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At least 127 records · Page 7

X-57 Ground Dynamics Modeling and Analysis

This paper presents simulation work to assess the ground handling behavior of the X-57 airplane, prior to its first flight under electric propulsion. A tire deformation model was fit to manufacturer ground testing data to develop a detailed simulation model of previously unmodeled rolling drag forces on the tires. A special modeling effort corrected for a difference between the runway surface in the manufacturer data (grass) and in intended X-57 surface operations (asphalt/concrete). Analysis based on variation in the test conditions of the manufacturer test data showed that uncertainty in the new estimated rolling drag model should lead to no more than 1.5-percent uncertainty in the takeoff acceleration. Another batch simulation series swept across ground operating conditions and airplane configurations, characterizing turning radii and roll angles experienced for different open-loop steering commands in these various situations. This simulation allowed the identification of ground handling characteristics even beyond the regime of normal operations. As part of this task, a new, modified variant of the Fibonacci search algorithm identified the correct steering inputs for maintaining a straight path as a function of the operating condition. Finally, this paper describes a fixed-base piloted simulator assessment. This assessment supplements the previous simulated ground dynamics data with pilot-in-the-loop data and pilot feedback and confirms the overall acceptability of the ground handling qualities of the X-57 airplane prior to first flight.

Loren J. Newton↗

Cruise noise measurements of a scale model advanced ducted propulsor

A scale model Advanced Ducted Propulsor (ADP) was tested in NASA Lewis Research Center's 8- by 6-Foot Wind Tunnel to obtain acoustic data at cruise conditions. The model, designed and manufactured by Pratt & Whitney Division of United Technologies, was tested with three inlet lengths. The model has 16 rotor blades and 22 stator vanes, which results in a cut-on condition with respect to rotor-stator interaction noise. Comparisons of the noise directivity of the ADP with that of a previously tested high-speed, unducted propeller showed that the ADP peak blade passing tone was about 30 dB below that of the propeller, and therefore, should not present a cabin or enroute noise problem. The maximum blade passing tone first increased with increasing helical tip Mach number, peaked, and then decreased at a higher Mach number. The ADP tests with the shortest inlet showed more noise in the inlet arc than did tests with either of the other two inlet lengths.

Dittmar, James H.↗

Predicting Melt Properties Using Atomistic Simulations With A Highly Accurate Physically Informed Neural Network Interatomic Potential

The use of a recently developed machine learning (ML) interatomic potential for molecular dynamics simulations of aluminum melt properties will be presented. Such properties are critical for process modeling in additive manufacturing, including the melt pool size, solidification, and formation of solidification microstructures. Direct first-principles modeling of these processes is computationally prohibitive whereas simulations employing ML potentials combine the high accuracy of quantum-mechanical methods with high computational speeds. The physically-informed neural network (PINN) method used herein, integrates a high-dimensional regression implemented by an artificial neural network with a physics-based bond-order interatomic potential. PINN potentials can accurately reproduce many properties of aluminum in both crystalline-solid and liquid phases. We examine the accuracy of a PINN Al potential in predicting the density, self-diffusivity, viscosity, and the tension of the liquid surface and liquid-solid interfaces. Comparison with experimental data and ab initio molecular dynamics calculations shows very good agreement for all properties tested.

molecular dynamics↗

Correlated Electromagnetic Levitation Actuator: A Reaction Sphere Based Attitude Control System

To address problems experienced by current reaction wheels and control moment gyroscopebased attitude control systems (ACS), researchers at NASA’s Marshall Space Flight Center have begun developing a reaction sphere actuator based on correlated electromagnetic levitation that will be immune to destructive bearing friction, momentum saturation, and gimbal lock. The Correlated Electromagnetic Levitation Actuator (CELA) advances the state of the art of reaction sphere ACSs by employing the concept of correlated magnetics. It is a frictionless, direct-drive reaction sphere that harnesses a unique technology with an array of applications across multiple disciplines. Correlated electromagnets function in a manner that is analogous to a matched filter; the convolution of two signals is peaked at the index representing the greatest match. For CELA, the signals are the patterns of magnetic flux density as a function of position. The magnitude of the convolution equates to an attractive or repulsive force, and these forces can be azimuthal or radial. The development of CELA is based in four distinct disciplines: Advanced Manufacturing, Prototype Development, Electromagnetic Modeling, and Controls. We are developing novel manufacturing techniques required to build arrays of permanent and electromagnet dipoles on curved surfaces. To print the permanent magnetic array, we have developed a probe with pyramidal magnets that will reside on a robotic arm to induce localized magnetic fields on a surface. The probe also includes the ability to erase dipole patterns from a permanent magnet by heating the surface to its Curie temperature. A number of test articles and prototypes have been developed using additive manufacturing methods. These prototypes have included hemispherical motors to test the drive algorithm, and a levitation test bed that demonstrates a magnetic bearing method based on attractive magnetic forces and ratiometric Hall effect sensors. We developed an array of electromagnetic dipoles on a printed circuit board (PCB) with individual H-bridges controlling each coil. This device created various flux density patterns and we measured their magnetic fields using a custom Hall effect 3-D probe and a LabVIEW virtual instrument. These data will serve as a benchmark for characterizing the accuracy of future models. Current work is focused on modeling the magnetic fields of our prototype arrays using COMSOL Finite Element Analysis and verifying the model against our test data. Accurate modeling will allow us to quickly test new patterns of electromagnets and their macro behavior. Eventually, the magnetic field models will be implemented in our controls simulations to facilitate precise control of the reaction sphere. Initial model results agree with field measurements to within 1 G (5% of measured flux density). Currently, we are testing different material properties of the electromagnets and their magnetic fields and thermal effects. These results will be used to refine the design of the electromagnetic dipoles. Our control efforts have centered on developing commutation, levitation, and field pattern shaping hardware in the form of breadboards and PCBs with software running on a local microcontroller. In addition, our partners developed MATLAB Simulink models to demonstrate a PID controller thatmitigates disturbance forces resulting from the interaction of drive and levitation magnetics. Finally, we have designed a three-axis test stand that will be used in future work to demonstrate CELA’s orientation control capability.

controls↗

Correlated Electromagnetic Levitation Actuator: A Reaction Sphere-Based Attitude Control System

To address problems experienced by current reaction wheels and control moment gyroscopebased attitude control systems (ACS), researchers at National Aeronautics and Space Administration’s (NASA’s) Marshall Space Flight Center (MSFC) have begun developing a reaction sphere actuator based on correlated electromagnetic levitation that will be immune to destructive bearing friction, momentum saturation, and gimbal lock. The Correlated Electromagnetic Levitation Actuator (CELA) advances the state of the art of reaction sphere ACSs by employing the concept of correlated magnetics. It is a frictionless, direct-drive reaction sphere that harnesses a unique technology with an array of applications across multiple disciplines. Correlated electromagnets function in a manner that is analogous to a matched filter; the convolution of two signals is peaked at the index representing the greatest match. For CELA, the signals are the patterns of magnetic flux density as a function of position. The magnitude of the convolution equates to an attractive or repulsive force, and these forces can be azimuthal or radial. The development of CELA is based in four distinct disciplines: Advanced Manufacturing, Prototype Development, Electromagnetic Modeling, and Controls. We are developing novel manufacturing techniques required to build arrays of permanent and electromagnet dipoles on curved surfaces. To print the permanent magnetic array, we have developed a probe with pyramidal magnets that will reside on a robotic arm to induce localized magnetic fields on a surface. We have also used high temperature ovens to erase dipole patterns from a permanent magnet by heating the surface to its Curie temperature. A number of test articles and prototypes have been developed using additive manufacturing methods. These prototypes have included hemispherical motors to test the drive algorithm, and a levitation test bed that demonstrates a magnetic bearing method based on attractive magnetic forces and ratiometric Hall effect sensors. We developed an array of electromagnetic dipoles on a printed circuit board (PCB) with individual H-bridges controlling each coil. This device created various flux density patterns and we measured their magnetic fields using a custom Hall effect 3-D probe and a LabVIEW virtual instrument. These data will serve as a benchmark for characterizing the accuracy of future models. Current work is focused on modeling the magnetic fields of our prototype arrays using COMSOL finite element analysis (FEA) and verifying the model against our test data. Accurate modeling will allow us to quickly test new patterns of electromagnets and their macro behavior. Eventually, the magnetic field models will be implemented in our controls simulations to facilitate precise control of the reaction sphere. Initial model results agree with field measurements to within 1 G (5% of measured flux density). Currently, we are testing different material properties of the electromagnets and their magnetic fields and thermal effects. These results will be used to refine the design of the electromagnetic dipoles. Our control efforts have centered on developing commutation, levitation, and field pattern shaping hardware in the form of breadboards and PCBs with software running on a local microcontroller. In addition, our partners developed MATLAB Simulink models to demonstrate a PID controller that mitigates disturbance forces resulting from the interaction of drive and levitation magnetics. Finally, we have designed a three-axis test stand that will be used in future work to demonstrate CELA’s orientation control capability.

reaction sphere↗

Low Average Sidelobe Slot Array Antennas for Radiometer Applications

In radiometer applications, it is required to design antennas that meet low average sidelobe levels and low average return loss over a specified frequency bandwidth. It is a challenge to meet such specifications over a frequency range when one uses resonant elements such as waveguide feed slots. In addition to their inherent narrow frequency band performance, the problem is exacerbated due to modeling errors and manufacturing tolerances. There was a need to develop a design methodology to solve the problem. An iterative design procedure was developed by starting with an array architecture, lattice spacing, aperture distribution, waveguide dimensions, etc. The array was designed using Elliott s technique with appropriate values of the total slot conductance in each radiating waveguide, and the total resistance in each feed waveguide. Subsequently, the array performance was analyzed by the full wave method of moments solution to the pertinent integral equations. Monte Carlo simulations were also carried out to account for amplitude and phase errors introduced for the aperture distribution due to modeling errors as well as manufacturing tolerances. If the design margins for the average sidelobe level and the average return loss were not adequate, array architecture, lattice spacing, aperture distribution, and waveguide dimensions were varied in subsequent iterations. Once the design margins were found to be adequate, the iteration was stopped and a good design was achieved. A symmetric array architecture was found to meet the design specification with adequate margin. The specifications were near 40 dB for angular regions beyond 30 degrees from broadside. Separable Taylor distribution with nbar=4 and 35 dB sidelobe specification was chosen for each principal plane. A non-separable distribution obtained by the genetic algorithm was found to have similar characteristics. The element spacing was obtained to provide the required beamwidth and close to a null in the E-plane end-fire direction. Because of the alternating slot offsets, grating lobes called butterfly lobes are produced in non-principal planes close to the H-plane. An attempt to reduce the influence of such grating lobes resulted in a symmetric design.

Rengarajan, Sembiam↗

Feasibility of Additive Manufacturing for Thermal Protection Systems

Thermal Protection Systems (TPS) use advanced materials to protect vehicles from aerodynamic heating during atmospheric entry. Manufacturing of these composite materials is often very time consuming and labor-intensive. Leveraging the additive manufacturing FDM (Fused Deposition Modeling) process enables NASA to design and manufacture advanced ablative TPS materials while reducing manufacturing time and cost. Since additive manufacturing is an automated process, it ensures part consistency over the entire heat shield area. The purpose for this presentation will be three-fold. 1) Introduce novel low-density ablative materials capable of utilizing additive manufacturing capabilities 2) show feasibility of additively manufacturing TPS coupons using the downselected TPS materials 3) Side by side comparison of high temperature test results for printable paste and state of the art low-density ablators

T. Boghozian↗

Computational Modeling as a Design Tool in Microelectronics Manufacturing

Plans to introduce pilot lines or fabs for 300 mm processing are in progress. The IC technology is simultaneously moving towards 0.25/0.18 micron. The convergence of these two trends places unprecedented stringent demands on processes and equipments. More than ever, computational modeling is called upon to play a complementary role in equipment and process design. The pace in hardware/process development needs a matching pace in software development: an aggressive move towards developing "virtual reactors" is desirable and essential to reduce design cycle and costs. This goal has three elements: reactor scale model, feature level model, and database of physical/chemical properties. With these elements coupled, the complete model should function as a design aid in a CAD environment. This talk would aim at the description of various elements. At the reactor level, continuum, DSMC(or particle) and hybrid models will be discussed and compared using examples of plasma and thermal process simulations. In microtopography evolution, approaches such as level set methods compete with conventional geometric models. Regardless of the approach, the reliance on empricism is to be eliminated through coupling to reactor model and computational surface science. This coupling poses challenging issues of orders of magnitude variation in length and time scales. Finally, database development has fallen behind; current situation is rapidly aggravated by the ever newer chemistries emerging to meet process metrics. The virtual reactor would be a useless concept without an accompanying reliable database that consists of: thermal reaction pathways and rate constants, electron-molecule cross sections, thermochemical properties, transport properties, and finally, surface data on the interaction of radicals, atoms and ions with various surfaces. Large scale computational chemistry efforts are critical as experiments alone cannot meet database needs due to the difficulties associated with such controlled experiments and costs.

Meyyappan, Meyya↗

In Situ Manufacturing is a Necessary Part of Any Planetary Architecture

The key to any sustainable presence in space is the ability to manufacture necessary tools, parts, structures, spares, etc. in situ and on demand. Cost, volume, and up-mass constraints prohibit launching everything needed for long-duration or long-distance missions from Earth, including spare parts and replacement systems. There are many benefits to building items as-needed in situ using computer aided drafting (CAD) models and additive manufacturing technology: (1) Cost, up-mass, and volume savings for launch due to the ability to manufacture specific parts when needed. (2) CAD models can be generated on Earth and transmitted to the station or spacecraft, or they can be designed in situ for any task. Thus, multiple people in many locations can work on a single problem. (3) Items can be produced that will enhance the safety of crew and vehicles (e.g., latches or guards). (4) Items can be produced on-demand in a small amount of time (i.e., hours or days) compared to traditional manufacturing methods and, therefore, would not require the lengthy amount of time needed to machine the part from a solid block of material nor the wait time required if the part had to be launched from Earth. (5) Used and obsolete parts can be recycled into powder or wire feedstock for use in later manufacturing. (6) Ultimately, the ability to produce items as-needed will reduce mission risk, as one will have everything they need to fix a broken system or fashion a new part making it available on a more timely basis.

Edmunson, Jennifer E.↗

Toward Failure Modeling In Complex Dynamic Systems: Impact of Design and Manufacturing Variations

When designing vehicle vibration monitoring systems for aerospace devices, it is common to use well-established models of vibration features to determine whether failures or defects exist. Most of the algorithms used for failure detection rely on these models to detect significant changes during a flight environment. In actual practice, however, most vehicle vibration monitoring systems are corrupted by high rates of false alarms and missed detections. Research conducted at the NASA Ames Research Center has determined that a major reason for the high rates of false alarms and missed detections is the numerous sources of statistical variations that are not taken into account in the. modeling assumptions. In this paper, we address one such source of variations, namely, those caused during the design and manufacturing of rotating machinery components that make up aerospace systems. We present a novel way of modeling the vibration response by including design variations via probabilistic methods. The results demonstrate initial feasibility of the method, showing great promise in developing a general methodology for designing more accurate aerospace vehicle vibration monitoring systems.

Tumer, Irem Y.↗

High Temperature Material Property Data and Challenges to Thermal Process Model Predictions and In-Situ/Ex-Situ Measurements for Metallic Additive Manufacturing

Understanding and predicting performance properties of parts produced by metallic additive manufacturing has improved significantly over the past decade; however, difficult to measure material properties and process outcomes continue to be challenges. The qualification or certification of aerospace parts require extensive measures to quantify variable part properties in order to buy down the risk of component failure. The variability, inherent to the additive manufacturing, process adds unwanted uncertainty in the production of load critical structural components. Process modeling has proven valuable in providing predictions and context for understanding outcomes of the additive manufacturing process; however, these physically informed process models require material properties at temperatures that are difficult to measure and rarely available. Further, calibrating or validating such models is difficult because the process itself is challenging to measure. This talk will explore some of the challenges resulting from difficult to acquire input data by relating thermal process model predictions to in-situ and ex-situ optical microscopy measurements.

Process Model↗

Structural and Acoustic Numerical Modeling of a Curved Composite Honeycomb Panel

The finite and boundary element modeling of the curved section of a composite honeycomb aircraft fuselage sidewall was validated for both structural response and acoustic radiation. The curved panel was modeled in the pre-processor MSC/PATRAN. Geometry models of the curved panel were constructed based on the physical dimensions of the test article. Material properties were obtained from the panel manufacturer. Finite element models were developed to predict the modal parameters for free and supported panel boundary conditions up to a frequency of 600 Hz. Free boundary conditions were simulated by providing soft foam support under the four comers of the panel or by suspending the panel from elastic bands. Supported boundary conditions were obtained by clamping the panel between plastic tubing seated in grooves along the perimeter of a stiff and heavy frame. The frame was installed in the transmission loss window of the Structural Acoustic Loads and Transmission (SALT) facility at NASA Langley Research Center. The structural response of the curved panel due to point force excitation was predicted using MSC/NASTRAN and the radiated sound was computed with COMET/Acoustics. The predictions were compared with the results from experimental modal surveys and forced response tests on the fuselage panel. The finite element models were refined and updated to provide optimum comparison with the measured modal data. Excellent agreement was obtained between the numerical and experimental modal data for the free as well as for the supported boundary conditions. Frequency response functions (FRF) were computed relating the input force excitation at one panel location to the surface acceleration response at five panel locations. Frequency response functions were measured at the same locations on the test specimen and were compared with the calculated FRF values. Good agreement was obtained for the real and imaginary parts of the transfer functions when modal participation was allowed up to 3000 Hz. The validated finite element model was used to predict the surface velocities due to the point force excitation. Good agreement was obtained between the spatial characteristics of the predicted and measured surface velocities. The measured velocity data were input into the acoustic boundary element code to compute the sound radiated by the panel. The predicted sound pressure levels in the far-field of the panel agreed well with the sound pressure levels measured at the same location.

Grosveld, Ferdinand W.↗

Manufacturing stresses and strains in filament wound cylinders

Tests were performed to verify a previously developed model for simulating the manufacturing process of filament wound cylinders. The axial and hoop strains were measured during cure inside a filament wound Fiberite T300/976 graphite-epoxy cylinder. The measured strains were compared to those computed by the model. Good agreements were found between the data and the model, indicating that the model is a useful representation of the process. For the conditions of the test, the manufacturing stresses inside the cylinder were also calculated using the model.

Calius, E. P.↗

Lightweight Thrust Chamber Assemblies using Multi-Alloy Additive Manufacturing and Composite Overwrap

Additive Manufacturing (AM) has brought significant design and fabrication opportunities for complex components with internal features such as liquid rocket engine thrust chambers not previously possible. This technology allows for significant cost savings and schedule reductions in addition to new performance optimization through weight reduction and increased margins. Specific to regeneratively-cooled combustion chambers and nozzles for liquid rocket engines, additive manufacturing offers the ability to form the complex internal coolant channels and the closeout of the channels to contain the high pressure liquid propellants with a single operation. Much of additive manufacturing development has focused on monolithic alloys using Laser Powder Bed Fusion (L-PBF), which do not allow for complete optimization of the structure. The National Aeronautics and Space Administration (NASA) completed feasibility of an AM bimetallic L-PBF GRCop-84 copper-alloy combustion chamber with an AM electron beam freeform Inconel 625 structural jacket under the Low Cost Upper Stage Propulsion (LCUSP) Project. A follow-on project called Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) is under development to further expand large-scale multi-alloy thrust chambers while maturing composite overwrap technology for significant weight savings opportunities. The RAMPT project has three primary objectives: 1) Advancing blown powder Directed Energy Deposition (DED) to fabricate integral-channel large scale nozzles, 2) Develop composite overwrap technology to reduce weight and provide structural capability for thrust chamber assemblies, and 3) Develop bimetallic and multi-metallic additively manufactured radial and axial joints to optimize material performance. In addition to these primary manufacturing developments, analytical modeling efforts compliment the process development to simulate the AM processes to reduce build failures and distortions. The RAMPT project is also maturing the supply chain for various manufacturing processes described above in addition to L-PBF of GRCop-42. This paper will present an overview of the RAMPT project, the process development and hardware progress to date, material and hot-fire testing results, along with future developments.

Additive Manufacturing↗

Electrostatic Levitation for Studies of Additive Manufactured Materials

The electrostatic levitation (ESL) laboratory at NASA's Marshall Space Flight Center is a unique facility for investigators studying high temperature materials. The laboratory boasts two levitators in which samples can be levitated, heated, melted, undercooled, and resolidified. Electrostatic levitation minimizes gravitational effects and allows materials to be studied without contact with a container or instrumentation. The lab also has a high temperature emissivity measurement system, which provides normal spectral and normal total emissivity measurements at use temperature. The ESL lab has been instrumental in many pioneering materials investigations of thermophysical properties, e.g., creep measurements, solidification, triggered nucleation, and emissivity at high temperatures. Research in the ESL lab has already led to the development of advanced high temperature materials for aerospace applications, coatings for rocket nozzles, improved medical and industrial optics, metallic glasses, ablatives for reentry vehicles, and materials with memory. Modeling of additive manufacturing materials processing is necessary for the study of their resulting materials properties. In addition, the modeling of the selective laser melting processes and its materials property predictions are also underway. Unfortunately, there is very little data for the properties of these materials, especially of the materials in the liquid state. Some method to measure thermophysical properties of additive manufacturing materials is necessary. The ESL lab is ideal for these studies. The lab can provide surface tension and viscosity of molten materials, density measurements, emissivity measurements, and even creep strength measurements. The ESL lab can also determine melting temperature, surface temperatures, and phase transition temperatures of additive manufactured materials. This presentation will provide background on the ESL lab and its capabilities, provide an approach to using the ESL in supporting the development and modeling of the selective laser melting process for metals, and provide an overview of the results to date.

SanSoucie, Michael P.↗

Microburst model requirements for flight simulation: An airframe manufacturer's perspective

A brief outline is given of topics for presentation and discussion at the workshop. As manufacturers and certifiers of transport airplanes and associated on-board systems, an interest in the prevention of wind shear related accidents and incidents is inherent. The near term objectives are to provide the customers technical support in the areas of training as well as to research existing and potentially improved on-board systems. In the future, many improved systems should be implemented. This will require certification as well as further educational activity in the use of these new systems. A set of wind models is needed for design work which characterize a wide variety of real microbursts as measured during the JAWS project. The wind models should be limited in both size and complexity to just those features which degrade aircraft performance.

Schoenman, Richard L.↗

Melt Pool Imaging using a Configurable Architecture Additive Testbed System

This paper describes the inline (coaxial to laser) near infrared (NIR) camera sensor on the Configurable Architecture Additive Testbed (CAAT). The CAAT is an instrument that provides the capability to investigate laser based additive manufacturing (AM) processes and is configured for the metal powder bed fusion process. A low cost NIR camera is radiometrically calibrated to obtain coaxial, inline, imagery of laser generated melt pools. The camera capabilities, system optical path, and the uncertainty in the temperature measurement from NIR surface area scans on a bare titanium alloy plate are presented and discussed. The surface radiance measurements are compared to optical microscopy images of the melt pool width and depth. A metallic additive manufacturing process thermal model is developed in order to predict thermal distributions during laser scanning. The predicted thermal distributions by the model for different configurations are compared to the coaxial NIR measurements and discussed.

Additive manufacturing↗

IDSE Version 1 User's Manual

The integrated development support environment (IDSE) is a suite of integrated software tools that provide intelligent support for information modelling. These tools assist in function, information, and process modeling. Additional tools exist to assist in gathering and analyzing information to be modeled. This is a user's guide to application of the IDSE. Sections covering the requirements and design of each of the tools are presented. There are currently three integrated computer aided manufacturing definition (IDEF) modeling methodologies: IDEF0, IDEF1, and IDEF2. Also, four appendices exist to describe hardware and software requirements, installation procedures, and basic hardware usage.

Mayer, Richard↗