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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
NASA NTRS1995

Surface modeling and grid generation for aeropropulsion CFD

The efforts in geometry modeling and grid generation at the NASA Lewis Research Center, as applied to the computational fluid dynamic (CFD) analysis of aeropropulsion systems, are presented. The efforts are mainly characterized by a focus on the analysis of components of an aeropropulsion system, which involve turbulent viscous flow with heat transfer and chemistry. Thus, this discussion will follow that characterization and will sequence through the components of typical propulsion systems consisting of inlets, compressors, combustors, turbines, and nozzles. For each component, some applications of CFD analysis will be presented to show how CFD is used to compute the desired performance information, how geometry modeling and grid generation are performed, and what issues have developed related to geometry modeling and grid generation. The discussion will illustrate the following needs related to geometry modeling and grid generation as observed in aeropropulsion analysis: (1) accurate and efficient resolution of turbulent viscous and chemically-reacting flowfields; (2) easy-to-use interfaces with CAD data for automated grid generation about complex geometries; and (3) automated batch grid generation software for use with design and optimization software.

Choo, Yung K.↗
NASA NTRS2011

Probability of Detection (POD) Demonstration Transferability: Phase II

NASA Special Level POD demonstration tests are typically performed on flat plates of a single material containing fatigue cracks with aspect rations between 0.3 and 0.5. In many cases, the inspectors that pass the demonstration tests use (transfer) the NDE technique to inspect different materials and part geometries and for varying types of flaws. The objective of the task is to investigate several of the factors that may influence the transferability of POD demonstration tests. An existing set of 30 6061-T6 aluminum crack panels will be used to create parts with a square tube and pocket type geometries. These same aluminum crack panels were used in a study of the effect of penetrant sensitivity level on POD. Hence, we should be able to directly compare the POD for flat panels versus larger parts with more complex geometries.

Parker, Bradford H.↗
DOE OSTI2022

High-order dimensionally-split Cartesian embedded boundary method for non-dissipative schemes

Centered finite-difference schemes are commonly used for high-fidelity turbulent flow simulations in canonical configurations because of their non-dissipative property and computational efficiency. However, their use in flow simulations over complex geometries is limited by the requirements of a structured grid and a stable boundary treatment in the absence of artificial (numerical) dissipation. Cartesian embedded boundary (EB) approaches provide an efficient structured-grid framework to apply difference schemes over complex domains. However, they are often restricted to low orders of accuracy because of numerical instabilities at the embedded boundaries and the issues of small-cell problem that are difficult to address with high-order accuracy. The present work discusses a systematic approach to obtain high-order EB methods with non-dissipative centered schemes in the interior. This approach, based on satisfying the primary and secondary conservation conditions, is employed to derive EB schemes that are up to sixth-order accurate in the interior and fourth-order accurate globally for hyperbolic, parabolic as well as incompletely parabolic problems. The proposed finite-difference discretization is, by construction, dimensionally split and addresses the small-cell problem without any cell/geometry transformations, thus, highly simplifying implementation in a flow solver. Various linear and non-linear numerical tests are performed to evaluate the stability and the accuracy of the proposed EB schemes.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Approaches for the Simulation of Coupled Processes in Evolving Fractured Porous Media Enabled by Exascale Computing

Models have historically represented fractured porous media with continuum descriptions that characterize the media using bulk parameters. The impact of small-scale features is not captured in these models, although they may be controlling the performance of subsurface applications. Pore-scale models can simulate processes in small-scale features by representing the pore space geometry explicitly but are computationally expensive for large domains. The alternative multiscale approach entails the combination of pore-scale and continuum-scale descriptions in a single framework. We use Chombo-Crunch, a computational capability that discretizes complex geometries with an adaptive, embedded boundary method to contrast these two approaches. Chombo-Crunch takes advantage of recent computational performance and memory bandwidth improvements resulting from the emergence of exascale computing resources. These combined improvements enable the efficient simulation of reactive transport in fractured media with a high degree of fidelity and the ability to capture the control small-scale processes exert on the overall medium evolution.

42 ENGINEERING↗
DOE OSTI2022

Tailoring Corrosion Resistance of Additively Manufactured Metals with Atomic Layer Deposition

The goal of this work is to develop a scalable post-manufacturing capability at LANL that utilizes atomic layer deposition (ALD) for corrosion-resistant coatings onto additively manufactured (AM) metals. This will provide fundamentally new and essential capabilities towards the interchangeability of AM metals with traditionally wrought or machined material. This will be accomplished by (1) formulating novel ALD precursor doses and film thicknesses onto as-printed coupons of AM metals and (2) providing electrochemical characterization of corrosion susceptibility as a function of deposited film thickness. While ALD is well-established, the unique aspect (risk) of this work is application to rough AM surfaces. This risk is mitigated by repeating ALD deposition cycles, where thicker coatings laterally branch, resulting in a uniform coating. This risk will be assessed in the phase 1 feasibility study, wherein the application of ALD coatings to small AM coupon surfaces will be demonstrated using existing hardware and characterization tools at Sigma. This study alone will provide ground-breaking insight on the compatibility of ALD coating techniques with AM metals. Going beyond the phase 1 study, a standalone deposition chamber will be built, so full AM components can be coated and tested. While this MFR investment is focused on corrosion mitigation, it is critical to highlight external benefits of this technique outside the scope of this proposed study. ALD has extraordinary universality, whereby almost any material can be given almost any coating or graded density coating with atomic precision; and, the only limiting factors to scalability is the size of the dosing chamber. The self-limiting reactions intrinsic to ALD offers high conformity to part geometry and tolerance, even for internal surfaces where electroplating or conventional chemical vapor deposition falls short due to differential diffusion. This uniquely positions ALD at the forefront of post-manufacturing strategies for AM components, especially for those with complex geometry and internal surfaces.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Non-destructive structural characterization of graphite components using mechanical resonance and deep learning

As compared to conventional nuclear reactors, microreactors have the potential to significantly reduce construction timelines and capital costs, decreasing the barriers for advanced nuclear reactor technologies. However, the lower power output of these microreactors (typically < 20 MWe) creates challenging economics if operation and maintenance costs cannot be sufficiently reduced. The compact size of these designs presents an opportunity for comprehensive in-situ structural health monitoring to provide real-time feedback in order to reduce operational costs associated with maintenance and downtime. Many microreactor concepts use graphite for both in-core neutron moderation and as a structural material, which has typically required some form of periodic and laborious inspection. This report provides a description and assessment of recent work with graphite to couple acoustic-based experimental measurements and characterization with machine learning models to mature structural health monitoring capabilities and generate benefits for the nuclear microreactor industry. With resilient embedded sensors in development in other programs funded by the US Department of Energy’s Office of Nuclear Energy and elsewhere, the work described herein builds upon previously funded efforts to mature non-destructive testing technology that relates measured vibrational signatures to structural changes, using a combination of new experimental measurements and machine learning processing. Building on past successful demonstrations of predictive workflows to identify structural changes in a hexagonal stainless steel test article with excellent acoustic propagation, we first performed baseline characterization on graphite samples with canonical geometries to ensure compatibility and confidence in the applied techniques for a material with distinctly different mechanical properties. In contrast to efforts in previous years, we worked exclusively with unidirectional vibration data that is more comparable to those expected from the existing embedded sensor technologies which are suitable for deployment in a reactor setting. Established acoustic and modern machine-learning-based characterization approaches were applied to the resulting datasets from these simple geometries. Both approaches were found to be highly capable of detecting even small geometric irregularities amongst nominally identical samples. As such, we then moved to testing these approaches for detection of artificial local stress perturbations introduced into a more complex geometry: a hexagonal block with drilled holes. A main outcome of this work is that a generalizable ML workflow can be used to detect and predict the characteristics of small artificial anomalies in a graphite component with a relevant geometry. While this work was performed using surficial vibration data, we expect the approach to be flexible and viable for other monitoring scenarios, such as those with different arrangements or types of sensor arrays. As compared to previously funded efforts, an existing ML workflow based on neural networks was enhanced through the addition of recently developed Fourier neural operators. As applied to previously collected and new vibration datasets, prediction accuracies of anomaly characterizations were greatly improved with minimal added computational cost. As trained on small durations of vibration data (tens of seconds) collected over a realistic number of locations, the model was able to reliably determine the presence of a subtle stress anomaly and begin to provide location estimates. Such an approach is likely to be viable for more relevant reactor damage scenarios for graphite components, such as progressive crack growth or creep.

36 MATERIALS SCIENCE↗
NASA NTRS1991

Aerodynamic shape optimization of arbitrary hypersonic vehicles

A new method was developed to optimize, in terms of aerodynamic wave drag minimization, arbitrary (nonaxisymmetric) hypersonic vehicles in modified Newtonian flow, while maintaining the initial volume and length of the vehicle. This new method uses either a surface fitted Fourier series to represent the vehicle's geometry or an independent point motion algorithm. In either case, the coefficients of the Fourier series or the spatial locations of the points defining each cross section were varied and a numerical optimization algorithm based on a quasi-Newton gradient search concept was used to determine the new optimal configuration. Results indicate a significant decrease in aerodynamic wave drag for simple and complex geometries at relatively low CPU costs. In the case of a cone, the results agreed well with known analytical optimum ogive shapes. The procedure is capable of accepting more complex flow field analysis codes.

Dulikravich, George S.↗
DOE OSTI2026

Development of MOSCATO: A CFD-Level Electrochemistry and Corrosion Simulator for Molten Salt Systems

For both coolant and fueled variants of molten salt reactors (MSRs), the corrosion of structural materials is a significant challenge. The corrosion stems from chemical and electrochemical reactions initiated by fissile material, fission products, and impurities in the salt. Lower-fidelity models rely on empirical correlations for mass transfer, simplified lumped temperature profiles, and similar assumptions. They do not capture detailed spatial variations in complex geometries, creating the need for high-fidelity modeling to bridge this gap.As we approach the demonstration and possible deployment of MSRs in this decade, the development of a high-fidelity, high-performance simulator becomes imperative. To simulate the complex electrochemical environment and corrosion within molten salt systems, we have developed the Molten Salt Chemistry And TranspOrt (MOSCATO) code. This endeavor is comprised of three essential components. First, mass transfer equations are coupled with the Navier-Stokes equations in order to account for the transport of species in the salt. Second, the diffusion of alloy constituents, such as Cr, Fe, Ni, etc. is simulated within the structural metals. Third, the alloy and salt domains are coupled to account for the heterogeneous chemical and electrochemical reactions that occur at the salt-alloy interface.MOSCATO manages all three components within the framework of the highly scalable, open-source spectral element method computational fluid dynamics code Nek5000/NekRS. This integration enables MOSCATO to harness the immense computational power of modern high-performance computing resources, ensuring both high fidelity and computational speed.In addition to code development, we have initiated a comprehensive verification and validation campaign, utilizing data from diverse sources. First, MOSCATO's electrochemical solver was verified with reference numerical data. Then validation occurred against experiments: one of a thermal galvanic cell and the other for corrosion in flowing molten salt of FLiNaK (LiF-NaF-KF). This campaign verified and validated MOSCATO as a reliable tool for simulating electrochemical environments and corrosion in molten salt systems.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

mesoflow [SWR-22-56]

Mesoflow is a continuum scale simulation tool developed specifically for modeling transport and chemistry at the mesoscale. Our solver utilizes Cartesian block-structured adaptive mesh refinement to resolve complex surface morphologies (of catalysts/biomass particles among others) directly obtained from X-ray tomography data. An immersed boundary based formulation enables rapid representation of complex geometries prevalent in most mesoporous interfaces. The solver is developed on top of open-source performance portable library, AMReX, providing parallel execution capabilities on current and upcoming high-performance-computing (HPC) architectures. Our flexible software framework enables integration of complex chemical mechanisms at heterogenous interfaces and time-split algorithms for circumventing highly disparate reaction and flow time-scales. Our current studies indicate a ten-fold performance gain by using graphics-processing-units (GPU) compared to a single processor for representative problem sizes (2 million cell mesh).

Sitaraman, Hariswaran↗
NASA NTRS1997

Constrained Multipoint Aerodynamic Shape Optimization Using an Adjoint Formulation and Parallel Computers

An aerodynamic shape optimization method that treats the design of complex aircraft configurations subject to high fidelity computational fluid dynamics (CFD), geometric constraints and multiple design points is described. The design process will be greatly accelerated through the use of both control theory and distributed memory computer architectures. Control theory is employed to derive the adjoint differential equations whose solution allows for the evaluation of design gradient information at a fraction of the computational cost required by previous design methods. The resulting problem is implemented on parallel distributed memory architectures using a domain decomposition approach, an optimized communication schedule, and the MPI (Message Passing Interface) standard for portability and efficiency. The final result achieves very rapid aerodynamic design based on a higher order CFD method. In order to facilitate the integration of these high fidelity CFD approaches into future multi-disciplinary optimization (NW) applications, new methods must be developed which are capable of simultaneously addressing complex geometries, multiple objective functions, and geometric design constraints. In our earlier studies, we coupled the adjoint based design formulations with unconstrained optimization algorithms and showed that the approach was effective for the aerodynamic design of airfoils, wings, wing-bodies, and complex aircraft configurations. In many of the results presented in these earlier works, geometric constraints were satisfied either by a projection into feasible space or by posing the design space parameterization such that it automatically satisfied constraints. Furthermore, with the exception of reference 9 where the second author initially explored the use of multipoint design in conjunction with adjoint formulations, our earlier works have focused on single point design efforts. Here we demonstrate that the same methodology may be extended to treat complete configuration designs subject to multiple design points and geometric constraints. Examples are presented for both transonic and supersonic configurations ranging from wing alone designs to complex configuration designs involving wing, fuselage, nacelles and pylons.

Reuther, James↗
NASA NTRSDate not supplied

Separation and Transition on a CCF: Experimental Campaigns

Several experimental campaigns have been conducted across a number of Mach-6 facilities on the hypersonic flow around a CCF (CCF) geometry with a 5° half-angle cone and a 12° half-angle flare. These experiments were conducted as part of the NATO STO Research Task Group AVT-346, which is focused on predicting hypersonic boundary-layer transition on complex geometries. Two conventional wind tunnels (AFRL M6LT and ONERA R2Ch) and one quiet tunnel (Purdue BAM6QT) were used to test the same CCF geometry and to study the instabilities in both the boundary layer in the attached parts of the flow and the shear layer above the axisymmetric separation bubble near the cylinder-cone junction. Two nosetip radii (one nominally sharp and one blunt with a 5 mm radius) were tested. For the sharp nosetip case, there was a great deal of agreement between the measurements of both second-mode and shear-layer instabilities across the two conventional facilities. However, the measured spectra for the blunt nosetip case showed more significant differences between the two tunnels, potentially due to an alternate dominant instability mechanism coupled with the variations in the freestream noise spectra. The quiet facility resulted in a flow that remained laminar to much higher freestream unit Reynolds numbers, as well as in instability measurements that had more distinct spectral peaks for the sharp tip case and broadband rises for the blunt one. The instability mechanisms at play in the sharp quiet case were found to be the same as those in the conventional facilities.

Boundary Layer Transition↗
NASA NTRS2016

Tangle-Free Finite Element Mesh Motion for Ablation Problems

Mesh motion is the process by which a computational domain is updated in time to reflect physical changes in the material the domain represents. Such a technique is needed in the study of the thermal response of ablative materials, which erode when strong heating is applied to the boundary. Traditionally, the thermal solver is coupled with a linear elastic or biharmonic system whose sole purpose is to update mesh node locations in response to altering boundary heating. Simple mesh motion algorithms rely on boundary surface normals. In such schemes, evolution in time will eventually cause the mesh to intersect and "tangle" with itself, causing failure. Furthermore, such schemes are greatly limited in the problems geometries on which they will be successful. This paper presents a comprehensive and sophisticated scheme that tailors the directions of motion based on context. By choosing directions for each node smartly, the inevitable tangle can be completely avoided and mesh motion on complex geometries can be modeled accurately.

Droba, Justin↗
NASA NTRS2019

Direct-Write Printing on Three-Dimensional Geometries for Miniaturized Detector and Electronic Assemblies

Aerosol Jet Printing (AJP) and other additive electronics technologies will enable new detector assemblies that were not previously possible with traditional assembly processes. This technology has the potential to reduce mass and volume for fabrication and assembly of detector, instrument and electronics concepts by reducing trace widths down to 10 microns, printing on complex geometries, and allowing new concept production. This poster summarizes development efforts of printed interconnects for space applications.

Printed Hybrid Electronics↗
DOE OSTI2022

Mesoflow: An Open-Source Reacting Flow Solver for Catalysis at Mesoscale

We present the capabilities and software performance metrics of our open-source continuum solver for catalysis, Mesoflow, developed specifically for modeling transport and chemistry at the mesoscale. Our solver utilizes Cartesian block-structured adaptive mesh refinement to resolve complex catalyst surface morphologies directly obtained from X-ray tomography data. An immersed boundary based formulation enables rapid representation of complex geometries prevalent in most mesoporous catalyst interfaces. The solver is developed on top of open-source performance portable library, AMReX, providing parallel execution capabilities on current and upcoming high-performance-computing (HPC) architectures. Our flexible software framework enables integration of complex chemical mechanisms at heterogenous interfaces and time-split algorithms for circumventing highly disparate reaction and flow time-scales. Our current studies indicate a ten-fold performance gain by using graphics-processing-units (GPUs) compared to a single processor for representative problem sizes (2 million cell mesh). We will also present a brief introduction on how to build and use this software for application problems pertaining to catalytic upgrading and gas transport within porous catalyst particles.

adaptive meshing↗
NASA NTRS1996

Comparative Study of Advanced Turbulence Models for Turbomachinery

A computational study has been undertaken to study the performance of advanced phenomenological turbulence models coded in a modular form to describe incompressible turbulent flow behavior in two dimensional/axisymmetric and three dimensional complex geometry. The models include a variety of two equation models (single and multi-scale k-epsilon models with different near wall treatments) and second moment algebraic and full Reynolds stress closure models. These models were systematically assessed to evaluate their performance in complex flows with rotation, curvature and separation. The models are coded as self contained modules that can be interfaced with a number of flow solvers. These modules are stand alone satellite programs that come with their own formulation, finite-volume discretization scheme, solver and boundary condition implementation. They will take as input (from any generic Navier-Stokes solver) the velocity field, grid (structured H-type grid) and computational domain specification (boundary conditions), and will deliver, depending on the model used, turbulent viscosity, or the components of the Reynolds stress tensor. There are separate 2D/axisymmetric and/or 3D decks for each module considered. The modules are tested using Rocketdyn's proprietary code REACT. The code utilizes an efficient solution procedure to solve Navier-Stokes equations in a non-orthogonal body-fitted coordinate system. The differential equations are discretized over a finite-volume grid using a non-staggered variable arrangement and an efficient solution procedure based on the SIMPLE algorithm for the velocity-pressure coupling is used. The modules developed have been interfaced and tested using finite-volume, pressure-correction CFD solvers which are widely used in the CFD community. Other solvers can also be used to test these modules since they are independently structured with their own discretization scheme and solver methodology. Many of these modules have been independently tested by Professor C.P. Chen and his group at the University of Alabama at Huntsville (UAH) by interfacing them with own flow solver (MAST).

Hadid, Ali H.↗
NASA NTRS1997

Numerical Simulations Using the Immersed Boundary Technique

The immersed-boundary method can be used to simulate flows around complex geometries within a Cartesian grid. This method has been used quite extensively in low Reynolds-number flows, and is now being applied to turbulent flows more frequently. The technique will be discussed, and three applications of the method will be presented, with increasing complexity. to illustrate the potential and limitations of the method, and some of the directions for future work.

Piomelli, Ugo↗
DOE OSTI2025

Metal additive manufacturing simulation across length, time, and computing scales

Metal additive manufacturing (AM) offers a unique opportunity for production of advanced materials and complex geometries. However, variability in microstructure and properties challenges conventional approaches to design, process optimization, qualification, and materials selection. Modeling and simulation can improve understanding of AM processing and materials, but also poses major challenges for existing computational methods. Simultaneously, modern scientific computing hardware has become increasingly complex, most notably with the adoption of hybrid architectures such as Graphical Processing Units (GPUs). If appropriately utilized, emerging computational capabilities provide an opportunity to reveal new insight into AM processing and the resulting material structure and properties. In this review we describe the computational AM landscape, identify critical gaps, and highlight opportunities to impact the development and application of AM. First, the requirements and challenges of representative AM problem statements will be defined. Here, these problems range from scientific studies to industrial applications and are designed to capture the breadth of challenges facing the AM community. Next, the current state of AM modeling and simulation is evaluated, broken down by enabling hardware and software, process simulation, microstructure simulation, and property simulation. Each section describes the diversity of simulation approaches and associated trade-offs in physical fidelity and computational expense. Each area is then assessed based on their suitability and readiness for current and developing computational architectures. Lastly, the greatest opportunities for future research and application are highlighted, including gaps in modeling capabilities, opportunities for near-term application, and key scientific challenges.

additive manufacturing↗
DOE OSTI2022

Crosslink V.0.11.x User Manual

CrossLink is a novel two-dimensional and three-dimensional geometry and mesh generation software package developed by the Simulation Tools team at Los Alamos National Laboratory. This software represents the third generation of topology-based mesh generation technology developed by the Department of Defense and the Department of Energy with a special focus on complex multi-material hydrodynamic applications, mesh scalability, and high-order element mesh generation. The topology-based meshing approach offered by CrossLink enables users to quickly and easily mesh complex geometries in a repeatable and robust manner. CrossLink’s topology-based meshing approach is well-suited for parametric design studies, parametric design optimization, damage scenario assessment, and iterative design modification (i.e. feature addition and/or removal). CrossLink’s python API allows workflow scripting of the geometry creation and mesh generation process for traceability, repeatability, data provenance, and version control. CrossLink consists of three main components: a graphical user interface (GUI), a geometry creation and mesh generation engine, and a python API that provides a workflow scripting interface to the geometry and meshing functions.

97 MATHEMATICS AND COMPUTING↗