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At least 19 records

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NASA NTRS2018

Characterizing Material Scalability for Ultralight Lattice Design

Stiff yet ultra-light lattice structures constructed using digital materials have many practical applications as the building block for aircraft and other structures. By furthering our understanding of how material configuration affects the structural properties of an ultralight lattice, we can intelligently design these structures based on their intended function. Here we compare the behavior of ultralight lattice structures when fabricated by different materials. The individual unit cells of the lattice structures are referred to as voxels. The stiffness, elastic modulus, and yield strength of the specimens in compression and tension are determined through mechanical testing. Specimens are tested both as single voxel as well as 4x4x4 voxel constructions on an Instron 5982 Universal Testing System until failure. Each voxel is manufactured in bulk through injection molding, with a unit cell pitch of 76.2 mm. Individual voxels are fastened with machine screws and nuts to create assemblies. Four separate materials are used as voxel compositions in this experiment. These include a homogeneous polymer referred to as Ultem 1000, a glass-fiber reinforced polymer referred to as Ultem 2200, a polymer with chopped carbon fibers as 30% of its fill, and homogenous polypropylene. This work compares mechanical behavior, as well as the convergence behavior of the lattice as the size of the lattice assembly increases for various materials. The goal of this study is to characterize the behavior of homogenous lattices such that heterogenous lattices can be designed with different material voxels to achieve target material properties for ultralight space applications.

Sajjadi, Afsheen↗

NASA NTRS1922

Notes on the design of latticed columns subject to lateral loads

No rational column formula has yet been developed which gives results which are sufficiently precise for the design of airplane members, and consequently it is necessary to fall back upon experimental testing. In order to derive the maximum benefit from experiments, however, it is necessary that the experiments be guided by theory. It is the object here to modify existing formulae that may be obtained with a minimum number of tests. A discussion is given that is limited to the case of a simple column supported at both ends and subjected to uniformly distributed loads perpendicular to its axis and to end loads either axially or eccentrically applied. Discussed here are forces in the bracing of latticed columns, the application of theory to practical columns, loads in lattice members, and the strength of individual lattices.

Mccarthy, Charles J↗

NASA NTRS2007

Open-Lattice Composite Design Strengthens Structures

Advanced composite materials and designs could eventually be applied as the framework for spacecraft or extraterrestrial constructions for long-term space habitation. One such structure in which NASA has made an investment is the IsoTruss grid structure, an extension of a two-dimensional "isogrid" concept originally developed at McDonnell Douglas Astronautics Company, under contract to NASA's Marshall Space Flight Center in the early 1970s. IsoTruss is a lightweight and efficient alternative to monocoque composite structures, and can be produced in a manner that involves fairly simple techniques. The technology was developed with support from NASA to explore space applications, and is garnering global attention because it is extremely lightweight; as much as 12 times stronger than steel; inexpensive to manufacture, transport, and install; low-maintenance; and is fully recyclable. IsoTruss is expected to see application as utility poles and meteorological towers, for the aforementioned reasons and because its design offers superior wind resistance and is less susceptible to breaking and woodpeckers. Other applications, such as reinforcement for concrete structures, stand-alone towers, sign supports, prostheses, irrigation equipment, and sporting goods are being explored

Source record↗

NASA NTRS2026

Evaluation of Superalloy 718 Additively Manufactured Lattice Blocks

Lattice block structures made up of high temperature superalloys could offer advantages in density, efficiency, and tailored properties. Three candidate lattice designs were screened through additive manufacturing of superalloy 718. Laser powder bed fusion was applied with 718 powder to produce lattice blocks for three-dimensional octahedral unit cell designs of three heights. As-designed versus additively manufactured 718 lattices were compared, including structural dimensions, densities, defects, grain structures, crystallographic texture, and surface residual stresses. Manufactured lattice I diverged the most from its design, with both corner and center nodes merged into continuous columns. Manufactured lattice III came closest to its design, though the actual nodes and struts were still larger in cross section than in the design. Only modest grain coarsening and negligible chemical segregation were observed for all three designs, suggesting uniform thermo-physical and mechanical properties are possible. Significant tensile residual stresses were present at the surface of the manufactured blocks, with highest stresses in the building direction. Current findings indicate this concept could produce useful superalloy structures for high-temperature-capable static components requiring tailored density, and thermo-physical/mechanical properties.

super alloys↗

NASA NTRS1981

Computer program documentation for a subcritical wing design code using higher order far-field drag minimization

A subsonic, linearized aerodynamic theory, wing design program for one or two planforms was developed which uses a vortex lattice near field model and a higher order panel method in the far field. The theoretical development of the wake model and its implementation in the vortex lattice design code are summarized and sample results are given. Detailed program usage instructions, sample input and output data, and a program listing are presented in the Appendixes. The far field wake model assumes a wake vortex sheet whose strength varies piecewise linearly in the spanwise direction. From this model analytical expressions for lift coefficient, induced drag coefficient, pitching moment coefficient, and bending moment coefficient were developed. From these relationships a direct optimization scheme is used to determine the optimum wake vorticity distribution for minimum induced drag, subject to constraints on lift, and pitching or bending moment. Integration spanwise yields the bound circulation, which is interpolated in the near field vortex lattice to obtain the design camber surface(s).

Kuhlman, J. M.↗

NASA NTRSDate not supplied

Evaluations of Additively Manufactured Superalloy Lattice Blocks

Cast lattice block structures made up of high-temperature superalloys were previously shown to offer advantages in density, efficiency, and tailored properties. However, inconsistencies in casting die-fill, composition, and microstructure were identified as persistent issues with the casting process path. Three candidate lattice designs were screened through additive manufacturing of a superalloy. Laser powder bed fusion was applied with superalloy powder to produce lattice blocks for three-dimensional octahedral unit-cell designs of three heights. Properties of the structural designs versus additively manufactured lattices were compared, including structural dimensions, densities, defects, grain structures, crystallographic texture, and surface residual stresses. Findings indicate this concept could produce useful superalloy structures for high-temperature-capable static components requiring tailored density, and thermophysical and mechanical properties.

superalloy↗

NASA NTRS2003

Designer Infrared Filters using Stacked Metal Lattices

We have designed and fabricated infrared filters for use at wavelengths greater than or equal to 15 microns. Unlike conventional dielectric filters used at the short wavelengths, ours are made from stacked metal grids, spaced at a very small fraction of the performance wavelengths. The individual lattice layers are gold, the spacers are polyimide, and they are assembled using integrated circuit processing techniques; they resemble some metallic photonic band-gap structures. We simulate the filter performance accurately, including the coupling of the propagating, near-field electromagnetic modes, using computer aided design codes. We find no anomalous absorption. The geometrical parameters of the grids are easily altered in practice, allowing for the production of tuned filters with predictable useful transmission characteristics. Although developed for astronomical instrumentation, the filters arc broadly applicable in systems across infrared and terahertz bands.

Smith, Howard A.↗

NASA NTRS2024

Scalability in SLA lattice through lattice orientation and hybrid frame and plate architectures

Lightweighting has been a key goal for engineers and designers, with lattice structures widely explored as the building blocks for structural components. Cellular structure-inspired lattice truss frame designs made of struts, have been extensively studied. All plate-based lattice designs have superior mechanical performance. Limits in scalability occur from formation of closed pockets limiting uv curing in processes like stereolithography (SLA). We examine hybrid frame and plate body-centered cubic-simply cubic (BCC-SC) lattices under compression. Unit cells and scaled up lattice exhibit an increase in yield stress and modulus with the addition of plates. The loading direction on the hybrid frame and plate unit cells affected the magnitude of improvement. Simulations and measurements indicated that the optimal lightweight lattice was determined to be when two plates were placed opposite each other with plates buttressing the struts, inhibiting buckling of the struts aligned with the loading direction. This lattice resulted in 63% improvement in specific modulus, a 137% improvement in specific yield point, and a 360% improvement in specific energy absorption (SEA) and the scaled up 4 × 4 × 4 scaled-up structures, showed a 107%, 148%, and 297% in specific modulus, specific yield point, and SEA, respectively A combined stretching-bending behavior was identified in optimal orientations reflecting the delayed buckling mechanism paired to a rising stress-strain curve past the elastic yield indicating bending resistance. The mass moment of inertia was found to be a key parameter correlating optimum orientation for the same number of plates added to the BCC-SC frame.

Mahan Ghosh↗

NASA NTRS1976

Applications of vortex lattice theory to preliminary aerodynamic design

Some applications of the vortex-lattice theory to the preliminary aerodynamic design and analysis of subsonic aircraft were presented. These methods include the Rockwell-Tulinius vortex-lattice theory for estimating aerodynamic characteristics, a Trefftz plane optimization procedure for determining the span loads for minimum induced drag, and a modification of the Trefftz plane procedure to estimate the induced drag for specified span loads. The first two methods are used to aerodynamically design aircraft planforms, twists, and cambers, and the latter method is used to estimate the drag for components such as flaps and control surfaces. Results from the theories for predicting lift and pitching moment, drag due to lift, and the drag of control surfaces are compared with experimental data. This data was obtained on a general aviation model with flaps and a close-coupled canard-wing model.

Paulson, J. W., Jr.↗

NASA NTRSDate not supplied

Low-Noise Propeller Design with the Vortex Lattice Method: Preliminary Results

The unsteady vortex lattice method (VLM) is a popular approach to mid-fidelity aerodynamic prediction. In this work, an unsteady VLM code is coupled with a form of Farassat’s formulation 1A acoustic analogy and used to design low-noise propellers via gradient-based optimization. Solutions to a few unexpected problems with computing the gradients of the VLM code are discussed, as are preliminary results for an isolated propeller and a propeller-wing interaction case.

Acoustics↗

NASA NTRS1992

Design of a lattice-based faceted classification system

We describe a software reuse architecture supporting component retrieval by facet classes. The facets are organized into a lattice of facet sets and facet n-tuples. The query mechanism supports precise retrieval and flexible browsing.

Eichmann, David A.↗

NASA NTRSDate not supplied

Low-Noise Propeller Design with the Vortex Lattice Method and Gradient-Based Optimization

This work aims to combine an aerodynamic model based on the unsteady vortex lattice method with an acoustic model provided by Farassat’s formulation 1A to perform gradient-based propeller optimizations with aerodynamic and acoustic constraints. Two optimization cases are attempted and successfully converged: an isolated propeller and a propeller-wing configuration, both operating in a 0.11 Mach freestream, representative of a cruise condition. The results show that simultaneously decreasing the RPM and increasing the collective angle of a propeller is an effective noise reduction technique, as expected, and little difference is observed between the two cases. A vortex dissipation model was found to be needed to stabilize the derivatives of the vortex lattice outputs, and a constraint on the propeller blade’s chord distribution concavity was needed to produce realistic-looking blade chord distributions.

Propellers↗

NASA NTRS1980

Higher order farfield drag minimization for a subcritical wing design code

A higher order Trefftz plane model of the undistorted interacting wing wakes of two symmetric subsonic planforms has been developed and integrated with an existing vortex lattice wing design code. The Trefftz plane calculation provides continuous, piecewise quadratically varying bound circulations, which are then interpolated in the nearfield vortex lattice representation of the wing. Integration of the surface slopes for a specified chord loading function provides the design wing camber surfaces. This paper outlines the theoretical development and presents comparisons between results obtained using the present theory and (1) previous exact solutions for minimum induced drag and (2) previous wing designs obtained using a discrete vortex wake moded.

Kuhlman, J. M.↗

NASA NTRS2016

Aerodynamic Modeling of Transonic Aircraft Using Vortex Lattice Coupled with Transonic Small Disturbance for Conceptual Design

The need to rapidly scan large design spaces during conceptual design calls for computationally inexpensive tools such as the vortex lattice method (VLM). Although some VLM tools, such as Vorview have been extended to model fully-supersonic flow, VLM solutions are typically limited to inviscid, subcritical flow regimes. Many transport aircraft operate at transonic speeds, which limits the applicability of VLM for such applications. This paper presents a novel approach to correct three-dimensional VLM through coupling of two-dimensional transonic small disturbance (TSD) solutions along the span of an aircraft wing in order to accurately predict transonic aerodynamic loading and wave drag for transport aircraft. The approach is extended to predict flow separation and capture the attenuation of aerodynamic forces due to boundary layer viscosity by coupling the TSD solver with an integral boundary layer (IBL) model. The modeling framework is applied to the NASA General Transport Model (GTM) integrated with a novel control surface known as the Variable Camber Continuous Trailing Edge Flap (VCCTEF).

Transonic Small Disturbance↗

NASA NTRS2003

Superalloy Lattice Block Developed for Use in Lightweight, High-Temperature Structures

Successful development of advanced gas turbine engines for aircraft will require lightweight, high-temperature components. Currently titanium-aluminum- (TiAl) based alloys are envisioned for such applications because of their lower density (~4 g/cm3) in comparison to superalloys (~8.5 g/cm3), which have been utilized for hot turbine engine parts for over 50 years. However, a recently developed concept (lattice block) by JAMCORP, Inc., of Willmington, Massachusetts, would allow lightweight, high-temperature structures to be directly fabricated from superalloys and, thus, take advantage of their well-known, characterized properties. In its simplest state, lattice block is composed of thin ligaments arranged in a three dimensional triangulated trusslike configuration that forms a structurally rigid panel. Because lattice block can be fabricated by casting, correctly sized hardware is produced with little or no machining; thus very low cost manufacturing is possible. Together, the NASA Glenn Research Center and JAMCORP have extended their lattice block methodology for lower melting materials, such as Al alloys, to demonstrate that investment casting of superalloy lattice block is possible. This effort required advances in lattice block pattern design and assembly, higher temperature mold materials and mold fabrication technology, and foundry practice suitable for superalloys (ref. 1). Lattice block panels have been cast from two different Ni-base superalloys: IN 718, which is the most commonly utilized superalloy and retains its strength up to 650 C; and MAR M247, which possesses excellent mechanical properties to at least 1100 C. In addition to the open-cell lattice block geometry, same-sized lattice block panels containing a thin (~1-mm-thick) solid face on one side have also been cast from both superalloys. The elevated-temperature mechanical properties of the open cell and face-sheeted superalloy lattice block panels are currently being examined, and the microstructure is being characterized in terms of casting defects. In addition, a small study (ref. 3) is being undertaken with GE Aircraft Engines to determine the suitability of superalloy lattice block for engine components.

Hebsur, Mohan G.↗

NASA NTRSDate not supplied

Towards Low-Noise Design of a Proprotor with the Vortex Lattice Method and Gradient-Based Optimization

This work aims to combine an aerodynamic model based on the unsteady vortex lattice method with an acoustic model provided by Farassat's formulation 1A to perform gradient-based optimizations of a proprotor with aerodynamic and acoustic constraints. The resulting combination of tools is applied to the problem of designing a single proprotor operating at a cruise condition, with and without an acoustic constraint and wing placed downstream of the proprotor rotation plane. Results are compared to a baseline design studied previously, and to similar optimizations performed with a simpler blade element momentum theory aerodynamic model. Each optimization case achieved feasibility and made significant improvements in the objective function, but the optimality criterion was not satisfied. Overall the designs the optimizer found roughly comported with our previous experience with similar problems, with some discrepancies that are discussed.

Aerodynamics↗

NASA NTRSDate not supplied

Towards Low-Noise Design of a Proprotor with the Vortex Lattice Method and Gradient-Based Optimization

Aerodynamics↗

NASA NTRS1979

A program to compute three-dimensional subsonic unsteady aerodynamic characteristics using the doublet lattice method, L216 (DUBFLEX). Volume 2: Supplemental system design and maintenance document

The information necessary for execution of the digital computer program L216 on the CDC 6600 is described. L216 characteristics are based on the doublet lattice method. Arbitrary aerodynamic configurations may be represented with combinations of nonplanar lifting surfaces composed of finite constant pressure panel elements, and axially summetric slender bodies composed of constant pressure line elements. Program input consists of configuration geometry, aerodynamic parameters, and modal data; output includes element geometry, pressure difference distributions, integrated aerodynamic coefficients, stability derivatives, generalized aerodynamic forces, and aerodynamic influence coefficient matrices. Optionally, modal data may be input on magnetic field (tape or disk), and certain geometric and aerodynamic output may be saved for subsequent use.

Harrison, B. A.↗