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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 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Colossal Tooling Design: 3D Simulation for Ergonomic Analysis

The application of high-level 3D simulation software to the design phase of colossal mandrel tooling for composite aerospace fuel tanks was accomplished to discover and resolve safety and human engineering problems. The analyses were conducted to determine safety, ergonomic and human engineering aspects of the disassembly process of the fuel tank composite shell mandrel. Three-dimensional graphics high-level software, incorporating various ergonomic analysis algorithms, was utilized to determine if the process was within safety and health boundaries for the workers carrying out these tasks. In addition, the graphical software was extremely helpful in the identification of material handling equipment and devices for the mandrel tooling assembly/disassembly process.

Hunter, Steve L.↗
NASA NTRS2016

Command and Data Handling Branch Internship

Modular Integrated Stackable Layers (MISL) is a computer system designed for simple, fast, and cost effective flexible reconfiguration in space environments such as the ISS and Orion projects for various uses. Existing applications include wireless and wired communications, data acquisition and instrumentation, and camera systems, and potential applications include bus protocol converters and subsystem control. MISL is based on Texas Instruments (TI)' MSP430 16-bit ultra-low-power microcontroller device. The purpose of my project was to integrate the MISL system with a liquid crystal display (LCD) touchscreen. The LCD, manufactured by Crystalfontz and part number CFAF320240F-035T-TS, is a 320 by 240 RGB resistive color screen including an optional carrier board. The vast majority of the project was done with Altium Designer, a tool for printed circuit board (PCB) schematic capture, 3D design, and FPGA (Field Programmable Gate Array) development. The new PCB was to allow the LCD to directly stack to the rest of MISL. Research was done with datasheets for the TI microcontroller and touchscreen display in order to meet desired hardware specifications. Documentation on prior MISL projects was also utilized. The initial step was to create a schematic for the LCD, power bus, and data bus connections between components. A layout was then designed with the required physical dimensions, routed traces and vias, power and ground planes, layer stacks, and other specified design rules such as plane clearance and hole size. Multiple consultation sessions were held with Hester Yim, the technical discipline lead for the Command and Data Handling Branch, and Christy Herring, the lead PCB layout designer in the Electronic Design and Manufacturing Branch in order to ensure proper configuration. At the moment, the PCB is awaiting revision by the latter-mentioned branch. Afterwards, the board will begin to undergo the manufacturing and testing process. Throughout the internship at Johnson Space Center, I gained several technical and professional skills. I gained proficiency in Altium Designer and experience using subversion clients, as well as knowledge in PSpice with OrCAD and battery design for spaceflight from on-site. I also gained networking, organization, and communication skills throughout meetings with coworkers and other interns. This internship at Johnson Space Center has impacted my future aspirations by further inspiring me to follow a career path into space rated engineering technology and human spaceflight applications. After graduation, I plan to attend graduate Modular Integrated Stackable Layers (MISL) is a computer system designed for simple, fast, and cost effective flexible reconfiguration in space environments such as the ISS and Orion projects for various uses. Existing applications include wireless and wired communications, data acquisition and instrumentation, and camera systems, and potential applications include bus protocol converters and subsystem control. MISL is based on Texas Instruments’ MSP430 16 bit ultra-low power microcontroller device. The purpose of my project was to integrate the MISL system with a liquid crystal display touchscreen. The LCD, manufactured by Crystalfontz and part number CFAF320240F-035T-TS, is a 320x240 RGB resistive color screen including an optional carrier board.The vast majority of the project was done with Altium Designer, a tool for printed circuit board (PCB) schematic capture, 3D design, and FPGA development. The new PCB was to allow the LCD to directly stack to the rest of MISL. Research was done with datasheets for the TI microcontroller and touchscreen display in order to meet desired hardware specifications. Documentation on prior MISL projects was also utilized. The initial step was to create a schematic for the LCD, power bus, and data bus connections between components. A layout was then designed with the required physical dimensions, routed traces and vias, power and ground planes, layer stacks, and other specified design rules such as plane clearance and hole size. Multiple consultation sessions were held with Hester Yim, the technical discipline lead for the Command and Data Handling Branch, and Christy Herring, the lead PCB layout designer in the Electronic Design and Manufacturing Branch in order to ensure proper configuration. At themoment, the PCB is awaiting revision by the latter-mentioned branch. Afterwards, the board will begin to undergo the manufacturing and testing process.Throughout the internship at Johnson Space Center, I gained several technical and professional skills. I gained proficiency in Altium Designer and experience using subversion clients, as well as knowledge in PSpice with OrCAD and battery design for spaceflight from on-site. I also gained networking, organization, and communication skills throughout meetings with coworkers and other interns. This internship at Johnson Space Center has impacted my future aspirations by further inspiring me to follow a career path into space rated engineering technology and human spaceflight applications. After graduation, I plan to attend graduate school for a master's or doctorate degree in electrical or computer engineering.

Billings, Rachel Mae↗
NASA NTRSDate not supplied

Estimation of 3D Woven Design Sensitivities Using a Rapid Multiscale Analysis Technique

Highly-refined finite element models of three-dimension (3D) woven composite systems currently require excessive computational demands that limit their use in sensitivity analysis, uncertainty quantification, and optimization. An alternative analysis methodology was developed using the NASA Multiscale Analysis Tool (NASMAT) where multiscale models of a 3D woven composite (including inter-tow matrix voids and constituent failure) can be completed on a single central processing unit(CPU)on the order of ~30 s. To develop inputs and validation data for the NASMAT model, coupon and acid-digesting testing and x-ray computed tomography were performed. The NASMAT inputs were parameterized using a set of 25 input variables and distributions. These inputs were randomly sampled to generate a total of 100,000 NASMAT analyses that could be used to understand the influence of different material and geometric properties on the warp and weft-direction stiffness and strength. These analyses (including pre/post-processing) were performed in less than eight hours on a 120 CPU cluster. The computational efficiency of the NASMAT model enabled a sensitivity analysis to be performed, and dominant input variables were able to be identified. Key results were consistent with theoretical and experimental observations for the specific 3D woven system studied in this work.

NASMAT↗
NASA NTRSDate not supplied

Estimation of 3D Woven Design Sensitivities Using a Rapid Multiscale Analysis Technique

Highly-refined finite element models of three-dimension (3D) woven composite systems currently require excessive computational demands that limit their use in sensitivity analysis, uncertainty quantification, and optimization. An alternative analysis methodology was developed using the NASA Multiscale Analysis Tool (NASMAT) where multiscale models of a 3D woven composite (including inter-tow matrix voids and constituent failure) can be completed on a single central processing unit (CPU) on the order of ~30s. To develop inputs and validation data for the NASMAT model, coupon and acid-digesting testing and x-ray computed tomography were performed. The NASMAT inputs were parameterized using a set of 25 input variables and distributions. These inputs were randomly sampled to generate a total of 100,000 NASMAT analyses that could be used to understand the influence of different material and geometric properties on the warp and weft-direction stiffness and strength. These analyses (including pre/post-processing) were performed in less than eight hours on a 120 CPU cluster. The computational efficiency of the NASMAT model enabled a sensitivity analysis to be performed, and dominant input variables were able to be identified. Key results were consistent with theoretical and experimental observations for the specific 3D woven system studied in this work.

NASMAT↗
NASA NTRS2020

March of the Interns

Summer 2019 brought 70 interns — from Puerto Rico, 44 continental US states, Sweden, and the Republic of Trinidad and Tobago — into the NASA Ames Aeromechanics Branch. Some were high school students learning engineering for the first time, while most were mechanical and aerospace engineering students, though two physics majors and a math major jumped into the mix to provide balance. This year’s interns completed work on 30 different projects with a collective of 30,000 dedicated hours of work. The projects this year were on urban air mobility (UAM), search and rescue vehicle design, all things Mars, Titan exploration concept designs, 3D modeling (i.e. computer aided design, CAD), computational fluid dynamics (CFD), and much more. Last year we addressed the question of what to do with an army of interns. This year, we are following its path to change the world.

Dromiack, Hannah↗
NASA NTRS2012

A Large-Scale Design Integration Approach Developed in Conjunction with the Ares Launch Vehicle Program

This paper presents a method for performing large-scale design integration, taking a classical 2D drawing envelope and interface approach and applying it to modern three dimensional computer aided design (3D CAD) systems. Today, the paradigm often used when performing design integration with 3D models involves a digital mockup of an overall vehicle, in the form of a massive, fully detailed, CAD assembly; therefore, adding unnecessary burden and overhead to design and product data management processes. While fully detailed data may yield a broad depth of design detail, pertinent integration features are often obscured under the excessive amounts of information, making them difficult to discern. In contrast, the envelope and interface method results in a reduction in both the amount and complexity of information necessary for design integration while yielding significant savings in time and effort when applied to today's complex design integration projects. This approach, combining classical and modern methods, proved advantageous during the complex design integration activities of the Ares I vehicle. Downstream processes, benefiting from this approach by reducing development and design cycle time, include: Creation of analysis models for the Aerodynamic discipline; Vehicle to ground interface development; Documentation development for the vehicle assembly.

Redmon, John W.↗
NASA NTRS2014

Aerodynamic Limits on Large Civil Tiltrotor Sizing and Efficiency

The NASA Large Civil Tiltrotor (2nd generation, or LCTR2) has been the reference design for avariety of NASA studies of design optimization, engine and gearbox technology, handling qualities, andother areas, with contributions from NASA Ames, Glenn and Langley Centers, plus academic and industrystudies. Ongoing work includes airfoil design, 3D blade optimization, engine technology studies, andwingrotor aerodynamic interference. The proposed paper will bring the design up to date with the latestresults of such studies, then explore the limits of what aerodynamic improvements might hope toaccomplish. The purpose is two-fold: 1) determine where future technology studies might have the greatestpayoff, and 2) establish a stronger basis of comparison for studies of other vehicle configurations andmissions.

Large Civil Tiltrotor↗
NASA NTRS2024

Development of a Single Level Assessment Module for Simulating the Human Factors Concept Trade Space

This paper is a synopsis of the design and development of the Single Level Assessment Module (SLAM), a habitation mockup aimed at simulating volumetric conditions for astronauts in transit to Mars. Utilizing repurposed materials to enable low cost and constrained by various other design requirements from its parent vehicle, the SLAM embodies a critical step towards understanding human/habitat dynamics and interactions within the framework of the Mars Transit Habitat (TH) concept trade space. The synopsis begins by outlining the design constraints and goals, focusing on material availability and functional area volume requirements. Through various 3D design solutions, the SLAM emerges as a versatile habitat prototype, capable of accommodating various functional areas within its reconfigurable framework. The construction phase is then explored, highlighting the practical challenges and solutions encountered in assembling the SLAM's components. From panel assembly to outfitting functional areas, the construction process demonstrates a methodical approach to realizing the habitat's design intent. Looking ahead, the paper outlines future work, emphasizing the SLAM's adaptability for analysis and its potential to inform the design trade space future habitation concepts across the Moon to Mars architecture. By incorporating hinges for reconfigurability and facilitating volume assessments, the SLAM emerges as a crucial tool in advancing NASA’s ability to assess focused habitation configurations in conjunction with the development of the Moon to Mars architecture. In conclusion, this paper showcases the iterative process of habitat design, from conceptualization to construction.

Keith Lindsey↗
NASA NTRS1998

Transition in Turbine Flows

We have further developed our capabilities to analyze transition in turbine boundary layers from first principles by integrating the nonlinear parabolized stability equations (PSE) with improved initial and boundary conditions. With modified iteration schemes, we are able to proceed deeper into the transition region where skin friction coefficient and heat transfer coefficient significantly increase. Initial and boundary conditions at elevated turbulence levels can be derived by receptivity analysis. Test runs for ERCOFTAC test case T3A at 2.4\% turbulence level provide results in good agreement with the experimental data. The sharper minimum of the skin coefficient also shown by DNS results is likely due to the missing intermittency. The method has been applied to various experimentally studied turbine blades (UTRC, VKI, Zierke, Langston, Hippensteele, and others). The PSE results, though physically reasonable, do not agree as well as expected with the experimental findings. We have, therefore, performed an extensive search for the reasons of the seemingly systematic deviations. A first source of uncertainty has been found in the often insufficient documentation of the experiments (e.g. on blockage by end-wall boundary layers). However, variation of the relevant parameters does not lead to more satisfactory agreement. A second reason has been found in the "standard procedure" which considers a 2D flow at midspan and uses a panel code and subsequent boundary-layer code to obtain the laminar basic flow for the transition analysis. Comparison with the pressure distribution obtained with a 3D design code (RVC3D) shows significant three-dimensionality of the flow (e.g. in the UTRC experiments). The spanwise variation has been neglected in our original PSE code. To overcome this problem, we have developed the PSE/3D for fully 3D boundary layers to account for streamwise and spanwise variations. Since the design code does not provide the boundary-layer flow with sufficient resolution, we have generated the Euler solution and employed a 3D boundary-layer code to obtain the viscous basic flow. Although only the linear stability level of PSE/3D has been implemented so far, the discrepancies with the experiments change but do not disappear. We still find deviations between the computed and experimental variations of C(sub f), and St along the blade for laminar flow. The main reason can be seen by comparing the solution of the boundary-layer code with the viscous results of the design code. The conventional boundary-layer solution exhibits an asymptotic behavior appropriate in external aerodynamics but does not match the steep gradients of the inviscid flow through the passage and consequently provides biased results for C(sub f), and St. An attempt is currently being made to correct this deficiency. Before attempting to perform the transition analysis for the viscous flow provided by the design code, we have analyzed the implementation and "best possible" results. Code and results exhibit flaws that may negatively affect the design and are intolerable for transition analysis. Therefore, we have decided to develop a new code to obtain a reliable basis for stability and transition studies. We expect to report improved results by the time of the meeting.

Herbert, Thorwald↗
NASA NTRS1995

The 3D Navier-Stokes analysis of a Mach 2.68 bifurcated rectangular mixed-compression inlet

The supersonic diffuser of a Mach 2.68 bifurcated, rectangular, mixed-compression inlet was analyzed using a three-dimensional (3D) Navier-Stokes flow solver. A two-equation turbulence model, and a porous bleed model based on unchoked bleed hole discharge coefficients were used. Comparisons were made with experimental data, inviscid theory, and two-dimensional Navier-Stokes analyses. The main objective was to gain insight into the inlet fluid dynamics. Examination of the computational results along with the experimental data suggest that the cowl shock-sidewall boundary layer interaction near the leading edge caused a substantial separation in the wind tunnel inlet model. As a result, the inlet performance may have been compromised by increased spillage and higher bleed mass flow requirements. The internal flow contained substantial waves that were not in the original inviscid design. 3D effects were fairly minor for this inlet at on-design conditions. Navier-Stokes analysis appears to be an useful tool for gaining insight into the inlet fluid dynamics. It provides a higher fidelity simulation of the flowfield than the original inviscid design, by taking into account boundary layers, porous bleed, and their interactions with shock waves.

Mizukami, M.↗
NASA NTRS2014

Design of 3D-Printed Titanium Compliant Mechanisms

This paper describes 3D-printed titanium compliant mechanisms for aerospace applications. It is meant as a primer to help engineers design compliant, multi-axis, printed parts that exhibit high performance. Topics covered include brief introductions to both compliant mechanism design and 3D printing in titanium, material and geometry considerations for 3D printing, modeling techniques, and case studies of both successful and unsuccessful part geometries. Key findings include recommended flexure geometries, minimum thicknesses, and general design guidelines for compliant printed parts that may not be obvious to the first time designer.

Merriam, Ezekiel G.↗
NASA NTRS2020

Bioinspired multilayered cellular composites with enhanced energy absorption and shape recovery

Inspired by the multiscale configuration of the microstructure of cork, the paper describes the design, 3D printing, and evaluation of a new type of multilayered cellular composite (MCC) structure composed of hard brittle and soft flexible phases. The mechanical behavior of 3D printed MCC structures have been investigated both experimentally and numerically. The experiments show that the MCC structure absorbs four times the amount of energy of a conventional cellular configuration under compressive strains up to 70%. Finite element simulations and 2D digital image correlation (DIC) also show that the multilayered architecture provides a more uniform strain distribution and higher stress transfer efficiency, with a resulting progressive failure mode rather than a catastrophic one. Cyclic loading tests demonstrate that the MCC structure also possesses exceptional shape recoverability under compressive deformations up to 40%. These remarkable performance characteristics result from synergies between the properties of the two constituent materials and the chosen multilayered cellular microstructure. The soft phase, in particular, plays a pivotal role in absorbing elastic energy during loading and then releasing the stored energy while unloading. The volume fraction of the soft phase is also essential to control energy absorption and the transition of failure modes. The deformation mechanisms demonstrated here are robust and applicable to other architected cellular materials across multiple length scales and suggest new ways to design lightweight and high-resilience structural materials.

bioinspired composites↗
NASA NTRS2012

An Update on Design Tools for Optimization of CMC 3D Fiber Architectures

Objective: Describe and up-date progress for NASA's efforts to develop 3D architectural design tools for CMC in general and for SIC/SiC composites in particular. Describe past and current sequential work efforts aimed at: Understanding key fiber and tow physical characteristics in conventional 2D and 3D woven architectures as revealed by microstructures in the literature. Developing an Excel program for down-selecting and predicting key geometric properties and resulting key fiber-controlled properties for various conventional 3D architectures. Developing a software tool for accurately visualizing all the key geometric details of conventional 3D architectures. Validating tools by visualizing and predicting the Internal geometry and key mechanical properties of a NASA SIC/SIC panel with a 3D orthogonal architecture. Applying the predictive and visualization tools toward advanced 3D orthogonal SiC/SIC composites, and combining them into a user-friendly software program.

Lang, J.↗
NASA NTRS2014

Design Curve Generation for 3D SiC Fiber Architecture

The design tool provides design curves that allow a simple and quick way to examine multiple factors that can influence the processing and key properties of the preforms and their final SiC-reinforced ceramic composites without over obligating financial capital for the fabricating of materials. Tool predictions for process and fiber fraction properties have been validated for a HNS 3D preform.The virtualization aspect of the tool will be used to provide a quick generation of solid models with actual fiber paths for finite element evaluation to predict mechanical and thermal properties of proposed composites as well as mechanical displacement behavior due to creep and stress relaxation to study load sharing characteristic between constitutes for better performance.Tool predictions for the fiber controlled properties of the SiCSiC CMC fabricated from the HNS preforms will be valuated and up-graded from the measurements on these CMC

matrix materials↗
NASA NTRS2017

Programmable Spectral Source and Design Tool for 3D Imaging Using Complementary Bandpass Filters

An endoscopic illumination system for illuminating a subject for stereoscopic image capture, includes a light source which outputs light; a first complementary multiband bandpass filter (CMBF) and a second CMBF, the first and second CMBFs being situated in first and second light paths, respectively, where the first CMBF and the second CMBF filter the light incident thereupon to output filtered light; and a camera which captures video images of the subject and generates corresponding video information, the camera receiving light reflected from the subject and passing through a pupil CMBF pair and a detection lens. The pupil CMBF includes a first pupil CMBF and a second pupil CMBF, the first pupil CMBF being identical to the first CMBF and the second pupil CMBF being identical to the second CMBF, and the detection lens includes one unpartitioned section that covers both the first pupil CMBF and the second pupil CMBF.

Shahinian, Hrayr Karnig↗
NASA NTRS2020

Evaluation of Packing_3D Code for Design of Variable-Depth, Bent-Chamber Acoustic Liners

Increases in the bypass ratio for commercial aircraft engines have caused the broadband fan noise component to become dominant. As a result, there is a need to develop improved acoustic liners suitable for absorption of this fan noise over a wide frequency range, preferably up to at least two octaves. Variable depth liners with bent chambers and three-dimensional geometries present one way to achieve this goal, however, they can be difficult and time-consuming to design due to their complexity and volume constraints. A packing code, called Packing3D, has been developed that automatically designs the chamber configurations of such liners once the chamber dimensions and volume constraints are known. The code uses a randomized trial and error approach to place each chamber in a representation of the liner sample, then returns a colored diagram and sufficient information for the liner sample to be fabricated. For evaluation, the code is used to design four liner samples of varying levels of complexity. These samples are tested with and without a mesh facesheet in the NASA Langley Normal Incidence Tube, and the results are compared to predictions computed in COMSOL. The results indicate that the packing code is able to quickly design samples that are predictable, achieve the desired absorption spectrum, fit the given constraints, and are able to be built. This code is flexible, lends itself to optimization, and allows samples to be designed quickly, accurately, and efficiently.

Marinova, Miroslava M.↗
NASA NTRS2023

A 3D Printable Alloy Designed for Extreme Environments

Multiprincipal-element alloys are an enabling class of materials owing to their impressive mechanical and oxidation-resistant properties, especially in extreme environments. Here we develop a new oxide-dispersion-strengthened NiCoCr-based alloy using a model-driven alloy design approach and laser-based additive manufacturing. This oxide-dispersion-strengthened alloy, called GRX-810, uses laser powder bed fusion to disperse nanoscale Y 2 O 3 particles throughout the microstructure without the use of resource-intensive processing steps such as mechanical or in situ alloying. We show the successful incorporation and dispersion of nanoscale oxides throughout the GRX-810 build volume via high-resolution characterization of its microstructure. The mechanical results of GRX-810 show a twofold improvement in strength, over 1,000-fold better creep performance and twofold improvement in oxidation resistance compared with the traditional polycrystalline wrought Ni-based alloys used extensively in additive manufacturing at 1,093 °C. The success of this alloy highlights how model-driven alloy designs can provide superior compositions using far fewer resources compared with the ‘trial-and-error’ methods of the past. These results showcase how future alloy development that leverages dispersion strengthening combined with additive manufacturing processing can accelerate the discovery of revolutionary materials.

Timothy M. Smith↗
NASA NTRS1992

On the use of a three-dimensional Navier-Stokes solver for rocket engine pump impeller design

A 3D Reynolds-averaged Navier-Stokes Solver and a Fast Grid Generator (FGG), developed specially for centrifugal impeller design, were incorporated into the pump impeller design process. The impeller performance from the CFD analysis was compared to one-dimensional prediction. Both analyses showed good agreement of the impeller hydraulic efficiency, 94.5 percent, but with an 8 percent discrepancy of Euler head prediction. The impeller blade angle, discharge hub to shroud width, axial length and blade stacking were systematically changed to achieve an optimum impeller design. Impeller overall efficiency, loss distribution, hub-to-tip flow angle distortion and blade-to-blade flow angle change are among those criteria used to evaluate impeller performance. Two grid sizes, one with 10 K grid points and one with 80 K grid points were used to evaluate grid dependency issues. The effects of grid resolution on the accuracy and turnaround time are discussed. In conclusion, it is demonstrated that CFD can be effectively used for design and optimization of rocket engine pump components.

Chen, Wei-Chung↗