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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Structural Design Exploration of an Electric Powered Multi-Propulsor Wing Configuration

Advancements in aircraft electric propulsion may enable an expanded operational envelope for electrically powered vehicles compared to their internal combustion engine counterparts. High aspect ratio wings provide additional lift and drag reduction for a proposed multi-propulsor design, however, the challenge is to reduce the weight of wing structures while maintaining adequate structural and aeroelastic margins. Design exploration using a conventional design-and-build philosophy coupled with a finite element method (FEM)-based design of experiments (DOE) strategy are presented to examine high aspect ratio wing structures that have spanwise distributed electric motors. Multiple leading-edge-mounted engine masses presented a challenge to design a wing within acceptable limits for dynamic and aeroelastic stability. Because the first four primary bending eigenmodes of the proposed wing structure are very sensitive to outboard motor placement, safety-of-flight requirements drove the need for multiple spars, rib attachments, and outboard structural reinforcements in the design. Global aeroelasticity became an increasingly important design constraint during the on-going design process, with outboard motor pod flutter ultimately becoming a primary design constraint. Designers successively generated models to examine stress, dynamics, and aeroelasticity concurrently. This research specifically addressed satisfying multi-disciplinary design criteria to generate fluid-structure interaction solution sets, and produced high aspect ratio primary structure designs for the NASA Scalable Convergent Electric Propulsion Technology and Operations Research (SCEPTOR) project in the Aeronautic Research Mission Directorate at NASA. In this paper, a dynamics-driven, quasi-inverse design methodology is presented to address aerodynamic performance goals and structural challenges encountered for the SCEPTOR demonstrator vehicle. These results are compared with a traditional computer aided design based approach.

Moore, James B.↗
NASA NTRSDate not supplied

Optimization of a Solver for Computational Materials and Structures Problems on NVIDIA Volta and AMD Instinct GPUs

The Scalable Implementation of Finite Elements by NASA (ScIFEN) is a software package developed to solve complex computational materials and structures problems using the finite element method (FEM). In this paper, we describe optimization techniques to speed up the linear solver computation that occurs within the ScIFEN application. We consider GPUs from two different vendors, NVIDIA and AMD as our target platforms for optimization and highlight differences in performance and optimization techniques. The NVIDIA GPU Volta V100 is used in the Summit system deployed at Oak Ridge National Laboratory, and the new exascale system, Frontier, will be using AMD Radeon Instinct GPU. We evaluated the performance of various optimization techniques on test matrices, ranging in size from100K to 4M, that are representative of ScIFEN applications. The linear solver computation is memory-bound on both GPUs. Our experiments show that on the NVIDIA GPU we obtained up to79%of the theoretical peak bandwidth, while the AMD GPU achieved 59%. Overall, the NVIDIA V100 GPU outperforms the AMD MI 25 GPU1. We observed an overall speedup of up to37X on an NVIDIA V100 compared to an Intel Skylake 12-coremachine. The solver for a 4M degree of freedom system took under 2.5 seconds.

Mohammad Zubair↗
NASA NTRS2018

A Dichroic Plate with Rounded Corners for NASA’s 34m Beam Waveguide Antenna

A S/K-band frequency selective surface (FSS) or a dichroic plate is designed, manufactured and tested for use in NASA’s Deep Space Network (DSN) 34m beam waveguide (BWG) antennas. Due to its large size, the proposed dichroic incorporates a new design feature, waveguides with rounded corners to cut cost and allow ease of manufacturing the plate. The dichroic is designed using an analysis that combines the Finite Element Method (FEM) for arbitrarily shaped guides with the Method of Moments and Floquet mode theory for periodic structures. The software was verified by comparison with previously measured and computed dichroic plates. The large plate was manufactured with end-mill machining. Their RF performance was measured and is in excellent agreement with the analytical results. The dichroic has been successfully installed and in operational at three NASA Deep Space Stations.

Imbriale, William↗
NASA NTRSDate not supplied

Development of Acoustic Mufflers for Cabin Noise Reduction in Orion Spacecraft

Controlling cabin acoustic noise levels in the Crew Module (CM) of the Orion spacecraft is critical to ensure adequate speech intelligibility, to avoid fatigue, and prevent any possibility of temporary and permanent hearing loss to the crew. The primary source of cabin noise for the on-orbit phase of the mission is from the Environmental Control and Life Support System (ECLSS) which recycles and conditions breathing air and maintains cabin pressurization through its duct network and components. Unfortunately, as a side effect, noise from the ECLSS fans propagates through theses ducts and emanate into the cabin habitable volume via the ECLSS inlet and outlets. To mitigate excessive duct-borne noise, two ECLSS mufflers have been designed to provide significant acoustic transmission loss (TL) so that the cabin noise requirements can be met. Each muffler is meant to be installed in the ducting of the ECLSS air inlet and outlet sides, respectively. Packaging constraints and tight volume requirements necessitated the mufflers to be of complex geometry and compatible with the bends of the ECLSS duct layout. To design and characterize the acoustic performance of the inlet and outlet mufflers, computational acoustic models were developed using the Finite Element Method (FEM) with 𝑤𝑎𝑣𝑒଺ vibroacoustic software. Characterization of the acoustic material and perforations in the mufflers were addressed with poroelastic theory. Once the mufflers were designed on paper and its TL predicted, prototypes of these mufflers were created using additive manufacturing. The muffler prototypes were subsequently tested for acoustic TL in the laboratory with various con-figurations of acoustic materials. Comparing the analytical predictions to the test performance yielded excellent correlation for acoustic TL and demonstrated significant broadband noise attenuation. The ECLSS mufflers are currently scheduled to be installed on the Artemis II Crew Module (CM) of the Orion spacecraft and will provide significant cabin comfort to crew during the mission.

Indranil Dandaroy↗
NASA NTRSDate not supplied

Thermostructural Qualification of PICA-D for NASA Planetary Science Missions

Phenolic Impregnated Carbon Ablator (PICA) has been used as the heatshield TPS material for many NASA planetary science missions. Due to a supply issue with the heritage Rayon fibers used in PICA fabrication, NASA started a project in 2017 to develop a sustainable replacement for PICA using a domestic fiber source, named PICA-D. This material has been selected as the heatshield TPS material for two upcoming NASA planetary science missions, Dragonfly mission to Titan and Mars Sample Retrieval Lander (SRL). While most PICA-D thermal and mechanical properties are very similar to PICA, early test data suggest that PICA-D is stiffer in tension in the in-plane (IP) direction, with higher strength but lower strain-to-failure. Preliminary thermostructural analysis using Finite Element Methods (FEM) tools predict IP compressive failure in the near-surface layers of PICA-D, for both Dragonfly and SRL flight environments. This talk provides an overview of the thermostructural qualification plans for PICA-D. A two-pronged approach is being pursued to demonstrate that the material and heatshield design has adequate capability for both SRL and Dragonfly design environments. The first part is to improve the accuracy of analytical predictions through a comprehensive characterization of PICA-D mechanical properties. The second, and more critical, part of the qualification approach is a subsystem-level test of PICA-D to demonstrate material capability under flight-relevant combined mechanical and thermal loads. The team is currently preparing for two test series in Sandia’s Solar Tower facility, scheduled in September 2023 and focusing on PICA-D acreage, followed by additional tests in the Solar Tower and LHMEL facilities focusing on design features and repair methods.

TPS↗
NASA NTRSDate not supplied

Thermostructural Testing of PICA-D for NASA Planetary Science Missions

Phenolic Impregnated Carbon Ablator–Domestic (PICA‑D) has been selected as the heatshield thermal protection system (TPS) material for two upcoming NASA planetary science missions: the Dragonfly mission to Titan and the Mars Sample Retrieval Lander (SRL). Early testing revealed differences between PICA‑D and heritage PICA, particularly in in‑plane (IP) tensile stiffness and thermal expansion. Thermostructural analyses using Finite Element Method (FEM) tools subsequently predicted the potential for IP compressive failure in the near‑surface layers of PICA‑D under both Dragonfly and SRL flight environments. Over the past three years, the Dragonfly and SRL teams have carried out an extensive thermostructural qualification campaign to address these concerns and validate PICA‑D for flight. This effort began with a comprehensive mechanical property characterization program at Kratos test laboratories, which significantly improved understanding of PICA‑D mechanical behavior and increased the fidelity of FEM predictions. The teams also conducted six large‑scale test entries at the National Solar Thermal Test Facility (NSTTF) solar tower, exposing PICA‑D articles—including gap fillers and representative design features or flaws—to combined thermal and mechanical loads. The talk will summarize key findings from these mechanical and thermostructural test campaigns and present the current status of PICA‑D qualification for NASA’s planetary science missions.

TPS↗
DOE OSTI2021

THERMAL/STRUCTURAL ANALYSIS OF THE AXION QUANTUM METROLOGY CAVITY AND ITS COMPONENTS

This research was centered around maximizing the capability to cool dielectric material within a containment unit, or Photonic Band Gap (PBG) cavity, designed for detecting axion dark matter and identifying the unit’s thermal properties. There are multiple types of PBG cavities, but the latest version that axion researchers wish to use has been theorized to contain possible issues related to its thermal properties. Thermal conductivity is an issue with the dielectric material because it is made from alumina which is highly insulative. This is important since the research is being done in a cryogenic environment and the thermal noise affects the quantum bit used for detecting the axion to photon conversion process. Therefore, any improvements to this unit should be justified and implemented but are not entirely limited to thermal contact related aspects of PBG cavities. A prospect of using sapphire in place of alumina also exists, but this is a more expensive, less tested, and more elusive material to justify the creation of a full dielectric structure out of sapphire. Thermal aspects of the cavity were analyzed using finite element method (FEM) and an experiment designed to test different thermal joint materials. FEM was used to check the contraction of the cavity during cooling, the contact quality between the dielectric material and cavity wall, theheat flow rate through the assembly, and helps visualize the cavity’s reaction to different design changes. A simple comparison between thermal conductivity curves justified the usage of sapphire over alumina from a thermal property point of view. Thus, the method of experimentation had an additional dielectric material, sapphire, to test with and compare to alumina. The thermal test identified which material is best to use for a thermal joint but also simultaneously found the conductance of the joint and dielectric material as well as an estimate for what the temperature is inside the larger scale cavity since a thermometer cannot be placed inside the PBG when it cools. Initially, the cavity simulation was tested for structural deformation properties and stress distribution since it is made of copper which contracts heavily in comparison to most other materials. The reduction in volume of the cavity was less than anticipated which gave more room for a possible usage of a modified thermal joint for additional contact area and higher conductivity.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Meshfree Methods for Modeling Chemo-Mechanical Cathode Cracking in Li-Ion Batteries

Through repeated charging and discharging, the electrodes of a Li-ion battery experience cyclic loading causing swelling and contraction due to the movement of lithium, also known as intercalation. This research focuses specifically on the chemo-mechanical cracking in the cathode. Because cathode particles are comprised of many randomly-oriented grains, which have highly anisotropic material properties, the expansion and contraction is very non-uniform. As a result, stress concentrations tend to form between grains, which necessitates the modeling of crack propagation largely along grain boundaries. Chemo-mechanical models are simulated mainly by two methods: the cohesive zone model (CZM) and the continuous damage model (CDM). The CZM is more accurate at capturing the sharp discontinuities of a crack but is very computationally expensive and intractable for large-scale models as a result. Conversely, the CDM is easily computed but not well-suited to easily allow for discontinuous field variables, which are inherent across a crack. This study aims to improve the CDM's ability to capture discontinuous cracks. Current versions of the CDM use the finite element method (FEM), which is one of the most widely used approaches for spatial discretization. This research investigates the use of the Reproducing Kernel Particle Method (RKPM), a meshfree method, for spatial discretization and aims to achieve a chemo-mechanical crack propagation model that achieves both intermediate accuracy and computational time between a CDM and CZM. To gain a better understanding of how the meshfree model compares to the current FEM model in capturing cathode crack propagation, further investigation is needed.

cathode cracking↗
DOE OSTI2023

Meshfree Multiphysics Damage Modeling of Li-ion Battery Materials

Through repeated charging and discharging cycles, the electrodes of a Li-ion battery experience significant swelling and contraction due to the movement of lithium, also known as intercalation. This research focuses specifically on the chemo-mechanical cracking in the cathode. Because cathode particles are comprised of many randomly-oriented grains, which have highly anisotropic material properties, the expansion and contraction is very non-uniform. As a result, stress concentrations tend to form between grains, which necessitates the modeling of crack propagation largely along grain boundaries and material interfaces. Chemo-mechanical damage models are generally simulated by one of two methods: the cohesive zone model (CZM) and the continuous damage model (CDM). The CZM is more accurate at capturing the sharp discontinuities of a crack but is very computationally expensive and intractable for large-scale models as a result. Conversely, the CDM is easily computed but not well-suited to easily allow for discontinuous field variables, which are inherent across a crack. This study aims to improve the CDM's ability to capture discontinuous cracks. Current versions of the CDM use the finite element method (FEM), which is one of the most widely used approaches for spatial discretization. This research investigates the use of the Reproducing Kernel Particle Method (RKPM), a meshfree method, for spatial discretization and aims to achieve a coupled chemo-mechanical crack propagation model that enhances accuracy while maintaining high computational efficiency. This model features a fully coupled, iterative electrochemistry solution, which informs the meshfree damage model of impending crack formation. To gain a better understanding of how the meshfree model compares to the current FEM model in capturing cathode crack propagation, further investigation is needed.

damage modeling↗
NASA NTRS2022

The Discontinuous Galerkin Finite Element Method

The purpose of this report is to present details of the Discontinuous Galerkin (DG) Finite Element Method (DG FEM). First the weighted-residual (WR) form is introduced and then the Galerkin Finite Element (FE) (GFE) and the Petrov-Galerkin FE (PG FE) methods are discussed. The details of the implementation of the DG FEM are presented along with two examples, 2nd order and 4th order differential equations, and the performance of the method is discussed.

Finite element↗
DOE OSTI2022

Quasi-Helmholtz decomposition, Gauss' laws and charge conservation for finite element particle-in-cell

Development of particle-in-cell (PIC) methods using finite element based methods (FEMs) have been a topic of renewed interest; this has largely been driven by (a) the ability of finite element methods to better model geometry, (b) better understanding of function spaces that are necessary to represent all Maxwell quantities, and (c) more recently, the fundamental rubrics that should be obeyed in space and time so as to satisfy Gauss' laws and the equation of continuity. In that vein, methods have been developed recently that satisfy these equations and are agnostic to time stepping methods. While this development is indeed a significant advance, it should be noted that implicit FEM transient solvers support an underlying null space that corresponds to a gradient of a scalar potential ∇Φ(r) (or t∇Φ(r) in the case of wave equation solvers). While explicit schemes do not suffer from this drawback, they are only conditionally stable with time step sizes that are mesh dependent and very small. Furthermore, the null space produces spurious charge that can corrupt the desired physics of a PIC simulation. The way to overcome this bottleneck, and indeed, satisfy all four Maxwell's equation is to use a quasi-Helmholtz formulation on a tessellation. In the re-formulation presented, we strictly satisfy the equation of continuity and Gauss' laws for both the electric and magnetic flux densities. Results illustrating the efficacy of this scheme will be demonstrated by analyzing non-neutral beams with space-charge and the adiabatic expansion of a neutral plasma with realistic parameters (Debye length and real mass ratios).

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

Finite Element Modeling of Diffusion in Fractured Porous Media by Using Hierarchical Material Properties

Abstract Fractured porous media challenge modeling approaches due to high computational costs and excessive mesh refinement imposed by the extreme scale variability of fractures and the heterogeneity of the surrounding porous rock. To overcome such difficulties, we utilize the hierarchical finite element method ( Hi ‐FEM) that has been developed previously to simulate the electrical potential distribution in complex geologic environments. The method employs the hierarchical basis functions in classical finite element analysis to enable representation of material properties on each dimensional component of a given 3D unstructured finite element, thereby inherently allowing for interactions at the boundary between fracture and a host rock. In this study, we extend its application to transient fluid flow and heat conduction in the Laplace domain. Time‐domain flow solutions are obtained by numerical inverse Laplace transform. We evaluate the accuracy of the method using different flow models and demonstrate its robustness for large‐scale, rock mass models featuring complex fracture networks. Moreover, for the computation of nodal Darcian velocity fields in fractured porous media where the fractures are represented as 2D features, a new approach that employs the Yeh's Galerkin model for both volume and facet elements is proposed. Results show that Hi ‐FEM can produce accurate flow solutions for fractured porous media without any need of coupling or transfer mechanism while still being computationally economical and numerically robust, even for large‐scale simulations.

Beskardes, G. D.↗
NASA NTRS1994

Analysis of random structure-acoustic interaction problems using coupled boundary element and finite element methods

A coupled boundary element (BEM)-finite element (FEM) approach is presented to accurately model structure-acoustic interaction systems. The boundary element method is first applied to interior, two and three-dimensional acoustic domains with complex geometry configurations. Boundary element results are very accurate when compared with limited exact solutions. Structure-interaction problems are then analyzed with the coupled FEM-BEM method, where the finite element method models the structure and the boundary element method models the interior acoustic domain. The coupled analysis is compared with exact and experimental results for a simplistic model. Composite panels are analyzed and compared with isotropic results. The coupled method is then extended for random excitation. Random excitation results are compared with uncoupled results for isotropic and composite panels.

Mei, Chuh↗
DOE OSTI2022

Novel processing route for design and manufacturing of metal toughened nanoceramics: Al–Al 2 O 3 nanocermets

Monolithic alumina is a highly brittle ceramic with a very low fracture toughness, making it an unreliable material for mechanical and structural applications. Ceramic-metal composites (cermets) are the subject of intensive interest to obtain materials which can address the intrinsic brittleness of ceramics without compromising their high strength and light weight. In the present investigation, aluminium-alumina (Al–Al 2 O 3 ) nanocermets were developed. The nanocermets possessed the toughness of Al phase and the strength of reinforced nano Al 2 O 3 particles. Here, the nanocermets green bodies were prepared such that upon sintering each adjacent Al 2 O 3 grain was conformally coated with a continuous Al film. Mechanical milling via a combination of cryo-milling and ball-milling was used to prepare Al–Al 2 O 3 nano-powder mixture. Spark plasma sintering was used to consolidate the green nanocermets. Results show that specimens prepared from 35 h milled powders exhibited superior mechanical properties as compared to other nanocermets, with an improvement in microhardness, elastic modulus, compressive strength, and flexural strength by 88%, 78%, 69% and 40% with respect to sintered pure Al. The indentation toughness of 35 h milled nanocermet showed an increment of 12.5% with respect to sintered pure Al 2 O 3 . Characterization techniques such as XRD, SEM, HR-TEM, X-ray tomography were employed to investigate the phase evolution and structural morphology, while FEM simulations were performed for understanding the crack propagation mechanisms in nanocermets.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Improving stability of ALD ZrN thin film coatings over U-Mo dispersion fuel

Atomic layer deposition (ALD) of ZrN is a candidate technology for coating U-Mo dispersion fuel as a diffusion barrier coating. During the early development stages of the coating the ZrN deposition showed to be mechanically unstable and ultimately resulted in spalling. Based on experimental outcomes it was found that instabillity can be eliminated through the introduction of a thin amorphous (a) Al 2 O 3 interlayer coating deposited in between the ~1-μm thick ZrN and the U-Mo. substrate. To elucidate these findings simulations were performed with density functional theory (DFT) to measure work of adhesions at different interfaces while finite element modeling (FEM) was performed to measure the residual stress distribution. DFT indicated that the ZrN coating deposited over (a)-Al 2 O 3 is ~2.5 times stronger when compared to direct deposition over U or UO 2 substrate. While calculations from FEM recognized; (1) large stress concentrations can originate from the irregularly distributed native surface oxides (UO 2 ) over U-Mo and (2) stress concentrations can be reduced if those surface UO 2 can be modified to a uniform layer (achieved after application of a 8 nm (a)-Al 2 O 3 interlayer). These results provided explanations and confirmed the role played by interlayer in eliminating the original mechanical instability of the ZrN.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Mechanical analysis of heterogeneous materials with higher-order parameters

Abstract Even though heterogeneous porous materials are widely used in a variety of engineering and scientific fields, such as aerospace, energy-storage technology, and bio-engineering, the relationship between effective material properties of porous materials and their underlying morphology is still not fully understood. To contribute to this knowledge gap, this paper adopts a higher-order asymptotic homogenization method to numerically investigate the effect of complex micropore morphology on the effective mechanical properties of a porous system. Specifically, we use the second-order scheme that is an extension of the first-order computational homogenization framework, where a generalized continuum enables us to introduce length scale into the material constitutive law and capture both pore size and pore distribution. Through several numerical case studies with different combinations of porosity, pore shapes, and distributions, we systematically studied the relationship between the underlying morphology and effective mechanical properties. The results highlight the necessity of higher-order homogenization in understanding the mechanical properties and reveal that higher-order parameters are required to capture the role of realistic pore morphologies on effective mechanical properties. Furthermore, for specific pore shapes, higher-order parameters exhibit dominant influence over the first-order continuum.

42 ENGINEERING↗
DOE OSTI2021

Monitoring of corrosion effects in pipes with multi-mode acoustic signals

Current commercial long-range guided wave inspection and monitoring technologies for pipes usually require establishment of certain specific acoustic modes for wave propagation and use a large number of sensors in a certain geometric arrangement (for example, uniformly-spaced arrays of sensors on a collar, placed around a pipe). This paper, in contrast, presents a long-range corrosion detection method in pipes based on multi-mode guided acoustic waves, generated and received using simple, single-element sensors. In this technique, available guided wave modes in any interrogated zone of the structure are automatically down-selected by the medium, and changes in energy distribution over the selected modes are analyzed through signal processing to monitor material loss or addition. Here, to investigate the feasibility of the proposed method, we have performed both experimental and numerical simulation studies on 50.8-mm (2-in)-diameter schedule-40 carbon steel pipes. In these studies, a linear chirp signal is injected in compression mode, perpendicular to the surface of the pipe, generating multi-mode, multi-directional guided waves that travel within the pipe wall. Corrosion effects in the pipes are simulated numerically and experimentally. To reduce errors in the measurement technique due to changes in the local or global temperature of the measured media, a universal temperature compensation algorithm is introduced. The experimental results show good agreement with simulation results, indicating that the proposed multi-mode wave generation and detection in a pipe could be used for long-range detection and monitoring of corrosion effects, such as pipe wall losses or solid material deposits.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Monitoring of mechanical changes in a pipe assembly with complex geometry using multi-mode acoustic signals

Guided wave ultrasonic testing has been widely used for nondestructive and long-range evaluation of diverse mechanical structures, such as pipes and plates. In general, a large number of guided wave modes exist even in the simplest geometries, and they exhibit highly dispersive characteristics. Thus, sophisticated excitation methods and elaborate modal analyses need to be implemented to excite, acquire, and process well-defined pure modes as part of such a measurement method. If the interrogated structure has complex geometry, for example, with cross-sectional variations or multiple joints, the utilization of pure modes becomes significantly more difficult. To overcome this difficulty, this paper proposes the use of multi-mode, multi-frequency guided waves for long-range inspection of structures with arbitrarily complex geometries. Furthermore, using broadband chirp signals and multi-mode time–frequency analysis in a prototypical complex pipe assembly that includes multiple pipe diameters, elbows, and flange connections, we experimentally show sensitive detection of mechanical changes (both material addition and loss). In addition, we demonstrate that the complexity of the structure can be modeled in the digital domain with sufficient detail to allow accurate numerical simulation of the acoustic response using this method.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗