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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 NTRS1977

Use of experimental separation limits in the theoretical design of V/STOL inlets

Experimental data from several model inlets have been used to generate two parameters which are related to the limit of operation for inlet flow separation. One parameter, called the diffusion ratio, is the ratio of the peak velocity on the inlet surface to the velocity at the diffuser exit and is related to the boundary-layer separation at low throat Mach numbers. The other parameter, the peak Mach number on the inlet surface, is related to the separation at high throat Mach numbers. These parameters are easily calculated from potential flow solutions and thus can be used as a design tool in screening proposed inlet geometries. Any of the geometric design variables can be analyzed by this technique; but, this paper is restricted to the consideration of the internal lip contraction ratio. An illustrative example of an application to an inlet design study for a tilt nacelle VTOL airplane is presented. The study will show what value of contraction ratio is required to meet the operating requirements yet allow the inlet to remain free of separation as indicated by the two separation parameters.

Boles, M. A.↗

NASA NTRS2016

Why an Eye Limiting Display Resolution Matters and How to Achieve It

Many factors affect the suitability of an out-the-window simulator visual system. Contrast, brightness, resolution, field-of-view, update rate, scene content and a number of other criteria are common factors often used to define requirements for simulator visual systems. Since 2008, NASA has worked with the USAF on the Operational Based Vision Assessment Program. The purpose of this program has been to provide the USAF School of Aerospace Medicine with a scientific testing laboratory to study human vision and testing standards in an operationally relevant environment. It was determined early in the design that current commercial and military training systems weren't well suited for the available budget as well as the highly research oriented requirements. During various design review meetings, it was determined the OBVA requirements were best met by using commercial-off-the-shelf equipment to minimize technical risk and costs. In this paper we will describe how the simulator specifications were developed in order to meet the research objectives and the resulting architecture and design considerations. In particular we will discuss the image generator architecture, database developments to meet eye limited resolution, and future reusablity in other projects.

flight simulator↗

NASA NTRSDate not supplied

LS-DYNA User-Defined Internal Ballistic Modeling

One of the challenges in modeling deflagration of solid propellants with LS-DYNA is its limited capability, which is mostly applicable to airbag systems that use gaseous nitrogen generated by burning sodium azide. To overcome this limitation and enable the modeling of custom propellant grains with specific geometries, perforations, surface inhibitors, impetus, burn rates, and co-volumes, a user-defined burn model must be defined. In this study, a custom internal ballistic analysis code is integrated into LS-DYNA to simulate kinematic systems driven by pyro-mechanical devices such as pyro pushers, cutters, thrusters, separations bolts, ejection seat catapults, etc. Step-by-step guidance is provided on implementing a user-defined loading subroutine and the requirements for compiling a custom LS-DYNA executable along with a simple pyro thruster example.

pyrotechnics↗

NASA NTRS2003

Orbital Space Plane (OSP) Program

Lockheed Martin has been an active participant in NASA's Space Launch Initiative (SLI) programs over the past several years. SLI, part of NASA's Integrated Space Transportation Plan (ISTP), was restructured in November of 2002 to focus the overall theme of safer, more afford-able space transportation along two paths - the Orbital Space Plane Program and the Next Generation Launch Technology programs. The Orbital Space Plane Program has the goal of providing rescue capability from the International Space Station by 2008 and transfer capability for crew (and limited cargo) by 2012. The Next Generation Launch Technology program is combining research and development efforts from the 2nd Generation Reusable Launch Vehicle (2GRLV) program with cutting-edge, advanced space transportation programs (previously designated 3rd Generation) into one program aimed at enabling safe, reliable, cost-effective reusable launch systems by the middle of the next decade. Lockheed Martin is one of three prime contractors working to bring Orbital Space Plane system concepts to a system definition level of maturity by December of 2003. This paper and presentation will update the international community on the progress of the' OSP program, from an industry perspective, and provide insights into Lockheed Martin's role in enabling the vision of a safer, more affordable means of taking people to and from space.

McKenzie, Patrick M.↗

NASA NTRS1977

The IMS Satellite Situation Center

Following a brief historical review of the SSC (Satellite Situation Center), created by the U.S. for the IMS (International Magnetospheric Study), its main functions are discussed. The services of the SSC include the accurate orbit determination of the satellites, 12-18 months in advance and the coordination of simultaneous observations by a multispacecraft system, which are essential for the optimization of the scientific gains from experiments conducted with limited resources. For 1976 SSC generated plots of the satellites Vela 5B, Vela 6A, Vela 6B, Hawkeye 1, Imp H (7), Imp J (8) by computing certain projections of the solar ecliptic, solar magnetospheric, and solar magnetic coordinate systems. The SSC system was automated by the addition of a computer system capable of interactive graphics. The SSC can also provide the ground-based campaigns with a graphical or tabular information about the position low-altitude satellites in any coordinate system. The possible participation of the SSC in future Electrodynamics Explorer mission, Space Shuttle programs is also being explored.

Sugiura, M.↗

NASA NTRS1978

Space Shuttle data acquisition and processing

The techniques of minimizing the amount of Space Shuttle data processed by using real-time ground data and on board computer to prescreen the data are presented. With the advent of long duration space flight and the large amounts of data generated, it became necessary to limit the amount of data to be processed and also to present data in a manner that highlights the most important data. The Shuttle operational data system with output of 128 kilobits/sec, the developmental flight instrumentation system, and screening of data by the analysts, flight crew, or onboard computers is described, noting that by using these monitoring methods the mission evaluation team can rapidly determine time periods for which postflight data processing is required. Postflight processing systems, batch system output products, data compression techniques, the interactive computer system, and the special telemetry conversion system are discussed, and it is concluded that the combination of Shuttle on board and ground data processing systems enhances the ability to perform a functional evaluation of the Space Shuttle vehicle.

Foster, G. B., Jr.↗

NASA NTRS1979

Prospects for advances in microwave atomic frequency standards

Traditional standards based on rubidium, cesium and hydrogen have been greatly refined over the past decade, such that the frequency stability of the current generation of devices is generally limited by those basic concepts on which they are based. Future advances in frequency stability will principally come from changes in the concepts on which the standards are based, and only secondarily from more careful engineering of the old concepts. The fundamental limitations in these standards are considered and the important conceptual and component advances which could have a major impact on future performance of these standards are indicated. A very promising new class of microwave standards based on ion storage techniques is examined.

Walls, F. L.↗

NASA NTRS1979

User's manual for flight Simulator Display System (FSDS)

The capabilities of the flight simulator display system (FSDS) are described. FSDS is a color raster scan display generator designed to meet the special needs of Flight Simulation Laboratories. The FSDS can update (revise) the images it generates every 16.6 mS, with limited support from a host processor. This corresponds to the standard TV vertical rate of 60 Hertz, and allows the system to carry out display functions in a time critical environment. Rotation of a complex image in the television raster with minimal hardware is possible with the system.

Egerdahl, C. C.↗

NASA NTRS1982

An assessment of the performance of the Spanwise Iron Magnet rolling moment generating system for magnetic suspension and balance systems using the finite element computer program GFUN

The development of a powerful method of magnetic roll torque generation is essential before construction of a large magnetic suspension and balance system (LMSBS) can be undertaken. Some preliminary computed data concerning a relatively new dc scheme, referred to as the spanwise iron magnet scheme are presented. Computations made using the finite element computer program 'GFUN' indicate that adequate torque is available for at least a first generation LMSBS. Torque capability appears limited principally by current electromagnet technology.

Britcher, C. P.↗

NASA NTRS1987

NORAD/SPACECMD comments concerning the atmospheric density models

Recent models do not produce more accurate neutral densities (although they require more computer time), regardless of the level of solar activity. This implies that there has been no measurable improvement of the calculation of neutral density since the early 60s. With known solar flux and geomagnetic activity (Ap) inputs, the density evaluation needs improvement. For highly eccentric orbits which span low to high altitude, the accuracy generated which has an altitude limitation of 1000 km remains comparable with those obtained by more recent models. This implies that either the density at 1000 km and above is insignificant or that the values provided by the recent models at high altitudes may not be reliable or both. Prediction accuracies obtained through the use of precision data from the Defense Mapping Agency are generally comparable to those obtained by using operational sensor data. This implies that the prediction accuracy problem is not necessarily caused by less accurate observations. The definition of the mean solar flux F10.7 is not universal.

Liu, Joseph J. F.↗

NASA NTRS1988

Constraints on the microwave opacity of gaseous methane and water vapor in the Jovian atmosphere

Gaseous NH3's microwave absorption in the Jovian atmosphere appears too great to be due to a solar abundance of this gas. The additional capacity of microwave absorption is presently sought in measurements of the microwave absorption of CH4 and H2O under simulated Jovian conditions at 2.25 GHz, 8.5 GHz, 21.7 GHz; due to large error bars, measurements represent upper limits on the microwave opacity generated by H2O and CH4. The results obtained are consistent with theoretical expressions for microwave opacity in a Jovian atmosphere at the specified frequencies. The presence of an NH3 abundance exceeding the solar level by a factor of 1.5 is indicated by test results.

Jenkins, Jon M.↗

NASA NTRS1992

Delaunay triangulation and computational fluid dynamics meshes

In aerospace computational fluid dynamics (CFD) calculations, the Delaunay triangulation of suitable quadrilateral meshes can lead to unsuitable triangulated meshes. Here, we present case studies which illustrate the limitations of using structured grid generation methods which produce points in a curvilinear coordinate system for subsequent triangulations for CFD applications. We discuss conditions under which meshes of quadrilateral elements may not produce a Delaunay triangulation suitable for CFD calculations, particularly with regard to high aspect ratio, skewed quadrilateral elements.

Posenau, Mary-Anne K.↗

NASA NTRS1994

A Cartesian grid approach with hierarchical refinement for compressible flows

Many numerical studies of flows that involve complex geometries are limited by the difficulties in generating suitable grids. We present a Cartesian boundary scheme for two-dimensional, compressible flows that is unfettered by the need to generate a computational grid and so it may be used, routinely, even for the most awkward of geometries. In essence, an arbitrary-shaped body is allowed to blank out some region of a background Cartesian mesh and the resultant cut-cells are singled out for special treatment. This is done within a finite-volume framework and so, in principle, any explicit flux-based integration scheme can take advantage of this method for enforcing solid boundary conditions. For best effect, the present Cartesian boundary scheme has been combined with a sophisticated, local mesh refinement scheme, and a number of examples are shown in order to demonstrate the efficacy of the combined algorithm for simulations of shock interaction phenomena.

Quirk, James J.↗

NASA NTRS1996

Towards Numerical Simulations of Trailing-Edge Aeroacoustics

The aeroacoustics of flow-hydrofoil interactions exhibits distinct characteristics depending on the physical length scales involved. In the small-foil (relative to acoustic wavelength) limit characteristic of the noise generated by large-scale vortex shedding at low flow Mach number, the noise calculation is facilitated by the use of the Lighthill analogy in conjunction with a free-space Green's function, in the sense of Curle's formulation. A methodology for computing the vortex-shedding noise using the Curle formulation, including both surface-induced dipole sources and volume quadrupole sources, has been developed.

Wang, Meng↗

NASA NTRS1998

Autonomous Satellite Command and Control through the World Wide Web: Phase 3

NASA's New Millenium Program (NMP) has identified a variety of revolutionary technologies that will support orders of magnitude improvements in the capabilities of spacecraft missions. This program's Autonomy team has focused on science and engineering automation technologies. In doing so, it has established a clear development roadmap specifying the experiments and demonstrations required to mature these technologies. The primary developmental thrusts of this roadmap are in the areas of remote agents, PI/operator interface, planning/scheduling fault management, and smart execution architectures. Phases 1 and 2 of the ASSET Project (previously known as the WebSat project) have focused on establishing World Wide Web-based commanding and telemetry services as an advanced means of interfacing a spacecraft system with the PI and operators. Current automated capabilities include Web-based command submission, limited contact scheduling, command list generation and transfer to the ground station, spacecraft support for demonstrations experiments, data transfer from the ground station back to the ASSET system, data archiving, and Web-based telemetry distribution. Phase 2 was finished in December 1996. During January-December 1997 work was commenced on Phase 3 of the ASSET Project. Phase 3 is the subject of this report. This phase permitted SSDL and its project partners to expand the ASSET system in a variety of ways. These added capabilities included the advancement of ground station capabilities, the adaptation of spacecraft on-board software, and the expansion of capabilities of the ASSET management algorithms. Specific goals of Phase 3 were: (1) Extend Web-based goal-level commanding for both the payload PI and the spacecraft engineer; (2) Support prioritized handling of multiple PIs as well as associated payload experimenters; (3) Expand the number and types of experiments supported by the ASSET system and its associated spacecraft; (4) Implement more advanced resource management, modeling and fault management capabilities that integrate the space and ground segments of the space system hardware; (5) Implement a beacon monitoring test; (6) Implement an experimental blackboard controller for space system management; (7) Further define typical ground station developments required for Internet-based remote control and for full system automation of the PI-to-spacecraft link. Each of those goals is examined in the next section. Significant sections of this report were also published as a conference paper.

Cantwell, Brian↗

NASA NTRS1999

Control of Meridional Flow in Circular Cylinders by a Travelling Axial Magnetic Field

Convective flow in a Bridgman or float zone configuration significantly affects the interface shape and segregation phenomena. While the primary causative factor for this flow is buoyancy induced convection in an enclosed Bridgman melt, the presence of a free surface gives rise to surface tension driven flows in the floating zone processing of melts. It is of interest to curtail these flows in order to realize near quiescent growth conditions that have shown to result in crystals with good longitudinal and radial homogeneity and thereby of better overall quality. While buoyancy effects can be reduced by careful processing in a low gravity (space) environment, the reduction of Marangoni flows due to surface tension variations is not that straight forward. Attempts have been made with some limited success with the use of external fields to affect the melt thermo-fluid behavior. The use of a static magnetic field that reduces convective contamination through the effects of a non-intrusively induced, dissipative Lorentz force in an electrically conducting melt is one such approach. Experiments have shown that axial fields of the order of 5 Tesla can significantly eliminate convection and yield close to diffusion limited crystal growth conditions. The generation and use of such high magnetic fields require substantial hardware and incur significant costs for its operation. Lately, the use of rotating magnetic fields has been tested in semiconductor crystal growth. The method is fairly well known and commonly used in metal processing but its adaptation to crystal growth of semiconductors is fairly recent. The elegance of the technique rests in its low power requirement (typically 10-20 milli-Tesla at 50-400 Hz) and its efficacy in curtailing deleterious temperature fluctuations in the melt. A rotating magnetic field imposes a rotational force and thereby induces a circulation within the melt that tends to dominate other sporadic convective effects. Thus a known low level of convective flow is introduced into the system. A new novel variation of the Lorentz force mechanism is proposed and investigated in this study. Since one of the desired process conditions in melt crystal growth is the minimization of convective effects, this investigation examines the use of an external field of magnetic origin to counteract existing convective flow within the melt. This is accomplished by utilizing a running or traveling axial magnetic wave in the system. The concept is similar to the use of vibrational means in order to induce streaming flows that oppose buoyant or surface tension driven convection in the system. The rotation direction as well as the magnitude (strength) of this circulation can be easily controlled by external inputs thus affording a direct means of controlling the developing shape of the crystallizing front (interface). The theoretical model of this technique is fully developed and presented in this paper. Results from the solution of the developed governing equations and boundary conditions are also presented. An experimental demonstration of the concept is presented through the suppression of natural convective flow in a mercury column. Implications to crystal growth systems will be fully explored in the final manuscript.

Mazuruk, K.↗

NASA NTRS2002

Structural Life and Reliability Metrics: Benchmarking and Verification of Probabilistic Life Prediction Codes

Over the past two decades there has been considerable effort by NASA Glenn and others to develop probabilistic codes to predict with reasonable engineering certainty the life and reliability of critical components in rotating machinery and, more specifically, in the rotating sections of airbreathing and rocket engines. These codes have, to a very limited extent, been verified with relatively small bench rig type specimens under uniaxial loading. Because of the small and very narrow database the acceptance of these codes within the aerospace community has been limited. An alternate approach to generating statistically significant data under complex loading and environments simulating aircraft and rocket engine conditions is to obtain, catalog and statistically analyze actual field data. End users of the engines, such as commercial airlines and the military, record and store operational and maintenance information. This presentation describes a cooperative program between the NASA GRC, United Airlines, USAF Wright Laboratory, U.S. Army Research Laboratory and Australian Aeronautical & Maritime Research Laboratory to obtain and analyze these airline data for selected components such as blades, disks and combustors. These airline data will be used to benchmark and compare existing life prediction codes.

Litt, Jonathan S.↗