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DOE OSTI2023

Toward accurate prediction of partial-penetration laser weld performance informed by three-dimensional characterization – Part II: μCT based finite element simulations

The mechanical behavior of partial-penetration laser welds exhibits significant variability in engineering quantities such as strength and apparent ductility. Understanding the root cause of this variability is important when using such welds in engineering designs. In Part II of this work, we develop finite element simulations with geometry derived from micro-computed tomography (μCT) scans of partial-penetration 304L stainless steel laser welds that were analyzed in Part I. We use these models to study the effects of the welds’ small-scale geometry, including porosity and weld depth variability, on the structural performance metrics of weld ductility and strength under quasi-static tensile loading. We show that this small-scale geometry is the primary cause of the observed variability for these mechanical response quantities. Additionally, we explore the sensitivity of model results to the conversion of the μCT data to discretized model geometry using different segmentation algorithms, and to the effect of small-scale geometry simplifications for pore shape and weld root texture. The modeling approach outlined and results of this work may be applicable to other material systems with small-scale geometric features and defects, such as additively manufactured materials.

36 MATERIALS SCIENCE↗

NASA NTRS2019

Bounding Methods for Heterogeneous Lidar-derived Navigational Geofences

Safe Unmanned Aerial Vehicle (UAV) operations near the ground require navigation methods that avoid fixed obstacles such as buildings, power lines and trees. Aerial lidar surveys of ground structures are available with the precision and accuracy to geolocate obstacles, but the high volume of raw survey data can exceed the compute power of onboard processors and the rendering ability of ground-based flight planning maps. Representing ground structures with bounding polyhedra instead of point clouds greatly reduces the data size and can enable effective obstacle avoidance, as long as the bounding geometry envelopes the structures with high spatial fidelity. This report describes in detail four methods to compute bounding geometries of ground obstacles from lidar point clouds. The four methods are: 1) 2.5D Maximum Elevation Box, 2) 2.5D Ground Map Extrusion, 3) 3D Bounding Cylinder, and 4) 3D Bounding Box. The methods are applied to five point cloud datasets from lidar surveys of UAV flight research sites in Georgia and Virginia with an average point spacing that ranges from 0.1m to 0.6m. The methods are assessed using survey areas with geometrically heterogeneous ground structures: buildings, vegetation, power lines, and sub-meter structures such as road signs and guy wires. The 2.5D Maximum Elevation Box method is useful for simple structures. The 2.5D Ground Map Extrusion method efficiently encloses vegetation, but requires handdrawn ground footprints. The 3D Bounding Cylinder method excels at enclosing linear structures such as power lines and fences. The 3D Bounding Box method excels at enclosing planar structures such as buildings. The methods are compared on the basis of data compression and boundary fidelity on selected areas. The 2.5D methods yield the highest data compression but the polyhedra produced by them enclose significant amounts of empty space. Boundary fidelity is superior for the 3D methods, though this fidelity comes at the cost of a roughly thirtyfold lower data compression ratio than the 2.5D Maximum Elevation Box method. A mix of these output geometries is proposed for autonomous UAV navigation with limited on-board computing. Both the accuracy and spatial detail of emerging satellite-based survey technology lower than that of aerial lidar scanning survey technology. Sub-meter structures and thin linear structures are not reliably mapped at present by satellite-based surveys.

Moore, Andrew J.↗

NASA NTRSDate not supplied

Scalability of GlennICE in a Parallel Environment

The Glenn Icing Computational Environment (GlennICE) is a computational tool designed to calculate ice growth on complex three-dimensional geometries using the input from a user-supplied computational fluid dynamics (CFD) solution for the geometry of interest. The most significant developments in the advancement of GlennICE have been investigating the convergence of the collection efficiency, efficiently finding trajectories, and improving the refinement methodology. Such developments have increased the efficiency of GlennICE for practical engineering application. With the increasing demand for applying GlennICE for more memory-intensive problems, the scalability of GlennICE has yet to be investigated. This paper is aimed at presenting a method to benchmark the scalability of GlennICE utilizing a relevant engineering problem within a parallel environment. This leads to the final goal of investigating whether an increase in the number of processors utilized results in a linear speedup of the GlennICE software.

Computational Icing, Icing, CFD, MPI↗

NASA NTRS1991

Vortex ring bubbles

Toroidal bubbles with circulation are studied numerically and by means of a physically motivated model equation. Two series of computations are performed by a boundary-integral method. One set shows the starting motion of an initially spherical bubble as a gravitationally driven liquid jet penetrates through the bubble from below causing a toroidal geometry to develop. The jet becomes broader as surface tension increases and fails to penetrate if surface tension is too large. The dimensionless circulation that develops is not very dependent on the surface tension. The second series of computations starts from a toroidal geometry, with circulation determined from the earlier series, and follows the motion of the rising and spreading vortex ring. Some modifications to the boundary-integral formulation were devised to handle the multiply connected geometry. The computations uncovered some unexpected rapid oscillations of the ring radius. These oscillations and the spreading of the ring are explained by the model equation which provides a more general description of vortex ring bubbles than previously available.

Lundgren, T. S.↗

NASA NTRS2003

Advanced Computational Aeroacoustics Methods for Fan Noise Prediction

Direct computation of fan noise is presently not possible. One of the major difficulties is the geometrical complexity of the problem. In the case of fan noise, the blade geometry is critical to the loading on the blade and hence the intensity of the radiated noise. The precise geometry must be incorporated into the computation. In computational fluid dynamics (CFD), there are two general ways to handle problems with complex geometry. One way is to use unstructured grids. The other is to use body fitted overset grids. In the overset grid method, accurate data transfer is of utmost importance. For acoustic computation, it is not clear that the currently used data transfer methods are sufficiently accurate as not to contaminate the very small amplitude acoustic disturbances. In CFD, low order schemes are, invariably, used in conjunction with unstructured grids. However, low order schemes are known to be numerically dispersive and dissipative. dissipative errors are extremely undesirable for acoustic wave problems. The objective of this project is to develop a high order unstructured grid Dispersion-Relation-Preserving (DRP) scheme. would minimize numerical dispersion and dissipation errors. contains the results of the funded portion of the project. scheme on an unstructured grid has been developed. constructed in the wave number space. The characteristics of the scheme can be improved by the inclusion of additional constraints. Stability of the scheme has been investigated. Stability can be improved by adopting the upwinding strategy.

Envia, Edmane↗

NASA NTRS1982

Numerical solution of transonic wing flow fields

A fast, fully implicit, approximate factorization algorithm designed to solve the conservative full-potential equation is used to compute lifting-wing flow fields with embedded transonic flow. The computer program (TWING - transonic wing analysis) uses an elliptic-solver numerical grid-generation routine and is capable of analyzing arbitrary wing geometries with sweep, twist, taper, and section variation. Computed flowfield results for several wing geometries are presented; they demonstrate substantial improvement in convergence speed relative to the FL028 computer code.

Holst, T. L.↗

NASA NTRS1968

Analysis of geometry and design point performance of axial flow turbines. Part 2 - Computer program

Computer program for solving equations governing flow in axial turbines

Carter, A. F.↗

NASA NTRS1986

Three-dimensional, conservative, Euler computations using patched grid systems and explicit methods

The method of 'zonal approach' (in which the flow field is partitioned into regions with independent grids) for computation of flow over complex geometries, such as aircraft configuration, requires application of a grid-interfacing procedure. A three-dimensional conservative, boundary scheme for patched grids, applicable in generalized coordinates for arbitrary point distributions on a planar zonal surface is presented. The computation technique is derived within the framework of the Osher (1983) upwind scheme, using Euler equations. The three-dimensional interfacing method is applied to the computation of flow about a wing-canard combination using a two-zone, patched grid.

Hessenius, K. A.↗

DOE OSTI2020

The influence of boundary and edge-plasma modeling in computations of axisymmetric vertical displacement

A number of previously published studies apply extended-MHD computations to model macroscopic dynamics of tokamak vertical displacement events (VDEs). The characteristic plasma-wall contact and resistive-wall diffusion imply sensitivity to boundary conditions in a general sense, but which conditions have significant influence depends on how the plasma is modeled. This work examines these dependencies by comparing results of axisymmetric extended-MHD computations with different sets of boundary conditions, plasma thermal-conduction models, and wall resistivity values. The geometry and plasma parameters of the computations represent a modest-sized tokamak. The forced-displacement scenario and computational setup are similar to those used in previous 3D computations. The results show that for a given wall resistivity, the VDE time-scale is most sensitive to variations in the boundary and thermal-conduction parameters that affect electron thermal transport. The electrical conductivity depends on electron temperature, and the dependence on thermal transport stems from its influence on the electrical circuit that includes the open-field halo current. Lastly, conditions that lead to hotter, broader halo regions slow the evolution. Significant sensitivity to the boundary condition on plasma flow-velocity exists when electron thermal conduction is restricted and electron energy loss is convective, which is expected for conditions at the entrance of the magnetic presheath.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1990

Unsteady airloads due to separated flow on airfoils and wings

Experimental and computational studies of airloads due to separated flows over airfoils and wings conducted at the NASA Langley Research Center are surveyed. Results are presented for cases involving local flow separation such as shock-induced separation, for the initiation of leading-edge vortex flows, and for cases involving unsteady airloads due to flows separating over remote aircraft components. Good correlation is obtained between experiment and computation for cases of locally separating flow and steady computations of vortex flow over delta wings and complex forebody geometries are shown. Physical flow modeling issues and computational requirements for the case of vertical tail buffeting are developed.

Edwards, John W.↗

NASA NTRS1990

Unsteady airloads due to separated flow on airfoils and wings

Edwards, John W.↗

NASA NTRS1996

Computational Analysis of Static and Dynamic Behaviour of Magnetic Suspensions and Magnetic Bearings

Static modelling of magnetic bearings is often carried out using magnetic circuit theory. This theory cannot easily include nonlinear effects such as magnetic saturation or the fringing of flux in air-gaps. Modern computational tools are able to accurately model complex magnetic bearing geometries, provided some care is exercised. In magnetic suspension applications, the magnetic fields are highly three-dimensional and require computational tools for the solution of most problems of interest. The dynamics of a magnetic bearing or magnetic suspension system can be strongly affected by eddy currents. Eddy currents are present whenever a time-varying magnetic flux penetrates a conducting medium. The direction of flow of the eddy current is such as to reduce the rate-of-change of flux. Analytic solutions for eddy currents are available for some simplified geometries, but complex geometries must be solved by computation. It is only in recent years that such computations have been considered truly practical. At NASA Langley Research Center, state-of-the-art finite-element computer codes, 'OPERA', 'TOSCA' and 'ELEKTRA' have recently been installed and applied to the magnetostatic and eddy current problems. This paper reviews results of theoretical analyses which suggest general forms of mathematical models for eddy currents, together with computational results. A simplified circuit-based eddy current model proposed appears to predict the observed trends in the case of large eddy current circuits in conducting non-magnetic material. A much more difficult case is seen to be that of eddy currents in magnetic material, or in non-magnetic material at higher frequencies, due to the lower skin depths. Even here, the dissipative behavior has been shown to yield at least somewhat to linear modelling. Magnetostatic and eddy current computations have been carried out relating to the Annular Suspension and Pointing System, a prototype for a space payload pointing and vibration isolation system, where the magnetic actuator geometry resembles a conventional magnetic bearing. Magnetostatic computations provide estimates of flux density within airgaps and the iron core material, fringing at the pole faces and the net force generated. Eddy current computations provide coil inductance, power dissipation and the phase lag in the magnetic field, all as functions of excitation frequency. Here, the dynamics of the magnetic bearings, notably the rise time of forces with changing currents, are found to be very strongly affected by eddy currents, even at quite low frequencies. Results are also compared to experimental measurements of the performance of a large-gap magnetic suspension system, the Large Angle Magnetic Suspension Test Fixture (LAMSTF). Eddy current effects are again shown to significantly affect the dynamics of the system. Some consideration is given to the ease and accuracy of computation, specifically relating to OPERA/TOSCA/ELEKTRA.

Britcher, Colin P.↗

NASA NTRS1986

Application of NCOREL to aircraft configurations

The NCOREL computer program and methodology (Grossman, 1979) modified for computation of flows over complex geometries is described. The newly introduced features include a more flexible grid-generation package, capable of generating grids for realistic wing-body cross sections, and a more general numerical method, developed for the capture of highly three-dimensional embedded, oblique shocks. In addition, an inlet capability is included, by means of which the cross section is allowed to change discontinuously with the addition of the inlet geometry. The new cross section is regridded and the potentials and their derivatives are interpolated for the marching to continue. Hence, a discontinuity in the grid or mappings is taken into account at the inlet station. The results of the flow-field computation for a realistic fighter configuration are discussed.

Siclari, M. J.↗

NASA NTRS1990

Effects of forebody geometry on subsonic boundary-layer stability

As part of an effort to develop computational techniques for design of natural laminar flow fuselages, a computational study was made of the effect of forebody geometry on laminar boundary layer stability on axisymmetric body shapes. The effects of nose radius on the stability of the incompressible laminar boundary layer was computationally investigated using linear stability theory for body length Reynolds numbers representative of small and medium-sized airplanes. The steepness of the pressure gradient and the value of the minimum pressure (both functions of fineness ratio) govern the stability of laminar flow possible on an axisymmetric body at a given Reynolds number. It was found that to keep the laminar boundary layer stable for extended lengths, it is important to have a small nose radius. However, nose shapes with extremely small nose radii produce large pressure peaks at off-design angles of attack and can produce vortices which would adversely affect transition.

Dodbele, Simha S.↗

DOE OSTI2025

Machining of Thin-Walled Structures From Stiffness-Driven Additively Manufactured Preform Geometry

Additive manufacturing provides the means to build component preforms with reduced excess material to create functional parts. In the case of aero-structural and aero-engine components, additive manufacturing technologies offer the possibility to substantially reduce the volume of material to be removed by machining operations. To achieve this objective, the preform must be built with the minimum material necessary to contain the final geometry and simultaneously provide enough stiffness to withstand the magnitude of the machining forces. This work describes a computationally efficient method to calculate the geometry required from the preform to reliably manufacture typical thin-walled structures via finish machining processes. This is achieved by defining the preform with near constant static stiffness across the width of the preform, in combination with a prescribed magnitude of stiffness at the top edge of the preform. The prescribed static stiffness is the function of the machining force magnitude, a direct consequence of the preselected cutting conditions. In conclusion, this article illustrates the application of the method to a straight single boundary thin-walled structure as an introduction case and for ease of description.

Additive manufacturing↗

NASA NTRSDate not supplied

Energy of Fluid (EOF) Simulation of Large-Scale Densification and Solidification of Hydrogen

The current research develops a finite volume-based Computation Fluid Dynamic (CFD) model utilizing an Energy of Fluid (EOF) approach to generate a simulation of the densification of liquid hydrogen (LH2) in the Integrated Refrigeration and Storage (IRAS) experimental tank for the Ground Operations Demonstration Unit for Liquid Hydrogen Project (GODU-LH2) at the Kennedy Space Center (KSC). The computational code will integrate a commercial software pressure-based model with User Defined Functions (UDF) generated and added to the model. The modified model will solve the energy equation in terms of internal energy and provide temperature and pressure calculations for a given tank geometry. This method will decrease computational time when compared to the built-in commercially available Enthalpy solvers. Currently the research focused on utilizing User Defined Scalars (UDS) compared to the enthalpy model and a lumped node analysis to show the written UDS is as accurate as the built-in solvers, and the models will be verified using known solutions for solidification and validated with the experimental results from the Cryogenics Test Laboratory (CTL) at KSC for the IRAS densification process.

C. Mahony↗

NASA NTRS1989

Optical distributed sensing and computation for a proposed flexible beam experiment

A new technology is being developed that supports distributed sensing and computation wherein crystal mediums are used with real-time holography to gather images that contain vibration and instantaneous geometry data for a spacecraft. Optical computation techniques are employed to process the image data and to compute commands to actuators located on the spacecraft. This paper presents an integrated sensor/processor design for an experiment to demonstrate this technology. A performance estimate for the design is presented in terms of the optical spatial bandwidth of the imaging system, as opposed to the temporal bandwidth. The advantages of an integrated optical sensor/processor relative to control of large spacecraft are addressed.

Welch, S. S.↗

DOE OSTI2020

Threadsafe Dynamic Neighbor Lists for Monte Carlo Ray Tracing

Monte Carlo (MC) transport codes offer high-fidelity modeling of particle transport physics, but their high computational cost makes them impractical for many applications. For some applications such as multiphysics and depletion that use finely discretized geometries, a large portion of this computational cost is attributable to ray tracing. Neighbor lists are a well-known method for accelerating ray-tracing calculations in a MC code, but despite their prevalence, little work has been published on the details of their implementation. The fine details can have a significant impact on performance, particularly when using shared-memory parallelism. This paper addresses these details of implementation with a discussion of different neighbor list schemes and their impact on software runtime. Performance tests were run by using OpenMC on a pin-cell problem discretized with up to 200 axial regions. The results demonstrate that switching from surface-based to cell-based neighbor lists leads to a 10 faster calculation rate for the most fine discretization. Finally, using a threadsafe shared-memory data structure results in a 20% faster calculation rate versus simple threadprivate neighbor lists. Results here show that a data structure that is contiguous in memory improves performance by only 1% to 2% over noncontiguous linked lists.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗