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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 523 records · Page 29
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Thermoviscoelastic modelling of high strain thin-ply composites by means of multiscale plate and beam model

High strain thin-ply (HS-TPC) technology is being increasingly adopted for high-performanceaerospace applications. Albeit many of these structures such as deployable booms can bemodeled as one-dimensional beam problems, there is a lack of themoviscoelastic beam mod-els to efficiently and accurately simulate HS-TPC. This work will use mechanics of struc-ture genome (MSG) to construct linear thermoviscoelastic beam models that can homogenizethree-dimensional heterogeneous materials made of constituents with time- and temperature-dependent behavior. The formulation derives the transient strain energy based on integralformulation for thermorheologically simple materials subject to finite temperature changeswith the restriction that the strain is small. A lenticular boom is used as a numerical exampleto verify the MSG-based linear thermoviscoelastic beam model against MSG-based shell/platemodel, which has already been validated against experimental data provided by NASA, anddirect numerical simulations performed in a finite element commercial package.

Orzuri Rique Garaizar↗
NASA NTRS2021

Molecular Dynamics Investigation of the Structural and Mechanical Properties of Off-Stoichiometric Epoxy Resins

Molecular dynamic (MD) simulations were performed to compute the mechanical properties of off-stoichiometric epoxy resins as a function of hardener/epoxy mixture ratio (r). Properties were characterized in relation to their microscopic structures. Such resins have been used recently for adhesive-free bonding of large-scale composite structures using the co-curing-ply method. In this process, two partially precured composite panels with hardener-poor (HP) off-stoichiometric resins are coupled with ply(ies) of complementary hardener-rich (HR) formulations and then cured simultaneously. This bonding process has the potential to produce reliable and certifiable composite joints without the need for additional fasteners, which are often required for many conventional bonding methods because even small amounts of contamination can cause a weak bond. The reflow and mixing of the HP/HR resin in this bonding process result in a joint with no discernable interface that should not be susceptible to surface contamination. However, incomplete mixing of the two offset resins may result in chemical heterogeneity of the cured polymeric joint. Thus, different r values may be obtained across the joint. Classical MD simulations were performed to compute the Young’s modulus of polymers with different r values and correlate their properties to network structures. High stiffness was associated with molecular packing due to chemical crosslinking, leading to a single network structure. Moreover, the networks became denser as the ratio approached the stoichiometric value r = 1. Thus, the r = 1 systems were single clusters, with high stiffness, high molecular weight, and a high degree of crosslinking. Structural properties such as radius of gyration and mean square displacement were determined to investigate the variation in the stiffness with respect to r. This MD simulation study was validated with experimental measurements.

Chang Woon Jang↗
NASA NTRS2020

Validation of Diffraction Models With Experimental Results From the Princeton Starshade Testbed

Starshades are a leading technology to detect and characterize Earth-like exoplanets. In this paper we report on optical experiments of sub-scale starshades that advance critical starlight suppression technologies in preparation for the next generation of space telescopes. These experiments were conducted at the Princeton starshade testbed, an 80 m long enclosure testing 1/1000th scale starshades at a ight-like Fresnel number. In this paper we summarize recent updates made to the starshade testbed and optical model. We present results from recent experiments testing two starshade masks with intentional perturbations built into their shape. One of the perturbed masks has three petals that are shifted radially outward by 7-11 microns and the other mask has two petals shifted radially outward plus two petal edge segments displaced from their nominal position. We show the model agrees with experiment to better than 25% accuracy. These results are placed into context with previous experiments on perturbed shapes and progress made towards satisfying a critical milestone in advancing starshade technology to TRL 5.

Galvin, Michael↗
NASA NTRS2022

Thermocouple Temperature Measurements in Selective Laser Melting Additive Manufacturing

The extreme thermal history resulting from selective laser melting leads to microstructural characteristics and residual stresses that have considerable impact on the mechanical behavior of the printed part. Accurate measurements of the temperature combined with thermal models are needed to better understand and control the thermal history to optimize mechanical properties. In order to calibrate and validate models, experimental temperature data must be accurately measured in a rapid fashion due to the high speeds of the laser. In this work, a novel method to read data from thermocouples is created with enhanced circuitry that achieves a sampling rate of 10 kHz. This data acquisition rate allows for high precision sampling of SLM heating and cooling cycles.

additive manufacturing↗
NASA NTRSDate not supplied

Validation of Thermodynamic Vent System Performance using Thermal Desktop

Cryogenic fluid management (CFM) for in-space propulsion systems is crucial to enabling future space missions. A means to control the pressure inside a propellant tank is necessary to prevent the venting of liquid propellant in microgravity environments. A thermodynamic vent system (TVS) is one way to regulate the pressure and temperature of the fluid inside a tank. A previous study created a simplified model of a TVS in a two-phase cryogenic heat exchanger. The TVS expands the working fluid across a Joule-Thomson (J-T) device and routes the cooled fluid through the heat exchanger to remove heat from the surrounding fluid. The model was able to predict the TVS heat extraction performance and was validated against experimental data using the same hardware. This study expands the model of the TVS into Thermal Desktop (TD) and recreates the results from both the original model and the experimental data. This new TD model has the potential to be used to predict TVS heat extraction performance in cryogenic propellant tanks for future space missions.

Cryogenic Fluid Management↗
NASA NTRSDate not supplied

Development and Validation of Two-Phase CFD Models for Key Elements of Propellant Tank CFM Operations in 1G and Microgravity –An Overview

This paper presents an overview of the state-of-the-art two-phase CFD models that have been developed for various propellant tank storage and transfer operations in 1g, partial gravity, and microgravity. The models are developed in the framework of the industry standard ANSYS/Fluent CFD code, the capabilities of which have been significantly enhanced and customized through the incorporation of unique submodels via User Defined Functions (UDF)s to satisfy the requirements of its intended variable gravity Cryogenic Fluid Management (CFM) applications. These models/submodels have been validated against experimental data that cross spatial scales, fluid types, and gravity levels in order to properly anchor the models’ physical and numerical fidelity. The CFM application/processes that have been modeled include tank self-pressurization, tank autogenous pressurization, tank pressure control using both subcooled jet mixing and droplet spray injection mechanisms, tank chilldown/filling, tank drainage, tank slosh for both volatile and non-volatile fluids. The strength and shortcomings of the two-phase models for each application are highlighted and discussed briefly.

Computational Fluid Dynamics↗
NASA NTRSDate not supplied

Finite Element Modeling of Plastic Deformation During Spin Forming of Aluminum 6061-O

Spin and flow forming are metal deformation techniques in which a disk or tube of material is radially thinned and axially lengthened over a rotating mandrel. A finite-element continuum model (FEM) based on commercial software (DEFORM®) was developed to determine the stress/strain distribution and damage accumulation in a flow-formed, near-net-shape part. Computational validation and experimental verification of the model was leveraged to assess the effectiveness of computer simulations. Quantitative comparisons between experimental and computational results show promise for applying a FEM to the flow forming process. Experimental failure locations correlated well with computed damage gradients, and there was good agreement between the measured and predicted roller forces during forming.

Elizabeth Urig↗
NASA NTRSDate not supplied

Development of an Optical Model for the MEDLI2 Radiometer

We present an optical model of the MEDLI2 radiometer, which was flown onboard the Mars 2020 vehicle during atmospheric entry on February 18, 2021. The proposed model takes into account the radiometer geometry and optical phenomena such as reflection, refraction, and absorption to estimate the signal loss inherent in the design of the radiometer. The model serves as a filter, which can be used to convert predicted total radiative heat fluxes on the radiometer window into predicted measured heat fluxes, enabling more accurate comparisons of the radiometer flight data with predicted radiometer measurements. Optical properties of the radiometer’s sapphire window are inferred from spectral transmissivity measurements. A modified Lorentz Oscillator Model is used to represent the dielectric function of the window and is fit to the transmission data. The resulting optical model of the radiometer is validated against experimental data used to measure the dependence of the radiometer output voltage on the incident angle of the light impinging on it. Comparison of predicted radiometer measurements with the MEDLI2 flight data show good agreement between the predicted and measured peak heat fluxes, though offset at different times. A linear increase in the signal loss due to radiometer optics alone is also demonstrated, suggesting that the changing shock angle over the course of the trajectory impacts the signal loss.

MEDLI2↗
NASA NTRSDate not supplied

Modeling of A Large-Scale Liquid Oxygen Propellant Transfer Test

Current planned NASA missions to the Moon and Mars involve the transfer of cryogenic propellants in orbit. Correctly predicting the flow rate during the propellant transfer operation could help with planning these operations. In lieu of expensive tests conducted on-orbit, accurate predictive computational models of these propellant transfer processes can be used to predict the propellant transfer flow rate. To gain confidence in these computational models, appropriate anchoring and validation to experimental data can be performed. Ground tests conducted at SpaceX involving the transfer of liquid oxygen were carried out to investigate the effect of the thermodynamic conditions including inlet pressure and temperature and downstream pressure on the flow rate. The results from the test were compared against flow rate predictions from a commercially available two-phase flow software. On average the model predicted the flow rates within 10% of the experimentally observed flow rates for the full range of thermodynamic inlet and outlet conditions.

Daniel Hauser↗
NASA NTRSDate not supplied

Optimizing the Electroforming Process to Enhance the Thickness Uniformity of Full Shell X-Ray Optics

Electroforming replication technology at Marshall Space Flight Center has a long heritage of producing highquality full-shell X-ray mirrors for various applications. Nickel alloys are electroformed onto a super-polished mandrel in the electroforming process, then separated to form the replicated full-shell optic. Various parameters in the electroplating configuration could result in the nonuniformity of the shell’s thickness. Thickness nonuniformities primarily occur due to non-uniform electric field distributions in the electroforming tank during the deposition. Using COMSOL Multiphysics simulations, we have studied the electric field distributions during the deposition process. Using these studies, we have optimized the electric fields inside the tank using customized shields and insulating gaskets on the mandrel. These efforts reduced thickness non-uniformity from over 20% to under 5% percent. Improving the thickness uniformity of the shell aids in better mounting and alignment of shells in the optics module. Optimization of the electroforming process, in some cases, improved the optical performance of the shells. COMSOL optimizing of the electroforming process and the experimental results validating these simulations are presented in this article.

X-ray optics↗
NASA NTRS2023

Modeling and Mitigation of dv/dt and Transmission Line Effect for Motor Drive System in Electric Aircraft Propulsion

Due to constraints in space and structure as well as other practical limitations in aircraft system, the motor controller or electric motor are often installed far away from each other and interconnected via long cables. This amplifies the transmission line effect excited by the dv/dt PWM voltage and induces high voltage stress on the machine winding. This paper investigates the state-of-art modeling approaches for such systems, identifies several limitations in matching the tested voltage reflection waveform in terms of peak voltage, oscillation frequency and damping speed, and offers several key considerations not well covered in literature or in engineering practice. It then proposes a practical modeling methodology which, as validated by experimental results, truly captures these critical reflection voltage specs. To mitigate the high peak voltage and strong oscillation, dv/dt filter is applied and a parametric design optimization based on widely adopted LC-R topology is illustrated, which not only alleviates the voltage stress but also minimized the power loss of the passive damping resistor.

Inductor↗
NASA NTRSDate not supplied

Assessment of Coupling One-Dimension and Three-Dimension CFD in Conjugate Heat Transfer Modeling and Simulations for Cooling of Turbine Engine

The CHT (conjugate heat transfer) modeling and simulation work fits under a bigger area in the TTT (Transformational Tools and Technologies) project called “Cooling Tools and Technologies for Combustor and Turbine.” The existing validation data sets such as TTT GRC (Glenn Research Center) THX (Turbulent Heat FLUX) IV experiments will be used to assess the solid/fluid heat transfer development and validation. The experimental configuration was a subsonic convergent nozzle with a square exit blowing a heated exhaust over an effusion-cooled deck. The simulation solutions were obtained and compared to experimental measurements of the profiles of flow velocities and temperatures, as well as deck surface temperatures. Cooling air blowing ratios of 0, 1, and 2 were considered. The three-dimensional cooling tubes were modelled by the medial axis of the cylindrical geometries due to large length over width ratios. It represented a typical coupling of one-dimension and three-dimension simulations of conjugate heat transfer approaches. The surface temperatures on the solid surfaces and the profiles of velocities and temperatures near the surfaces compared to the experimental data were presented.

nonlinear sub-filter stresses↗
NASA NTRSDate not supplied

Surface Instability of Liquid Propellants in Microgravity During Pulsed Settling Operations

Pulsing reaction control system (RCS) thrusters, vent valves, or other propulsion devices can preserve propellant resources in space, but this operation also effectively introduces a vibration to the vehicle. When the vibration is perpendicular to the liquid propellant surface, Faraday waves may be generated at the liquid-vapor interface. These Faraday instabilities can perturb or break up the liquid surface of cryogenic tanks, leading to inefficiencies in thermal management or even ullage collapse. Drawing from theory and experiments, an engineering model defining the allowable design regions for pulsed settling in microgravity was assembled and verified with computational fluid dynamics (CFD) simulations. A traditional settling metric, the Bond number, was also overlaid in the model to indicate which duty cycles were insufficient to overcome surface tension and aggregate propellant. Mission planners and engineers can consult the tool to rapidly evaluate the stability of a liquid-vapor interface given the pulse frequency and the excitation acceleration. Expressions developed for Faraday waves induced by a sinusoidal forcing input at standard gravity were found to provide excellent predictive capabilities for pulsed, or rectangular, waveforms in the absence of a consistent gravitational acceleration. This study extends the usage of these equations to an alternative forcing function and microgravity environments for the purpose of estimating natural frequencies, surface mode shapes, surface wave amplitudes, and the onset of droplet ejection. CFD simulations with the Loci/STREAM-VoF (Volume of Fluid) solver were initially validated against experimental results in standard gravity. Discrete points on the design map were then investigated with CFD and confirmed that the engineering model reliably indicates surface stability and most Faraday wave characteristics without requiring higher-fidelity tools. The engineering model is highly extensible and can be adapted for various propellant fill fractions, fluid properties, and tank sizes.

Faraday Waves↗
NASA NTRSDate not supplied

Surface Instability of Liquid Propellants in Microgravity During Pulsed Settling Operations

Pulsing reaction control system (RCS) thrusters, vent valves, or other propulsion devices can preserve propellant resources in space, but this operation also effectively introduces a vibration to the vehicle. When the vibration is perpendicular to the liquid propellant surface, Faraday waves may be generated at the liquid-vapor interface. These Faraday instabilities can perturb or break up the liquid surface of cryogenic tanks, leading to inefficiencies in thermal management or even ullage collapse. Drawing from theory and experiments, an engineering model defining the allowable design regions for pulsed settling in microgravity was assembled and verified with computational fluid dynamics (CFD) simulations. A traditional settling metric, the Bond number, was also overlaid in the model to indicate which duty cycles were insufficient to overcome surface tension and aggregate propellant. Mission planners and engineers can consult the tool to rapidly evaluate the stability of a liquid-vapor interface given the pulse frequency and the excitation acceleration. Expressions developed for Faraday waves induced by a sinusoidal forcing input at standard gravity were found to provide excellent predictive capabilities for pulsed, or rectangular, waveforms in the absence of a consistent gravitational acceleration. This study extends the usage of these equations to an alternative forcing function and microgravity environments for the purpose of estimating natural frequencies, surface mode shapes, surface wave amplitudes, and the onset of droplet ejection. CFD simulations with the Loci/STREAM-VoF (Volume of Fluid) solver were initially validated against experimental results in standard gravity. Discrete points on the design map were then investigated with CFD and confirmed that the engineering model reliably indicates surface stability and most Faraday wave characteristics without requiring higher-fidelity tools. The engineering model is highly extensible and can be adapted for various propellant fill fractions, fluid properties, and tank sizes.

Faraday Waves↗
NASA NTRS2024

Forced Response Aeromechanics Analysis in MATLAB®-Based Environment Code With Application to Distortion-Tolerant Fan R24 Blade Geometry

Researchers at the NASA Glenn Research Center have developed a research-level code for forced response analysis for turbomachinery that provides a streamlined framework for aeromechanics analysis, as well as for generating Goodman diagrams. The Forced Response Aeromechanics Analysis in a MATLAB-Based Environment (FRAAME, Version 1) code is designed to accept blade surface unsteady pressure time histories generated by three-dimensional (3D) Unsteady Reynolds-Averaged Navier-Stokes (URANS) code TURBO and modal displacements, modal stresses, and static stresses generated via expanded ANSYS® (Ansys, Inc.) cyclic symmetry analysis. The code’s looping structure allows for largescale analyses, including many blade surface pressure files, modal displacements, and modal stress files for full annulus forced response analysis, including a modal summation method for multiple engine orders and modes. This code is applied to the R24 fan geometry for the Boundary Layer Ingesting Inlet/Distortion-Tolerant Fan (BLI2DTF) project, a propulsion system being developed to increase the fuel efficiency of future aircraft, to serve as validation of experimental data as well as external simulation results. This tool’s functional, modular form is intended to allow users to make modifications easily. Those modifications can include requests for information for any step in the analysis process, as well as adding various functions to compute additional information of interest. It is also written, given sufficient input information, as a general blade geometry forced response solver that is not necessarily specific to the R24 geometry but is used here for verification of code functionality and accuracy. Although forced response analysis tools are also available in commercially available code packages, the post-processing FRAAME code offers reliable, fast, and scalable forced response analysis and Goodman diagram generation for large cases utilizing, specifically, TURBO and ANSYS® results information in an effort to streamline forced response and high cycle fatigue analyses.

Aeromechanics↗
NASA NTRSDate not supplied

Diffraction by Sharp Edges of Noncanonical Shape with Mean Flow and Surface Impedance

This paper presents a study on diffraction by sharp edges of noncanonical edge shape in the presence of mean flow and surface impedance, which are important features for aircraft noise but have not been accounted for in previous studies on sharp-edge diffraction. An analytical formula for the diffracted pressure is derived by applying asymptotic analysis to the integral representation of the total pressure scattered by a geometry that contains sharp edges. The asymptotic analysis is presented as a systematic process that can be carried out to any order, if needed. An illustration is given to use a higher-order result to eliminate the singularity in the first-order result to make the solution regular in the entire parameter domain. The formula for the diffracted pressure is validated by experimental data and is applied to parametric studies to reveal the effects of noncanonical edge shape, mean flow and surface impedance, as well as the impact of these effects on the total scattered pressure in the presence of other scattering components.

Yueping Guo↗
NASA NTRSDate not supplied

Gravity Offloading and Analysis of Long Imperfection-Sensitive Elements (GOALIE)

Use of large-scale deployable structures (e.g., iROSA) can enable space exploration and science missions (e.g., ACS3, Solar Cruiser). Numerical models predicting behavior of deployable structures in microgravity are difficult to validate because ground testing of long, slender, and flexible booms is challenging due to the influence of Earth’s gravity. The GOALIE team is collecting data for model validation through experimental testing to increase confidence in numerical models. Redwire, Inc. provided a subscale (7 m) and a full-scale (30 m) Triangular, Rollable, and Collapsible (TRAC) boom to use for test development. Other boom designs may be tested in the future.

Composites↗
NASA NTRSDate not supplied

Validation of a Two-Phase CFD Model for Autogenous Pressurization and Expulsion

This paper presents a two-phase computational fluid dynamics (CFD) model for simulating autogenous pressurization and expulsion in a cryogenic liquid hydrogen storage tank, utilizing a volume-of-fluid (VOF) approach combined with the kinetics-based Schrage equation to accurately capture the phase boundary and interfacial heat, mass, and momentum transfer between liquid and vapor phases. The model is validated against experimental data from NASA's K-site tank facility, specifically experimental case 225, which involved pressurization and controlled expulsion of liquid hydrogen. Various turbulence models are evaluated to assess their influence on model accuracy. The CFD simulations successfully replicate key thermodynamic behaviors observed during the experiments, including pressure evolution, temperature profiles, and phase-change dynamics at the vapor-liquid interface. The predicted tank pressures, temperatures, and pressurant requirements agree with experimental data, with pressurant mass predictions within 16\% of observed values. This study highlights the importance of selecting appropriate turbulence models to accurately simulate complex flow and heat transfer phenomena during tank pressurization and expulsion. By enhancing the accuracy and reliability of CFD models for liquid hydrogen under cryogenic conditions, this research contributes to developing efficient cryogenic propellant management strategies for future space missions.

Computational Fluid Dynamics↗