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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 379 records · Page 21
All sourcesNASA NTRSDOE OSTI
NASA NTRS1977

Laser-zone growth in a Ribbon-To-Ribbon (RTR) process silicon sheet growth development for the large area silicon sheet task of the low cost silicon solar array project

The Ribbon-to-Ribbon (RTR) approach to silicon ribbon growth was investigated. An existing RTR apparatus, RTR#1, was upgraded to allow for 5 cm wide ribbon growth with a finite stroke length of at least 15 cm. A second RTR apparatus, RTR#2, was designed, built, and operated which utilizes continuous feed mechanisms and allows continuous growth of 7.5 cm wide ribbons. RTR#2 includes development and utilization of advanced beam scanning (or shaping), high power lasers, and thermal profile modification elements to attain maximum growth velocities (with a design goal of 18 cm/min). Materials studies, process development, and thermal analyses are also described. Residual stresses and dislocation densities were minimized through theoretical and experimental efforts towards optimization of thermal profiles. Growth runs were performed on RTR#2 and solar cells were fabricated which demonstrated efficiencies greater than 10%.

Gurtler, R. W.↗
NASA NTRS1993

UARS in-flight jitter study for EOS

Response data collected from gyroscopes on board the Upper Atmosphere Research Satellite (UARS) provided a unique opportunity to analyze actual flight pointing jitter data. Flight modal frequencies and damping values are derived from the measured data using an Eigensystem Realization Algorithm (ERA). Flight frequencies at various solar array positions are compared to analytical predictions obtained with a Finite Element Model. The solar array modal frequencies change with position due to the modes acting about different spacecraft inertial axes. Higher order modes were difficult to identify due to the limited instrumentation. Future flight jitter studies on other spacecraft would be significantly aided by additional instrumentation. Spacecraft jitter due to continuous disturbance sources such as the 1.6 meter scanning microwave antenna, the solar array drive, and reaction wheels is presented. The solar array drive disturbance dominates the spacecraft response during normal operation.

Molnar, John↗
NASA NTRS1998

An Integrated Tool for the Coupled Thermal and Mechanical Analysis of Pyrolyzing Heatshield Materials

Materials that pyrolyze at elevated temperature have been commonly used as thermal protection materials in hypersonic flight, and advanced pyrolyzing materials for this purpose continue to be developed. Because of the large temperature gradients that can arise in thermal protection materials, significant thermal stresses can develop. Advanced applications of pyrolytic materials are calling for more complex heatshield configurations, making accurate thermal stress analysis more important, and more challenging. For non-pyrolyzing materials, many finite element codes are available and capable of performing coupled thermal-mechanical analyses. These codes do not, however, have a built-in capability to perform analyses that include pyrolysis effects. When a pyrolyzing material is heated, one or more components of the original virgin material pyrolyze and create a gas. This gas flows away from the pyrolysis zone to the surface, resulting in a reduction in surface heating. A porous residue, referred to as char, remains in place of the virgin material. While the processes involved can be complex, it has been found that a simple physical model in which virgin material reacts to form char and pyrolysis gas, will yield satisfactory analytical results. Specifically, the effects that must be modeled include: (1) Variation of thermal properties (density, specific heat, thermal conductivity) as the material composition changes; (2) Energy released or absorbed by the pyrolysis reactions; (3) Energy convected by the flow of pyrolysis gas from the interior to the surface; (4) The reduction in surface heating due to surface blowing; and (5) Chemical and mass diffusion effects at the surface between the pyrolysis gas and edge gas Computational tools for the one-dimensional thermal analysis these materials exist and have proven to be reliable design tools. The objective of the present work is to extend the analysis capabilities of pyrolyzing materials to axisymmetric configurations, and to couple thermal and mechanical analyses so that thermal stresses may be efficiently and accurately calculated.

Pronchick, Stephen W.↗
NASA NTRS2015

Aerodynamic Load Analysis of a Variable Camber Continuous Trailing Edge Flap System on a Flexible Wing Aircraft

This paper presents an investigative aerodynamic analysis conducted on the novel control surface known as a Variable Camber Continuous Trailing Edge Flap (VCCTEF). The VCCTEF is modeled as a control effector on the NASA Generic Transport Model (GTM) where wing flexibility is considered. Aerodynamic modeling of the aircraft is conducted using vortex-lattice method (VLM), and an aeroelastic model of the aircraft that utilizes a coupled finite-element analysis (FEA) vortex-lattice solution is employed. VLM solutions are used to determine quasi-steady aerodynamic loading over the aeroelastic wing structures with VCCTEF. The load data is used to calculate aerodynamic sensitivities to control surface deployment and is also integrated to determine overall hinge moments. This analysis is conducted for different flight conditions, where control sensitivities compare the VCCTEF effectiveness against conventional control surfaces. Hinge moment results provide insight into aeroelastic wing loads, and worst case hinge moments for the VCCTEF can be estimated. Results show that the VCCTEF offers greater control authority than conventional ailerons at cruise, and nominal flap settings are determined for a low-speed take-off condition where the VCCTEF maintains comparable control effectiveness. Worst case hinge moment values are presented, where for a possible VCCTEF configuration, the stiff wing model demonstrates up to a 5.90 percent increase in flap hinge moment relative to a rigid model, and a reduced stiffness model demonstrates up to an 11.42 percent increase.

Aeroelasticity↗
NASA NTRSDate not supplied

TPSAS-NF1676L-26160-DND

The structural performance of two advanced composite tow-steered shells is assessed using experiments and analyses. The fiber angles vary continuously around the shell circumference, and one shell has all 24 tows applied during fabrication, while the second shell uses the fiber placement systems tow drop/add capability to achieve a uniform wall thickness. The shells are tested in compression, and their axial stiffnesses and buckling loads are estimated using linear finite element analyses. Scaled passenger and cargo door cutouts are machined into one side of each shell. Axial stiffnesses and buckling loads of the shells with cutouts are computed using linear finite element analyses. The retested shells carry over 90 percent of the axial stiffness, and 85 percent of the buckling loads, of the shells without cutouts. These small reductions demonstrate the potential of tow steering to mitigate adverse effects of cutouts on the structural performance. The good correlation between experimental buckling loads and linear buckling analyses noted here may result from their circumferential stiffness variation, reducing geometric imperfection sensitivity. Analysis models of both shells were evaluated without and with measured geometric imperfections superposed in different longitudinal orientations. Small variations in prebuckling stiffness and buckling load of the shells are observed.

K C Wu↗
DOE OSTI2025

Predicting long-term stress relaxation on Alloy 709 using the crystal plasticity finite element method

This report summarizes the results of physics-based, crystal plasticity simulations for the long-term stress relaxation behavior of Alloy 709. The purpose of the study was to provide insight into five key questions related to long-term behavior in high temperatures materials which are difficult or impossible to answer experimentally: (1) is there a threshold stress for long-term relaxation? (2) is there strain threshold for relaxation damage, below which significant damage does not accumulate? (3) does damage continue to accumulate as the material relaxes or will damage accumulation plateau under some loading conditions? (4) does stress relaxation loading inevitably lead to failure? and (5) which, if any, engineering models for relaxation damage accumulation reasonably match the simulation results? The report summarizes the numerical simulations used to address these five questions and provides at least partial answers to each question.

36 MATERIALS SCIENCE↗
NASA NTRS1999

Crack Growth Simulation and Residual Strength Prediction in Airplane Fuselages

The objectives were to create a capability to simulate curvilinear crack growth and ductile tearing in aircraft fuselages subjected to widespread fatigue damage and to validate with tests. Analysis methodology and software program (FRANC3D/STAGS) developed herein allows engineers to maintain aging aircraft economically, while insuring continuous airworthiness, and to design more damage-tolerant aircraft for the next generation. Simulations of crack growth in fuselages were described. The crack tip opening angle (CTOA) fracture criterion, obtained from laboratory tests, was used to predict fracture behavior of fuselage panel tests. Geometrically nonlinear, elastic-plastic, thin shell finite element crack growth analyses were conducted. Comparisons of stress distributions, multiple stable crack growth history, and residual strength between measured and predicted results were made to assess the validity of the methodology. Incorporation of residual plastic deformations and tear strap failure was essential for accurate residual strength predictions. Issue related to predicting crack trajectory in fuselages were also discussed. A directional criterion, including T-stress and fracture toughness orthotropy, was developed. Curvilinear crack growth was simulated in coupon and fuselage panel tests. Both T-stress and fracture toughness orthotropy were essential to predict the observed crack paths. Flapping of fuselages were predicted. Measured and predicted results agreed reasonable well.

Chen, Chuin-Shan↗
NASA NTRS2011

Prognostics of Power Mosfets Under Thermal Stress Accelerated Aging Using Data-Driven and Model-Based Methodologies

An approach for predicting remaining useful life of power MOSFETs (metal oxide field effect transistor) devices has been developed. Power MOSFETs are semiconductor switching devices that are instrumental in electronics equipment such as those used in operation and control of modern aircraft and spacecraft. The MOSFETs examined here were aged under thermal overstress in a controlled experiment and continuous performance degradation data were collected from the accelerated aging experiment. Dieattach degradation was determined to be the primary failure mode. The collected run-to-failure data were analyzed and it was revealed that ON-state resistance increased as die-attach degraded under high thermal stresses. Results from finite element simulation analysis support the observations from the experimental data. Data-driven and model based prognostics algorithms were investigated where ON-state resistance was used as the primary precursor of failure feature. A Gaussian process regression algorithm was explored as an example for a data-driven technique and an extended Kalman filter and a particle filter were used as examples for model-based techniques. Both methods were able to provide valid results. Prognostic performance metrics were employed to evaluate and compare the algorithms.

Electrolytic capacitors↗
NASA NTRS2017

Near Real-Time Probabilistic Damage Diagnosis Using Surrogate Modeling and High Performance Computing

This work investigates novel approaches to probabilistic damage diagnosis that utilize surrogate modeling and high performance computing (HPC) to achieve substantial computational speedup. Motivated by Digital Twin, a structural health management (SHM) paradigm that integrates vehicle-specific characteristics with continual in-situ damage diagnosis and prognosis, the methods studied herein yield near real-time damage assessments that could enable monitoring of a vehicle's health while it is operating (i.e. online SHM). High-fidelity modeling and uncertainty quantification (UQ), both critical to Digital Twin, are incorporated using finite element method simulations and Bayesian inference, respectively. The crux of the proposed Bayesian diagnosis methods, however, is the reformulation of the numerical sampling algorithms (e.g. Markov chain Monte Carlo) used to generate the resulting probabilistic damage estimates. To this end, three distinct methods are demonstrated for rapid sampling that utilize surrogate modeling and exploit various degrees of parallelism for leveraging HPC. The accuracy and computational efficiency of the methods are compared on the problem of strain-based crack identification in thin plates. While each approach has inherent problem-specific strengths and weaknesses, all approaches are shown to provide accurate probabilistic damage diagnoses and several orders of magnitude computational speedup relative to a baseline Bayesian diagnosis implementation.

Warner, James E.↗
NASA NTRS2004

Design Analysis and Thermo-Mechanical Fatigue of a Polyimide Composite for Combustion Chamber Support

Polyimide composites are being evaluated for use in lightweight support structures designed to preserve the ideal flow geometry within thin shell combustion chambers of future space launch propulsion systems. Principles of lightweight design and innovative manufacturing techniques have yielded a sandwich structure with an outer face sheet of carbon fiber polyimide matrix composite. While the continuous carbon fiber enables laminated skin of high specific stiffness; the polyimide matrix materials ensure that the rigidity and durability is maintained at operation temperatures of 316 C. Significant weight savings over all metal support structures are expected. The protypical structure is the result of ongoing collaboration, between Boeing and NASA-GRC seeking to introduce polyimide composites to the harsh environmental and loads familiar to space launch propulsion systems. Design trade analyses were carried out using relevant closed form solutions, approximations for sandwich beams/panels and finite element analysis. Analyses confirm the significant thermal stresses exist when combining materials whose coefficients of thermal expansion (CTEs) differ by a factor of about 10 for materials such as a polymer composite and metallic structures. The ramifications on design and manufacturing alternatives are reviewed and discussed. Due to stringent durability and safety requirements, serious consideration is being given to the synergistic effects of temperature and mechanical loads. The candidate structure operates at 316 C, about 80% of the glass transition temperature T(sub g). Earlier thermomechanical fatigue (TMF) investigations of chopped fiber polyimide composites made this near to T(sub g), showed that cyclic temperature and stress promoted excessive creep damage and strain accumulation. Here it is important to verify that such response is limited in continuous fiber laminates.

Thesken, J. C.↗
DOE OSTI2022

A Realistic Full-Scale 3D Modeling of Turning Using Coupled Smoothed Particle Hydrodynamics and Finite Element Method for Predicting Cutting Forces

Computational modelling is an effective technique for understanding the complex physics of machining. Large deformations, material separation, and high computational requirements are the key challenges faced while simulating machining. This work introduces a full-scale three-dimensional model of turning operations using a combined approach based on the Smoothed Particle Hydrodynamics (SPH) and Finite Element (FE) methods. By exploiting the advantages of each method, this approach leads to high-fidelity coupled SPH-FE machining models. Cutting forces and chip morphology are the primary results of interest. The machining models are validated with the results of turning experiments. Two-dimensional machining model underpredicts the cutting force and feed force by approximately 49% and 70%, respectively. Moreover, passive force cannot be predicted using the two-dimensional model. On the other hand, with the three-dimensional models developed in this manuscript, the difference between the total simulated force and experimentally measured force is ∼17%. The chip morphologies correlate with experiments in terms of the direction of the chip movement and the “long” continuous chips observed while turning Al 6061. This work expands the realm of machining simulations from two-dimensional orthogonal machining or sectional three-dimensional model to a full-scale realistic simulation. The encouraging simulation results show the potential to study more complex phenomena, such as machining stability and tool path modulation.

42 ENGINEERING↗
NASA NTRS1988

Local-global analysis of crack growth in continuously reinforced ceramic matrix composites

The development is described of a mathematical model for predicting the strength and micromechanical failure characteristics of continuously reinforced ceramic matrix composites. The local-globe analysis models the vicinity of a propagating crack tip as a local heterogeneous region (LHR) consisting of spring like representation of the matrix, fibers and interfaces. This region is embedded in an anisotropic continuum (representing the bulk composite) which is modeled by conventional finite elements. Parametric studies are conducted to investigate the effects of LHR size, component properties, interface conditions, etc. on the strength and sequence of the failure processes in the unidirectional composite system. The results are compared with those predicted by the models developed by Marshall et al. (1985) and by Budiansky et al. (1986).

Ballarini, Roberto↗
NASA NTRS1993

Patterns of deformation and volcanic flows associated with lithospheric loading by large volcanoes on Venus

Magellan radar imaging and topography data are now available for a number of volcanoes on Venus greater than 100 km in radius. These data can be examined to reveal evidence of the flexural response of the lithosphere to the volcanic load. On Venus, erosion and sediment deposition are negligible, so tectonic evidence of deformation around large volcanoes should be evident except where buried by very young flows. Radar images reveal that most tectonic features and flow units on the flanks of these volcanoes have predominantly radial orientations. However, both Tepev Mons in Bell Regio and Sapas Mons in Atla Regio exhibit circumferential graben on their flanks. In addition, images reveal several flow units with an annular character around the north and west flanks of Tepev Mons. This pattern most likely results from ponding of flows in an annular flexural moat. Maat Mons in Atla Regio and Sif Mons in Eistla Regio are examples of volcanoes that lack circumferential graben and annular flows; discernible flow units and fractures on these constructs appear to be predominantly radial. Altimetry data can also provide evidence of flexural response. Tepev Mons is partially encircled by depressions that may be sections of a flexural moat that has not been completely filled. The locations of these depressions generally coincide with the annular flows described above. There is weaker evidence for such depressions around Maat Mons as well. The lack of circumferential tectonic features around most volcanoes on Venus might be explained by gradual moat filling and coverage by radial flows. The depressions around Tepev (and possible Maat) may indicate that this process is currently continuing. We use analytic models of plate flexure in an axisymmetric geometry to constrain the elastic plate thickness supporting Tepev Mons. If we consider the outer radius of the ponded flows to be the edge of a moat, we find that models with elastic plate thickness of 10-20 km fit best. Finite element models of a volcanic load detached from the underlying lithosphere predict overthrusting and radial normal faulting at the volcano's edge. Such a mechanism for the formation of radial rift zones on Venus volcanoes would make such features analogous to structures on the flanks of volcanoes on Earth.

Mcgovern, Patrick J.↗
DOE OSTI2024

Improving and Automating Building Model Data Exchange

There are many instances throughout a project’s lifecycle where there arises a need for quick and accurate risk assessment of building designs. For example, an unexpected design change during construction may necessitate structural engineers to perform a seismic risk assessment on analytical models of the updated building design using high fidelity structural analysis software, such as ANSYS or Abaqus. However, the efficiency of such workflows often depends upon the interoperability of architectural design software and structural analysis software. When the quality of this interoperability is lacking or even non-existent, the efficiency of virtual engineering workflows is hampered, which increases project costs. A McGraw Hill industry survey of professional users of Building Information Modeling (BIM) technologies found that there is high demand for BIM interoperability for structural analysis, but that the value/difficulty ratio is currently too low for practical use. There have been efforts by the academic community to facilitate model data exchange between the architectural design and structural analysis domains, but such solutions have not been widely adopted by industry, face technical challenges, and oftentimes are limited in applicability for users of various BIM software. Therefore, INL is developing capabilities to improve, automate, and generalize model data exchange between architectural BIM software (e.g., Revit) and structural analysis software (e.g., SAP2000, ANSYS). The goal is to help expedite and automate as much of the pre-processing step for creating analytical models in finite element analysis software as reasonably as possible. Such a "BIM-to-FEA" conversion tool should provide direct benefit to end-users through accuracy, automation, quick turn-around, and wide applicability. To generalize the application of this BIM-to-FEA conversion tool and increase its useability among the many different commercial BIM software currently used by industry, the program is being developed with the concept of openBIM. OpenBIM is the application of non-proprietary, open data standards that allow for BIM model data exchange in a format that is accessible, retainable, and useable for all users. The most widely used open, non-proprietary data exchange format for BIM is the Industry Foundation Classes (IFC) schema. IFC is developed by buildingSMART international and is ISO certified (ISO 16739-1:2018). The BIM-to-FEA conversion tool is being developed for compatibility with typical commercial building designs of steel framed structures. The tool is currently capable of importing architectural BIM data of framed building structures, recognizing and extracting the aspects of the model that are required for structural analysis, adjusting the connectivity of frame members, and finally exporting to an analytical model stored in the IFC format. The exported IFC analytical model can then be imported into various openBIM compliant software, such as SAP2000. Such capabilities have already been tested on commercial software, as shown above, and continue to be improved. Work is underway to test the conversion on various commercial BIM software, develop a user-friendly interface, incorporate the program into the broader DeepLynx data warehouse project being developed by INL, and to eventually open-source the tool for the benefit of the community. Future development of the tool envisions the ability for efficient iterative risk assessment of generative building designs, all within a workflow utilizing open-source tools. One such open-source tool will be MOOSE, an advanced finite element analysis tool developed at INL. The conversion tool will also branch out from typical commercial building designs and will aim to incorporate nuclear construction. The aim will be to convert both structural and non-structural components of nuclear facilities, such as curved concrete containment structures and piping systems, respectively.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Assessing Critical Conditions for Scour Near Obstructions using Bed Shear, Particle Onset of Motion Balances, and CFD-DEM Modeling of Granular Beds

Computational Fluid Dynamics combined with a Discrete Element Method is one of the computational methods that can be used to model multiphase flows. In this method various phases, gas and liquid or solid, are present in the same computational domain. The local averaged Navier–Stokes equations determine the flow of the continuous phase fluid and are solved using the traditional CFD finite volume approach. DEM is based on a Lagrangian formulation, which solves the equations of motion, expressed in ordinary differential equations, for representative particles as they move in space and time. The interactions between the continuous fluid phase and discrete solid phase are modeled with the use of Newton’s laws of motion via drag force. The particles interact with each other and with the boundaries of the fluid continuum, and the resulting contact forces are included in the equations of motion. The properties of solid particles and boundaries are treated as elastic bodies, with specified density, elastic modulus, and Poisson’s ratio. Particle shapes may vary from single spherical particles to more complex-shaped composite particles. The particles may be introduced into the domain by random or structured injection at a point, surface, or volume, depending on the application. More details on the formulation can be found in the Simcenter STAR-CCM+ User’s Manual and OpenFOAM website.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1975

Program design by a multidisciplinary team

The use of software engineering aids in the design of a structural finite-element analysis computer program for the STAR-100 computer is described. Nested functional diagrams to aid in communication among design team members were used, and a standardized specification format to describe modules designed by various members was adopted. This is a report of current work in which use of the functional diagrams provided continuity and helped resolve some of the problems arising in this long-running part-time project.

Voigt, S.↗
DOE OSTI2025

Pulse-by-pulse transient thermal deformation in crystal optics under high-repetition-rate FEL

Time-domain modeling of the thermal deformation of crystal optics can help define acceptable operational ranges across the pulse-energy repetition-rate phase space. In this paper, we have studied the transient thermal deformation of a water-cooled diamond crystal for a cavity-based X-ray free-electron laser (CBXFEL), either an X-ray free-electron laser oscillator (XFELO) or a regenerative amplifier X-ray free-electron laser (RAFEL), by numerical simulations including finite-element analysis and advanced data processing. Pulse-by-pulse transient thermal deformation of a 50 µm-thick diamond crystal has been performed with X-ray pulse repetition rates between 50 kHz and 1 MHz. Results for temperature and thermal deformation have been compared with the results of transient analysis using a continuous wave (CW) power loading. Temperature and thermal deformation results from pulse-by-pulse transient analysis vary with time about the results for the CW case for the same average power. The variation amplitude increases with pulse energy and decreases with repetition rate. When the repetition rate increases to infinity, both temperature and thermal deformation converge to the results for the CW case. Two critical time scales for the operation of crystal optics in a CBXFEL are (1) first-turn time, i.e. the time for the XFEL pulse to complete the first turn around the cavity so that the crystal sees the recirculated XFEL pulse, and (2) period-end time, i.e. the time that the next electron bunch arrives for the amplification, so that the crystal outcouples the amplified FEL power. For the same average power, simulation results show that the crystal thermal deformation seen by the XFEL beam decreases with repetition rate at the first-turn time of a 300 m-long cavity and increases with repetition rate at the period-end time. For the wavefront preservation requirement of the crystal optics, a pulse-energy versus repetition-rate phase space has been established. The upper bounds of the pulse energy at both first-turn and period-end times decreases with repetition rate, especially at the period-end time. The upper bound of the thermal deformation of the crystal at the period-end time for any repetition frequency can be estimated from the CW case. For a water-cooled diamond crystal of dimension 5 mm × 5 mm × 0.05 mm, the time to reach a quasi steady-state is about 50 ms for temperature and 50 µs for thermal deformation.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
NASA NTRS1987

Finite element methods of analysis for high speed viscous flows

Over the past three years a finite element based procedure for the solution of high speed viscous compressible flows was developed. The approach followed was to compute steady state solutions via a false transient, using an explicit time stepping scheme, and to attempt to improve the solution quality by incorporating adaptive mesh procedures. The main thrust of the work was to continue on the extension of the approach to the solution of some realistic compressible viscous flows. When flows at high Reynolds number are investigated, is soon becomes apparent that explicit techniwues have to be supplemented if they are to deal effectively with the large variations in element size and aspect ratio which characterize the computational grids necessary for adequate resolutin of the primary flow features. For this reason, the Taylor-Galerkin solution algorithm was rewritten in an explicit/implicit form. Solutions were computed for the problems of a flow past a flat plate, M-3, Re-100; shock/boundary layer interaction, M-2, Re-296000; flow over a compression corner, M-11.68, Re246000; and unifrom flow past a circular cylinder, M-6.34, Re-39770. A summary of the results is included and demonstrates the numerical performance of the scheme.

Source record↗