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All sources NASA NTRS DOE OSTI

NASA NTRSDate not supplied

Design and Testing of the BionicWingSat in a Zero-g Flight Campaign - A 2U-CubeSat with Deployable, Biologically-Inspired Wings

In this paper, recent developments in the design, manufacturing, and testing of a novel deployable structure with several potential applications in space will be described. Through a cooperative effort of the German Aerospace Center (DLR) and the National Aeronautics and Space Administration (NASA), a biologically inspired structurally integrated membrane featuring distributed functional elements has been developed and tested in a 2U CubeSat called BionicWingSat. Such a membrane structure could be useful for several applications in which a relatively flat area is desirable such as solar sails, drag sails, or solar shades. For SmallSats and CubeSats, the design proposed also has the desirable property of being self-deploying without the need for powered deployment mechanisms. Building on previous work inspired by the wings of earwigs, the research presented in this paper includes structural design of self-deploying hinges, a survey of various advanced additive layer manufacturing (ALM) methods for making hinges, mechanical characterization of the hinges, and finite element analysis (FEA) of the hinges. In this work, the conflicting goals of maximizing deployed structural stiffness, maximizing deployed area, maximizing stowed packaging efficiency, and maximizing resistance to creep when stowed must be considered. The resulting design concept is a gossamer structure that cannot support its own weight in gravity. For this reason, a focus in this paper is on a parabolic flight test campaign in which 24 fully integrated wings on two BionicWingSats were tested in a microgravity environment. From this test campaign, several lessons were learned regarding the wing design and procedures for carrying out microgravity tests of this manner.

CubeSat↗

NASA NTRS2022

Calculation of Transformer Leakage Inductance by Simplified Flux Path Geometries

Series inductance is a critical energy storage element in isolated power converters. Many have explored methods of estimating the total leakage inductance of transformers as an integrated series inductance without external inductors. However, this poses challenges with medium frequency converters and magnetic ribbon-based cores, e.g., metal amorphous nanocrystalline. The material’s relatively high conductivity allows eddy currents to develop when magnetic flux intersects wide surfaces. These eddy currents result in significant additional losses that increase with increasing power flow. This paper presents a simplified and accurate method of estimating leakage flux while identifying separate leakage flux paths that correlate with the magnetic material surfaces. This enables an understanding the proportion of leakage flux that will contribute to extra losses. The methods presented are applicable to both leakage and fringing (around heterogeneous material interfaces) fluxes. This paper includes detailed FEA studies and 3D flux vector measurements matching the presented analytical models.

transformer↗

NASA NTRS2023

A Hybrid Transfer Function Procedure for Broadband Auralization Within Small Flight Vehicle Interiors

Auralization of the sound fields within flight vehicle interiors is of interest to aircraft designers considering crew and passenger ride quality. Computer models can be used to predict the filtering effects that the fuselage structure and interior volume have on the exterior sound field in order to simulate the resulting cabin interior noise. However, this can become expensive when a wide frequency range of analysis suitable for passenger auralization is desired. This is particularly the case when using deterministic modeling methods such as finite element analysis (FEA) wherein prohibitively high levels of detail and finite element discretizations are required to resolve the wavelengths at high frequencies. On the contrary, Statistical Energy Analysis (SEA), while not capturing important modal behaviors at low frequencies, is better suited for higher frequency analyses where structural and interior dynamics exhibit high modal overlap and spatially averaged physical quantities suffice. For this reason, a hybrid procedure is considered here that utilizes FE modal solutions at lower frequencies and SEA results at higher frequencies. A transfer function dataset containing the exterior to interior vibroacoustic filtering effect is calculated accordingly and subsequently stored to be used for a variety of exterior dynamic load cases. At low frequencies, the transfer function dataset detail is related to the level of FE model refinement whereas at high frequencies it functions as an equalizer array with a level of detail corresponding to the SEA subsystem partitioning scheme. The above procedure is described herein and demonstrated on a six passenger flight vehicle with eight propulsors in a hover flight condition.

auralization↗

NASA NTRS2023

A Hybrid Transfer Function Procedure for Broadband Auralization Within Small Flight Vehicle Interiors

auralization↗

NASA NTRSDate not supplied

Design and Analysis of Shape Memory Spring Tires for Martian and Lunar Rover Vehicles

Shape memory alloys (SMAs) have played an important role in various innovative engineering and medical applications, such as aerospace actuators, vibration damping devices, and coronary stents. In applications, shape memory alloys are commonly utilized in two fundamentally different ways: (i) making use of the superelasticity/ pseudoelasticity (SE/PE) phenomena, as in applications in biomedical engineering, and (ii) taking advantages of the shape memory effect (SME), as is used for actuators. Their ability to act in such vastly different capacities is mainly due to their unique capability to recover large amounts of deformation produced by either applied stresses or temperature changes. One recent emerging application in use of SMAs has been in the area of non-pneumatic tire designs for Martian or Lunar roving vehicles. These vehicles require tires that are capable of traversing rugged terrain while withstanding extreme temperatures and atmospheric conditions. Inspired by the flexible wire mesh tires used on three Lunar Roving Vehicle (LRV) missions to the Moon on Apollo 15, 16, and 17, a new compliant tire technology was developed by the NASA Glenn Research Center (GRC) and Goodyear Tire & Rubber, known as the Spring Tire. The Spring Tire consists of several hundred coiled springs woven into a flexible mesh and formed into the shape of a tire. Like the LRV wire mesh tires, the original Spring Tires were made from spring steel and were prone to permanent deformation when undergoing high localized loads. Later, a new iteration of this technology was invented, known as the ‘Superelastic Tire’. This new technology incorporated the use of superelastic SMA springs, which could effectively undergo approximately 30 times more reversible deformation than the steel spring. It also provided even greater durability and allowed for more flexibility in design, such as the use of other structural forms to reduce mass or increase load carrying capacity. Because of the unique nature of both the SMA material and the complex interactions between the springs, designing Spring Tires for a specific application requires extensive effort. Historically, design decisions have relied on full-scale empirical testing; however, this is very expensive and time consuming, especially when multiple iterations are needed. Therefore, developing a large-scale, robust, and predictive numerical model entailing complex spring interactions and the shape memory material behavior within a tire construct is the first essential step towards a successful design program. The current work focuses on implementation of the user-defined Shape Memory Alloy (SMA) model, otherwise known as SMA-GVIPs, in the Finite Element analysis (FEA) program ABAQUS for large-scale simulations of the GRC-developed Spring Tires made of SMA. The novelty of this work lies in the thorough, detail-oriented, and computationally efficient finite element analysis of full-scale SMA tires. A well-thought material characterization plan followed by model validation and a systemic sensitivity study on SMA tires has never been reported in the previous literature. The main objective of this study is to help the team improve and optimize the structural design of the SMA tires through in-depth numerical analysis and sensitivity studies. Various design variables (wire diameter, coil diameter, pitch, bead angle, and number of springs) were varied to study their influence on the global load-displacement response of the tire construct. A detailed investigation of the three-dimensional stress states was also carried out to enhance our understanding of the local changes as the tire goes through global deformation. It was concluded that a robust numerical model with a good predictive capability, together with a thoughtfully crafted sensitivity study can result in improved design iterations required to reach a desired tire performance while, significantly reducing manufacturing, labor and testing expenses. A summary of the Finite Element (FE) model construction will be presented together with a description of the user-defined SMA model, characterization process, experimental results, model validation, and numerical sensitivity study results.

shape memory alloys↗

NASA NTRS2023

Elastic Modulus Testing for TriTruss Struts

The TriTruss is a novel structural module developed by researchers at NASA Langley Research Center (LaRC) that can be used in space to assemble large backing structures for a variety of applications. One such application is the metering truss and primary mirror backbone support structure of an in-space assembled telescope(iSAT). For the iSAT application, the TriTruss will be supporting mirror segments, payloads, and instruments, all of which require the TriTruss to have robust structural integrity. An accurate elastic modulus value is crucial to the finite element analysis(FEA) of the structure. Initial testing indicated that the equivalent elastic modulus provided by the manufacturer and used in the analyses did not accurately predict the behavior of the structure. In this paper, the in-house testing method developed at LaRC to accurately measure the equivalent elastic modulus of the composite struts for use in the analyses is described. A tensile and compressive equivalent elastic modulus was computed from the data obtained in this test. The testing resulted in a tensile equivalent elastic modulus of 24.6 Msi (standard deviation of 0.888 Msi) or 169 GPa (standard deviation of 6.20 GPa) and a compressive equivalent elastic modulus of 22.8 Msi (standard deviation of 0.780 Msi) or 157 GPa(standard deviation of 5.38 GPa) for the single wall thickness struts. For double wall thickness struts, the testing resulted in a tensile equivalent elastic modulus of32.1 Msi (standard deviation of 1.003 Msi) or 221 GPa (standard deviation of 6.91GPa) and a compressive equivalent elastic modulus of 31.9 Msi (standard deviation of 1.123) or 220 GPa (standard deviation of 7.74 GPa).1

TriTruss↗

NASA NTRSDate not supplied

Multiscale Prediction of Yarn Pullout Failure Mode in Unreinforced Textile Fabrics

Unreinforced woven fabrics have been implemented in a variety of high performance applications, including body armor, deployable structures, and as the reinforcement material in composites. Multiscale modeling techniques have significantly improved the capabilities of simulation-based tools to capture fabric mechanics efficiently and accurately, but often lack in their prediction of failure and require pairing with finite element analysis (FEA) software, limiting their application to the design of ‘fit-for-purpose’ materials. NASA’s Multiscale Analysis Tool (NASMAT) is a standalone multiscale program that has been traditionally used in the analysis of reinforced composites materials. More recently, it has been amended to simulate unreinforced fabric behavior by allowing the geometric state of the tows to change with applied loading due to the lack of a reinforcement material, such as the matrix seen in composites. Previous work has shown the ability of NASMAT to capture nonlinear macroscale behavior by predicting geometric changes in the state of each subcell as a function of the applied loading and allowing each subcell in the analysis to rotate according to these predicted changes, as well as predict nonlinear behavior due to the fiber breakage failure mode. In this work, the capability of predicting the onset and propagation of failure in plain woven fabrics in NASMAT is presented for the yarn pullout failure mode, which occurs when a fabric is loaded at an off-axis angle relative to the warp of weft tow direction. Yarn pullout behavior is initiated by determining the applied load in which the shear resistance of the contact area between yarn families is overcome. When failure is initiated, yarn pullout is determined to have occurred when the applied displacement, calculated from global strain, exceeds the deformed position of a given contact points between yarn families, determined from pin-joint kinematics. Contact points where pullout has occurred contribute to a global damage parameter used to modify the homogenized stiffness of the fabric, resulting in nonlinear behavior observed at the macroscale. The off-axis loading behavior and yarn pullout failure theory have been developed and implemented into NASMAT such that users can simulate off-axis tensile behavior of fabrics in a single, standalone multiscale tool. Simulations are compared to uniaxial tensile tests at various off-axis angles to demonstrate the capability of the tool in its prediction of both the onset of failure at each off-axis angles and the stress-strain behavior as failure progresses.

Materials↗

NASA NTRSDate not supplied

LS-DYNA User-Defined Internal Ballistic Modeling

- LS-DYNA Explicit Finite Element Analysis software and CADPROG Internal Ballistic Analysis code are integrated as a single modeling tool to analyze pyro-mechanical devices. - Combining these two codes allows the ballistic calculations to be performed without modeling the propellant in an FEA mesh. At each LS-DYNA time step, CADPROG is analytically run using the kinematic data (stroke, velocity, chamber volume) fed back from the LS-DYNA simulation. Calculated pressure is then applied to a piston or any applicable surface mesh in LS-DYNA model interactively. -All external loads such as friction, damping loads, assisting/resisting loads, locking/unlocking loads are modeled in LS-DYNA and coupled with pressure loads from CADPROG to create a fully defined equation of motion -Both codes are written in Fortran 77. CADPROG is inserted in LS-DYNA source code as a user-defined subroutine and re-compiled to generate a custom executable.

pyrotechnics↗

NASA NTRS2014

NASA Engineering and Safety Center Technical Bulletin No. 14-03: COPV Mechanical Model Validation

Global and local deformation measurements should be incorporated into the composite overwrapped pressure vessel (COPV) design and analysis process to allow correlation of these measurements with finite element analysis (FEA) models. This correlation improves understanding of liner, liner/overwrap interface, and composite deformation response in COPVs. The improved accuracy reduces error in subsequent analyses, such as fracture, fatigue, and stress rupture that are critical for COPV qualification.

Composite Overwrap Pressure Vehicle↗

NASA NTRSDate not supplied

LS-DYNA User-Defined Internal Ballistic Modeling

LS-DYNA Explicit Finite Element Analysis software and CADPROG Internal Ballistic Analysis code are integrated as a single modeling tool to analyze pyro-mechanical devices. Coupling these two codes allows the ballistic calculations to be performed without modeling the propellant in an FEA mesh. At each LS-DYNA time step, CADPROG is run analytically using the kinematic data (stroke, velocity, chamber volume) fed back from the LS-DYNA simulation. The calculated pressure is then applied to a piston or any applicable surface mesh in LS-DYNA model interactively. All external loads such as friction, damping loads, assisting/resisting loads, locking/unlocking loads are modeled in LS-DYNA and coupled with pressure loads from CADPROG to create a fully defined equation of motion Both codes are written in Fortran 77. CADPROG is integrated in the LS-DYNA source code as a user-defined subroutine and recompiled to generate a custom executable.

pyrotechnics↗

NASA NTRSDate not supplied

Mass Estimation Relationship for Conceptual Design of Blended-Wing-Body Cabin with Advanced Structures

Blended-Wing-Body (BWB) aircraft concepts achieve higher lift-to-drag ratios (L/D) than conventional tube and wing aircraft due to aerodynamic shaping of the non-circular pressure vessel that is made feasible using advanced composite technologies such as Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS). Due to the relatively new nature of the BWB configuration, sufficient historical data is not readily available for conceptual aircraft designers to base their structural weight estimations on, especially for estimating weights of the pressurized cabin center body. This paper describes a general parametric Mass Estimation Relationship (MER) based on high fidelity Finite Element Analysis (FEA) using PRSEUS for conceptual weight estimation of a BWB pressurized cabin structure that includes cabin area, center body sweep, fineness ratio, span ratio, and take-off gross weight as parametric design variables.

PRSEUS↗

NASA NTRSDate not supplied

Mass Estimation Relationship for Conceptual Design of Blended-Wing-Body Cabin with Advanced Structures

BWB↗

DOE OSTI2020

Sensitivity Analysis of Compensation Topologies for Dynamic WPT System

The dynamic wireless power transfer (DWPT) or in-motion charging of electric vehicles (EVs) may alleviate the challenges encountered by the plug-in charging systems and assist in the penetration of the EVs at a larger scale. Similar to its stationary charging counterpart, DPWT also makes use of compensation circuits to reduce the inductive reactance for enabling higher current on the coupler winding and improve the power transfer. However, the behavior of compensation circuits has not been comprehensively analyzed in a DWPT system. This paper analyzes in detail the performance of three compensation topologies applied to the DWPT system. A combination of finite element analysis (FEA) and circuit analysis is employed to study the compensation topologies when the receiving coil moves over the transmitting coil. Moreover, the variations in operating frequency have also been considered in the analysis. Furthermore, the theoretical calculations for the dynamic WPT system are verified using PLECS simulation model.

Haruna, Josiah↗

DOE OSTI2020

Integrated Traction Drive Thermal Management: Keystone Project 3

The presentation was developed for the U.S. Department of Energy (DOE) Vehicle Technologies Program 2020 Annual Merit Review and Peer Evaluation Meeting. It reports on progress and accomplishments of DOE funded Integrated Traction Drive Thermal Management project. Highlighted are NREL's research accomplishments during FY 2020. Challenges associated with thermal management of integrated traction drives for electric vehicles arise due to the limited packaging space, coolant distribution, electrical connections, and ambient temperatures. For this project at NREL, research focuses on enabling thermal management technologies to support a modular, compact, self-contained integrated electric drive unit with motor and power electronics. Integration approaches, based on packaging location and coolant options for power electronics integrated with candidate motor technologies to reduce cables and connectors, are reviewed and compared using finite element analysis (FEA) tools. Automatic transmission fluid (ATF) jet impingement cooling characterization is carried out experimentally (measuring heat transfer coefficients) and using computational fluid dynamics (CFD) modeling.

47 OTHER INSTRUMENTATION↗

DOE OSTI2020

Software-Defined Ultrasonic Communication System Based on Time-reversal Signal Processing

Ultrasonic communication through solid channels suffers from channel dispersion, attenuation, and multipath effect. For example, in elbow shape pipes or complex structures, the elastic waves are reflected and reverberated in multipath resulting in a major dispersion of the signals. In solid channels such as flat bar, multipath propagation is the main reason for bit-wavelet spreading and intersymbol interference (ISI). The conventional modulation method like OOK (on-off-keying) or PSK (phase-shift-keying) fails to provide a useful Signal-to-Noise Ratio (SNR). Time-reversal (TR) signal processing method is a promising technique that can compress the spreading of the bit-wavelet and strengthen the peak signal energy on the receiver. In this study, Finite Element Analysis (FEA) using ABAQUS software tools is used to characterize the bit-wavelet spreading effect caused by dispersive communication channels. Also, this study presents the impact of TR ultrasonic communication as a function of excitation pulse width, channel length, and carrier frequency through a flat-bar channel. A Software-Defined System-on-Chip (SD-SoC) platform is examined as a viable solution for the low-complexity and energy-efficient ultrasonic communication system. The proposed TR based SD-SoC ultrasonic communication system can make full use of signal dispersion for peak performance by minimizing the ISI within a dispersive and reverberant metal channel.

FEM simulation↗

DOE OSTI2021

Design Optimization of A-Type Heat Exchangers based on High Performance, Non-Round Tubes

Air-to-refrigerant heat exchangers (HXs) have been the topic of considerable research as they are the fundamental heat transfer components of HVAC&R systems. For residential and commercial applications, indoor heat exchangers are often in A-type configurations to reduce air-conditioner system footprint while still delivering the required cooling or heating. Classical HX design practices typically assume a uniform frontal air velocity profile to facilitate the use of conventional tube-fin airside heat transfer and pressure drop correlations for performance prediction. However, it is well-reported throughout the literature that A-type HXs experience significant airflow maldistribution which can severely degrade HX performance. Additionally, recent advancements in simulation software such as Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA) and optimization algorithms have led researchers to consider primary heat transfer surface optimization to achieve highly compact HXs which do not require fins. In this paper, an A-type HX which utilizes shape-optimized non-round tubes is optimized for minimum duct size and airside pressure drop. This is achieved through coupling of an experimentally validated finite volume HX model with automated 2D CFD simulations of airflow through the HX for airside thermal-hydraulic performance evaluation. Preliminary results show that the optimal designs deliver similar capacity while achieving 20% reductions in airside pressure drop and duct cross-section area. Additionally, the optimal design apex angles in this study were similar to those from previous A-Type HX optimization studies for conventional tube-fin HX geometries, suggesting that the apex angle for optimal A-Type configuration performance may be independent of tube geometry.

42 ENGINEERING↗

DOE OSTI2022

DEFECT DETECTION USING DYNAMIC ANALYSIS FOR ADDITIVE MANUFACTURED METALS

Additive manufacturing (AM) has the ability to produce parts with complex geometries and internal features, however, for demanding applications such as the automotive and aerospace industries, it is crucial that the parts can meet the demanding functional and geometric requirements. Quality control for AM parts focuses on nondestructive methods of testing, but many of the current methods are expensive and time-consuming. The research presented in this report explores various methods of nondestructive evaluation (NDE) using dynamic analysis on stainless steel parts produced with selective laser melting (SLM). Methods include, but are not limited to, frequency response functions (FRF), impedance-based measurements, and scanning laser doppler vibrometry. Additionally, mode shape analysis was performed in MATLAB and FEA simulations were used for comparison with experimental results. The results indicate that dynamic analysis has the potential to be a feasible method of defect detection and NDE in AM parts and future work should focus on refining these methods, such as optimizing test parameters to improve sensitivity to defects.

Deonarain, Gita↗

DOE OSTI2022

Characterization of anisotropic mechanical properties of polymer composites from a hybrid additive manufacturing-compression molding process using x-ray computer tomography

In this study, anisotropic stiffness tensors were reconstructed based on fiber orientation distributions obtained from X-ray computer tomography (xCT). A preform was manufactured via a big area additive manufacturing (BAAM) system with carbon fiber (CF) filled acrylonitrile butadiene styrene (ABS). The tailored preform from additive manufacturing (AM) was used in the compression molding (CM) process to produce a low-void high-performance thermoplastic composite panel. An xCT technique was employed to detect the fiber orientations in CF/ABS composites manufactured via three different methods: AM from BAAM, extrusion compression molding (ECM), and AM-CM. The anisotropic stiffness tensor was obtained from the composite panel manufactured via the three manufacturing methods (AM, ECM, and AMCM). A micromechanics theory was used to obtain the orthotropic stiffness tensors of the composite panels and compared with the experimental values. The predicted stiffness tensors of AM and AM-CM composite panels were used to study the deformation characteristics of a steering wheel during airbag deployment by performing finite element analysis (FEA). The approach developed in this study can be utilized for evaluating high-performance composites.

Pokkalla, Deepak↗