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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 sources NASA NTRS DOE OSTI

NASA NTRS2010

Development of Testing Station for Prototype Rover Thermal Subsystem

In order to successfully and efficiently explore the moon or other planets, a vehicle must be built to assist astronauts as they travel across the surface. One concept created to meet this need is NASA's Space Exploration Vehicle (SEV). The SEV, a small pressurized cabin integrated onto a 12-wheeled chassis, can support two astronauts up to 14 days. Engineers are currently developing the second generation of the SEV, with the goal of being faster, more robust, and able to carry a heavier payload. In order to function properly, the rover must dissipate heat produced during operation and maintain an appropriate temperature profile inside the rover. If these activities do not occur, components of the rover will start to break down, eventually leading to the failure of the rover. On the rover, these requirements are the responsibility of the thermal subsystem. My project for the summer was to design and build a testing station to facilitate the design and testing of the new thermal subsystem. As the rover develops, initial low fidelity parts can be interchanged for the high fidelity parts used on the rover. Based on a schematic of the proposed thermal system, I sized and selected parts for each of the components in the thermal subsystem. For the components in the system that produced heat but had not yet been finalized or fabricated, I used power resistors to model their load patterns. I also selected all of the fittings to put the system together and a mounting platform to support the testing station. Finally, I implemented sensors at various points in the system to measure the temperature, pressure, and flow rate, and a data acquisition system to collect this information. In the future, the information from these sensors will be used to study the behavior of the subsystem under different conditions and select the best part for the rover.

Burlingame, Kaitlin↗

DOE OSTI2026

Hybrid Bio-Based Composites: Enabling Cellulose Nanofiber (CNF) Incorporation into Composites via Macroscale Natural Fiber Carriers

Cellulose nanofibers (CNFs) have significant potential in composites as additives to improve mechanical properties, melt rheology, and more. However, agglomeration of CNFs is a key challenge in composite melt processing as obtaining nano-level dispersion of CNFs often requires cost- and energy-intensive processes (e.g., solvent exchange or freeze drying) due to the strong hornification tendencies of CNF. Herein, we avoid these challenges by using a natural fiber carrier method to integrate CNF into thermoplastic composites. Fibers are co-dried to create a hybrid fiber feedstock for compounding in which natural fibers are decorated with dispersed nanofibers. The hybridized fibers result in up to a 24% increase in tensile strength and up to a 35% increase in Young’s modulus compared to composites only containing natural fibers. The lignocellulosic nanofibers are found to outperform their purely cellulosic counterpart, which is theorized to be due to either an increased propensity for fibrillation of the lignocellulosic fibers or the increased hydrophobicity of the fibers due to the presence of lignin. Surface analysis of fiber feedstocks, via streaming potential measurements and dynamic light scattering (DLS), confirmed a significant change in the feedstock hydrophobicity before and after hybridization. While mild additions of CNF (1 wt.% on the macroscale fiber) do not impact the composite melt viscosity, the viscosity is found to increase at higher CNF loadings (5 wt.% on the macroscale fiber), indicating its utility as a rheology modifier. Lastly, use of these materials as novel feedstocks for medium-scale additive manufacturing in high-fidelity part production was demonstrated.

bio-based↗

NASA NTRS2012

Aeroacoustic Study of a High-Fidelity Aircraft Model: Part 1- Steady Aerodynamic Measurements

In this paper, we present steady aerodynamic measurements for an 18% scale model of a Gulfstream air-craft. The high fidelity and highly-instrumented semi-span model was developed to perform detailed aeroacoustic studies of airframe noise associated with main landing gear/flap components and gear-flap interaction noise, as well as to evaluate novel noise reduction concepts. The aeroacoustic tests, being conducted in the NASA Langley Research Center 14- by 22-Foot Subsonic Tunnel, are split into two entries. The first entry, completed November 2010, was entirely devoted to the detailed mapping of the aerodynamic characteristics of the fabricated model. Flap deflections of 39?, 20?, and 0? with the main landing gear on and off were tested at Mach numbers of 0.16, 0.20, and 0.24. Additionally, for each flap deflection, the model was tested with the tunnel both in the closed-wall and open-wall (jet) modes. During this first entry, global forces (lift and drag) and extensive steady and unsteady surface pressure measurements were obtained. Preliminary analysis of the measured forces indicates that lift, drag, and stall characteristics compare favorably with Gulfstream?s high Reynolds number flight data. The favorable comparison between wind-tunnel and flight data allows the semi-span model to be used as a test bed for developing/evaluating airframe noise reduction concepts under a relevant environment. Moreover, initial comparison of the aerodynamic measurements obtained with the tunnel in the closed- and open-wall configurations shows similar aerodynamic behavior. This permits the acoustic and off-surface flow measurements, planned for the second entry, to be conducted with the tunnel in the open-jet mode.

Khorrami, Mehdi R.↗

DOE OSTI2023

Extrusion parameter control optimization for DIW 3D printing using image analysis techniques

Material extrusion is a well-recognized facet of additive manufacturing that involves the fabrication of parts through the deposition of structural material from an extrusion head from a bulk supply. In the subdivision of Direct Ink Writing (DIW) additive manufacturing, challenges arise when the structural material is flowable, synchronous extrusion control and tool movement becomes critical for achieving high-quality parts with low defect populations. DIW techniques are most used in laboratory settings using expensive custom instruments and may require specialized 3D slicing software. Here, in this study, the fabrication of an inexpensive, consumer-friendly progressive cavity pump dispensing system is detailed, in which can create high-quality parts by executing G-code commands produced from a commercial slicing software. The precision and repeatability of the movement-synchronized material extrusion is demonstrated through a series of optimization schemes, entailing the alteration of various control parameters, which directly affect the extrusion properties demonstrated during a print. In situ diagnostics were implemented to evaluate the results of the established optimization experiment. Using a machine vision technique, images of the optimization prints are processed. Following this, a supervised machine learning model was trained to autonomously judge whether or not the extrusion parameters produced a passing or failing result. The machine learning scheme serves as a preliminary benchmark for future layer-by-layer evaluation of more complex DIW parts. The construction of the printer and development of in situ characterization capabilities demonstrates the ability for this printer to create high-fidelity DIW parts for a fraction of the price of other systems.

42 ENGINEERING↗

NASA NTRSDate not supplied

TPSAS-NF1676L-18493-DND

The Air Traffic Operations Lab is a multi-fidelity, part-task, aircraft and air traffic operations simulation facility. Used to explore interactions between new airborne and ground-based tools in a NextGeneration ATC environment, including: - Concept-level flight operations research, looking at human decision making, situation awareness, transfer of authority/responsibility, etc. - Performance impact assessments of new operational concepts on the National Airspace System (NAS) - Rapid prototyping of new flight deck tools and automation - Concept-level safety assessments - Identification and evaluation of future communication, navigation, and surveillance (CNS) infrastructure requirements - Controller-pilot data link - Precision trajectory-based ops - Air-to-air data exchange

Michael T Palmer↗

NASA NTRS2012

Aeroacoustic Study of a High-Fidelity Aircraft Model: Unsteady Surface Pressures - Part 2

In this paper, we present unsteady surface pressure measurements for an 18%-scale, semi-span Gulfstream aircraft model. This high-fidelity model is being used to perform detailed studies of airframe noise associated with main landing gear, flap components, and gear-flap interaction noise, as well as to evaluate novel noise reduction concepts. The aerodynamic segment of the tests, conducted in the NASA Langley Research Center 14- by 22-Foot Subsonic Tunnel, was completed in November 2010. To discern the characteristics of the surface pressure fluctuations in the vicinity of the prominent noise sources, unsteady sensors were installed on the inboard and outboard flap edges, and on the main gear wheels, struts, and door. Various configurations were tested, including flap deflections of 0?, 20?, and 39?, with and without the main landing gear. The majority of unsteady surface pressure measurements were acquired for the nominal landing configuration where the main gear was deployed and the flap was deflected 39?. To assess the Mach number variation of the surface pressure amplitudes, measurements were obtained at Mach numbers of 0.16, 0.20, and 0.24. Comparison of the unsteady surface pressures with the main gear on and off shows significant interaction between the gear wake and the inboard flap edge, resulting in higher amplitude fluctuations when the gear is present.

Khorrami, Mehdi R.↗

DOE OSTI2024

PINN surrogate of Li-ion battery models for parameter inference, Part I: Implementation and multi-fidelity hierarchies for the single-particle model

To plan and optimize energy storage demands that account for Li-ion battery aging dynamics, techniques need to be developed to diagnose battery internal states accurately and rapidly. Here, this study seeks to reduce the computational resources needed to determine a battery's internal states by replacing physics-based Li-ion battery models - such as the single-particle model (SPM) and the pseudo-2D (P2D) model - with a physics-informed neural network (PINN) surrogate. The surrogate model makes high-throughput techniques, such as Bayesian calibration, tractable to determine battery internal parameters from voltage responses. This manuscript is the first of a two-part series that introduces PINN surrogates of Li-ion battery models for parameter inference (i.e., state-of-health diagnostics). In this first part, a method is presented for constructing a PINN surrogate of the SPM. A multi-fidelity hierarchical training, where several neural nets are trained with multiple physics-loss fidelities is shown to significantly improve the surrogate accuracy when only training on the governing equation residuals. The implementation is made available in a companion repository (https://github.com/NREL/PINNSTRIPES). The techniques used to develop a PINN surrogate of the SPM are extended in Part II for the PINN surrogate for the P2D battery model, and explore the Bayesian calibration capabilities of both surrogates.

25 ENERGY STORAGE↗

DOE OSTI2026

Hydrogen-based ore-to-part manufacturing of near-net-shape stainless steel

Decarbonizing iron and steelmaking, combined with global disruptions to raw material supply chains, necessitates novel approaches to iron and steel production. In this work, we demonstrate a direct ore-to-part manufacturing route using a mixture of ore-derived oxide powders of Fe 2 O 3 , Cr 2 O 3 , NiO, and MoO 3 as feedstock for additive manufacturing, combined with sintering under H 2 to produce a near-net-shape austenitic stainless-steel. Complete reduction of all constituent oxides, including MoO 3 and Cr 2 O 3 , is achieved in-situ at 1300 °C, resulting in dense, crack-free bulk alloy. The fabricated part retains geometric fidelity while undergoing substantial volumetric shrinkage inherent to redox and sintering. Thermodynamic calculations elucidate the co-reduction mechanisms and alloying pathways that enable complete metallization. This work is the first demonstration of net-shaping metal parts directly from ore derived oxides, and this ore-to-part approach can minimize the emissions and lead time for manufacturing associated with downstream processing such as rolling, forging, and machining.

Yang, Mingzhang [Univ. of Waterloo, ON (Canada); F↗

NASA NTRS2000

Multidisciplinary High-Fidelity Analysis and Optimization of Aerospace Vehicles: Formulation - Part 1

An objective of the High Performance Computing and Communication Program at the NASA Langley Research Center is to demonstrate multidisciplinary shape and sizing optimization of a complete aerospace vehicle configuration by using high-fidelity, finite element structural analysis and computational fluid dynamics aerodynamic analysis in a distributed, heterogeneous computing environment that includes high performance parallel computing. A software system has been designed and implemented to integrate a set of existing discipline analysis codes, some of them computationally intensive, into a distributed computational environment for the design of a highspeed civil transport configuration. The paper describes the engineering aspects of formulating the optimization by integrating these analysis codes and associated interface codes into the system. The discipline codes are integrated by using the Java programming language and a Common Object Request Broker Architecture (CORBA) compliant software product. A companion paper presents currently available results.

Walsh, J. L.↗

NASA NTRS2009

Aerodynamics of a Gulfstream G550 Nose Landing Gear Model

In this paper we discuss detailed steady and unsteady aerodynamic measurements of a Gulfstream G550 nose landing gear model. The quarter-scale, high-fidelity model includes part of the lower fuselage and the gear cavity. The full model configuration allowed for removal of various gear components (e.g. light cluster, steering mechanism, hydraulic lines, etc.) in order to document their effects on the local flow field. The measurements were conducted at a Reynolds number of 7.3 x 10(exp 4) based on the shock strut (piston) diameter and a freestream Mach number of 0.166. Additional data were also collected at lower Mach numbers of 0.12 and 0.145 and correspondingly lower Reynolds numbers. The boundary layer on the piston was tripped to enable turbulent flow separation, so as to better mimic the conditions encountered during flight. Steady surface pressures were gathered from an extensive number of static ports on the wheels, door, fuselage, and within the gear cavity. To better understand the resultant flow interactions between gear components, surface pressure fluctuations were collected via sixteen dynamic pressure sensors strategically placed on various subcomponents of the gear. Fifteen of the transducers were flush mounted on the gear surface at fixed locations, while the remaining one was a mobile transducer that could be placed at numerous varying locations. The measured surface pressure spectra are mainly broadband in nature, lacking any local peaks associated with coherent vortex shedding. This finding is in agreement with off-surface flow measurements using PIV that revealed the flow field to be a collection of separated shear layers without any dominant vortex shedding processes.

Neuhart, Dan H.↗

NASA NTRS2000

Multidisciplinary High-Fidelity Analysis and Optimization of Aerospace Vehicles: Preliminary Results - Part 2

An objective of the High Performance Computing and Communication Program at the NASA Langley Research Center is to demonstrate multidisciplinary shape and sizing optimization of a complete aerospace vehicle configuration by using high-fidelity finite-element structural analysis and computational fluid dynamics aerodynamic analysis in a distributed, heterogeneous computing environment that includes high performance parallel computing. A software system has been designed and implemented to integrate a set of existing discipline analysis codes, some of them computationally intensive, into a distributed computational environment for the design of a high-speed civil transport configuration. The paper describes both the preliminary results from implementing and validating the multidisciplinary analysis and the results from an aerodynamic optimization. The discipline codes are integrated by using the Java programming language and a Common Object Request Broker Architecture compliant software product. A companion paper describes the formulation of the multidisciplinary analysis and optimization system.

Walsh, J. L.↗

NASA NTRSDate not supplied

Observations of Keyhole Porosity and Comparisons to Analytical Models for Ti-6Al-4V Powder Bed Fusion

Keyhole porosity defects are a common concern in powder bed fusion (PBF) processing. Keyhole porosity prediction models have generally fallen into two categories – high fidelity computational fluid dynamics simulations and low fidelity analytical or empirical models based on keyhole vibration dynamics. The low computational cost of low fidelity models allows them to better approach part-scale predictions. However, studies on low fidelity modeling techniques are limited by the lack of experimental data to assess the validity of the calibration over a wide range of processing conditions. This work extracts and quantifies keyhole porosity across 14 laser velocities, two laser powers, and six+ repetitions for a total of 176 independent trials. The measured porosity data are compared to low fidelity keyhole models to assess their success in predictive porosity occurrence. This work impacts the field by providing independent validation of keyhole porosity models for PBF for use in part-scale defect prediction.

powder bed fusion↗

NASA NTRS1994

Determining the accuracy of maximum likelihood parameter estimates with colored residuals

An important part of building high fidelity mathematical models based on measured data is calculating the accuracy associated with statistical estimates of the model parameters. Indeed, without some idea of the accuracy of parameter estimates, the estimates themselves have limited value. In this work, an expression based on theoretical analysis was developed to properly compute parameter accuracy measures for maximum likelihood estimates with colored residuals. This result is important because experience from the analysis of measured data reveals that the residuals from maximum likelihood estimation are almost always colored. The calculations involved can be appended to conventional maximum likelihood estimation algorithms. Simulated data runs were used to show that the parameter accuracy measures computed with this technique accurately reflect the quality of the parameter estimates from maximum likelihood estimation without the need for analysis of the output residuals in the frequency domain or heuristically determined multiplication factors. The result is general, although the application studied here is maximum likelihood estimation of aerodynamic model parameters from flight test data.

Morelli, Eugene A.↗

NASA NTRS2011

A Transfer of Training Study of Control Loader Dynamics

The control inceptor used in a simulated vehicle is an important part in maintaining the fidelity of a simulation. The force feedback provided by the control inceptor gives the operator important cues to maintain adequate performance. The dynamics of a control inceptor are typically based on a second order spring mass damper system with damping, force gradient, breakout force, and natural frequency parameters. Changing these parameters can have a great effect on pilot or driver control of the vehicle. The neuromuscular system has a very important role in manipulating the control inceptor within a vehicle. Many studies by McRuer, Aponso, and Hess have dealt with modeling the neuromuscular system and quantifying the effects of a high fidelity control loader as compared to a low fidelity control loader. Humans are adaptive in nature and their control behavior changes based on different control loader dynamics. Humans will change their control behavior to maintain tracking bandwidth and minimize tracking error. This paper reports on a quasi-transfer of training experiment which was performed at the NASA Langley Research Center. The quasi transfer of training study used a high fidelity control loader and a low fidelity control loader. Subjects trained in both simulations and then were transferred to the high fidelity control loader simulation. The parameters for the high fidelity control loader were determined from the literature. The low fidelity control loader parameters were found through testing of a simple computer joystick. A disturbance compensatory task is employed. The compensatory task involves implementing a simple horizon out the window display. A disturbance consisting of a sum of sines is used. The task consists of the subject compensating for the disturbance on the roll angle of the aircraft. The vehicle dynamics are represented as 1/s and 1/s2. The subject will try to maintain level flight throughout the experiment. The subjects consist of non-pilots to remove any effects of pilot experience. First, this paper discusses the implementation of the disturbance compensation task. Second, the high and low fidelity parameters used within the experiment are presented. Finally, an explanation of results from the experiments is presented.

Cardullo, Frank M.↗

NASA NTRS2014

Shielding of Turbomachinery Broadband Noise from a Hybrid Wing Body Aircraft Configuration

The results of an experimental study on the effects of engine placement and vertical tail configuration on shielding of exhaust broadband noise radiation are presented. This study is part of the high fidelity aeroacoustic test of a 5.8% scale Hybrid Wing Body (HWB) aircraft configuration performed in the 14- by 22-Foot Subsonic Tunnel at NASA Langley Research Center. Broadband Engine Noise Simulators (BENS) were used to determine insertion loss due to shielding by the HWB airframe of the broadband component of turbomachinery noise for different airframe configurations and flight conditions. Acoustics data were obtained from flyover and sideline microphones traversed to predefined streamwise stations. Noise measurements performed for different engine locations clearly show the noise benefit associated with positioning the engine nacelles further upstream on the HWB centerbody. Positioning the engine exhaust 2.5 nozzle diameters upstream (compared to 0.5 nozzle diameters downstream) of the HWB trailing edge was found of particular benefit in this study. Analysis of the shielding performance obtained with and without tunnel flow show that the effectiveness of the fuselage shielding of the exhaust noise, although still significant, is greatly reduced by the presence of the free stream flow compared to static conditions. This loss of shielding is due to the turbulence in the model near-wake/boundary layer flow. A comparison of shielding obtained with alternate vertical tail configurations shows limited differences in level; nevertheless, overall trends regarding the effect of cant angle and vertical location are revealed. Finally, it is shown that the vertical tails provide a clear shielding benefit towards the sideline while causing a slight increase in noise below the aircraft.

Hutcheson, Florence V.↗

DOE OSTI2024

DETERMINATION OF STRUT QUALITY FACTORS IN ADDITIVELY MANUFACTURED LATTICES USING IN-SITU COMPRESSION TESTING µ-CT

In response to the need for an automated, commercial method to qualify additively manufactured (AM) lattice components, an experiment was conducted to evaluate the effects of defective lattice struts on the structural compression strength. Lattice samples with known defective or missing struts were compressed using a Deben CT5000RT and imaged using xray µ-CT. The compressive force and x-ray computed tomography results were compared to defect free standards to evaluate the impact of each defect type on the overall structure’s compressive strength. This analysis will allow for simplifications to Finite Element Analysis (FEA) on AM parts without sacrificing model fidelity. Understanding the contribution of each defect type and severity will also better inform non-destructive evaluation (NDE) personnel of the inspection parameters necessary to detect the smallest feature of importance.

Dinova, Vincent A.↗

DOE OSTI2023

Design and Development of a High Fidelity Cyber-Physical Testbed

In order to ensure that future critical infrastructure systems are resilient to various types of such advanced and persistent threats, it is important to develop and integrate tailored solutions that holistically address cyber-attack detection and mitigation in a timely manner such that adverse system impacts that impact a large population are avoided. Further, it is essential to create environments that allow control, protection and communication to exist within a realistic environment to analyze the effects of adverse conditions and system operating modes. This project aims to establish a high-fidelity testbed environment for modeling and simulating a single microgrid all the way up to a network of microgrids along with baseline controls, protection, and associated cyber communication. This is an important activity because accurately modeling and simulating the various power-electronics-based DERs and loads in a microgrid is critical to adequately capturing their behaviors over a wide range of off-normal conditions, as well as to evaluate the resilience of the system using the developed controls. The work presented in this report focuses on the process of building this high-fidelity testbed and the associated experimentation it enables. The model enables the creation of high-fidelity use cases and associated datasets that have been used extensively within the initiative to study resilience and support novel control development and prototyping. The work heavily leverages existing capability that is part of the high-fidelity cyber-physical system experimentation lab to create a power hardware-in-the-loop setup. The report also details the creation of an automated model building platform that can enable high-fidelity real-time models to be built without much effort allowing existing low-fidelity models to be analyzed in higher fidelity. Lastly, the report also discusses efforts center around scaling to large complex power system models to make the experimentation more effective.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS2012

Creation of a Rapid High-Fidelity Aerodynamics Module for a Multidisciplinary Design Environment

In the traditional aerospace vehicle design process, each successive design phase is accompanied by an increment in the modeling fidelity of the disciplinary analyses being performed. This trend follows a corresponding shrinking of the design space as more and more design decisions are locked in. The correlated increase in knowledge about the design and decrease in design freedom occurs partly because increases in modeling fidelity are usually accompanied by significant increases in the computational expense of performing the analyses. When running high fidelity analyses, it is not usually feasible to explore a large number of variations, and so design space exploration is reserved for conceptual design, and higher fidelity analyses are run only once a specific point design has been selected to carry forward. The designs produced by this traditional process have been recognized as being limited by the uncertainty that is present early on due to the use of lower fidelity analyses. For example, uncertainty in aerodynamics predictions produces uncertainty in trajectory optimization, which can impact overall vehicle sizing. This effect can become more significant when trajectories are being shaped by active constraints. For example, if an optimal trajectory is running up against a normal load factor constraint, inaccuracies in the aerodynamic coefficient predictions can cause a feasible trajectory to be considered infeasible, or vice versa. For this reason, a trade must always be performed between the desired fidelity and the resources available. Apart from this trade between fidelity and computational expense, it is very desirable to use higher fidelity analyses earlier in the design process. A large body of work has been performed to this end, led by efforts in the area of surrogate modeling. In surrogate modeling, an up-front investment is made by running a high fidelity code over a Design of Experiments (DOE); once completed, the DOE data is used to create a surrogate model, which captures the relationships between input variables and responses into regression equations. Depending on the dimensionality of the problem and the fidelity of the code for which a surrogate model is being created, the initial DOE can itself be computationally prohibitive to run. Cokriging, a modeling approach from the field of geostatistics, provides a desirable compromise between computational expense and fidelity. To do this, cokriging leverages a large body of data generated by a low fidelity analysis, combines it with a smaller set of data from a higher fidelity analysis, and creates a kriging surrogate model with prediction fidelity approaching that of the higher fidelity analysis. When integrated into a multidisciplinary environment, a disciplinary analysis module employing cokriging can raise the analysis fidelity without drastically impacting the expense of design iterations. This is demonstrated through the creation of an aerodynamics analysis module in NASA’s OpenMDAO framework. Aerodynamic analyses including Missile DATCOM, APAS, and USM3D are leveraged to create high fidelity aerodynamics decks for parametric vehicle geometries, which are created in NASA’s Vehicle Sketch Pad (VSP). Several trade studies are performed to examine the achieved level of model fidelity, and the overall impact to vehicle design is quantified.

Aerodynamic Properties↗