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All sources NASA NTRS DOE OSTI

NASA NTRS2013

Neutron Characterization for Additive Manufacturing

Oak Ridge National Laboratory (ORNL) is leveraging decades of experience in neutron characterization of advanced materials together with resources such as the Spallation Neutron Source (SNS) and the High Flux Isotope Reactor (HFIR) shown in Fig. 1 to solve challenging problems in additive manufacturing (AM). Additive manufacturing, or three-dimensional (3-D) printing, is a rapidly maturing technology wherein components are built by selectively adding feedstock material at locations specified by a computer model. The majority of these technologies use thermally driven phase change mechanisms to convert the feedstock into functioning material. As the molten material cools and solidifies, the component is subjected to significant thermal gradients, generating significant internal stresses throughout the part (Fig. 2). As layers are added, inherent residual stresses cause warping and distortions that lead to geometrical differences between the final part and the original computer generated design. This effect also limits geometries that can be fabricated using AM, such as thin-walled, high-aspect- ratio, and overhanging structures. Distortion may be minimized by intelligent toolpath planning or strategic placement of support structures, but these approaches are not well understood and often "Edisonian" in nature. Residual stresses can also impact component performance during operation. For example, in a thermally cycled environment such as a high-pressure turbine engine, residual stresses can cause components to distort unpredictably. Different thermal treatments on as-fabricated AM components have been used to minimize residual stress, but components still retain a nonhomogeneous stress state and/or demonstrate a relaxation-derived geometric distortion. Industry, federal laboratory, and university collaboration is needed to address these challenges and enable the U.S. to compete in the global market. Work is currently being conducted on AM technologies at the ORNL Manufacturing Demonstration Facility (MDF) sponsored by the DOE's Advanced Manufacturing Office. The MDF is focusing on R&D of both metal and polymer AM pertaining to in-situ process monitoring and closed-loop controls; implementation of advanced materials in AM technologies; and demonstration, characterization, and optimization of next-generation technologies. ORNL is working directly with industry partners to leverage world-leading facilities in fields such as high performance computing, advanced materials characterization, and neutron sciences to solve fundamental challenges in advanced manufacturing. Specifically, MDF is leveraging two of the world's most advanced neutron facilities, the HFIR and SNS, to characterize additive manufactured components.

Watkins, Thomas↗

NASA NTRS2003

RSRM and ETM03 Internal Flow Simulations and Comparisons

ETM03 (Engineering Test Motor-03) is an extended length RSRM (Reusable Solid Rocket Motor) designed to increase motor performance and create more severe internal environments compared with the standard four-segment RSRM motor configuration. This is achieved primarily through three unique design features. First is the incorporation of an additional RSRM center segment, second is a slight increase in throat diameter, and third is the use of an Extended Aft Exit Cone (EAEC). As a result of these design features, parameters such as web time, action time, head end pressure, web time average pressure, maximum thrust, mass flow rate, centerline Mach number, pressure and thrust integrals have all increased compared with nominal RSRM values. In some cases these increases are substantial. The primary objective of the ETM03 test program is to provide a platform for RSRM component margin testing. Test results will not only provide direct data concerning component performance under more adverse conditions, but serve as a second design data point for developing, validating and enhancing component analytical modeling techniques. To help component designers assess how the changes in motor environment will affect performance, internal flow simulations for both the nominal RSRM and ETM03 motor designs were completed to obtain comparisons of aero-thermal boundary conditions and system loads. Full geometries for both motors were characterized with two-dimensional axi-symmetric models at burn times of 1, 20, 54, 67 and 80-seconds. A sixth set considered burn times of 110 and 117-seconds for RSRM and ETM03, respectively. The simulations were performed using the computational fluid dynamics (CFD) commercial code FLUENT (trademark). Of particular interest were any differences between the two motor environments that could lead to a significant increase in system loads, or in internal insulation and/or nozzle component charring and erosion in ETM03 compared with RSRM. Based on these comparative analyses conducted in this study, the objective of ETM03 will be achieved by providing a more adverse operating environment for motor components than the nominal RSRM environment. For example: Higher chamber pressure drop in ETM03 than in RSRM; higher centerline Mach numbers approaching the nozzle in ETM03 than in RSRM; higher heat transfer rates for the internal insulation and nozzle components in ETM03 than in RSRM; and higher levels of droplet impingement and slag accumulation in ETM03 than in the RSRM.

Ahmad, R. A.↗

DOE OSTI2021

Effects of spatial energy distribution-induced porosity on mechanical properties of laser powder bed fusion 316L stainless steel

Laser powder bed fusion (LPBF) additive manufacturing (AM) offers a variety of advantages over traditional manufacturing, however its usefulness for manufacturing of high-performance components is currently hampered by internal defects (porosity) created during the LPBF process that have an unknown impact on global mechanical performance. By inducing porosity distributions through variations in print energy density and inspecting the resulting tensile samples using computed tomography, nearly 50,000 pores across 75 samples were identified. Porosity characteristics were quantitatively extracted from inspection data and compared with mechanical properties to understand the strength of relationships between porosity and global tensile performance. Useful porosity characteristics were identified for prediction of part performance. Results indicate that ductility and strain at ultimate tensile strength are the global tensile properties most significantly impacted by porosity and can be predicted with reasonable accuracy using simple porosity shape descriptors such as volume, diameter, and surface area. Moreover, it was found that the largest pores influenced behavior most significantly. Specifically, pores in excess of 125 µm in diameter were found to be a sufficient threshold for property estimation. These results establish an initial understanding of the complex defect-performance relationship in AM 316L stainless steel and can be leveraged to develop certification standards and improve confidence in part quality and reliability for the broader set of engineering alloys.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

NASA and Blue Origin Collaborative Assessment of Precision Landing Algorithms and Computing

NASA’s Safe and Precise Landing Integrated Capabilities Evolution (SPLICE) project is developing sensor, algorithm, and compute technologies for precision landing and hazard avoidance. These technologies are being tested as an integrated Precision Landing and Hazard Avoidance (PL&HA) system on Blue Origin’s New Shephard suborbital vehicle. A key goal for the computing element of this technology development is to characterize the performance of the SPLICE software workloads on the project’s Descent and Landing Computer (DLC). The DLC is a multi-core processor designed as a surrogate for NASA’s High-Performance Space Computer (HPSC). Measurements of the SPLICE workload performance on the DLC provides NASA insight on how PL&HA capabilities will perform on the HPSC, and guidance on how the SPLICE algorithms can be implemented to best utilize the DLC platform. This insight can also be used to derive requirements to guide trade studies on candidate computing architectures, for use on platforms like Blue Moon. NASA and Blue Origin are collaborating under an agreement to pursue this mutual benefit. Performance metrics collected are based on measurement of common compute resources such as percentage used of memory bandwidth, I/O utilization, interrupt latency, and kernel vs. user space code residency. Where possible existing performance counters and metrics that are part of the operating system kernel are used. As the design has a significant FPGA component, performance counters are identified and instantiated in the fabric to measure DMA performance and interface metrics. Collection of metrics is performed on the DLC with a representative workload that simulates a full landing cycle of the Blue Origin New Shepard vehicle. Consideration is given to the other compute implementations and whether they can run SPLICE algorithms at the same rate and with the same latency as the DLC. One option being considered is the use of a RISC-V soft core instantiated in a radiation resilient FPGA fabric such as the Xilinx KU60. Select algorithms from the SPLICE code will be run for comparison with the DLC. This paper describes how the DLC is instrumented to collect performance measurements of the SPLICE workloads, preliminary results from these measurements, and their implications on SPLICE algorithm implementation. The results of experimentation to derive candidate requirements for architecture trades on a PL&HA computing system are also presented.

computer performance↗

NASA NTRS2018

Examining the Conceptual Design Process for Future Hybrid-Electric Rotorcraft

Hybrid-electric propulsion systems introduce immense complexity and numerous design challenges not previously encountered in aircraft design. Traditional conceptual-level rotorcraft design approaches may not adequately capture the level of propulsion system detail desired for hybrid-electric vehicle conceptual design. As part of a NASA Small Business Innovative Research (SBIR) Phase II contract, Empirical Systems Aerospace (ESAero) investigated the implementation of several hybrid-electric propulsion architectures onto three rotorcraft configurations. Unique hybrid-electric variants of these configurations were compared against their conventionally-powered counterparts using typical metrics such as payload, range, and energy efficiency. The feasibility and performance of these vehicles was also investigated in the +15 and +30-year timeframes based on third-party estimations for future component performance. Using the lessons learned during this trade study, ESAero then conducted a conceptual design effort for a hybrid-electric tiltrotor demonstrator based on the XV-15. A detailed integration of the hybrid-electric propulsion system into the vehicle airframe was also performed. The hybrid-electric XV-15 concept vehicle was estimated to achieve a 10% reduction in cruise fuel consumption compared to the original NASA XV-15 at the cost of increasing the vehicle empty weight by almost 25%. The success of this design effort suggests that the design of a manned, hybrid-electric tiltrotor is technically feasible at current technology levels.

Future↗

NASA NTRS1948

Performance of J-33-A-21 Turbojet-Engine Compressor I - Over-All Performance Characteristics at Equivalent Impeller Speeds from 6000 to 13,400 RPM

The NACA is investigating a series of J-33 turbojet-engine compressors to determine the over-all and component performances and to improve theories of flow through large centrifugal compressors, The production model J-33-A-21 was operated over a range of inlet temperatures from 80 to -40 F and inlet pressures from 14 to 5 inches mercury absolute for equivalent impeller speeds from 6000 to 13,400 rpm. At the equivalent design speed of 11,500 rpm, the compressor had a peak pressure ratio of 3.98 at an equivalent weight flow of 73.4 pounds per second and an adiabatic temperature-rise , efficiency of 0.701. When the compressor speed was reduced from the design speed to 6000 rpm, the adiabatic temperature-rise efficiency increased to 0.747. At the maximum equivalent speed investigated (13,400 rpm), a peak pressure ratio of 5.09 was obtained at an adiabatic temperature-rise efficiency of 0.617 and an equivalent weight flow of 66.O pounds per second. An increase in inlet pressure from 5.5 to 14 inches mercury absolute, with a consequent increase in Reynolds number index, improved the pressure ratio but had no apparent effect on the ratio of temperature rise through the compressor to inlet temperature. The variation of the peak adiabatic temperature-rise efficiency with inlet pressure is in the direction that would be expected from a Reynolds number effect. Decrease in the inlet temperature from 80 to -40 F, with a consequent increase in Reynolds number index, resulted in scatter of the pressure-ratio data and increased values of temperature ratio. The variation of the adiabatic temperature-rise efficiency with inlet temperature is probably the result of heat-transfer effects and scatter in the pressure ratio.

Beede, William L.↗

NASA NTRS1982

Energy Efficient Engine core design and performance report

The Energy Efficient Engine (E3) is a NASA program to develop fuel saving technology for future large transport aircraft engines. Testing of the General Electric E3 core showed that the core component performance and core system performance necessary to meet the program goals can be achieved. The E3 core design and test results are described.

Stearns, E. Marshall↗

DOE OSTI2023

Rapid, Approximate Multi-Axis Vibration Testing [Thesis]

The aerospace industry uses vibration shaker tables to perform component durability testing. In these tests a component, piece of equipment, or entire system is attached to a shaker table where it is subjected to dynamic excitation. The goal is to understand how the article under test will perform in its service environment without having to run it through its entire service life via field testing. In a vibration test, an aerospace system or component is qualified if it is shown to survive a test meant to replicate its lifetime service conditions. The test is designed based on recorded field data. To develop a test, a system is taken through all of its intended environments, e.g., transportation, launch, and reentry. Acceleration data measured from these environments is then brought back to the lab and imported into a shaker table controller. The controller then drives a vibration test intended to mimic the acceleration conditions experienced by the system or specific components of the system in the field. However, it is often difficult to match the measured field response in a lab test. This is largely due to the test’s boundary conditions and excitation methods. In a lab test, a shaker table is the excitation source. The two most common shaker table types, differentiated by their number of independent degrees of freedom, are single-axis and multi-axis shaker tables. Multi-axis shakers have the ability to reproduce service environments more realistically, as real accelerations inevitably produce multiple degrees of freedom of excitation simultaneously. Figure 1 depicts a generic multi-axis testing setup on a three-axis shaker table. Often multi-axis tests use six-degree-of-freedom (6DOF) shaker tables. Yet multi-axis shakers are not yet common in the aerospace industry due in part to their high cost and the difficulty for shaker controllers to handle the added complexity. Single-axis shaker tables are much more common. They are not as expensive to purchase and have a wide range of control software options.

42 ENGINEERING↗

NASA NTRS1989

SSME fault monitoring and diagnosis expert system

An expert system, called LEADER, has been designed and implemented for automatic learning, detection, identification, verification, and correction of anomalous propulsion system operations in real time. LEADER employs a set of sensors to monitor engine component performance and to detect, identify, and validate abnormalities with respect to varying engine dynamics and behavior. Two diagnostic approaches are adopted in the architecture of LEADER. In the first approach fault diagnosis is performed through learning and identifying engine behavior patterns. LEADER, utilizing this approach, generates few hypotheses about the possible abnormalities. These hypotheses are then validated based on the SSME design and functional knowledge. The second approach directs the processing of engine sensory data and performs reasoning based on the SSME design, functional knowledge, and the deep-level knowledge, i.e., the first principles (physics and mechanics) of SSME subsystems and components. This paper describes LEADER's architecture which integrates a design based reasoning approach with neural network-based fault pattern matching techniques. The fault diagnosis results obtained through the analyses of SSME ground test data are presented and discussed.

Ali, Moonis↗

NASA NTRS2002

Fabry-Perot Interferometer for Column CO2

Global atmospheric CO2 measurements are essential to resolving significant discrepancies in our understanding of the global carbon budget and, hence, humankind's role in global climate change. The science measurement requirements for CO2 are extremely demanding (precision approx. 0.3%). No atmospheric chemical species has ever been measured from space with this precision. We are developing a novel application of a Fabry-Perot interferometer to detect spectral absorption of reflected sunlight by CO2 and O2 in the atmosphere. Preliminary design studies indicate that the method will be able to achieve the sensitivity and signal-to-noise detection required to measure column CO2 at the target specification. The objective of this program is to construct a prototype instrument for deployment on an aircraft to test the instrument performance and our ability to retrieve the data in the real atmosphere. To date we have assembled a laboratory bench system to begin testing the optical and electronic components. We are also measuring signal and noise levels in actual sunlight to evaluate component performance.

Heaps, William S.↗

DOE OSTI2026

The ePIC dual-radiator RICH detector

The dual radiator Ring Imaging Cherenkov (dRICH) detector is required to provide continuous hadron identification from ≈3 GeV/c up to ≈50 GeV/c, and to supplement electron and positron identification from a few hundred MeV/c up to about 15 GeV/c, in the forward (ion-side) end-cap of the ePIC experiment. Such an extended momentum range imposes the use of two radiators, gas and aerogel. The common imaging system, that ensures compactness and cost-effectiveness, is based on SiPM sensors to work in a high non-uniform magnetic field. During the R&D phase, the dual radiator principle and the single component performance have been validated. A status overview of the project is presented. The design and technological choices are discussed together with the results obtained from laboratory characterization of the component demonstrators and beam tests of the evolving prototypes.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NASA NTRS1977

Prototype solar heating and combined heating and cooling systems

System analysis activities were directed toward refining the heating system parameters. Trade studies were performed to support hardware selections for all systems and for the heating only operational test sites in particular. The heating system qualification tests were supported by predicting qualification test component performance prior to conducting the test.

Source record↗

NASA NTRS1993

Reliability Prediction

RELAV, a NASA-developed computer program, enables Systems Control Technology, Inc. (SCT) to predict performance of aircraft subsystems. RELAV provides a system level evaluation of a technology. Systems, the mechanism of a landing gear for example, are first described as a set of components performing a specific function. RELAV analyzes the total system and the individual subsystem probabilities to predict success probability, and reliability. This information is then translated into operational support and maintenance requirements. SCT provides research and development services in support of government contracts.

Source record↗

NASA NTRS2016

Practical Techniques for Modeling Gas Turbine Engine Performance

The cost and risk associated with the design and operation of gas turbine engine systems has led to an increasing dependence on mathematical models. In this paper, the fundamentals of engine simulation will be reviewed, an example performance analysis will be performed, and relationships useful for engine control system development will be highlighted. The focus will be on thermodynamic modeling utilizing techniques common in industry, such as: the Brayton cycle, component performance maps, map scaling, and design point criteria generation. In general, these topics will be viewed from the standpoint of an example turbojet engine model; however, demonstrated concepts may be adapted to other gas turbine systems, such as gas generators, marine engines, or high bypass aircraft engines. The purpose of this paper is to provide an example of gas turbine model generation and system performance analysis for educational uses, such as curriculum creation or student reference.

aerothermodynamics↗

NASA NTRS2016

Practical Techniques for Modeling Gas Turbine Engine Performance

aerothermodynamics↗

NASA NTRS1974

Generalized dynamic engine simulation techniques for the digital computer

Recently advanced simulation techniques have been developed for the digital computer and used as the basis for development of a generalized dynamic engine simulation computer program, called DYNGEN. This computer program can analyze the steady state and dynamic performance of many kinds of aircraft gas turbine engines. Without changes to the basic program DYNGEN can analyze one- or two-spool turbofan engines. The user must supply appropriate component performance maps and design-point information. Examples are presented to illustrate the capabilities of DYNGEN in the steady state and dynamic modes of operation. The analytical techniques used in DYNGEN are briefly discussed, and its accuracy is compared with a comparable simulation using the hybrid computer. The impact of DYNGEN and similar all-digital programs on future engine simulation philosophy is also discussed.

Sellers, J.↗

NASA NTRS1974

Generalized dynamic engine simulation techniques for the digital computer

Recently advanced simulation techniques have been developed for the digital computer and used as the basis for development of a generalized dynamic engine simulation computer program, called DYNGEN. This computer program can analyze the steady state and dynamic performance of many kinds of aircraft gas turbine engines. Without changes to the basic program, DYNGEN can analyze one- or two-spool turbofan engines. The user must supply appropriate component performance maps and design-point information. Examples are presented to illustrate the capabilities of DYNGEN in the steady state and dynamic modes of operation. The analytical techniques used in DYNGEN are briefly discussed, and its accuracy is compared with a comparable simulation using the hybrid computer. The impact of DYNGEN and similar all-digital programs on future engine simulation philosophy is also discussed.

Sellers, J.↗

NASA NTRS1975

Generalized dynamic engine simulation techniques for the digital computers

Recently advanced simulation techniques have been developed for the digital computer and used as the basis for development of a generalized dynamic engine simulation computer program, called DYNGEN. This computer program can analyze the steady state and dynamic performance of many kinds of aircraft gas turbine engines. Without changes to the basic program, DYNGEN can analyze one- or two-spool turbofan engines. The user must supply appropriate component performance maps and design point information. Examples are presented to illustrate the capabilities of DYNGEN in the steady state and dynamic modes of operation. The analytical techniques used in DYNGEN are briefly discussed, and its accuracy is compared with a comparable simulation using the hybrid computer. The impact of DYNGEN and similar digital programs on future engine simulation philosophy is also discussed.

Sellers, J.↗