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NASA NTRS2022

VULCAN-CFD User Manual: Ver. 7.2.0

VULCAN-CFD offers a comprehensive set of capabilities to enable the simulation of continuum flowfields from subsonic to hypersonic conditions. The governing equations that are employed include allowances for both chemical and thermal nonequilibrium processes, coupled with a wide variety of turbulence models for both Reynolds-averaged and large eddy simulations. The software package can simulate two-dimensional, axisymmetric, or three-dimensional problems on structured multiblock meshes or fully unstructured meshes. A parabolic (i.e., space-marching) treatment can also be used for any subset of a structured mesh that can accommodate this solution strategy. The flow solver provides a significant level of geometric flexibility for structured grid simulations by allowing for arbitrary face-to-face C(0) continuous and non-C(0) continuous block interface connectivities. The unstructured grid paradigm allows for mixed element unstructured meshes that contain any combination of tetrahedral, prismatic, pyramidal, and hexahedral cell elements. The flow solver is also fully parallelized using MPI (Message Passing Interface) libraries in a data-parallel fashion, allowing for efficient simulations on modern High Performance Computing (HPC) systems. This document provides information related to the installation and execution of the VULCAN-CFD software package. A detailed description of the physical and numerical models available in the software are provided in the VULCAN-CFD Theory Manual.

VULCAN-CFD User Manual↗
NASA NTRS2003

Algorithmic Enhancements to the VULCAN Navier-Stokes Solver

VULCAN (Viscous Upwind aLgorithm for Complex flow ANalysis) is a cell centered, finite volume code used to solve high speed flows related to hypersonic vehicles. Two algorithms are presented for expanding the range of applications of the current Navier-Stokes solver implemented in VULCAN. The first addition is a highly implicit approach that uses subiterations to enhance block to block connectivity between adjacent subdomains. The addition of this scheme allows more efficient solution of viscous flows on highly-stretched meshes. The second algorithm addresses the shortcomings associated with density-based schemes by the addition of a time-derivative preconditioning strategy. High speed, compressible flows are typically solved with density based schemes, which show a high level of degradation in accuracy and convergence at low Mach numbers (M less than or equal to 0.1). With the addition of preconditioning and associated modifications to the numerical discretization scheme, the eigenvalues will scale with the local velocity, and the above problems will be eliminated. With these additions, VULCAN now has improved convergence behavior for multi-block, highly-stretched meshes and also can solve the Navier-Stokes equations for very low Mach numbers.

Litton, D. K.↗
NASA NTRSDate not supplied

GPU Acceleration of VULCAN-CFD

This work presents a comprehensive overview of recent advancements in the application of GraphicsProcessing Units (GPUs) to accelerate the NASA-developed VULCAN-CFD code for hypersonic flow sim-ulations. The unstructured solver in VULCAN-CFD is undergoing a significant rewrite from modern Fortranto C++, enabling its execution on both GPUs and CPUs through the utilization of Kokkos, a programmingmodel for performance portability developed by Sandia National Labs. The paper outlines some modifica-tions that were made in the original implementation of VULCAN-CFD in order to harness the computationalpower of GPUs. Finally, we demonstrate performance improvements achieved through GPU acceleration.The accelerated code throughput on one GPU is shown to match approximately 200 CPU cores for bothsingle species and multi-species reacting cases.

Matthew O'Connell↗
NASA NTRS1998

The Dependence of Signal-To-Noise Ratio (S/N) Between Star Brightness and Background on the Filter Used in Images Taken by the Vulcan Photometric Planet Search Camera

The Vulcan Photometric Planet Search is the ground-based counterpart of Kepler Mission Proposal. The Kepler Proposal calls for the launch of telescope to look intently at a small patch of sky for four year. The mission is designed to look for extra-solar planets that transit sun-like stars. The Kepler Mission should be able to detect Earth-size planets. This goal requires an instrument and software capable of detecting photometric changes of several parts per hundred thousand in the flux of a star. The goal also requires the continuous monitoring of about a hundred thousand stars. The Kepler Mission is a NASA Discovery Class proposal similar in cost to the Lunar Prospector. The Vulcan Search is also a NASA project but based at Lick Observatory. A small wide-field telescope monitors various star fields successively during the year. Dozens of images, each containing tens of thousands of stars, are taken any night that weather permits. The images are then monitored for photometric changes of the order of one part in a thousand. These changes would reveal the transit of an inner-orbit Jupiter-size planet similar to those discovered recently in spectroscopic searches. In order to achieve a one part in one thousand photometric precision even the choice of a filter used in taking an exposure can be critical. The ultimate purpose of an filter is to increase the signal-to-noise ratio (S/N) of one's observation. Ideally, filters reduce the sky glow cause by street lights and, thereby, make the star images more distinct. The higher the S/N, the higher is the chance to observe a transit signal that indicates the presence of a new planet. It is, therefore, important to select the filter that maximizes the S/N.

Mena-Werth, Jose↗
NASA NTRS2001

ODC-Free Solvent Implementation Issues for Vulcanized Rubber and Bond Systems

Thiokol Propulsion has worked extensively to replace 1,1,1-trichloroethane (TCA) with ozone depleting chemicals (ODC)-free solvents for use in the manufacture of the Reusable Solid Rocket Motor (RSRM) for the Space Shuttle Program. As Thiokol has transitioned from sub-scale to full-scale testing and implementation of these new solvents, issues have been discovered which have required special attention. The original intent of Thiokol's solvent replacement strategy was to replace TCA with a single drop-in solvent for all equivalent applications. We have learned that a single candidate does not exist for replacing TCA. Solvent incompatibility with process materials has caused us to seek for niche solvents and/or processing changes that provide an ODC-free solution for special applications. This paper addresses some of the solvent incompatibilities, which have lead to processes changes and possible niche solvent usage. These incompatibilities were discovered during full-scale testing of ODC-free solvents and relate to vulcanized rubber and bond systems in the RSRM. Specifically, the following items are presented: (1) Cure effects of d-limonene based solvents on Silica Filled Ethylene Propylene Diene Monomer (SF-EPDM) rubber. During full-scale test operations, Thiokol discovered that d-limonene (terpene) based solvents inhibit the cure of EPDM rubber. Subsequent testing showed the same issue with Nitrile Butadiene Rubber (NBR). Also discussed are efforts to minimize uncured rubber exposure to solvents; and (2) Cured bond system sensitivity to ODC-free solvents. During full scale testing it was discovered that a natural rubber to steel vulcanized bond could degrade after prolonged exposure to ODC-free solvents. Follow on testing showed that low vapor pressure and residence time seemed to be most likely cause for failure.

Hodgson, James R.↗
NASA NTRSDate not supplied

Towards an Automated Unstructured Grid Adaptation Workflow with VULCAN

Early work is presented for an unstructured grid adaptation workflow with VULCAN and refine. Anisotropic simplex grids are iteratively adapted to match a Riemannian metric tensor field describing desired mesh spacing. The Riemannian metric tensor field is obtained from Hessians of CFD solution output scalar sensor fields; both Mach number and static temperature sensor fields are explored. In addition, we describe a Newton-method-based solver recently implemented in VULCAN utilizing Jacobian-Free-Newton-Krylov that can be used to increase flow solver automation on early grids in the adadptation process. Hypersonic flow solutions are presented on a high Reynolds number flat plate and wall heat flux is compared against a highly resolved structured solution. Additionally, complex shock boundary-layer interaction is explored in a high Mach number compression corner and complex 3D flow phenomena are evaluated on the Boundary Layer Transition (BOLT) vehicle.

Matthew O'Connell↗
NASA NTRSDate not supplied

Automatic Boundary-Layer Adaptation of Structured Grids in VULCAN-CFD

In supersonic and hypersonic flow computations, well-resolved boundary layers are essential for accurate quantification of surface heating and transition prediction, particularly via linear stability analysis. Grid design for hypersonic flows with shocks, boundary-layer separation, and/or complex mean flow features incorporating spanwise/azimuthal inhomogeneities is a difficult issue. In comparison to a manual grid adaptation procedure, an autonomous grid adaptation technique offers significant improvements in computing time and solution quality. The VULCAN-CFD solver already includes a validated procedure for automatic adaption of structured grids to the bow shock. The present focus is on implementing an automatic boundary-layer adaptation capability in VULCAN-CFD that adapts structured, multiblock grids to both the bow shock and the boundary layer at the same time. The boundary-layer adaptation algorithm allows the user to specify the number of cells within the boundary layer, along with the input parameters used for detecting the edge of the boundary layer, namely, the variable used in the edge detection criterion,the edge detection method, the detection direction, and the relaxation factor used during the morphing of the grid. The algorithm automatically distributes grid points along the wall-normal direction to achieve a smooth variation in grid spacing from the edge of the boundary layer to a"junction" location within the outer part of the grid. Illustrative results are presented for three different high-speed configurations: the two-dimensional flow over a cylinder at Mach 17.6 and unit Reynolds number of Re=0.38x10^6 m^-1, the axisymmetric flow over a cone-cylinder-flare model at Mach 6.0 and Re = 10.5×10^6 m^-1, and the three-dimensional flow over a blunt, 7-degree half-angle cone at 5-degree angle of attack in a Mach 9.79 flow with Re = 17.1×10^6 m^-1. The automated boundary-layer adaptation is shown to provide an adequate grid topology that is aligned with the bow shock in the outer part of the grid and also resolves the viscous boundary-layer region close to the surface.

boundary layer transition↗
NASA NTRS2022

VULCAN-CFD Theory Manual: Ver. 7.2.0

VULCAN-CFD offers a comprehensive set of capabilities to enable the simulation of continuum flowfields from subsonic to hypersonic conditions. The governing equations that are employed include allowances for both chemical and thermal nonequilibrium processes, coupled with a wide variety of turbulence models for both Reynolds-averaged and large eddy simulations. A description of the physical and numerical models available in the software are presented in this document. However, it is emphasized that the descriptions provided are not intended to fully document every aspect of the models employed. Instead, the governing equations, and the models required to simulate them numerically, are presented with the goal of providing a sufficient level of detail to understand their strengths and limitations. The reader is encouraged to access the references provided throughout this document for a more complete explanation of the formulations presented.

VULCAN-CFD Theory Manual↗
NASA NTRS1980

Topographic domes on Ganymede - Ice vulcanism or isostatic upwarping

Two formation processes are considered for two gently sloping domeshaped features on the surface of Ganymede, lying on grooved terrain and having diameters of roughly 250 km: (1) water vulcanism, triggered by a major impact, and (2) the isostatic upwarping of a crater formed in a thin crust. Numerical simulations show the volume of the domes to be consistent with eruption through fractures created by an impact that excavates partly through a thin crust. Isostatic upwarp rates calculated as a function of effective crustal temperature indicate that upwarping could also create such a dome if the impact excavated to a depth where the crust was sufficiently warm and mobile. Morphologic evidence suggests that both processes may have been important and, if either of the proposed models is correct, it is strongly implied that grooved terrain formation occurred prior to the thickening and stiffening of Ganymede's crust.

Squyres, S. W.↗
NASA NTRS2001

A Performance Comparison for Two Versions of the Vulcan Photometer

Analysis of the images produced by the first version (V1) of the Vulcan photometer indicated that two major sources of noise were sky brightness and image motion. To reduce the effect of the sky brightness, a second version (V2) with a longer focal length and a larger format detector was developed and tested. The first version consisted of 15-centimeter (cm) focal length, F/1.5 Aerojet Delft reconnaissance lens, and a 2048 x 2048 format front-illuminated charged coupled device (CCD) with 9 microns micropixels (Mpixels). The second version used a 30-cm focal length, F/2.5 Kodak AeroEktar lens, and a 4096 x 4096 format CCD with 9 micro pixels. Both have a 49-square-degree field of view (FOV) but the area of the sky subtended by each pixel in the V2 version is one-fourth that of the V1 version. This modification substantially reduces the shot noise due to the sky background and allows fainter stars to be monitored for planetary transits. To remove the data gap and consequent signal-level change caused by flipping the photometer around the declination axis and to reduce image movement on the detector, several other modifications were incorporated. These include modifying the mount and stiffening the photometer and autoguider structures to reduce flexure. This paper compares the performance characteristics of each photometer and discusses tests to identify sources of systematic noise.

Borucki, W. J.↗
NASA NTRS2004

Algorithmic Enhancements for the VULCAN Navier-Stokes Solver

Work performed over the last three years has resulted in the addition of several new algorithms to the VULCAN code, NASA's standard for Navier-Stokes calculations in high-speed aeropropulsion devices. This final report describes the new techniques in brief and presents sample results from their use.

Edwards, Jack R.↗
NASA NTRS2004

Algorithmic Enhancements for the VULCAN Navier-Stokes Solver

Work performed over the last three years has resulted in the addition of several new algorithms to the VULCAN code, NASA's standard for Navier-Stokes calculations in high-speed aeropropulsion devices. This final report describes the new techniques in brief and presents sample results from their use.

Edwards, Jack R.↗
NASA NTRS2015

An Automated DAKOTA and VULCAN-CFD Framework with Application to Supersonic Facility Nozzle Flowpath Optimization

Removing human interaction from design processes by using automation may lead to gains in both productivity and design precision. This memorandum describes efforts to incorporate high fidelity numerical analysis tools into an automated framework and applying that framework to applications of practical interest. The purpose of this effort was to integrate VULCAN-CFD into an automated, DAKOTA-enabled framework with a proof-of-concept application being the optimization of supersonic test facility nozzles. It was shown that the optimization framework could be deployed on a high performance computing cluster with the flow of information handled effectively to guide the optimization process. Furthermore, the application of the framework to supersonic test facility nozzle flowpath design and optimization was demonstrated using multiple optimization algorithms.

Axdahl, Erik L.↗
NASA NTRS2019

Weighted Least-Squares Cell-Average Gradient Construction Methods for the VULCAN-CFD Second-Order Accurate Unstructured-Grid Cell-Centered Finite-Volume Solver

The ability to solve the equations governing the hypersonic turbulent flow of a real gas on unstructured grids using a spatially-elliptic, 2nd-order accurate, cell-centered, finite-volume method has been recently implemented in the VULCAN-CFD code. The construction of cell-average gradients using a weighted linear least-squares method and the use of these gradients in the construction of the inviscid fluxes is the focus of this paper. A comparison of least-squares stencil construction methodologies is presented and approaches to augment the number of cells participating in the stencil while preserving accuracy are explored. Due to our interest in hypersonic flow, a robust multidimensional cell-average gradient limiter procedure that is consistent with the stencil used to construct the cell-average gradients is described and investigated. Canonical problems are computed to illustrate the challenges and investigate the accuracy, robustness and convergence behavior of the cell-average gradient methods on unstructured cell-centered finite-volume grids. Finally, thermally perfect, chemically frozen, Mach 8 turbulent flow of air around a blunt wedge is computed to demonstrate the robustness and convergence behavior of the new method for constructing stencils of use in a weighted linear least-squares gradient method for a hypersonic flow.

White, Jeffery A.↗
NASA NTRSDate not supplied

Material Characterization and Modeling of Room Temperature Vulcanizing Silicone

Room Temperature Vulcanizing silicone (RTV) is a high-temperature adhesive that has successfully been used as a gap-filler between Thermal Protection System (TPS) tiles for heatshields on numerous missions. It is also used to bond instrumentation plugs such as temperature and pressure sensors into the heatshields. While RTV has been traditionally assumed to be a non-porous and non-ablating material, numerous experiments have shown that RTV pyrolyzes and becomes highly porous as it is heated. Heating RTV has also shown swelling, or intumescence, which can pose unique problems that lead to roughness induced boundary-layer transition, surface oxide formation and contamination of heat shield sensors. Therefore, it is crucial to understand and model the intumescence phenomenon of RTV. As data for RTV material properties is limited, the first step in modeling RTV is to collect material properties such as pyrolysis mass-loss, microstructure change, virgin and char porosity, etc. which was performed in our initial study. Additionally, thermomechanical properties such as Young’s modulus and Poisson ratio are required for modeling the intumescence of RTV, which were taken from literature and the coefficient of thermal expansion was collected using in-situ heating and Micro Computed Tomography (µ-CT) in previous studies. Finally, numerous other properties such as pyrolysis gas properties, virgin and char thermal conductivity and specific heat were compiled from previous experiments and literature into a material database that can be used for simulations. In Porous Material Analysis Toolbox based on OpenFOAM (PATO) [4], structural mechanics coupled with material response was used for simulating the intumescence of RTV as it is heated. However, since the permeability of the material is very low, the pyrolysis gas creates an internal pressure build-up as the material is being heated, significantly contributing to the deformation of the material. To correctly characterize this phenomenon, additional physics models were implemented into PATO's stress analysis solver, and results were compared with RTV dilatometry test data as a preliminary verification case. Future work will include experiments of RTV at the Plasmatron X facility and the in-situ heating cell with µ-CT, and improvement of simulation tools to more accurately model RTV intumescence.

TPS↗