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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 NTRSDate not supplied

Thermoplastic Aircraft Manufacturing Model

A manufacturing process to produce 80 single aisle sized thermoplastic composite aircraft a month is presented. Within the Hi-Rate Composite Aircraft Manufacturing (HiCAM) program a baseline aircraft fuselage was designed and modeled based on the Boeing 787 one-piece barrel build, but scaled down to a single aisle aircraft. Key Performance Parameters (KPPs) of recurring cost, non-recurring cost, and weight are calculated from the model. The outcome of this simulation indicated a prohibitively high non-recurring cost, so the thermoplastic team modeled the manufacturing flow for a panelized fuselage concept. The minimum success criteria is a 30% cost reduction and less than two percent increase in weight compared to the baseline aircraft. Automated Fiber Placement (AFP) is used to layup skins, stamp forming is used to make body frames, stringers, and passenger door surround parts. In the model, Co-Fusion was used to consolidate the skin while simultaneously welding on stringers to make stiffened panels. Additional welding technologies were considered to minimize fastener use and a vertical build concept was used for final assembly to reduce factory size. This manufacturing concept for a thermoplastic aircraft indicated a 39% cost and 12% weight savings compared to the baseline. Additional trade studies were conducted using Northrop Grumman’s Automated Stiffener Forming technology to make stringers and stamp forming instead of AFP to make skins.

thermoplastic composites↗
NASA NTRSDate not supplied

Thermoplastic Composite Aircraft Manufacturing Model

A manufacturing process to produce 80 single aisle sized thermoplastic composite aircraft a month is presented. Within the Hi-Rate Composite Aircraft Manufacturing (HiCAM) program a baseline aircraft fuselage was designed and modeled based on the Boeing 787 one-piece barrel build, but scaled down to a single aisle aircraft. Key Performance Parameters (KPPs) of recurring cost, non-recurring cost, and weight are calculated from the model. The outcome of this simulation indicated a prohibitively high non-recurring cost, so the thermoplastic team modeled the manufacturing flow for a panelized fuselage concept. The minimum success criteria is a 30% cost reduction and less than two percent increase in weight compared to the baseline aircraft. Automated Fiber Placement (AFP) is used to layup skins, stamp forming is used to make body frames, stringers, and passenger door surround parts. In the model, Co-Fusion was used to consolidate the skin while simultaneously welding on stringers to make stiffened panels. Additional welding technologies were considered to minimize fastener use and a vertical build concept was used for final assembly to reduce factory size. This manufacturing concept for a thermoplastic aircraft indicated a 39% cost and 12% weight savings compared to the baseline. Additional trade studies were conducted using Northrop Grumman’s Automated Stiffener Forming technology to make stringers and stamp forming instead of AFP to make skins.

thermoplastic composites↗
DOE OSTI2021

AFRL Additive Manufacturing Modeling Series: Challenge 4, In Situ Mechanical Test of an IN625 Sample with Concurrent High-Energy Diffraction Microscopy Characterization

In this work, we describe 3D characterization of an additively manufactured Inconel 625 nickel-base superalloy specimen conducted during a uniaxial tension test using a suite of nondestructive x-ray techniques. High-energy diffraction microscopy in both near- and far-field modalities are employed in situ to track evolution of the material orientation and stress–strain fields at six points during the mechanical test, and these data streams are registered with micro-computed tomography reconstructions which probe the material density. This data volume was matched to a multi-modal serial sectioning characterization of the specimen taken after loading, described in this article’s companion. Twenty-eight grains which were monitored throughout the experiment were selected to form the basis for AFRL AM Modeling Series Challenge 4, Microscale Structure-to-Properties.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Fast and accurate reduced-order modeling of a MOOSE-based additive manufacturing model with operator learning

One predominant challenge in additive manufacturing (AM) is to achieve specific material properties by manipulating manufacturing process parameters during the runtime. Such manipulation tends to increase the computational load imposed on existing simulation tools employed in AM. The goal of the present work is to construct a fast and accurate reduced-order model (ROM) for an AM model developed within the Multiphysics Object-Oriented Simulation Environment (MOOSE) framework, ultimately reducing the time/cost of AM control and optimization processes. Our adoption of the operator learning (OL) approach enabled us to learn a family of differential equations produced by altering process variables in the laser’s Gaussian point heat source. More specifically, we used the Fourier neural operator (FNO) and deep operator network (DeepONet) to develop ROMs for time-dependent responses. Furthermore, we benchmarked the performance of these OL methods against a conventional deep neural network (DNN)-based ROM. Ultimately, we found that OL methods offer comparable performance and, in terms of accuracy and generalizability, even outperform DNN at predicting scalar model responses. The DNN-based ROM afforded the fastest training time. Furthermore, all the ROMs were faster than the original MOOSE model yet still provided accurate predictions. FNO had a smaller mean prediction error than DeepONet, with a larger variance for time-dependent responses. Unlike DNN, both FNO and DeepONet were able to simulate time series data without the need for dimensionality reduction techniques. Finally, the present work can help facilitate the AM optimization process by enabling faster execution of simulation tools while still preserving evaluation accuracy.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Techno-Economic Wind Blade Manufacturing Model to Identify Opportunities for Cost Improvements Phase II IACMI Project 4.6/4.8

In IACMI Project 4.6 and IACMI Project 4.8, an Excel-based Techno-Economic Model (TEM) of the manufacturing process for composite wind turbine blades and a DELMIA Factory Flow Simulation of a generic wind blade manufacturing facility was developed. Together, these two tools provide a combined economic modeling capability that accounts for the material, labor, overhead and full-lifecycle operating costs associated with wind blade manufacturing as well as the impact of process flow and factory layout on overall manufacturing efficiency. The tools provide a novel means of detailed comparative analysis of the economic feasibility of proposed technologies and process changes for blade manufacturing. The modeling tools were developed with close support from members of industry and visits to multiple blade manufacturing facilities. With industry oversight, a detailed generalized manufacturing process plan and facility layout were developed with manufacturing parameters, material costs and economic factors based on historical data. Dassault Systèmes and the University of Texas at Dallas (UTD) contributed to the development of the Techno-Economic Model by providing macros to enable the generation of Bill of Material (BOM) data from a 3D blade design in either CATIA or NuMAD format, respectively. The TEM was built with the capability to directly import a Bill of Materials for economic analysis, and with the addition of the macros provided by Dassault and UTD, the TEM can directly import blade designs from both CATIA and NuMAD file formats. The modeling tools developed in Project 4.6 were used to investigate four wind blade manufacturing concepts in detail and select one to explore with laboratory-scale experimentation in Project 4.8. The four manufacturing concepts that were investigated were down-selected by the full project team from a larger list of concepts. The selections were made based on a number of criteria ranking viability and level of interest for each concept. The ‘One-Step Close’ manufacturing concept was ultimately selected for investigation in Project 4.8 and the demonstration was performed at the NREL CoMET facility. The TPI advanced manufacturing facility in Warren, RI contributed the production of several prototype components, the designs for which were developed by Janicki Industries. The demonstration project provided clear indication of the viability of the One-Step Close manufacturing concept for blade manufacturing and good validation of the Techno-Economic Model’s prediction of its economic impact.

17 WIND ENERGY↗
DOE OSTI2021

AFRL Additive Manufacturing Modeling Series: Challenge 1, Characterization of Residual Strain Distribution in Additively-Manufactured Metal Parts Using Energy-Dispersive Diffraction

A machine component fabricated by additive manufacturing (AM) of metal powders often possesses steep residual stress gradients with significant magnitudes due to large temperature gradients that transpire within a localized area during fabrication. These processing-induced residual stresses can cause distortion of the part, and if they are of significant magnitude, they could induce cracking of the component, degrade printability, and/or diminish subsequent mechanical performance. The ability to predict these residual stresses imparted by AM is an important step in permeating AM technology for advanced manufacturing. Calibration and validation of AM process models used for prediction are, therefore, a critical step in understanding the origin and mitigating the challenges associated with residual stresses inherent to the AM process. In the present work, the residual strain distributions in components with simple geometries fabricated by a laser powder bed fusion (LBPF) process were characterized non-destructively using energy-dispersive X-ray diffraction in support of the US Air Force Research Laboratory Additive Manufacturing Modeling Challenge Series Groeber et al. (JOM 70:441-448, 2018). The measurement setup and approach are described in detail so that the data can be used as a benchmark to calibrate and validate models for the prediction of macro-scale residual stresses due to the LPBF process.

36 MATERIALS SCIENCE↗
NASA NTRS1988

Using a simulation assistant in modeling manufacturing systems

Numerous simulation languages exist for modeling discrete event processes, and are now ported to microcomputers. Graphic and animation capabilities were added to many of these languages to assist the users build models and evaluate the simulation results. With all these languages and added features, the user is still plagued with learning the simulation language. Futhermore, the time to construct and then to validate the simulation model is always greater than originally anticipated. One approach to minimize the time requirement is to use pre-defined macros that describe various common processes or operations in a system. The development of a simulation assistant for modeling discrete event manufacturing processes is presented. A simulation assistant is defined as an interactive intelligent software tool that assists the modeler in writing a simulation program by translating the modeler's symbolic description of the problem and then automatically generating the corresponding simulation code. The simulation assistant is discussed with emphasis on an overview of the simulation assistant, the elements of the assistant, and the five manufacturing simulation generators. A typical manufacturing system will be modeled using the simulation assistant and the advantages and disadvantages discussed.

Schroer, Bernard J.↗
NASA NTRSDate not supplied

Advancements to Wind Tunnel Testing at the Marshall Space Flight Center Aerodynamic Research Facility by the Utilization of Additively Manufactured Models

In recent years, the Aerodynamic Research Facility (ARF) at NASA’s Marshall Space Flight Center (MSFC) has heavily utilized additive manufacturing (AM) technology for the manufacturing of models for aerodynamic testing in the 14 x 14-inch Trisonic Wind Tunnel (TWT). This process change resulted in speed and cost improvements to the design and manufacture of model parts, which has provided the capability to perform parametric tests at a rapid pace with high fidelity models that are more finely detailed than previously tested. This paper outlines the model design and fabrication workflow of the ARF and the improvements made, focusing specifically on two vehicles tested. First, identical traditionally machined and AM models of a test missile configuration were tested to isolate effects of differences in manufacturing. Second, a high-fidelity model of NASA’s Space Launch System (SLS) was tested to investigate improvements in data quality possible by utilizing AM on small-scale wind tunnel tests. This paper also discusses detailed model inspections and data comparisons that were performed to prove the reliability of data across the TWT’s entire Mach range.

Ryan C Connelly↗
NASA NTRS2014

Additive Manufacturing Modeling and Simulation A Literature Review for Electron Beam Free Form Fabrication

Additive manufacturing is coming into industrial use and has several desirable attributes. Control of the deposition remains a complex challenge, and so this literature review was initiated to capture current modeling efforts in the field of additive manufacturing. This paper summarizes about 10 years of modeling and simulation related to both welding and additive manufacturing. The goals were to learn who is doing what in modeling and simulation, to summarize various approaches taken to create models, and to identify research gaps. Later sections in the report summarize implications for closed-loop-control of the process, implications for local research efforts, and implications for local modeling efforts.

Seufzer, William J.↗
DOE OSTI2020

Extended Finite Element Based Approach in Additive Manufacturing Modeling for Optimizing Highly Complex Manifold in Protonic Ceramic Electrochemical Cells

The objective of this project is to develop a novel numerical approach based on the extended finite element method (XFEM) for modeling moving boundaries of material deposited in additive manufacturing (AM) process with improved accuracy and reduced computational cost. One of the major challenges in simulating AM processes is that the boundaries of the computational domain need to change as material is deposited. Previous approaches have achieved this by activating new finite elements, but this requires a high level of mesh refinement to capture small movement of the boundary. XFEM allows the solution boundary to move independently of the mesh, permitting smooth representation of the evolution of the boundary as material is deposited. As a result, this new method will significantly improve the simulation accuracy while reducing the computational cost compared with existing approaches. Furthermore, this project will bring significant improvements for the design and AM process optimization in an iterative fashion among numerical simuation, parameter optimization, and experimental validation. Specifically, this project will support the protonic ceramic electrochemical cells (PCEC) stack development at INL by providing insights into the density, residual stress, thermal and mechanical properties of the PCEC manifold and interconnect, which is critical in enhancing the system lifetime and reducing the overall cost. Upon the success of proposed development and validation of the proposed approach, simulation will be applied to determine an optimal set of AM process parameters for the PCEC manifold production. This project will consolidate Idaho National Laboratory (INL)’s simulation capabilities provided by the MOOSE framework and the Valhalla AM simulation application, with encouraging expansion to emerging PCEC applications and AM technologies at INL and beyond.

97 MATHEMATICS AND COMPUTING↗
NASA NTRSDate not supplied

CFD Simulations of the IHF 13-Inch Nozzle Flow: 55-deg Sphere-Cone Model, Manufactured Fences and Gaps

This paper reports computational analyses of testsin a high enthalpy arc-jet facility at NASA Ames Research Center. These tests were conducted using 55-deg sphere-cone models placed in a free jet downstream of the 13-inch diameter conical nozzle in the Ames 60-MW Interaction Heating Facility. Some of the sphere-cone models include surface features such as manufactured fences and gaps intended to simulate effects of differential recession, all of which disturb the flow, producing augmented heating locally and downstream.Test calibration data were obtained using slug and Gardon gage stagnation calorimeters, and a sphere-cone calorimeter model with six Gardon gages and five pressure tabs.The present analysis comprises computational fluid dynamics simulations of the nonequilibrium flowfield in the facility nozzle and test box, including the models tested, and comparisons with the experimental measurements. These simulations take into account nonuniform total enthalpy and mass flux profiles at the nozzle inlet as well as the expansion waves emanating from the nozzle exit and their effects on the model flowfields.

Arc-jets↗
NASA NTRSDate not supplied

CFD Simulations of the IHF 13-Inch Nozzle Flow: 55-deg Sphere-Cone Model, Manufactured Fences and Gaps

This paper reports computational analyses of tests in a high enthalpy arc-jet facility at NASA Ames Research Center. These tests were conducted using 55-deg sphere-cone models placed in a free jet downstream of the 13-inch diameter conical nozzle in the Ames 60-MW Interaction Heating Facility. Some of the sphere-cone models include surface features such as manufactured fences and gaps intended to simulate effects of differential recession, all of which disturb the flow, producing augmented heating locally and downstream. Test calibration data were obtained using slug and Gardon gage stagnation calorimeters, and a sphere-cone calorimeter model with six Gardon gages and five pressure tabs. The present analysis comprises computational fluid dynamics simulations of the nonequilibrium flowfield in the facility nozzle and test box, including the models tested, and comparisons with the experimental measurements. These simulations take into account nonuniform total enthalpy and mass flux profiles at the nozzle inlet as well as the expansion waves emanating from the nozzle exit and their effects on the model flowfields.

Arc-jets↗
NASA NTRSDate not supplied

CFD Simulations of the IHF 13-Inch Nozzle Flow: 55-deg Sphere-Cone Model, Manufactured Fences and Gaps

This paper reports computational analyses of tests in a high enthalpy arc-jet facility at NASA Ames Research Center. These tests were conducted using 55-deg sphere-cone models placed in a free jet downstream of the 13-inch diameter conical nozzle in the Ames 60-MW Interaction Heating Facility. Some of the sphere-cone models include surface features such as manufactured fences and gaps intended to simulate effects of differential recession, all of which disturb the flow, producing augmented heating locally and downstream. Test calibration data were obtained using slug and Gardon gage stagnation calorimeters, and a sphere-cone calorimeter model with six Gardon gages and five pressure tabs. The present analysis comprises computational fluid dynamics simulations of the nonequilibrium flowfield in the facility nozzle and test box, including the models tested, and comparisons with the experimental measurements. These simulations take into account nonuniform total enthalpy and mass flux profiles at the nozzle inlet as well as the expansion waves emanating from the nozzle exit and their effects on the model flowfields.

Arc-jets↗
NASA NTRSDate not supplied

CFD Simulations of the IHF 13-Inch Nozzle Flow: 55° Sphere-Cone Model, Manufactured Fences and Gaps

This paper reports computational analyses of tests in a high enthalpy arc-jet facility at NASA Ames Research Center. These tests were conducted using 23.6-cm diameter, 55° sphere-cone models placed in a free jet downstream of the 33.0-cm diameter conical nozzle in the 60-MW Interaction Heating Facility. Some of the sphere-cone models include surface features such as manufactured fences and gaps intended to simulate effects of differential recession, all of which disturb the flow, producing augmented heating locally and downstream. Test calibration data were obtained using slug and Gardon gage stagnation calorimeters, and a sphere-cone calorimeter model with six Gardon heat flux gages and five pressure gages. The present analysis comprises computational fluid dynamics simulations of the nonequilibrium flowfield in the facility nozzle and test box, including the models tested, and comparisons with the experimental measurements. Various issues related to testing are considered: diffuser flow capture, flow characterization based on the calorimeter data, effects of the model surface recession, and prediction of surface quantities for the models with surface features. These simulations take into account nonuniform total enthalpy profiles at the nozzle inlet as well as the expansion waves emanating from the nozzle exit and their effects on the model flowfields.

Arc-jets↗
NASA NTRS2002

Design, Progressive Modeling, Manufacture, and Testing of Composite Shield for Turbine Engine Blade Containment

An effective design methodology was established for composite jet engine containment structures. The methodology included the development of the full and reduced size prototypes, and FEA models of the containment structure, experimental and numerical examination of the modes of failure clue to turbine blade out event, identification of materials and design candidates for future industrial applications, and design and building of prototypes for testing and evaluation purposes.

Binienda, Wieslaw K.↗
NASA NTRSDate not supplied

CFD Simulations of the IHF 13-Inch Nozzle Flow: 55° Sphere-Cone Model, Manufactured Fences and Gaps

Introduction to Arc-Jets and Testing - Arc-jets are primary facilities to test the performance of thermal protection systems (TPS) in an aerothermodynamic heating environment - Free jet test configuration with stagnation coupon or wedge models—conical nozzles - Semi-free jet test configuration with panel test articles—semi-elliptical nozzles A large-scale sphere-cone model, though similar to stagnation models, enables testing TPS materials in combinations of heat flux, pressure and shear different from those accessible in various stagnation and wedge tests

Arc-jets↗