm absorbers. Leveraging the high X-ray brightness of Ark 564, we are able to resolve the time evolution of the spectra and contemporaneous reverberation lags. The soft-band lag relative to the continuum increases with the X-ray flux, while Fe Kα lags are detected in only a subset of epochs and do not correlate with soft lags. Models based on a lamppost corona and reflection from a standard thin disk can broadly reproduce the observed lag-energy spectra of low-flux epochs; however, additional reverberation from the warm Comptonized atmosphere is required to explain the soft lags observed in high-flux epochs. A vertically puffed-up inner disk and a variable, vertically extended corona can better explain the observed evolution of the lags and covariance spectra. Our study underscores the importance of multiepoch, multiband analyses for a comprehensive understanding the inner accretion disk and corona.

Active galactic nuclei↗

NASA NTRS2021

A Summary of Normal Incidence Tube Tests of NASA'S Bio-inspired Broadband Acoustic Absorber

Motivated by the need to reduce noise pollution from aircraft engines, NASA has continued to design, manufacture and test recently patented structures that mimic the geometry and the broadband and low frequency acoustic absorption of assemblies of natural reeds. This report documents a screening test, which is a precursor to more controlled modelling experiments. The purpose of this experiment was to identify variables and prototype design features that might play a dominant role in the acoustic performance of these structures. To date, twenty-four prototypes, each with an overall shape of a cube (nominally 50 mm x 50 mm x 50 mm), were designed and additively manufactured from thermoplastics using a Fused Filament Fabrication technique. The prototypes were tested in the NASA Glenn and Langley Normal Incidence Tubes to experimentally determine the acoustic absorption as a function of frequency from 400 Hz to 3000 Hz. Results indicate that a variety of structures exhibit substantial acoustic absorption in that frequency range, with an average absorption coefficient greater than 0.6, especially in the frequency range of 400 Hz to 1000 Hz. Six basic prototype designs were chosen to inform future modeling research. Results of these experiments can be used to evaluate existing physics-based models of the interaction of sound waves with these structures or to develop new models. Validated physics-based models of these structures can help engineers optimize the designs for different commercial noise control applications.

Acoustics↗

NASA NTRS1987

IUE observations of the dwarf nova HL Canis Majoris and the winds of cataclysmic variables

An observational and theoretical study is conducted of the P Cygni profiles of cataclysmic variables, with attention to the profiles of the dwarf nova HL CMa, in light of the ionization structure of the wind for a given geometry. It is found that a spherically symmetric wind is capable of generating the observed profile shapes when the accretion disk is limb-darkened, provided that the acceleration of the wind is very low and that the wind represents a mass-loss rate of about 10 to the -11th/C IV ionization fraction of the solar mass per year; a wind of this magnitude, however, cannot be driven by radiation pressure.

Mauche, Christopher W.↗

NASA NTRS2019

Numerical Investigation and Optimization of a Flushwall Injector for Scramjet Applications at Hypervelocity Flow Conditions

An investigation utilizing Reynolds-averaged simulations (RAS) was performed in order to demonstrate the use of design and analysis of computer experiments (DACE) methods in Sandia’s DAKOTA software package for surrogate modeling and optimization. These methods were applied to a flow- path fueled with an interdigitated flushwall injector suitable for scramjet applications at hyper- velocity conditions and ascending along a constant dynamic pressure flight trajectory. The flight Mach number, duct height, spanwise width, and injection angle were the design variables selected to maximize two objective functions: the thrust potential and combustion efficiency. Because the RAS of this case are computationally expensive, surrogate models are used for optimization. To build a surrogate model a RAS database is created. The sequence of the design variables comprising the database were generated using a Latin hypercube sampling (LHS) method. A methodology was also developed to automatically build geometries and generate structured grids for each design point. The ensuing RAS analysis generated the simulation database from which the two objective functions were computed using a one-dimensionalization (1D) of the three-dimensional simulation data. The data were fitted using four surrogate models: an artificial neural network (ANN), a cubic polynomial, a quadratic polynomial, and a Kriging model. Variance-based decomposition showed that both objective functions were primarily driven by changes in the duct height. Multiobjective design optimization was performed for all four surrogate models via a genetic algorithm method. Optimal solutions were obtained at the upper and lower bounds of the flight Mach number range. The Kriging model predicted an optimal solution set that exhibited high values for both objective functions. Additionally, three challenge points were selected to assess the designs on the Pareto fronts. Further sampling among the designs of the Pareto fronts may be required to lower the surrogate model errors and perform more accurate surrogate-model-based optimization.

Shenoy, Rajiv R.↗

NASA NTRS1994

Probabilistic assessment of space nuclear propulsion system nozzle

In assessing the reliability of a space nuclear propulsion system (SNPS) nozzle, uncertainties associated with the following design parameters were considered: geometry, boundary conditions, material behavior, and thermal and pressure loads. A preliminary assessment of the reliability was performed using NESSUS (Numerical Evaluation of Stochastic Structures Under Stress), a finite-element computer code developed at the NASA Lewis Research Center. The sensitivity of the nozzle reliability to the uncertainties in the random variables was quantified. With respect to the effective stress, preliminary results showed that the nozzle spatial geometry uncertainties have the most significant effect at low probabilities whereas the inner wall temperature has the most significant effect at higher probabilities.

Shah, Ashwin R.↗

DOE OSTI2022

2.2.1.410 - Significant Cost Reduction Potential for Wave Energy Conversion Devices with Variable-Geometry Modules

The Technology Commercialization Fund (TCF) award is built upon NREL's previous research exploring a bottom-fixed variable-geometry oscillating surge wave energy converter (VGOSWEC); however, unlike previous investigations, the VGOSWEC will be raised off the sea floor. Researchers believe that advances in offshore pilings and foundations, such as 3D printing, will provide low cost and easily deployable structures. There are several benefits to designing a raised VGOSWEC such as 1) reducing issues with sediment transport and environmental impacts near shore, 2) less expensive deployment and installation as work boats will not risk grounding in shallow water, and 3) deeper water deployments improve the wave resource.

oscillating surge wave energy converter↗

DOE OSTI2023

EPiC-GAN: Equivariant point cloud generation for particle jets

With the vast data-collecting capabilities of current and future high-energy collider experiments, there is an increasing demand for computationally efficient simulations. Generative machine learning models enable fast event generation, yet so far these approaches are largely constrained to fixed data structures and rigid detector geometries. In this paper, we introduce EPiC-GAN - equivariant point cloud generative adversarial network - which can produce point clouds of variable multiplicity. This flexible framework is based on deep sets and is well suited for simulating sprays of particles called jets. The generator and discriminator utilize multiple EPiC layers with an interpretable global latent vector. Crucially, the EPiC layers do not rely on pairwise information sharing between particles, which leads to a significant speed-up over graph- and transformer-based approaches with more complex relation diagrams. We demonstrate that EPiC-GAN scales well to large particle multiplicities and achieves high generation fidelity on benchmark jet generation tasks.

Buhmann, Erik↗

NASA NTRS1990

Disintegration of liquid sheets

The development, stability, and disintegration of liquid sheets issuing from a two-dimensional air-assisted nozzle is studied. Detailed measurements of mean drop size and velocity are made using a phase Doppler particle analyzer. Without air flow the liquid sheet converges toward the axis as a result of surface tension forces. With airflow a quasi-two-dimensional expanding spray is formed. The air flow causes small variations in sheet thickness to develop into major disturbances with the result that disruption starts before the formation of the main break-up region. In the two-dimensional variable geometry air-blast atomizer, it is shown that the air flow is responsible for the formation of large, ordered, and small chaotic 'cell' structures.

Mansour, Adel↗

NASA NTRS1992

Design, analysis, and testing of the Phase 1 CSI Evolutionary Model erectable truss

This report addressed the design, analysis, and testing of the erectable truss structure for the Phase 1 CSI Evolutionary Model (CEM) testbed. The Phase 1 CEM testbed is the second testbed to form part of an ongoing program of focused research at NASA/LaRC in the development of Controls-Structures Integration (CSI) technology. The Phase 1 CEM contains the same overall geometry, weight, and sensor locations as the Phase 0 CEM, but is based in an integrated controller and structure design, whereby both structure and controller design variables are sized simultaneously. The Phase 1 CEM design features seven truss sections composed of struts with tailored mass and stiffness properties. A common erectable joint is used and the strut stiffness is tailored by varying the cross-sectional area. To characterize the structure, static tests were conducted on individual struts and 10-bay truss assemblies. Dynamic tests were conducted on 10-bay truss assemblies as well as the fully-assembled CEM truss. The results indicate that the static and dynamic properties of the structure are predictable, well-characterized, and within the performance requirements established during the Phase 1 CEM integrated controller/structure design analysis.

Gronet, M. J.↗