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Center for Computational Structures Technology

The Center for Computational Structures Technology (CST) is intended to serve as a focal point for the diverse CST research activities. The CST activities include the use of numerical simulation and artificial intelligence methods in modeling, analysis, sensitivity studies, and optimization of flight-vehicle structures. The Center is located at NASA Langley and is an integral part of the School of Engineering and Applied Science of the University of Virginia. The key elements of the Center are: (1) conducting innovative research on advanced topics of CST; (2) acting as pathfinder by demonstrating to the research community what can be done (high-potential, high-risk research); (3) strong collaboration with NASA scientists and researchers from universities and other government laboratories; and (4) rapid dissemination of CST to industry, through integration of industrial personnel into the ongoing research efforts.

Noor, Ahmed K.↗

Graphite fiber textile preform/copper matrix composites

Graphite fiber reinforced/copper matrix composites have sufficiently high thermal conduction to make them candidate materials for critical heat transmitting and rejection components. The term textile composites arises because the preform is braided from fiber tows, conferring three-dimensional reinforcement and near net shape. The principal issues investigated in the past two years have centered on developing methods to characterize the preform and fabricated composite and on braidability. It is necessary to have an analytic structural description for both processing and final property modeling. The structure of the true 3-D braids used is complex and has required considerable effort to model. A structural mapping has been developed as a foundation for analytic models for thermal conduction and mechanical properties. The conductivity has contributions both from the copper and the reinforcement. The latter is accomplished by graphitization of the fibers, the higher the amount of graphitization the greater the conduction. This is accompanied by an increase in the fiber modulus, which is desirable from a stiffness point of view but decreases the braidability; the highest conductivity fibers are simply too brittle to be braided. Considerable effort has been expended on determining the optimal braidability--conductivity region. While a number of preforms have been fabricated, one other complication intervenes; graphite and copper are immiscible, resulting in a poor mechanical bond and difficulties in infiltration by molten copper. The approach taken is to utilize a proprietary fiber coating process developed by TRA, of Salt Lake City, Utah, which forms an itermediary bond. A number of preforms have been fabricated from a variety of fiber types and two sets of these have been infiltrated with OFHC copper, one with the TRA coating and one without. Mechanical tests have been performed using a small-scale specimen method and show the coated specimens to have superior mechanical properties. Final batches of preforms, including a finned, near net shape tube, are being fabricated and will be infiltrated before summer.

Gilatovs, G. J.↗

Multi-Window Controllers for Autonomous Space Systems

Multi-window controllers select between elementary linear controllers using nonlinear windows based on the amplitude and frequency content of the feedback error. The controllers are relatively simple to implement and perform much better than linear controllers. The commanders for such controllers only order the destination point and are freed from generating the command time-profiles. The robotic missions rely heavily on the tasks of acquisition and tracking. For autonomous and optimal control of the spacecraft, the control bandwidth must be larger while the feedback can (and, therefore, must) be reduced.. Combining linear compensators via multi-window nonlinear summer guarantees minimum phase character of the combined transfer function. It is shown that the solution may require using several parallel branches and windows. Several examples of multi-window nonlinear controller applications are presented.

Lurie, B, J.↗

3D GeoWall Analysis System for Shuttle External Tank Foreign Object Debris Events

An analytical, advanced imaging method has been developed for the initial monitoring and identification of foam debris and similar anomalies that occur post-launch in reference to the space shuttle s external tank (ET). Remote sensing technologies have been used to perform image enhancement and analysis on high-resolution, true-color images collected with the DCS 760 Kodak digital camera located in the right umbilical well of the space shuttle. Improvements to the camera, using filters, have added sharpness/definition to the image sets; however, image review/analysis of the ET has been limited by the fact that the images acquired by umbilical cameras during launch are two-dimensional, and are usually nonreferenceable between frames due to rotation translation of the ET as it falls away from the space shuttle. Use of stereo pairs of these images can enable strong visual indicators that can immediately portray depth perception of damaged areas or movement of fragments between frames is not perceivable in two-dimensional images. A stereoscopic image visualization system has been developed to allow 3D depth perception of stereo-aligned image pairs taken from in-flight umbilical and handheld digital shuttle cameras. This new system has been developed to augment and optimize existing 2D monitoring capabilities. Using this system, candidate sequential image pairs are identified for transformation into stereo viewing pairs. Image orientation is corrected using control points (similar points) between frames to place the two images in proper X-Y viewing perspective. The images are then imported into the WallView stereo viewing software package. The collected control points are used to generate a transformation equation that is used to re-project one image and effectively co-register it to the other image. The co-registered, oriented image pairs are imported into a WallView image set and are used as a 3D stereo analysis slide show. Multiple sequential image pairs can be used to allow forensic review of temporal phenomena between pairs. The observer, while wearing linear polarized glasses, is able to review image pairs in passive 3D stereo.

Brown, Richard↗

Format for Interchange and Display of 3D Terrain Data

Visible Scalable Terrain (ViSTa) is a software format for production, interchange, and display of three-dimensional (3D) terrain data acquired by stereoscopic cameras of robotic vision systems. ViSTa is designed to support scalability of data, accuracy of displayed terrain images, and optimal utilization of computational resources. In a ViSTa file, an area of terrain is represented, at one or more levels of detail, by coordinates of isolated points and/or vertices of triangles derived from a texture map that, in turn, is derived from original terrain images. Unlike prior terrain-image software formats, ViSTa includes provisions to ensure accuracy of texture coordinates. Whereas many such formats are based on 2.5-dimensional terrain models and impose additional regularity constraints on data, ViSTa is based on a 3D model without regularity constraints. Whereas many prior formats require external data for specifying image-data coordinate systems, ViSTa provides for the inclusion of coordinate-system data within data files. ViSTa admits highspeed loading and display within a Java program. ViSTa is designed to minimize file sizes and maximize compressibility and to support straightforward reduction of resolution to reduce file size for Internet-based distribution.

Backes, Paul↗

Reply to Comment by Laprise on 'the Added Value to Global Model Projections of Climate Change by Dynamical Downscaling: a Case Study over the Continental U.S. Using the GISS-ModelE2 and WRF Models'

In his comment, Laprise raises several points that we agree merit consideration. His primary critique is that our study [Racherla et al., 2012] tested the ability of the WRF regional climate model to reproduce historical temperature and precipitation change relative to the driving global climate model (GCM) using only a single simulation rather than an ensemble. He asserts that the observed changes are smaller than the internal variability in the climate system (i.e., not statistically significant) and that thus a single simulation should not necessarily be able to capture the observations. Laprise points out that the statistical signal is reduced for a multi-decadal trend such as the one we analyzed in comparison with mean climatology and cites two studies showing that for particular climate parameters it can take any years for a signal to be discerned over internal variability. He states that The results of theexperiment as designed were strongly influenced by the presence of internal variability and sampling errors,which masked the rather small climate changes that may have occurred as a consequence of changes inforcing during the period considered. While Laprise discusses statistics in general terms at some length, for the actual climate trends examined in our study, he offers no evidence that the forced signal was smallcompared with internal variability. The two studies he cites [de Ela et al., 2013; Maraun, 2013] do not provide convincing evidence as they concern climate variables averaged over different times and areas. One in fact examines extreme precipitation events, which by definition are rare and thus have a lower significance level. We accept the general point that it is important to consider internal variability, and as noted in our paper we agree that an ensemble of simulations is in principle an optimal, though computationally expensive, approach. While we did not present the statistical significance of the observations in our original paper, we have now evaluated those for the regional temperature trends used in our study to evaluate the added value of WRF and thus can analyze data as to the magnitude of the trends with respect to internal variability.

climate↗

Automation of Structural Sizing of Aircraft Concepts Under Static Aeroelastic Constraints

This paper presents an automation process for structural sizing of subsonic and supersonic aircraft concepts under static aeroelastic constraints. The automation process starts with an OpenVSP geometry and ends with a PATRAN plot of a NASTRAN solution for static aeroelastic analysis or optimization. ModelCenter is used to integrate all analysis codes with easy-to-use interfaces. Automation tools are developed to streamline the setup process and avoid user errors. Fuel is distributed by solving an optimization problem to match the center of gravity of aircraft at a specified flight condition. Fuel weights are also automatically attached to the structural model as point masses. All other weights used in FLOPS mission analysis (excluding fuselage and wing structural weights) are automatically attached to or smeared on the structural model. For any given OpenVSP geometry and FLOPS analysis data, a static aeroelastic sizing model for NASTRAN analysis can be generated in a couple of hours. The empirical fuselage and wing structural weights from FLOPS are replaced by structural panel weights from the sized finite-element model. Three supersonic and two subsonic aircraft concepts are used to demonstrate the automation process as a physics-based weight estimation tool for aircraft conceptual design.

Li, Wu↗

The Origins Space Telescope

The Universe has never been seen like this before. The window into the infrared opens only above Earth's atmosphere, and humanity has barely glimpsed outside. About half of the light emitted by stars, planets, and galaxies over the lifetime of the Universe emerges in the infrared. With an unparalleled sensitivity increase — up to a factor of 1,000 more than any previous or planned mission — the advance offered by the Origins Space Telescope (OST) is akin to that from the naked eye to humanity's first telescope, or from Galileo's first telescope to the first telescope in space. While key path-finding missions have glimpsed a rich infrared cosmos, extraordinary discovery space awaits; the time for a far-infrared revolution has begun.Are we alone or is life common in the Universe? OST will directly address this long-standing question by searching for signs of life in the atmospheres of potentially habitable terrestrial planets transiting M dwarf stars. How do planets become habitable? OST will trace the trail of cold water from the interstellar medium, through protoplanetary disks and into the outer reaches of our own Solar System. How do stars, galaxies, black holes and the elements of life form, from the cosmic dawn to today? With broad wavelength coverage and fast mapping speeds, OST will map millions of galaxies, simultaneously measuring star formation rates and black hole growth across cosmic time, peering deeper into the far reaches of the Universe than ever before.OST will be maintained at a temperature of 4 K, enabling its tremendous sensitivity gain, and will operate from 5 m to 600 m, encompassing the mid- and far-infrared. OST has two Mission Concepts: Concept 1 with a 9.1-m deployed off-axis primary, and Concept 2, described here, a non-deployed 5.9-m on-axis telescope with the equivalent collecting area of the James Webb Space Telescope (JWST). Concept 2 includes four instruments with capabilities for imaging (large surveys and pointed), spectroscopy (survey and high-resolution modes) and polarimetry, as well as an instrument for high-precision spectroscopy of transiting exoplanets. Concept 2 is optimized for maximum science return and minimal complexity, and offers fast mapping (approximately 60 arcseconds per second). We describe here the three key science themes for OST and the basic mission specifications.

Battersby, Cara↗

Combined 1-MW Solar Electric and Chemical Propulsion for Crewed Mars Missions

The current Moon to Mars Architecture defines functional capabilities that are essential to achieving NASA’s specific exploration goals and objectives. The transportation system goals and objectives or functional capabilities do not prescribe a solution, leaving an open tradespace to be explored. NASA is working to identify power and propulsion technologies that enable feasible transportation options for crewed missions to Mars. During NASA’s Strategic Analysis Cycle 2021 (SAC21), nuclear enabled spacecraft concepts were analyzed for moderate duration 850-day Earth-Mars roundtrip mission2. During SAC22, the transportation tradespace was expanded to understand the feasibility of using different propulsion systems for crewed Mars missions using a moderate duration reference mission as a comparison point. This paper explores the mission analysis performed for a conceptual MW-class hybrid Solar Electric Propulsion (SEP)-chemical propulsion system (SEP-Chem) spacecraft optimized for an 850-day crewed Mars mission for the 2039 opportunity.

SEP-Chem↗

Experimental study of the impact of scavenging efficiency on diesel combustion in an opposed-piston two-stroke engine

The opposed-piston two-stroke (OP2S) engine is a promising alternative powertrain technology that can offer thermal and brake efficiency improvements over conventional four-stroke engines. In recent years, many of the technical barriers of the OP2S engine architecture have been overcome. However, there is still a need for fundamental studies to provide insight into the scavenging and combustion processes of the OP2S engine to help design and operate the most efficient combustion systems using this engine architecture. This work aims to provide such insights by analyzing experimental data collected on a 3-cylinder, 4.9 L OP2S engine. Specifically, a scavenging efficiency sweep, an engine speed sweep with a constant scavenging efficiency, and an engine speed with a constant pressure differential across the engine were studied in detail. It was found that in diesel combustion, as the scavenging efficiency decreased, the increase in temperature of the hot, internal residuals resulted in a significant increase in heat transfer. Despite lowering pumping losses, this resulted in an overall decrease in brake efficiency. When the bulk thermodynamic conditions of two different scavenging efficiency cases (67% and 72%) were matched at port closing, the lower scavenging efficiency case still displayed a 0.7 percentage point penalty in net thermal efficiency and an increase in engine-out indicated specific emissions of NOx of 18% due to residual stratification in the cylinder. The results presented in this work show that the optimal breathing strategy in diesel combustion on an OP2S engine architecture is one that results in a slightly under-scavenged environment at port closing. However, the results did show potential system-level efficiency benefits of decreasing scavenging efficiency, meaning that alternative fuels and combustion strategies without the constraints of diesel combustion could achieve system-level efficiency gains by running significantly under-scavenged.

Engineering↗

Unbalanced and Minimal Point Equivalent Estimation Second-Order Split-Plot Designs

Restricting the randomization of hard-to-change factors in industrial experiments is often performed by employing a split-plot design structure. From an economic perspective, these designs minimize the experimental cost by reducing the number of resets of the hard-to- change factors. In this paper, unbalanced designs are considered for cases where the subplots are relatively expensive and the experimental apparatus accommodates an unequal number of runs per whole-plot. We provide construction methods for unbalanced second-order split- plot designs that possess the equivalence estimation optimality property, providing best linear unbiased estimates of the parameters; independent of the variance components. Unbalanced versions of the central composite and Box-Behnken designs are developed. For cases where the subplot cost approaches the whole-plot cost, minimal point designs are proposed and illustrated with a split-plot Notz design.

Parker, Peter A.↗

Numerical and experimental analysis of precooled desiccant system

This paper presents a numerical and experimental study of four novel, desiccant air-conditioning systems based on pre-cooling of the ambient air. The purpose of the study is to: 1) establish which configuration is most profitable for the future studies through numerical and experimental methods; 2) verify the concept of precooled system and confirm that it is working in experimental conditions (for this purpose two prototypes of evaporative cooling units were developed and compared for different operation arrangements with desiccant wheel); 3) Analyze practical aspects of the systems, which includes water consumption analysis, economic analysis and establishing operational modes during a cooling season in temperate climate conditions (the proposed solution has a significant advantage during operation in a temperate climate, since it can utilize its first evaporative cooler the only source of cooling energy when the humidity of outdoor air allows to to meet the latent cooling load). Four arrangements of the system with different dew point evaporative air cooler prototypes were selected and developed for comparative analysis. The system was simulated as a whole, also, each component was individually tested on measurement station. develop the optimal arrangement of the system through numerical and experimental analysis. Four different performance indicators were considered: thermal COP (Coefficient Of Performance), the ERR (Energy Efficiency Ratio), coefficient a describing the potential in compensating indoor cooling loads, water consumption ratio. Also costs of the systems were compared through economic analysis. It was established that arrangement which is characterized by best-averaged performance in terms of all considered factors is a unit combined with two different types of evaporative coolers (marked as System B)- this is caused by the favorable arrangement of two units, where one is better suited to the pre-cooler role, while the other is better suited as the post-cooler.

42 ENGINEERING↗

A Virtual Space Vector Model Predictive Control for a Seven-Level Hybrid Multilevel Converter

This paper proposes a virtual space vector (VSV) model predictive control (MPC) for a three-phase seven-level (7L) hybrid multilevel converter (HMC), where each phase consists of an active-neutral-point-clamped converter with a floating H-bridge. To achieve the best current tracking, which is the primary goal of the proposed algorithm, a novel geometrical positioning approach is proposed to select the optimal voltage vector among all the realspace vectors and VSVs. Then, all the possible switching sequences that belong to the optimal voltage vector are evaluated to realize the dc capacitor voltage balancing and common-mode voltage reduction. Through an external modulator, the optimal voltage vector can be synthesized by using either one-, three-, or seven-segment switching sequence. Compared with the conventional MPC, the proposed VSV-MPC can reduce not only the computational burden but also the current THD. Both simulation and experimental results obtained on silicon carbide based 7L-HMC prototype are presented to validate the feasibility and effectiveness of the proposed VSVMPC strategy.

42 ENGINEERING↗

Discontinuous Spectral Difference Method for Conservation Laws on Unstructured Grids

A new, high-order, conservative, and efficient discontinuous spectral finite difference (SD) method for conservation laws on unstructured grids is developed. The concept of discontinuous and high-order local representations to achieve conservation and high accuracy is utilized in a manner similar to the Discontinuous Galerkin (DG) and the Spectral Volume (SV) methods, but while these methods are based on the integrated forms of the equations, the new method is based on the differential form to attain a simpler formulation and higher efficiency. Conventional unstructured finite-difference and finite-volume methods require data reconstruction based on the least-squares formulation using neighboring point or cell data. Since each unknown employs a different stencil, one must repeat the least-squares inversion for every point or cell at each time step, or to store the inversion coefficients. In a high-order, three-dimensional computation, the former would involve impractically large CPU time, while for the latter the memory requirement becomes prohibitive. In addition, the finite-difference method does not satisfy the integral conservation in general. By contrast, the DG and SV methods employ a local, universal reconstruction of a given order of accuracy in each cell in terms of internally defined conservative unknowns. Since the solution is discontinuous across cell boundaries, a Riemann solver is necessary to evaluate boundary flux terms and maintain conservation. In the DG method, a Galerkin finite-element method is employed to update the nodal unknowns within each cell. This requires the inversion of a mass matrix, and the use of quadratures of twice the order of accuracy of the reconstruction to evaluate the surface integrals and additional volume integrals for nonlinear flux functions. In the SV method, the integral conservation law is used to update volume averages over subcells defined by a geometrically similar partition of each grid cell. As the order of accuracy increases, the partitioning for 3D requires the introduction of a large number of parameters, whose optimization to achieve convergence becomes increasingly more difficult. Also, the number of interior facets required to subdivide non-planar faces, and the additional increase in the number of quadrature points for each facet, increases the computational cost greatly.

Liu, Yen↗

Robust and Simple ADMM Penalty Parameter Selection

We present a new method for online selection of the penalty parameter for the alternating direction method of multipliers (ADMM) algorithm. ADMM is a widely used method for solving a range of optimization problems, including those that arise in signal and image processing. In its standard form, ADMM includes a scalar hyperparameter, known as the penalty parameter, which usually has to be tuned to achieve satisfactory empirical convergence. In this work, we develop a framework for analyzing the ADMM algorithm applied to a quadratic problem as an affine fixed point iteration. Using this framework, we develop a new method for automatically tuning the penalty parameter by detecting when it has become too large or small. We analyze this and several other methods with respect to their theoretical properties, i.e., robustness to problem transformations, and empirical performance on several optimization problems. Our proposed algorithm is based on a theoretical framework with clear, explicit assumptions and approximations, is theoretically covariant/invariant to problem transformations, is simple to implement, and exhibits competitive empirical performance.

42 ENGINEERING↗

The Design of a Transparent Vertical Multizone Furnace: Application to Thermal Field Tuning and Crystal Growth

We present an innovative design of a vertical transparent multizone furnace which can operate in the temperature range of 25 C to 750 C and deliver thermal gradients of 2 C/cm to 45 C/cm for the commercial applications to crystal growth. The operation of the eight zone furnace is based on a self-tuning temperature control system with a DC power supply for optimal thermal stability. We show that the desired thermal profile over the entire length of the furnace consists of a functional combination of the fundamental thermal profiles for each individual zone obtained by setting the set-point temperature for that zone. The self-tuning system accounts for the zone to zone thermal interactions. The control system operates such that the thermal profile is maintained under thermal load, thus boundary conditions on crystal growth ampoules can be predetermined prior to crystal growth. Temperature profiles for the growth of crystals via directional solidification, vapor transport techniques, and multiple gradient applications are shown to be easily implemented. The unique feature of its transparency and ease of programming thermal profiles make the furnace useful in scientific and commercial applications for determining the optimized process parameters for crystal growth.

Duvual, Walter M. B.↗

Design, optimization, and validation of a triply periodic minimal surface based heat exchanger for extreme temperature applications

Heat exchanger (HX) innovation offers potential for significant improvements in energy efficiency for a host of applications including but not limited to aviation and power generation cycles. Triply Periodic Minimal Surfaces (TPMS) have received significant attention in recent years due to their incredibly high surface area density, which makes them very attractive from a heat transfer point of view. Recent efforts have largely focused on thermal-hydraulic characterization of the many available TPMS and the testing of small-scale HX prototypes. However, practical implementation remains largely unexplored, partially due to the extreme computational cost associated with accurately simulating these complex structures. In this work, we present the design, simulation, and optimization of a TPMS-HX for high temperature (900 °C) and pressure (25 MPa) applications. Detailed analysis of HX sub-sections is conducted to define the smallest repeatable section which may be used to characterize the thermal-hydraulic performance of the entire HX, enabling rapid design and iteration with significantly reduced computational cost. Compared to preliminary results for a water-to-water experiment, calibrated heat transfer and pressure drop predictions were within ±5 % and ±10 %, respectively. Optimization results show a 10x increase in volumetric power density over the initial design, which is verified against a parametric exhaustive search of the HX design space. Furthermore, it was found that reducing the unit cell hydraulic diameter cell plays the largest role in increasing heat transfer, increasing the surface area density and enabling a more compact and efficient HX.

42 ENGINEERING↗

Force-Free Identification of Minimum-Energy Pathways and Transition States for Stochastic Electronic Structure Theories

Here, the accurate mapping of potential energy surfaces (PESs) is crucial to our understanding of the numerous physical and chemical processes mediated by atomic rearrangements, such as conformational changes and chemical reactions, and the thermodynamic and kinetic feasibility of these processes. Stochastic electronic structure theories, e.g., Quantum Monte Carlo (QMC) methods, enable highly accurate total energy calculations that in principle can be used to construct the PES. However, their stochastic nature poses a challenge to the computation and use of forces and Hessians, which are typically required in algorithms for minimum-energy pathway (MEP) and transition state (TS) identification, such as the nudged elastic band (NEB) algorithm and its climbing image formulation. Here, we present strategies that utilize the surrogate Hessian line-search method, previously developed for QMC structural optimization, to efficiently identify MEP and TS structures without requiring force calculations at the level of the stochastic electronic structure theory. By modifying the surrogate Hessian algorithm to operate in path-orthogonal subspaces and at saddle points, we show that it is possible to identify MEPs and TSs by using a force-free QMC approach. We demonstrate these strategies via two examples, the inversion of the ammonia (NH 3 ) molecule and the nucleophilic substitution (S N 2) reaction F – + CH 3 F → FCH 3 + F – . We validate our results using Density Functional Theory (DFT)- and Coupled Cluster (CCSD, CCSD(T))-based NEB calculations. We then introduce a hybrid DFT-QMC approach to compute thermodynamic and kinetic quantities, free energy differences, rate constants, and equilibrium constants that incorporates stochastically optimized structures and their energies, and show that this scheme improves upon DFT accuracy. Our methods generalize straightforwardly to other systems and other high-accuracy theories that similarly face challenges computing energy gradients, paving the way for highly accurate PES mapping, transition state determination, and thermodynamic and kinetic calculations at significantly reduced computational expense.

Iyer, Gopal R.↗

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