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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Rheology guiding the design and printability of aqueous colloidal composites for additive manufacturing

Vat photopolymerization (VP) and direct ink write (DIW) additive manufacturing (AM) provide complex geometries with precise spatial control employing a vast array of photo-reactive polymeric systems. Although VP is recognized for superior resolution and surface finish, DIW provides versatility for higher viscosity systems. However, each AM platform presents specific rheological requirements that are essential for successful 3D printing. First, viscosity requirements constrain VP polymeric materials to viscosities below 10 Pa s. Thus, this requirement presents a challenging paradox that must be overcome to attain the physical performance of high molecular weight polymers while maintaining suitable viscosities for VP polymeric materials. Second, the necessary rheological complexity that is required for DIW pastes requires additional rheological measurements to ensure desirable thixotropic behavior. Further, this manuscript describes the importance of rheological measurements when designing polymeric latexes for AM. Latexes effectively decouple the dependency of viscosity on molecular weight, thus enabling high molecular weight polymers with low viscosities. Photo-crosslinking of water-soluble monomers and telechelic oligomeric diacrylates in the presence of the latex enables the fabrication of a scaffold, which is restricted to the continuous aqueous phase and effectively surrounds the latex nanoparticles enabling the printing of otherwise inaccessible high molecular weight polymers. Rheological testing, including both steady and oscillatory shear experiments, provides insights into system properties and provides predictability for successful printing. This perspective article aims to provide an understanding of both chemical functionality (photo- and thermal-reactivity) and rheological response and their importance for the successful design and evaluation of VP and DIW processable latex formulations.

36 MATERIALS SCIENCE↗
NASA NTRS2003

Gust Acoustic Response of a Single Airfoil Using the Space-Time CE/SE Method

A 2D parallel Euler code based on the space-time conservation element and solution element (CE/SE) method is validated by solving the benchmark problem I in Category 3 of the Third CAA Workshop. This problem concerns the acoustic field generated by the interaction of a convected harmonic vortical gust with a single airfoil. Three gust frequencies, two gust configurations, and three airfoil geometries are considered. Numerical results at both near and far fields are presented and compared with the analytical solutions, a frequency-domain solver GUST3D solutions, and a time-domain high-order Discontinuous Spectral Element Method (DSEM) solutions. It is shown that the CE/SE solutions agree well with the GUST3D solution for the lowest frequency, while there are discrepancies between CE/SE and GUST3D solutions for higher frequencies. However, the CE/SE solution is in good agreement with the DSEM solution for these higher frequencies. It demonstrates that the CE/SE method can produce accurate results of CAA problems involving complex geometries by using unstructured meshes.

Scott, James↗
DOE OSTI2024

Low‐Volume Cores for Fabrication of Compact, Versatile, and Intelligent Soft Systems

Abstract This study introduces the low‐volume core (LVC) fabrication method, which enables the monolithic molding of compact, complex, versatile, and intelligent soft robotic systems. This method uses thin and flexible thermoplastic sheets to mold internal chambers in soft fluidic actuators, valves, and circuits. The LVC fabrication method creates low‐volume networks in soft actuators (LV‐net actuators) that can be made with compact and complex geometries, enabling both low actuation volume input and multi‐degree‐of‐freedom actuators. LVC fabrication can also be used for compact, completely soft, and monolithic logic components (valves with low‐volume core, also called as LV valves) to provide directional resistance as well as a switching mechanism that enables fluidic logic in soft systems. The compatibility of the fabrication methods for both soft actuators and valves facilitates the creation of compact, integrated, and versatile soft robotic systems with embodied intelligence. This study introduces two examples of such intelligent soft robotic systems that integrate both LV‐net actuators and LV valves to demonstrate capability for complex system fabrication.

Yu, Qifan↗
DOE OSTI2025

High-resolution 3D-printed plastic scintillators with tertiary dye

Additive manufacturing offers efficient production of plastic scintillators with nontrivial geometries using vat polymerization, allowing fabrication of geometries which would be difficult or even impossible to produce using conventional subtractive manufacturing. This work presents a novel photocurable scintillator formula that includes coumarin 450 as a tertiary dye to enable high-resolution 3D printing via the manipulation of the 405 nm cure light. Bulk photocured and 3D printed (with and without tertiary dye) samples were compared through observational assessment and spectral response. All samples showed pulse shape discrimination between neutron and gamma events. Inclusion of the tertiary dye has minimal impact on emission spectrum and light output, but significant impact on print resolution as shown by comparison of printed high-complexity geometries and feature resolution test objects. With the use of a cure-limiting dye, unsupported features — such as freestanding pillars — were resolvable down to 0.7 mm. Even finer resolution at or below 0.1 mm was achieved in fully supported, integrated structures printed with off-the-shelf 405 nm desktop 3D printer. Scintillators demonstrated a light output up to 50% of EJ-200 with a PSD figure of merit up to 1.35 at 0.9–1.1 MeVee.

36 MATERIALS SCIENCE↗
NASA NTRS2006

Metallurgical Mechanisms Controlling Mechanical Properties of Aluminum Alloy 2219 Produced by Electron Beam Freeform Fabrication

The electron beam freeform fabrication (EBF3) layer-additive manufacturing process has been developed to directly fabricate complex geometry components. EBF3 introduces metal wire into a molten pool created on the surface of a substrate by a focused electron beam. Part geometry is achieved by translating the substrate with respect to the beam to build the part one layer at a time. Tensile properties demonstrated for electron beam deposited aluminum and titanium alloys are comparable to wrought products, although the microstructures of the deposits exhibit cast features. Understanding the metallurgical mechanisms controlling mechanical properties is essential to maximizing application of the EBF3 process. Tensile mechanical properties and microstructures were examined for aluminum alloy 2219 fabricated over a range of EBF3 process variables. Unique microstructures were observed within the deposited layers and at interlayer boundaries, which varied within the deposit height due to microstructural evolution associated with the complex thermal history experienced during subsequent layer deposition. Microstructures exhibited irregularly shaped grains with interior dendritic structures, described based on overall grain size, morphology, distribution, and dendrite spacing, and were correlated with deposition parameters. Fracture features were compared with microstructural elements to define fracture paths and aid in definition of basic processing-microstructure-property correlations.

Domack, Marcia S.↗
DOE OSTI2022

Autonomous aerial flight path inspection using advanced manufacturing techniques

Robotic systems have shown capabilities to perform inspection tasks in dangerous and difficult-to-access environments, such as those found in different components of power plants. However, most of the current robotic inspection technology is designed for specific components. Aerial robots, commonly termed as Drones, have raised an option to inspect a wider range of structural components. Nevertheless, current aerial inspecting technology still relies on a human pilot with limited line of sight, field of view and a reduced perception as the drone flies away, which prevents performing close-quarter inspection in intricate, structurally complex and GPS-denied environments. This work introduces offline inspection path generation methods based on robotics-integrated to manufacturing techniques. One method uses computer-aided manufacturing (CAM) techniques and the other an additive manufacturing (AM) approach to generate the flight path. That is to say, the drone would fly along the path described by a 3D (Three Dimensional) printer’s extruder or a CNC (Computer Numerical Control) machining tool, enabling to fly very close the structure even in physical structures with a complex geometry. Once the trajectories are generated, they are introduced for its validation in the Gazebo robotics simulator. Simulation results demonstrate the proper performance of the method and confirm that this approach can be used for close inspection of structural components.

42 ENGINEERING↗
NASA NTRS1986

Transonic Navier-Stokes wing solutions using a zonal approach. Part 2: High angle-of-attack simulation

A computer code is under development whereby the thin-layer Reynolds-averaged Navier-Stokes equations are to be applied to realistic fighter aircraft configurations. This transonic Navier-Stokes code (TNS) utilizes a zonal approach in order to treat complex geometries and satisfy in-core computer memory constraints. The zonal approach was applied to isolated wing geometries in order to facilitate code development. The TNS finite difference algorithm, zonal methodology, and code validation with experimental data is addressed. Also addressed are some numerical issues such as code robustness, efficiency, and accuracy at high angles of attack. Special free-stream-preserving metrics proved an effective way to treat H-mesh singularities over a large range of severe flow conditions, including strong leading edge flow gradients, massive shock induced separation, and stall. Furthermore, lift and drag coefficients were computed for a wing up through CLmax. Numerical oil flow patterns and particle trajectories are presented both for subcritical and transonic flow. These flow simulations are rich with complex separated flow physics and demonstrate the efficiency and robustness of the zonal approach.

Chaderjian, Neal M.↗
NASA NTRS1994

Modeling of Wall-Bounded Complex Flows and Free Shear Flows

Various wall-bounded flows with complex geometries and free shear flows have been studied with a newly developed realizable Reynolds stress algebraic equation model. The model development is based on the invariant theory in continuum mechanics. This theory enables us to formulate a general constitutive relation for the Reynolds stresses. Pope was the first to introduce this kind of constitutive relation to turbulence modeling. In our study, realizability is imposed on the truncated constitutive relation to determine the coefficients so that, unlike the standard k-E eddy viscosity model, the present model will not produce negative normal stresses in any situations of rapid distortion. The calculations based on the present model have shown an encouraging success in modeling complex turbulent flows.

Shih, Tsan-Hsing↗
NASA NTRS2004

On the Use of CAD and Cartesian Methods for Aerodynamic Optimization

The objective for this paper is to present the development of an optimization capability for Curt3D, a Cartesian inviscid-flow analysis package. We present the construction of a new optimization framework and we focus on the following issues: 1) Component-based geometry parameterization approach using parametric-CAD models and CAPRI. A novel geometry server is introduced that addresses the issue of parallel efficiency while only sparingly consuming CAD resources; 2) The use of genetic and gradient-based algorithms for three-dimensional aerodynamic design problems. The influence of noise on the optimization methods is studied. Our goal is to create a responsive and automated framework that efficiently identifies design modifications that result in substantial performance improvements. In addition, we examine the architectural issues associated with the deployment of a CAD-based approach in a heterogeneous parallel computing environment that contains both CAD workstations and dedicated compute engines. We demonstrate the effectiveness of the framework for a design problem that features topology changes and complex geometry.

Nemec, M.↗
NASA NTRS2004

Frequency Domain Calculations Of Acoustic Propagation

Two complex geometry problems are solved using the linearized Euler equations. The impedance mismatch method1 is used to impose the solid surfaces without the need to use a body-fitted grid. The problem is solved in the frequency domain to avoid long run times. Although the harmonic assumption eliminates all time dependence, a pseudo-time term is added to allow conventional iterative methods to be employed. A Jameson type, Runge-Kutta scheme is used to advance the solution in pseudo time. The spatial operator is based on a seven-point, sixth-order finite difference. Constant coefficient, sixth-derivative artificial dissipation is used throughout the domain. A buffer zone technique employing a complex frequency to damp all waves near the boundaries is used to minimize reflections. The results show that the method is capable of capturing the salient features of the scattering, but an excessive number of grid points are required to resolve the phenomena in the vicinity of the solid bodies because the wavelength of the acoustics is relatively short compared with the size of the bodies. Smoothly transitioning into the immersed boundary condition alleviates the difficulties, but a fine mesh is still required.

Lockard, David P.↗
DOE OSTI2020

Overset meshes for incompressible flows: On preserving accuracy of underlying discretizations

This study on overset meshes for incompressible-flow simulations is motivated by accurate prediction of wind farm aerodynamics involving large motions and deformations of components with complex geometry. Specifically, using first-order hyperbolic and elliptic equation proxies for the incompressible Navier-Stokes (NS) equations, we investigate the influence of information exchange between overset meshes on numerical performance where the underlying discretization is second-order accurate. The first aspect of information exchange surrounds interpolation of solution where we examine Lagrange and point-cloud-based interpolation for creating constraint equations between overset meshes. To maintain overall second-order accuracy, higher-order interpolation is required for elliptic problems, but linear interpolation is sufficient for hyperbolic problems in first-order form. Higher-order point-cloud-based interpolation provides a pathway to maintaining accuracy in unstructured meshes, but at higher complexity. The second aspect of information exchange focuses on comparing the approaches of overset single system (OSS) and overset Additive Schwarz (OAS) for coupling the linear systems of the overlapping meshes. While the former involves a single linear system, in the latter the discrete linear systems are solved separately, and solving the global system is accomplished through outer iterations and sequential information exchange in a Jacobi fashion. For the test cases studied, accuracy for hyperbolic problems is maintained by performing two outer iterations, whereas many outer iterations are required for elliptic systems. The order-of-accuracy studies explored here are critical for verifying the overset-mesh coupling algorithms used in engineering simulations. Accuracy of these simulations themselves is, however, quantified using engineering quantities of interest such as drag, power, etc. Consequently, we conclude with numerical experiments using NS equations for incompressible flows where we show that linear interpolation and few outer iterations are sufficient for achieving asymptotic convergence of engineering quantities of interest.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Numerical framework for integrated additive manufacturing-compression molding (AM-CM) of thermoplastic composites

Additive manufacturing-compression molding (AM-CM) has emerged as a transformative technology in advanced composite manufacturing. Additive manufacturing (AM) offers high design flexibility and the ability to produce complex geometries with precisely aligned fibers in the preferred orientation. Compression molding (CM) enhances composite materials by providing excellent dimensional stability, reduced porosity, high production rates, and a smooth surface finish. Despite these advantages, extensive integrated analysis is required to optimize processing conditions for improved fiber orientation distribution (FOD) and porosity control. Here, this study develops a comprehensive numerical model to simulate the AM-CM manufacturing process. The model isolates the effects of both the AM and CM phases while also capturing their integration. Additionally, it accounts for heat transfer, temperature-dependent viscosity, and fiber orientation in the extruded fiber-filled polymer, accurately representing material behavior during processing. This approach enables the analysis of interactions between deposited beads of complex strand shapes and their interface regions after full compression. Moreover, the model predicts key parameters such as polymer flowability, fiber orientation, and temperature evolution in AM-CM parts. By optimizing processing conditions, it facilitates a controlled and predictable microstructure.

36 MATERIALS SCIENCE↗
NASA NTRS1986

Transonic Navier-Stokes wing solutions using a zonal approach. Part 2: High angle-of-attack simulation

A computer code is under development whereby the thin-layer Reynolds-averaged Navier-Stokes equations are to be applied to realistic fighter-aircraft configurations. This transonic Navier-Stokes code (TNS) utilizes a zonal approach in order to treat complex geometries and satisfy in-core computer memory constraints. The zonal approach has been applied to isolated wing geometries in order to facilitate code development. Part 1 of this paper addresses the TNS finite-difference algorithm, zonal methodology, and code validation with experimental data. Part 2 of this paper addresses some numerical issues such as code robustness, efficiency, and accuracy at high angles of attack. Special free-stream-preserving metrics proved an effective way to treat H-mesh singularities over a large range of severe flow conditions, including strong leading-edge flow gradients, massive shock-induced separation, and stall. Furthermore, lift and drag coefficients have been computed for a wing up through CLmax. Numerical oil flow patterns and particle trajectories are presented both for subcritical and transonic flow. These flow simulations are rich with complex separated flow physics and demonstrate the efficiency and robustness of the zonal approach.

Chaderjian, N. M.↗
DOE OSTI2020

Cathodoluminescence of Ultrathin Twisted Ge 1–x Sn x S van der Waals Nanoribbon Waveguides

Ultrathin van der Waals semiconductors have shown extraordinary optoelectronic and photonic properties. Propagating photonic modes make layered crystal waveguides attractive for photonic circuitry and for studying hybrid light-matter states. Accessing guided modes by conventional optics is challenging due to limited spatial resolution and poor out-of-plane far field coupling. Scanning near-field optical microscopy (SNOM) can overcome these issues and can characterize waveguide modes down to tens of nm resolution, albeit for planar samples or nanostructures with moderate height variations. Electron microscopy provides atomic-scale localization also for more complex geometries, and recent advances extended the accessible excitations from interband transitions to phonons. In this work, bottom-up synthesized layered semiconductor (Ge 1-x Sn x S) nanoribbons with axial twist and deep sub-wavelength thickness are demonstrated as a platform for realizing waveguide modes, and cathodoluminescence (CL) spectroscopy is introduced as a tool to characterize them. Combined experiments and simulations show the excitation of guided modes by the electron beam and their efficient detection via photons emitted in the ribbon plane, which enables measuring key properties such as the evanescent field into the vacuum cladding with nanometer resolution. The results identify van der Waals waveguides operating in the infrared and highlight an electron microscopy-based approach for probing complex-shaped nanophotonic structures.

36 MATERIALS SCIENCE↗
NASA NTRS1994

Computational analysis of forebody tangential slot blowing

An overview of the computational effort to analyze forebody tangential slot blowing is presented. Tangential slot blowing generates side force and yawing moment which may be used to control an aircraft flying at high-angle-of-attack. Two different geometries are used in the analysis: (1) The High Alpha Research Vehicle; and (2) a generic chined forebody. Computations using the isolated F/A-18 forebody are obtained at full-scale wind tunnel test conditions for direct comparison with available experimental data. The effects of over- and under-blowing on force and moment production are analyzed. Time-accurate solutions using the isolated forebody are obtained to study the force onset timelag of tangential slot blowing. Computations using the generic chined forebody are obtained at experimental wind tunnel conditions, and the results compared with available experimental data. This computational analysis compliments the experimental results and provides a detailed understanding of the effects of tangential slot blowing on the flow field about simple and complex geometries.

Gee, Ken↗
NASA NTRS2012

Development and Validation of an Interactive Liner Design and Impedance Modeling Tool

The Interactive Liner Impedance Analysis and Design (ILIAD) tool is a LabVIEW-based software package used to design the composite surface impedance of a series of small-diameter quarter-wavelength resonators incorporating variable depth and sharp bends. Such structures are useful for packaging broadband acoustic liners into constrained spaces for turbofan engine noise control applications. ILIAD s graphical user interface allows the acoustic channel geometry to be drawn in the liner volume while the surface impedance and absorption coefficient calculations are updated in real-time. A one-dimensional transmission line model serves as the basis for the impedance calculation and can be applied to many liner configurations. Experimentally, tonal and broadband acoustic data were acquired in the NASA Langley Normal Incidence Tube over the frequency range of 500 to 3000 Hz at 120 and 140 dB SPL. Normalized impedance spectra were measured using the Two-Microphone Method for the various combinations of channel configurations. Comparisons between the computed and measured impedances show excellent agreement for broadband liners comprised of multiple, variable-depth channels. The software can be used to design arrays of resonators that can be packaged into complex geometries heretofore unsuitable for effective acoustic treatment.

Howerton, Brian M.↗
NASA NTRS2015

Tetrahedral-Mesh Simulation of Turbulent Flows with the Space-Time Conservative Schemes

Direct numerical simulations of turbulent flows are predominantly carried out using structured, hexahedral meshes despite decades of development in unstructured mesh methods. Tetrahedral meshes offer ease of mesh generation around complex geometries and the potential of an orientation free grid that would provide un-biased small-scale dissipation and more accurate intermediate scale solutions. However, due to the lack of consistent multi-dimensional numerical formulations in conventional schemes for triangular and tetrahedral meshes at the cell interfaces, numerical issues exist when flow discontinuities or stagnation regions are present. The space-time conservative conservation element solution element (CESE) method - due to its Riemann-solver-free shock capturing capabilities, non-dissipative baseline schemes, and flux conservation in time as well as space - has the potential to more accurately simulate turbulent flows using unstructured tetrahedral meshes. To pave the way towards accurate simulation of shock/turbulent boundary-layer interaction, a series of wave and shock interaction benchmark problems that increase in complexity, are computed in this paper with triangular/tetrahedral meshes. Preliminary computations for the normal shock/turbulence interactions are carried out with a relatively coarse mesh, by direct numerical simulations standards, in order to assess other effects such as boundary conditions and the necessity of a buffer domain. The results indicate that qualitative agreement with previous studies can be obtained for flows where, strong shocks co-exist along with unsteady waves that display a broad range of scales, with a relatively compact computational domain and less stringent requirements for grid clustering near the shock. With the space-time conservation properties, stable solutions without any spurious wave reflections can be obtained without a need for buffer domains near the outflow/farfield boundaries. Computational results for the isotropic turbulent flow decay, at a relatively high turbulent Mach number, show a nicely behaved spectral decay rate for medium to high wave numbers. The high-order CESE schemes offer very robust solutions even with the presence of strong shocks or widespread shocklets. The explicit formulation in conjunction with a close to unity theoretical upper Courant number bound has the potential to offer an efficient numerical framework for general compressible turbulent flow simulations with unstructured meshes.

Chang, Chau-Lyan↗
NASA NTRS1998

Studying Turbulence Using Numerical Simulation Databases: Proceedings of the Summer Program - No. 7

The Seventh Summer Program of the Center for Turbulence Research took place in the four-week period, July 5 to July 31, 1998. This was the largest CTR Summer Program to date, involving thirty-six participants from the U. S. and nine other countries. Thirty-one Stanford and NASA-Ames staff members facilitated and contributed to most of the Summer projects. A new feature, and perhaps a preview of the future programs, was that many of the projects were executed on non-NASA computers. These included supercomputers located in Europe as well as those operated by the Departments of Defense and Energy in the United States. In addition, several simulation programs developed by the visiting participants at their home institutions were used. Another new feature was the prevalence of lap-top personal computers which were used by several participants to carry out some of the work that in the past were performed on desk-top workstations. We expect these trends to continue as computing power is enhanced and as more researchers (many of whom CTR alumni) use numerical simulations to study turbulent flows. CTR's main role continues to be in providing a forum for the study of turbulence for engineering analysis and in facilitating intellectual exchange among the leading researchers in the field. Once again the combustion group was the largest. Turbulent combustion has enjoyed remarkable progress in using simulations to address increasingly complex and practically more relevant questions. The combustion group's studies included such challenging topics as fuel evaporation, soot chemistry, and thermonuclear reactions. The latter study was one of three projects related to the Department of Energy's ASCI Program (www.llnl.gov/asci); the other two (rocket propulsion and fire safety) were carried out in the turbulence modeling group. The flow control and acoustics group demonstrated a successful application of the so-called evolution algorithms which actually led to a previously unknown forcing strategy for jets yielding increased spreading rate. A very efficient algorithm for flow in complex geometries with moving boundaries based on the immersed boundary forcing technique was tested with very encouraging results. Also a new strategy for the destruction of aircraft trailing vortices was introduced and tested. The Reynolds Averaged Modeling (RANS) group demonstrated that the elliptic relaxation concept for RANS calculations is also applicable to transonic flows with shocks; however, prediction of laminar/turbulent transition remains an important pacing item. A large fraction of the LES effort was devoted to the development and testing of a new algorithmic procedure (as opposed to phenomenological model) for subgrid scale modeling based on regularized de-filtering of the flow variables. This appears to be a very promising approach, and a significant effort is currently underway to assess its robustness in high Reynolds number flows and in conjunction with numerical methods for complex flows. As part of the Summer Program two review tutorials were given on Turbulent structures in hydrocarbon pool fires (Sheldon Tieszen), and Turbulent combustion modeling: from RANS to LES via DNS (Luc Vervisch); and two seminars entitled Assessment of turbulence models for engineering applications (Paul Durbin) and Subgrid-scale modeling for non-premixed, turbulent reacting flows (James Riley) were presented. A number of colleagues from universities, government agencies, and industry attended the final presentations of the participants on July 31 and participated in the discussions. There are twenty-six papers in this volume grouped in five areas. Each group is preceded with an overview by its coordinator.

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