SEARCH · Engineering Papers

Results for “direct casting”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 235 records · Page 13

All sources NASA NTRS DOE OSTI

DOE OSTI2022

Non-Destructive In-Process Assessment of Thermal Spray Repairs

This exploratory project, entitled “Non-Destructive In-process Assessment of Thermal Spray Repairs,” evaluated the capabilities and limitations of four non-destructive testing (NDE) technologies for detection of defects in as-sprayed thermal spray coatings: acousto-ultrasonics, vibro-thermography, thermal wave infrared (IR) imaging, and flash IR thermography. The project goal was to identify a single technology suitable for use as an in-process inspection for two common classes of defects in thermal spray coatings, porosity and disbonds. Two rounds of test coupons were fabricated with intentionally seeded defects in AISI 420 stainless steel coatings deposited by twin wire arc (TWA) spray onto gray cast iron substrates. These standardized test coupons allowed the sensitivity of the four NDE methods to be directly compared. The results indicated that the acousto-ultrasonic method will not meet requirements for accuracy, inspection time, and reproducibility, while the vibrothermography method will not meet requirements for integration within remanufacturing cells and process flows. The IR methods, thermal wave imaging and flash thermography, both exhibited acceptable accuracy and reproducibility; however, the former method does not meet the requirement for inspection time. Flash IR thermography met all requirements in the initial round of testing, and that result was confirmed in a second round of testing on samples with a larger, more complex geometry. A final recommendation for further development of flash IR thermography was therefore made based upon i) detection performance, and ii) feasibility of deployment into the target application of resurfacing CAT engine blocks and headers.

36 MATERIALS SCIENCE↗

NASA NTRS1986

Photoelectronic Monitor of Motion Sickness

Instrument includes gallium arsenide light-emitting diode (LED) and silicon phototransistor with infrared filter, all cast in single plastic housing. Housing attached to subject's face with transparent doublesided adhesive tape. LED directs pulses of infrared light to skin, which reflects them to phototransistor. Phototransistor produces signal that is processed by external circuits to yield plot of infrared reflectance with time. External circuits temperature-compensated and respond only to pulsed component of detector output, rejecting those components caused by stray light. Circuits also extract blood-volume pulse amplitude and heart rate.

Oman, C. M.↗

NASA NTRS1997

Topography of the Moon from the Clementine Lidar

Range measurements from the lidar instrument carried aboard the Clementine spacecraft have been used to produce an accurate global topographic model of the Moon. This paper discusses the function of the lidar; the acquisition, processing, and filtering of observations to produce a global topographic model; and the determination of parameters that define the fundamental shape of the Moon. Our topographic model: a 72nd degree and order spherical harmonic expansion of lunar radii, is designated Goddard Lunar Topography Model 2 (GLTM 2). This topographic field has an absolute vertical accuracy of approximately 100 m and a spatial resolution of 2.5 deg. The field shows that the Moon can be described as a sphere with maximum positive and negative deviations of approx. 8 km, both occurring on the farside, in the areas of the Korolev and South Pole-Aitken (S.P.-Aitken) basins. The amplitude spectrum of the topography shows more power at longer wavelengths as compared to previous models, owing to more complete sampling of the surface, particularly the farside. A comparison of elevations derived from the Clementine lidar to control point elevations from the Apollo laser altimeters indicates that measured relative topographic heights generally agree to within approx. 200 in over the maria. While the major axis of the lunar gravity field is aligned in the Earth-Moon direction, the major axis of topography is displaced from this line by approximately 10 deg to the cast and intersects the farside 24 deg north of the equator. The magnitude of impact basin topography is greater than the lunar flattening (approx. 2 km) and equatorial ellipticity (approx. 800 m), which imposes a significant challenge to interpreting the lunar figure. The floors of mare basins are shown to lie close to an equipotential surface, while the floors of unflooded large basins, except for S.P.-Aitken, lie above this equipotential. The radii of basin floors are thus consistent with a hydrostatic mechanism for the absence of significant farside maria except for S.P.-Aitken, whose depth and lack of mare require significant internal compositional and/or thermal heterogeneity. A macroscale surface roughness map shows that roughness at length scales of 10(exp 1) - 10(exp 2) km correlates with elevation and surface age.

Smith, David E.↗

NASA NTRS1990

Reflected Sunlight Reduction and Characterization for a Deep-Space Optical Receiver Antenna (DSORA)

A baffle system for the elimination of first-order specular and diffuse reflection of sunlight from the sunshade of a deep-space optical receiver telescope is presented. This baffle system consists of rings of 0.5cm blades spaced 2.5 cm apart on the walls of GO hexagonal sunshade tubes that combine to form the telescope sunshade. The shadow cast by the blades, walls, and rims of the tubes prevent all first-order reflections of direct sunlight from reaching the primary mirror of the telescope. A reflection model of the sunshade without baffles is also presented for comparison. Since manufacturers of absorbing surfaces do not measure data near grazing incidence, the reflection properties at anticipated angles of incidence must be characterized. A description of reflection from matte surfaces in term of bidirectional reflection distribution function (BRDF) is presented along with a discussion of measuring BRDF near grazing incidence.

Clymer, B. D.↗

NASA NTRS2005

Analysis of Slope Limiters on Irregular Grids

This paper examines the behavior of flux and slope limiters on non-uniform grids in multiple dimensions. Many slope limiters in standard use do not preserve linear solutions on irregular grids impacting both accuracy and convergence. We rewrite some well-known limiters to highlight their underlying symmetry, and use this form to examine the proper - ties of both traditional and novel limiter formulations on non-uniform meshes. A consistent method of handling stretched meshes is developed which is both linearity preserving for arbitrary mesh stretchings and reduces to common limiters on uniform meshes. In multiple dimensions we analyze the monotonicity region of the gradient vector and show that the multidimensional limiting problem may be cast as the solution of a linear programming problem. For some special cases we present a new directional limiting formulation that preserves linear solutions in multiple dimensions on irregular grids. Computational results using model problems and complex three-dimensional examples are presented, demonstrating accuracy, monotonicity and robustness.

Berger, Marsha↗

NASA NTRS2019

The Role of Alerting System Failures in Loss of Control Accidents CAST SE-210 Output 2

This report is part of a series of reports that address flight deck design and evaluation, written as a response to loss of control accidents. In particular, this activity is directed at failures in airplane state awareness in which the pilot loses awareness of the airplane's energy state or attitude and enters an upset condition. In a report by the Commercial Aviation Safety Team, an analysis of accidents and incidents related to loss of airplane state awareness determined that hazard alerting was not effective in producing the appropriate pilot response to a hazard (CAST, 2014). In the current report, we take a detailed look at 28 airplane state awareness accidents and incidents to determine how well the hazard alerting worked. We describe a five-step integrated alerting-to-recovery sequence that prescribes how hazard alerting should lead to effective flight crew actions for managing the hazard. Then, for each hazard in each of the 28 events, we determine if that sequence failed and, if so, how it failed. The results show that there was an alerting failure in every one of the 28 safety events, and that the most frequent failure (20/28) was tied to the flight crew not orienting to (not being aware of) the hazard. The discussion section summarizes findings and identifies alerting issues that are being addressed and issues that are not currently being addressed. We identify a few recent upgrades that have addressed certain alerting failures. Two of these upgrades address alerting design, but one response to the safety events is to upgrade training for approach to stall and stall recovery. We also describe issues that are not being addressed adequately: better alert integration for flight path management types of hazards, airplanes in the fleet that do not meet the current alerting regulations, a lack of innovation for addressing cases of channelized attention, and existing vulnerabilities in managing data validity.

aviation safety↗

NASA NTRS2015

Evaluation of Primary Dendrite Arm Spacings from Aluminum-7wt% Silicon alloys Directionally Solidified aboard the International Space Station - Comparison with Theory

Aluminum – 7wt% silicon alloys were directionally solidified in the microgravity environment aboard the International Space Station as part of the “MIcrostructure Formation in CASTing of Technical Alloys under Diffusive and Magnetically Controlled Convective Conditions” (MICAST) European led program. Cross-sections of the sample during periods of steady-state growth were metallographically prepared from which the primary dendrite arm spacing (lambda 1) was measured. These spacings were found to be in reasonable agreement with the Hunt-Lu model which assumes a diffusion-controlled, convectionless, environment during controlled solidification. Deviation from the model was found and is attributed to gravity-independent thermocapillary convection where, over short distances, the liquid appears to have separated from the crucible wall.

Angart, Samuel↗

NASA NTRS2023

Recrystallization of A Shot Peened Single Crystal Nickel-Base Superalloy

Single crystal nickel-base superalloys used as turbine engine airfoils can have much higher creep and thermal fatigue resistance required for blades and vanes than polycrystalline superalloys due to the absence of weak grain boundaries, as well as the low elastic modulus in the [001] single crystal growth direction (Refs. 1 and 2). This has allowed an increase in the turbine rim inlet temperatures for improved performance and efficiency. However, these advantages in performance require constraints on acceptable levels of single crystal defects, such as macroscopic grain boundaries at low angles to the primary grain (i.e., low angle boundaries or LAB), higher angle boundaries, small new grains nucleated at the blade surface (a.k.a. freckles), larger new grains, and also the single crystal blades’ orientation, typically degrees off of the [001] direction and the orientation of a transverse [010] direction with respect to blade geometry. Therefore, single crystal turbine airfoils, which are frequently used with as-cast surfaces, are grain etched and inspected before and after heat treatments to ensure these aspects conform to acceptability limits.

single crystal↗

DOE OSTI2025

Effects of Surface Treatments on the Outgassing of 3D-Printed 316L Stainless Steel.

Fermi National Accelerator Laboratory (Fermilab) is a world leader in designing and operating particle accelerators for nuclear and particle physics research. These accelerators rely on electric fields to propel particle beams, which are then directed and focused using magnetic fields. To ensure these beams travel without interference, they must move through an ultra-high vacuum environment, typically around 10⁻⁹ torr. Maintaining such a vacuum requires materials with exceptionally low outgassing rates. 316L stainless steel is a common material choice for vacuum systems due to its low outgassing rates, excellent corrosion resistance, non-magnetic properties, and high mechanical strength. When manufactured using traditional methods like machining, extrusion, and casting, the vacuum properties of 316L stainless steel are well understood. However, the behavior of 316L stainless steel produced through additive manufacturing, such as Direct Metal Laser Sintering (DMLS), is not as well documented. This study aims to determine the outgassing rate of 316L stainless steel fabricated using DMLS. The investigation focuses on measuring the outgassing rates of 1.5 2 vacuum reducers and evaluating the effects of surface preparation techniques, such as mechanical polishing and electropolishing, on the outgassing performance. Understanding the outgassing performance of 3D-printed 316L stainless steel could enable Fermilab engineers to adopt this fabrication method for producing complex parts designed for ultra-high vacuum environments. These advancements have the potential to benefit projects, such as the Long-Baseline Neutrino Facility (LBNF) and the Proton Improvement Plan-II (PIP-II), by improving design flexibility and fostering innovation in accelerator development.

Cloud, Jaiden [Central State University]↗

DOE OSTI2020

Bus Clustering for Distribution Grid Topology Identification

Recovering the distribution grid topology is essential to perform several distribution system operator functions. Many algorithms that address the topology recovery problem have already been proposed in the literature. Most are based on a priori information regarding which buses are fed by which substation; however, this information might not be available because frequent grid reconfigurations change the distribution grid portion connected to each substation. This paper addresses the problem of assigning every substation the set of buses that it is feeding, given field data. First, the aforementioned task is cast as a nonconvex optimization problem. Second, a relaxed version of the optimization problem is solved via the alternating direction method of multipliers. Finally, the performance of our approach is validated through numerical simulations of realistic scenarios using a standard IEEE benchmark feeder.

bus clustering↗

NASA NTRS1979

Effect of grain orientation and coating on thermal fatigue resistance of a directionally solidified superalloy (MAR-M 247)

The effect of off-axis directionally solidified (DS) grain growth on thermal fatigue life of Mar-M 247 alloy was evaluated. Uncoated conventionally cast as well as DS wedge bars were cycled in a burner rig between 1070 C and room temperature. The longitudinal axis and leading edge of the specimen coincided. As the angle between the specimen longitudinal axis and growth axis increased, the thermal fatigue life decreased for both the uncoated and aluminide-coated bars. Life increases of about 50 cycles for the DS conditions were attributed to coating. The decrease in thermal fatigue life with increasing angle is primarily attributed to the increase in modulus of elasticity with increasing angle and not to the intersection of DS grain boundaries with the specimen leading edge. The thermal fatigue cracks were observed to be transgranular in the DS material. Limited tensile and stress-rupture properties of conventionally cast and off-axis DS Mar-M 247 alloy are also presented.

Bizon, P. T.↗

NASA NTRS1992

Solar radiation on a catenary collector

A tent-shaped structure with a flexible photovoltaic blanket acting as a catenary collector is presented. The shadow cast by one side of the collector on the other side producing a self shading effect is analyzed. The direct beam, the diffuse and the albedo radiation on the collector are determined. An example is given for the insolation on the collector operating on the martian surface for the location of Viking Lander 1 (VL1).

Crutchik, M.↗

DOE OSTI2020

Mechanism-Based Energy Regularization in Computational Modeling of Quasibrittle Fracture

Abstract Quasibrittle materials are featured by a strain-softening constitutive behavior under many loading scenarios, which could eventually lead to localization instability. It has long been known that strain localization would result in spurious mesh sensitivity in finite element (FE) simulations. Previous studies have shown that, for the case of fully localized damage, the mesh sensitivity can be mitigated through energy regularization of the material constitutive law. However, depending on the loading configuration and structural geometry, quasibrittle structures could exhibit a complex damage process, which involves both localized and diffused damage patterns at different stages of loading. This study presents a generalized energy regularization method that considers the spatial and temporal evolution of damage pattern. The method introduces a localization parameter, which describes the local damage pattern. The localization parameter governs the energy regularization of the constitutive model, which captures the transition from diffused to localized damage during the failure process. The method is cast into an isotropic damage model, and is further extended to rate-dependent behavior. The energy regularization scheme is directly incorporated into the kinetics of damage growth. The model is applied to simulate static and dynamic failures of ceramic specimens. It is shown that the present model is able to effectively mitigate the spurious mesh sensitivity in FE simulations of both types of failure. The present analysis demonstrates the essential role of mechanism-based energy regularization of constitutive relation in FE simulations of quasibrittle fracture.

Mechanics↗

DOE OSTI2024

Comparative Life Cycle Analysis of Carbon Dioxide Utilization in Concrete Products

In this study, a comparative LCA of CO2U concrete processes is conducted, revealing promise in several research areas. The environmental impacts of replacing conventional binder and aggregates with carbonated steel slag and direct carbonation of concrete are investigated in ten different product systems, which include both ready-mix and pre-cast concretes. The results indicate that cement substitution, CO2 uptake, electricity consumption, and the electricity grid mix constitute critical levers for deep decarbonization of concrete building materials. This presentation applies LCA to inform the use of CO2U concrete technology pathways in the design of sustainable concrete while promoting transparency and rational assumptions in the presence of uncertainty. Broader themes in the work include LCA of emerging technologies and the sensitivity of LCA results to co-product management methods.

Clarke, James↗

NASA NTRS1993

Pseudospectral simulation of compressible turbulence using logarithmic variables

The direct numerical simulation of dissipative, highly compressible turbulent flow is performed using a pseudospectral Fourier technique. The governing equations are cast in a form where the important physical variables are the fluid velocity and the natural logarithms of the fluid density and temperature. Bulk viscosity is utilized to model polyatomic gases more accurately and to ensure numerical stability in the presence of strong shocks. Numerical examples include three-dimensional supersonic homogeneous turbulence and two-dimensional shock-turbulence interactions.

Shebalin, John V.↗

NASA NTRS1995

Mathematical Model Of Curing Behavior Of A Polymer

Mathematical model predicts selected aspects of chemical, thermal and mechanical responses of polymeric liner and propellant materials during curing process. Predictions made both prior to processing and during process in quasi-real time. Developed specifically for use in designing and analyzing process in which bondline materials (including polymeric liners) and propellant cast and cured in rocket motor. With modifications, model applicable to curing of other polymeric materials. Further development may provide direct "in-line" program for calculations, including comparisons, in real time. This will constitute basis for more sophisticated control of process.

Loomis, Willard C.↗

NASA NTRS2001

Toward Understanding Pore Formation and Mobility During Controlled Directional Solidification in a Microgravity Environment Investigation (PFMI)

Porosity in the form of "bubbles and pipes" can occur during controlled directional solidification processing of metal alloys. It is detrimental to material properties and precludes obtaining meaningful scientific results. On Earth, density differences allow an initiated bubble can rise through the liquid and "pop" at the surface resulting in a sound casting. This is not likely to occur in a microgravity environment and, unfortunately, a number of experiments conducted in microgravity have suffered from porosity effects. The current investigation is a systematic effort towards understanding porosity formation and mobility during controlled directional solidification in a microgravity environment. This will be investigated by utilizing a transparent material, succinonitrile (SCN), in conjunction with a translating temperature gradient stage so that direct observation and recording of pore generation and mobility can be made. The talk will cover the porosity problem, the details of the proposed experiments and the experimental hardware, and the expectations from the microgravity experiments.

Grugel, R. N.↗

NASA NTRS2002

Pore Formation and Mobility (PFMI): An International Space Station Glovebox Investigation

Grugel, R. N.↗