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NASA NTRS2025

Physics-Based Modeling and Simulation of Self-Reacting Friction Stir Welding Using Computational Fluid Dynamics

A physics-based model was developed to simulate the behavior of material in a self-reacting friction stir welding (SR-FSW) process for the joining of metals. This steady-state model builds upon fundamental computational fluid dynamic (CFD) principles within Ansys Fluent to solve the discretized equations. The effective viscosity is calculated using a viscoplastic model using a Sheppard-Wright formulation of flow stress. Numerous advancements have been made in the incorporated physics including (1) temperature-dependent material properties; (2) locally adaptable flow and thermal boundary conditions; and (3) adapting material properties in nugget in response to microstructural changes. Simulation strategies to accelerate computation and improve numerical stability include adapting the mesh refinement and solver relaxation factors during simulation. The result is a highly robust and computationally efficient model capable of providing the material flow and temperature history across the domain. As material history determines the local microstructure and ultimately weld strength, an accurate and detailed physics-based model has the potential to accelerate SR-FSW process development. The model is highly adaptable to changes in process parameters, tool design, or alloy.

Process Modeling↗

NASA NTRS2005

Verification and Validation: High Charge and Energy (HZE) Transport Codes and Future Development

In the present paper, we give the formalism for further developing a fully three-dimensional HZETRN code using marching procedures but also development of a new Green's function code is discussed. The final Green's function code is capable of not only validation in the space environment but also in ground based laboratories with directed beams of ions of specific energy and characterized with detailed diagnostic particle spectrometer devices. Special emphasis is given to verification of the computational procedures and validation of the resultant computational model using laboratory and spaceflight measurements. Due to historical requirements, two parallel development paths for computational model implementation using marching procedures and Green s function techniques are followed. A new version of the HZETRN code capable of simulating HZE ions with either laboratory or space boundary conditions is under development. Validation of computational models at this time is particularly important for President Bush s Initiative to develop infrastructure for human exploration with first target demonstration of the Crew Exploration Vehicle (CEV) in low Earth orbit in 2008.

Wilson, John W.↗

NASA NTRS1994

Some Problems and Solutions in Transferring Ecosystem Simulation Codes to Supercomputers

Many computer codes for the simulation of ecological systems have been developed in the last twenty-five years. This development took place initially on main-frame computers, then mini-computers, and more recently, on micro-computers and workstations. Recent recognition of ecosystem science as a High Performance Computing and Communications Program Grand Challenge area emphasizes supercomputers (both parallel and distributed systems) as the next set of tools for ecological simulation. Transferring ecosystem simulation codes to such systems is not a matter of simply compiling and executing existing code on the supercomputer since there are significant differences in the system architectures of sequential, scalar computers and parallel and/or vector supercomputers. To more appropriately match the application to the architecture (necessary to achieve reasonable performance), the parallelism (if it exists) of the original application must be exploited. We discuss our work in transferring a general grassland simulation model (developed on a VAX in the FORTRAN computer programming language) to a Cray Y-MP. We show the Cray shared-memory vector-architecture, and discuss our rationale for selecting the Cray. We describe porting the model to the Cray and executing and verifying a baseline version, and we discuss the changes we made to exploit the parallelism in the application and to improve code execution. As a result, the Cray executed the model 30 times faster than the VAX 11/785 and 10 times faster than a Sun 4 workstation. We achieved an additional speed-up of approximately 30 percent over the original Cray run by using the compiler's vectorizing capabilities and the machine's ability to put subroutines and functions "in-line" in the code. With the modifications, the code still runs at only about 5% of the Cray's peak speed because it makes ineffective use of the vector processing capabilities of the Cray. We conclude with a discussion and future plans.

Skiles, J. W.↗

NASA NTRS2015

Update on Advection-Diffusion Purge Flow Model

Gaseous purge is commonly used in sensitive spacecraft optical or electronic instruments to prevent infiltration of contaminants and/or water vapor. Typically, purge is sized using simplistic zero-dimensional models that do not take into account instrument geometry, surface effects, and the dependence of diffusive flux on the concentration gradient. For this reason, an axisymmetric computational fluid dynamics (CFD) simulation was recently developed to model contaminant infiltration and removal by purge. The solver uses a combined Navier-Stokes and Advection-Diffusion approach. In this talk, we report on updates in the model, namely inclusion of a particulate transport model.

purging↗

NASA NTRS1994

Development and application of computational aerothermodynamics flowfield computer codes

Research was performed in the area of computational modeling and application of hypersonic, high-enthalpy, thermo-chemical nonequilibrium flow (Aerothermodynamics) problems. A number of computational fluid dynamic (CFD) codes were developed and applied to simulate high altitude rocket-plume, the Aeroassist Flight Experiment (AFE), hypersonic base flow for planetary probes, the single expansion ramp model (SERN) connected with the National Aerospace Plane, hypersonic drag devices, hypersonic ramp flows, ballistic range models, shock tunnel facility nozzles, transient and steady flows in the shock tunnel facility, arc-jet flows, thermochemical nonequilibrium flows around simple and complex bodies, axisymmetric ionized flows of interest to re-entry, unsteady shock induced combustion phenomena, high enthalpy pulsed facility simulations, and unsteady shock boundary layer interactions in shock tunnels. Computational modeling involved developing appropriate numerical schemes for the flows on interest and developing, applying, and validating appropriate thermochemical processes. As part of improving the accuracy of the numerical predictions, adaptive grid algorithms were explored, and a user-friendly, self-adaptive code (SAGE) was developed. Aerothermodynamic flows of interest included energy transfer due to strong radiation, and a significant level of effort was spent in developing computational codes for calculating radiation and radiation modeling. In addition, computational tools were developed and applied to predict the radiative heat flux and spectra that reach the model surface.

Venkatapathy, Ethiraj↗

NASA NTRS2016

First-Order SPICE Modeling of Extreme-Temperature 4H-SiC JFET Integrated Circuits

A separate submission to this conference reports that 4H-SiC Junction Field Effect Transistor (JFET) digital and analog Integrated Circuits (ICs) with two levels of metal interconnect have reproducibly demonstrated electrical operation at 500 C in excess of 1000 hours. While this progress expands the complexity and durability envelope of high temperature ICs, one important area for further technology maturation is the development of reasonably accurate and accessible computer-aided modeling and simulation tools for circuit design of these ICs. Towards this end, we report on development and verification of 25 C to 500 C SPICE simulation models of first order accuracy for this extreme-temperature durable 4H-SiC JFET IC technology. For maximum availability, the JFET IC modeling is implemented using the baseline-version SPICE NMOS LEVEL 1 model that is common to other variations of SPICE software and importantly includes the body-bias effect. The first-order accuracy of these device models is verified by direct comparison with measured experimental device characteristics.

JFET↗

NASA NTRS1986

System analysis for the Huntsville Operation Support Center distributed computer system

A simulation model of the NASA Huntsville Operational Support Center (HOSC) was developed. This simulation model emulates the HYPERchannel Local Area Network (LAN) that ties together the various computers of HOSC. The HOSC system is a large installation of mainframe computers such as the Perkin Elmer 3200 series and the Dec VAX series. A series of six simulation exercises of the HOSC model is described using data sets provided by NASA. The analytical analysis of the ETHERNET LAN and the video terminals (VTs) distribution system are presented. An interface analysis of the smart terminal network model which allows the data flow requirements due to VTs on the ETHERNET LAN to be estimated, is presented.

Ingels, F. M.↗

NASA NTRS1991

Composite load spectra for select space propulsion structural components

The objective of this program is to develop generic load models with multiple levels of progressive sophistication to simulate the composite load spectra that are induced in space propulsion system components, representative of Space Shuttle Main Engines (SSME), such as transfer ducts, turbine blades, and liquid oxygen (LOX) posts and system ducting. These models will be developed using two independent approaches. The first approach consists of using state-of-the-art probabilistic methods to describe the individual loading conditions and combinations of these loading conditions to synthesize the composite load spectra simulation. The methodology required to combine the various individual load simulation models (hot-gas dynamic, vibrations, instantaneous position, centrifugal field, etc.) into composite load spectra simulation models will be developed under this program. A computer code incorporating the various individual and composite load spectra models will be developed to construct the specific load model desired. The second approach, which is covered under the options portion of the contract, will consist of developing coupled models for composite load spectra simulation which combine the (deterministic) models for composite load dynamic, acoustic, high-pressure and high rotational speed, etc., load simulation using statistically varying coefficients. These coefficients will then be determined using advanced probabilistic simulation methods with and without strategically selected experimental data. This report covers the efforts of the third year of the contract. The overall program status is that the turbine blade loads have been completed and implemented. The transfer duct loads are defined and are being implemented. The thermal loads for all components are defined and coding is being developed. A dynamic pressure load model is under development. The parallel work on the probabilistic methodology is essentially completed. The overall effort is being integrated in an expert system code specifically developed for this project.

Newell, J. F.↗

NASA NTRS2005

A CFD Analysis of Easterly Wind Flow Impacting the Vehicle Assembly Building

In an attempt to explain the high loss of panels from the south face of the Vehicle Assembly Building (VAB) during Hurricane Frances, a three-dimensional computational fluid dynamics (3-D CFD) model was developed to simulate local velocity and pressure distributions resulting from such a storm. A preconditioned compressible Navier-Stokes flow solver 1 was used to compute the flow field around the VAB complex, including the Launch Control Center, the Low and High Bays of the VAB, and several outbuildings in the immediate LC-39 area. The mapping of the forces and velocities on and along the affected faces of the VAB correlated surprisingly well with the extensive damage areas realized on both on the south face and on the southeast section of the roof. The model results were also consistent with the minimal damage seen on the east, north, and west faces of the structure.

Vu, B. T.↗

NASA NTRS1985

AC motor and generator requirements for isolated WECS

After surveying electrically driven loads used on productive farms, the investigators chose three pumps for testing at voltages and frequencies far outside the normal operating range. These loads extract and circulate water and move heat via air, and all are critical to farm productivity. The object was to determine the envelope of supply voltage and frequency over which these loads would operate stably for time intervals under 1 hour. This information is among that needed to determine the feasibility of supplying critical loads, in case of a utility outage, from a wind driven alternator whose output voltage and frequency will vary dramatically in most continental wind regimes. Other related work is surveyed. The salient features and limitations of the test configurations used and the data reduction are described. The development of simulation models suitable for a small computer are outlined. The results are primarily displayed on the voltage frequency plane with the general conclusion that the particular pump models considered will operate over the range of 50 to 90 Hz and a voltage band which starts below rated, decreases as frequency decreases, and is limited on the high side by excessive motor heating. For example, centrifugal pump operating voltage ranges as extensive .4 to 1.4 appear possible. Particular problems with starting, stalling due to lack of motor torque, high speed cavitation, and likely overheating are addressed in a listing of required properties for wind driven alternators and their controllers needed for use in the isolated or stand alone configuration considered.

Park, G. L.↗

NASA NTRS1993

Experimental and analytical study of cryogenic propellant boiloff to develop and verify alternate pressurization concepts for Space Shuttle external tank using a scaled down tank

Self pressurization by propellant boiloff is experimentally studied as an alternate pressurization concept for the Space Shuttle external tank (ET). The experimental setup used in the study is an open flow system which is composed of a variable area test tank and a recovery tank. The vacuum jacketed test tank is geometrically similar to the external LOx tank for the Space Shuttle. It is equipped with instrumentation to measure the temperature and pressure histories within the liquid and vapor, and viewports to accommodate visual observations and Laser-Doppler Anemometry measurements of fluid velocities. A set of experiments were conducted using liquid Nitrogen to determine the temperature stratification in the liquid and vapor, and pressure histories of the vapor during sudden and continuous depressurization for various different boundary and initial conditions. The study also includes the development and calibration of a computer model to simulate the experiments. This model is a one-dimensional, multi-node type which assumes the liquid and the vapor to be under non-equilibrium conditions during the depressurization. It has been tested for a limited number of cases. The preliminary results indicate that the accuracy of the simulations is determined by the accuracy of the heat transfer coefficients for the vapor and the liquid at the interface which are taken to be the calibration parameters in the present model.

Akyuzlu, K. M.↗

NASA NTRS1995

Annual Research Briefs: 1995

This report contains the 1995 annual progress reports of the Research Fellows and students of the Center for Turbulence Research (CTR). In 1995 CTR continued its concentration on the development and application of large-eddy simulation to complex flows, development of novel modeling concepts for engineering computations in the Reynolds averaged framework, and turbulent combustion. In large-eddy simulation, a number of numerical and experimental issues have surfaced which are being addressed. The first group of reports in this volume are on large-eddy simulation. A key finding in this area was the revelation of possibly significant numerical errors that may overwhelm the effects of the subgrid-scale model. We also commissioned a new experiment to support the LES validation studies. The remaining articles in this report are concerned with Reynolds averaged modeling, studies of turbulence physics and flow generated sound, combustion, and simulation techniques. Fundamental studies of turbulent combustion using direct numerical simulations which started at CTR will continue to be emphasized. These studies and their counterparts carried out during the summer programs have had a noticeable impact on combustion research world wide.

Source record↗

NASA NTRS1997

Empirical and Analytic Studies Human/Automation Dynamics in Airspace Management for Free Flight

NASA and the FAA have initiated programs of research and development to provide flight crew, airline operations and air traffic managers with automation aids to increase capacity in en route and terminal area to support the goals of free flight for safe, flexible, predictable, and efficient operations. To support the development of those aiding systems human performance in automated aiding has been examined in empirical and computationally analytic studies. This paper presents a set of those studies in full mission simulation and the development of a predictive computational model of human performance. We have found that the combination of methodologies provide a powerful design-aiding process. We will describe three research programs in support of Free Flight Operations from the perspective of human performance requirements. We have examined procedures and communications in the use of voice and data-link operation at the transition between unconstrained (enroute) and constrained (terminal) airspace operations. We have examined the timing and form of Center TRACON Automation System (CTAS) advisories in descent. We have investigated the shape and dimensions of an 'alert zone' for air-based separation in unconstrained operations. Finally, we have examined the interaction of a ground-based conflict detection/resolution aiding system, as it interacts with a cockpit-based conflict alerting mechanism. Additional information is contained in the original extended abstract.

Corker, Kevin M.↗

NASA NTRS2003

Flame-Generated Vorticity Production in Premixed Flame-Vortex Interactions

In this study, we use detailed time-dependent, multi-dimensional numerical simulations to investigate the relative importance of the processes leading to FGV in flame-vortex interactions in normal gravity and microgravity and to determine if the production of vorticity in flames in gravity is the same as that in zero gravity except for the contribution of the gravity term. The numerical simulations will be performed using the computational model developed at NRL, FLAME3D. FLAME3D is a parallel, multi-dimensional (either two- or three-dimensional) flame model based on FLIC2D, which has been used extensively to study the structure and stability of premixed hydrogen and methane flames.

Patnaik, G.↗

NASA NTRS2008

Cryogenic Pressure Control Modeling for Ellipsoidal Space Tanks in Reduced Gravity

A computational fluid dynamics (CFD) model is developed to simulate pressure control of an ellipsoidal-shaped liquid hydrogen tank under external heating in low gravity. Pressure control is provided by an axial jet thermodynamic vent system (TVS) centered within the vessel that injects cooler liquid into the tank, mixing the contents and reducing tank pressure. The two-phase cryogenic tank model considers liquid hydrogen in its own vapor with liquid density varying with temperature only and a fully compressible ullage. The axisymmetric model is developed using a custom version of the commercially available FLOW-3D software and simulates low gravity extrapolations of engineering checkout tests performed at Marshall Space Flight Center in 1999 in support of the Solar Thermal Upper Stage Technology Demonstrator (STUSTD) program. Model results illustrate that stable low gravity liquid-gas interfaces are maintained during all phases of the pressure control cycle. Steady and relatively smooth ullage pressurization rates are predicted. This work advances current low gravity CFD modeling capabilities for cryogenic pressure control and aids the development of a low cost CFD-based design process for space hardware.

Hedayat, Ali↗

NASA NTRS2007

Cryogenic Pressure Control Modeling for Ellipsoidal Space Tanks

A computational fluid dynamics (CFD) model is developed to simulate pressure control of an ellipsoidal-shaped liquid hydrogen tank under external heating in normal gravity. Pressure control is provided by an axial jet thermodynamic vent system (TVS) centered within the vessel that injects cooler liquid into the tank, mixing the contents and reducing tank pressure. The two-phase cryogenic tank model considers liquid hydrogen in its own vapor with liquid density varying with temperature only and a fully compressible ullage. The axisymmetric model is developed using a custom version of the commercially available FLOW-31) software. Quantitative model validation is ,provided by engineering checkout tests performed at Marshall Space Flight Center in 1999 in support of the Solar Thermal Upper Stage_ Technology Demonstrator (STUSTD) program. The engineering checkout tests provide cryogenic tank self-pressurization test data at various heat leaks and tank fill levels. The predicted self-pressurization rates, ullage and liquid temperatures at discrete locations within the STUSTD tank are in good agreement with test data. The work presented here advances current CFD modeling capabilities for cryogenic pressure control and helps develop a low cost CFD-based design process for space hardware.

Lopez, Alfredo↗

NASA NTRS2011

NASA Aerosciences Activities to Support Human Space Flight

The Lyndon B. Johnson Space Center (JSC) has been a critical element of the United State's human space flight program for over 50 years. It is the home to NASA s Mission Control Center, the astronaut corps, and many major programs and projects including the Space Shuttle Program, International Space Station Program, and the Orion Project. As part of JSC's Engineering Directorate, the Applied Aeroscience and Computational Fluid Dynamics Branch is charted to provide aerosciences support to all human spacecraft designs and missions for all phases of flight, including ascent, exo-atmospheric, and entry. The presentation will review past and current aeroscience applications and how NASA works to apply a balanced philosophy that leverages ground testing, computational modeling and simulation, and flight testing, to develop and validate related products. The speaker will address associated aspects of aerodynamics, aerothermodynamics, rarefied gas dynamics, and decelerator systems, involving both spacecraft vehicle design and analysis, and operational mission support. From these examples some of NASA leading aerosciences challenges will be identified. These challenges will be used to provide foundational motivation for the development of specific advanced modeling and simulation capabilities, and will also be used to highlight how development activities are increasing becoming more aligned with flight projects. NASA s efforts to apply principles of innovation and inclusion towards improving its ability to support the myriad of vehicle design and operational challenges will also be briefly reviewed.

LeBeau, Gerald J.↗

NASA NTRS2008

ESMD Space Grant Faculty Report

The strength of the Exploration Systems Mission Directorate ESMD Faculty Project lies in its ability to meet National Aeronautics Space Administration NASA's Strategic Educational Outcome 1 by developing a sustainable and long-term integration of student involvement at academic institutions with all NASA Centers. This outcome is achieved by a three-fold approach: 1) by collecting Senior Design projects pertaining to Constellation work performed at each of the ten NASA Centers, 2) by engaging students at Minority Serving Institutions in the art of systems engineering and systems design of technologies required for space exploration, and 3) by identifying potential internships at each Center relative to exploration that provide students who are supported by their institutional Space Grant to engage in on-going mission-level and explorative systems designs. The objectives of the ESMD Faculty Project are to: 1. Aid the Centers (both Education Offices and associated technical organizations) in providing relevant opportunities for the ESMD Space Grant Program to support student and faculty in Senior Design projects 2. Enable better matches between the ESMD work required and what the Space Grant Consortia can do to effectively contribute to NASA programs 3. Provide the Space Grant Consortia an opportunity to strengthen relations with the NASA Centers 4. Develop better collective understanding of the U.S. Space Exploration Policy by the Center, Space Grant, faculty, Education Office, and students 5. Enable Space Grant institution faculty to better prepare their students to meet current and future NASA needs 6. Enable the Center Education Offices to strengthen their ties to their technical organizations and Space Grant Consortia 7. Aid KSC in gaining a greater and more detailed understanding of each of the Center activities Senior Design projects are intended to stimulate undergraduate students on current NASA activities related to lunar, Mars, and other planetary missions and to bring out innovative and novel ideas that can be used to complement those currently under development at respective NASA Centers. Additionally, such academic involvement would better the prospects for graduating seniors to pursue graduate studies and to seek careers in the space industry with a strong sense for systems engineering and understanding of design concepts. Internships, on the other hand, are intended to provide hands-on experience to students by engaging them in diverse state-of-the-art technology development, prototype bread-boarding, computer modeling and simulations, hardware and software testing, and other activities that provide students a strong perspective of NASA's vision and mission in enhancing the knowledge of Earth and space planetary sciences. Ten faculty members, each from a Space Grant Consortium-affiliated university, worked at ten NASA Centers for five weeks between June 2 and July 3, 2008. The project objectives listed above were achieved. In addition to collecting data on Senior Design ideas and identifying possible internships that would benefit NASA/ESMD, the faculty fellows promoted and collected data when required for other ESMD-funded programs and helped the Center's Education Office, as,needed. 4

Guo, Jiang↗