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At least 613 records · Page 34

All sources NASA NTRS DOE OSTI

NASA NTRS2008

Effect of Weld Tool Geometry on Friction Stir Welded AA2219-T87 Properties

In this study, flat panels of AA2219-T87 were friction stir welded (FSWed) using weld tools with tapered pins The three pin geometries of the weld tools included: 0 (straight cylinder), 30 , and 60 angles on the frustum. For each weld tool geometry, the FSW process parameters were optimized to eliminate defects. A constant heat input was maintained while varying the process parameters of spindle rpm and travel speed. This provided a constant heat input for each FSW weld panel while altering the hot working conditions imparted to the workpiece. The resulting mechanical properties were evaluated from tensile test results of the FSW joint.

Querin, Joseph A.↗

NASA NTRS2008

Effect of Weld Tool Geometry on Friction Stir Welded Ti-6Al-4V

In this study, flat 0.250" thick Ti-6Al-4V panels were friction stir welded (FSWed) using weld tools with tapered pins. The five different pin geometries of the weld tools included: 0 degree (straight cylinder), 15 degree, 30 degree, 45 degree, and 60 degree angles on the frustum. All weld tools had a smooth 7 degree concave shoulder and were made from microwave sintered tungsten carbide. For each weld tool geometry, the FSW process parameters were optimized to eliminate internal defects. All the welds were produced in position control with a 2.5 degree lead angle using a butt joint configuration for the panels. The process parameters of spindle rpm and travel speed were varied, altering the hot working conditions imparted to the workpiece. Load cells on the FSWing machine allowed for the torque, the plunge force, and the plow force to be recorded during welding. Resulting mechanical properties were evaluated from tensile tests results of the FSWjoints. Variations in the material flow were investigated by use of microstructural analysis including optical microscopy (OM), scanning electron microscopy (SEM), and orientation image mapping (aIM).

Querin, Joseph A.↗

NASA NTRS2007

Self-Advancing Step-Tap Drills

Self-advancing tool bits that are hybrids of drills and stepped taps make it possible to form threaded holes wider than about 1/2 in. (about 13 mm) without applying any more axial force than is necessary for forming narrower pilot holes. These self-advancing stepped-tap drills were invented for use by space-suited astronauts performing repairs on reinforced carbon/carbon space-shuttle leading edges during space walks, in which the ability to apply axial drilling forces is severely limited. Self-advancing stepped-tap drills could also be used on Earth for making wide holes without applying large axial forces. A self-advancing stepped-tap drill (see figure) includes several sections having progressively larger diameters, typically in increments between 0.030 and 0.060 in. (between about 0.8 and about 1.5 mm). The tip section, which is the narrowest, is a pilot drill bit that typically has a diameter between 1/8 and 3/16 in. (between about 3.2 and about 4.8 mm). The length of the pilot-drill section is chosen, according to the thickness of the object to be drilled and tapped, so that the pilot hole is completed before engagement of the first tap section. Provided that the cutting-edge geometry of the drill bit is optimized for the material to be drilled, only a relatively small axial force [typically of the order of a few pounds (of the order of 10 newtons)] must be applied during drilling of the pilot hole. Once the first tap section engages the pilot hole, it is no longer necessary for the drill operator to apply axial force: the thread engagement between the tap and the workpiece provides the axial force to advance the tool bit. Like the pilot-drill section, each tap section must be long enough to complete its hole before engagement of the next, slightly wider tap section. The precise values of the increments in diameter, the thread pitch, the rake angle of the tap cutting edge, and other geometric parameters of the tap sections must be chosen, in consideration of the workpiece material and thickness, to prevent stripping of threads during the drilling/tapping operation. A stop-lip or shoulder at the shank end of the widest tap section prevents further passage of the tool bit through the hole.

Pettit, Donald R.↗

NASA NTRS2011

Euclid Mission: Mapping the Geometry of the Dark Universe. Mission and Consortium Status

Euclid concept: (1) High-precision survey mission to map the geometry of the Dark Universe (2) Optimized for two complementary cosmological probes: (2a) Weak Gravitational Lensing (2b) Baryonic Acoustic Oscillations (2c) Additional probes: clusters, redshift space distortions, ISW (3) Full extragalactic sky survey with 1.2m telescope at L2: (3a) Imaging: (3a-1) High precision imaging at visible wavelengths (3a-2) Photometry/Imaging in the near-infrared (3b) Near Infrared Spectroscopy (4) Synergy with ground based surveys (5) Legacy science for a wide range of in astronomy

dark energy↗

NASA NTRS2012

Geometric Reasoning for Automated Planning

An important aspect of mission planning for NASA s operation of the International Space Station is the allocation and management of space for supplies and equipment. The Stowage, Configuration Analysis, and Operations Planning teams collaborate to perform the bulk of that planning. A Geometric Reasoning Engine is developed in a way that can be shared by the teams to optimize item placement in the context of crew planning. The ISS crew spends (at the time of this writing) a third or more of their time moving supplies and equipment around. Better logistical support and optimized packing could make a significant impact on operational efficiency of the ISS. Currently, computational geometry and motion planning do not focus specifically on the optimized orientation and placement of 3D objects based on multiple distance and containment preferences and constraints. The software performs reasoning about the manipulation of 3D solid models in order to maximize an objective function based on distance. It optimizes for 3D orientation and placement. Spatial placement optimization is a general problem and can be applied to object packing or asset relocation.

Clement, Bradley J.↗

NASA NTRS2013

Advances in SiC/SiC Composites for Aero-Propulsion

In the last decade, considerable progress has been made in the development and application of ceramic matrix composites consisting of silicon carbide (SiC) based matrices reinforced by small-diameter continuous-length SiC-based fibers. For example, these SiC/SiC composites are now in the early stages of implementation into hot-section components of civil aero-propulsion gas turbine engines, where in comparison to current metallic components they offer multiple advantages due to their lighter weight and higher temperature structural capability. For current production-ready SiC/SiC, this temperature capability for long time structural applications is ~1250 degC, which is better than ~1100 degC for the best metallic superalloys. Foreseeing that even higher structural reliability and temperature capability would continue to increase the advantages of SiC/SiC composites, progress in recent years has also been made at NASA toward improving the properties of SiC/SiC composites by optimizing the various constituent materials and geometries within composite microstructures. The primary objective of this chapter is to detail this latter progress, both fundamentally and practically, with particular emphasis on recent advancements in the materials and processes for the fiber, fiber coating, fiber architecture, and matrix, and in the design methods for incorporating these constituents into SiC/SiC microstructures with improved thermo-structural performance.

DiCarlo, James A.↗

NASA NTRS2015

Full-Carpet Design of a Low-Boom Demonstrator Concept

The Cart3D adjoint-based design framework is used to mitigate the undesirable o -track sonic boom properties of a demonstrator concept designed for low-boom directly under the flight path. First, the requirements of a Cart3D design mesh are determined using a high-fidelity mesh adapted to minimize the discretization error of the CFD analysis. Low-boom equivalent area targets are then generated at the under-track and one off-track azimuthal position for the baseline configuration. The under-track target is generated using a trim- feasible low-boom target generation process, ensuring that the final design is not only low-boom, but also trimmed at the specified flight condition. The o -track equivalent area target is generated by minimizing the A-weighted loudness using an efficient adjoint-based approach. The configuration outer mold line is then parameterized and optimized to match the off-body pressure distributions prescribed by the low-boom targets. The numerical optimizer uses design gradients which are calculated using the Cart3D adjoint- based design capability. Optimization constraints are placed on the geometry to satisfy structural feasibility. The low-boom properties of the final design are verified using the adaptive meshing approach. This analysis quantifies the error associated with the CFD mesh that is used for design. Finally, an alternate mesh construction and target positioning approach offering greater computational efficiency is demonstrated and verified.

Ordaz, Irian↗

NASA NTRS2019

Materials and Processes for New Propulsion Systems with Reduced Environmental Impact

Aeronautics research at NASA Glenn Research Center includes development, characterization and modeling of high temperature, lightweight materials and fabrication processes for aircraft propulsion systems with increased efficiency and reduced emissions, fuel burn and noise. Current propulsion materials research includes Ceramic Matrix Composites and Environmental Barrier Coatings, Polymer Matrix Composites and Additive Manufacturing processes. This presentation will summarize recent progress and plans in these areas. Ceramic Matrix Composites for Turbine Components: As part of NASA's Aeronautics research, Glenn Research Center has developed Ceramic Matrix Composites for 2700 degrees Fahrenheit turbine engine applications in the next generation of ultra-efficient aircraft. In this presentation, the development of advanced fiber and matrix constituents that enabled this advancement will be reviewed, and characterization of the resulting improvements in mechanical properties and durability will be summarized. Progress toward the development and validation of models predicting the effects of the engine environment on durability of Ceramic Matrix Composites and Environmental Barrier Coatings will be summarized. Progress and plans for collaborative research with industry and other government agencies will be reviewed. Polymer Matrix Composites for Powertrain and Impact Protection: A lightweight, hybrid polymer matrix composite/steel gear concept for rotorcraft power transmission applications was evaluated at realistic speed, torque, and power conditions. Dynamic testing was performed at 5000 horsepower and 5400 revolutions per minute with no performance degradation. Test results demonstrated the potential of hybrid composite / metal gears to reduce gear weight by approximately 15 percent, enabling the implementation of multi-speed drive systems, which would otherwise have a weight penalty, for increased speed and efficiency. Results of post-test inspection and endurance tests will be presented. Separately, ballistic impact tests demonstrated improved damage tolerance in polymer matrix composites by incorporating lightweight, thermoplastic veil materials between selected composite plies during the composite fabrication process. Results of impact tests and post-test inspection will be presented. Additive Manufacturing for Electric Propulsion: Additive Manufacturing processes offer the potential to fabricate new, high power density electric motor designs with complex geometries, multi-material components and optimally designed components that would not be feasible with traditional manufacturing processes. High performance stator components using advanced 3-phase conductive coils were fabricated using direct printing with optimized silver pastes. Additional additive manufacturing methods are being used to fabricate rotors and motor housing components. Systems studies show that the higher performance and lower weight motors offer improved energy efficiency and reduced emissions. Improvements to motor performance resulting from optimized materials and component designs will be presented.

Additive Manufacturing↗

NASA NTRSDate not supplied

Mesh Deformation Boundary Conditions for Three-Dimensional Ablation Solvers

A method for determining boundary node displacements for three-dimensional ablation solvers is developed. The approach is applicable to a wide range of mesh motion algorithms used to determine internal node displacements. The method leverages radial basis functions to analytically define the geometry to which the boundary nodes should be constrained. Constrained optimization, elasticity, and spring analogy solvers are utilized to redistribute the nodes on the evolved geometry surface while maintaining mesh quality. The method is implemented in the CHarring Ablator Response (CHAR) code, and a realistic demonstration case is presented on the Boundary Layer Transition (BOLT) flight experiment configuration. The method is shown to be robust for highly-curved geometries with large domain deformations.

Adam J Amar↗

NASA NTRS2024

Optimizing Thin Cover Layers for Optically Clear Electrodynamic Dust Shields

This project looked at optimizing the dielectric cover layer on top of an optically clear glass electrodynamic dust shield (EDS). The EDS is a device that uses high voltage electric fields to remove dust from surfaces. Currently, the EDS uses 2000 volts to remove dust, but by optimizing the cover layer and the geometry of the EDS, this voltage can be lowered to improve safety and reduce electromagnetic interference (EMI) and the complexity of supporting systems. This project was able to demonstrate successful dust clearing on an EDS with 750 volts in high vacuum (~1E-5 torr) conditions. The EDS had a trace spacing of 500 μm, and the Parylene C cover layer had a thickness of 25 μm. There is still a substantial amount of room for improvement of these devices, which may be able to push the operating voltage even lower.

Particulate Contamination↗

DOE OSTI2023

Reducing warpage in a hybrid large-scale additive manufacturing and compression molding process

In recent years, a hybrid manufacturing process, developed by combining extrusion-based large-scale additive manufacturing (AM) and compression molding (CM) techniques, has shown promising outcomes for producing structurally functional parts. The process can be used with both short fiber-reinforced composites and neat polymers and hence, even multi-material parts can be manufactured easily. This process offers the advantages of structural enhancement by having a desired fiber orientation using a large-scale AM process, as well as rapid manufacturing capability using a CM process. In the large-scale AM process, the alignment of fibers in the deposition direction enables significant improvement in the mechanical properties of the manufactured parts. However, the anisotropy resulting from the directional arrangement of fibers also introduces challenges related to warpage in the produced parts. This study aims to identify the causes of warpage and propose strategies to mitigate it. The research involves the use of preforms manufactured through the large-scale AM, which are then combined with the neat resin for CM manufacturing. A finite element-based numerical simulation model is developed, employing a sequentially coupled thermomechanical approach. Through a parametric study using the simulation models, optimization of printing direction and preform geometry is performed to minimize warpage. This contributes to the advancement and wider adoption of AM/CM hybrid manufacturing to produce structurally functional parts.

Jo, Eonyeon↗

NASA NTRS1992

Computational studies of metal-metal and metal-ligand interactions

The geometric structure of Cr(CO)6 is optimized at the modified coupled-pair functional (MCPF), single and double excitation coupled-cluster (CCSD) and CCSD(T) levels of theory (including a perturbational estimate for connected triple excitations), and the force constants for the totally symmetric representation are determined. The geometry of Cr(CO)5 is partially optimized at the MCPF, CCSD and CCSD(T) levels of theory. Comparison with experimental data shows that the CCSD(T) method gives the best results for the structures and force constants, and that remaining errors are probably due to deficiencies in the one-particle basis sets used for CO. A detailed comparison of the properties of free CO is therefore given, at both the MCPF and CCSD/CCSD(T) levels of treatment, using a variety of basis sets. With very large one-particle basis sets, the SSCD(T) method gives excellent results for the bond distance, dipole moment and harmonic frequency of free CO. The total binding energies of Cr(CO)6 and Cr(CO)5 are also determined at the MCPF, CCSD and CCSD(T) levels of theory. The CCSD(T) method gives a much larger total binding energy than either the MCPF or CCSD methods. An analysis of the basis set superposition error (BSSE) at the MCPF level of treatment points out limitations in the one-particle basis used here and in a previous study. Calculations using larger basis sets reduced the BSSE, but the total binding energy of Cr(CO)6 is still significantly smaller than the experimental value, although the first CO bond dissociation energy of Cr(CO)6 is well described. An investigation of 3s3p correlation reveals only a small effect. The remaining discrepancy between the experimental and theoretical total binding energy of Cr(CO)6 is probably due to limitations in the one-particle basis, rather than limitations in the correlation treatment. In particular an additional d function and an f function on each C and O are needed to obtain quantitative results. This is underscored by the fact that even using a very large primitive se (1042 primitive functions contracted to 300 basis functions), the superposition error for the total binding energy of Cr(CO)6 is 22 kcal/mol at the MCPF level of treatment.

Barnes, Leslie A.↗

DOE OSTI2023

Measurements of multijet event isotropies using optimal transport with the ATLAS detector

A measurement of novel event shapes quantifying the isotropy of collider events is performed in 140 fb -1 of proton-proton collisions with $\sqrt{s}$ = 13 TeV centre-of-mass energy recorded with the ATLAS detector at CERN’s Large Hadron Collider. These event shapes are defined as the Wasserstein distance between collider events and isotropic reference geometries. This distance is evaluated by solving optimal transport problems, using the ‘Energy-Mover’s Distance’. Isotropic references with cylindrical and circular symmetries are studied, to probe the symmetries of interest at hadron colliders. The novel event-shape observables defined in this way are infrared- and collinear-safe, have improved dynamic range and have greater sensitivity to isotropic radiation patterns than other event shapes. The measured event-shape variables are corrected for detector effects, and presented in inclusive bins of jet multiplicity and the scalar sum of the two leading jets’ transverse momenta. The measured distributions are provided as inputs to future Monte Carlo tuning campaigns and other studies probing fundamental properties of QCD and the production of hadronic final states up to the TeV-scale.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2023

Invertible neural networks for real-time control of extrusion additive manufacturing

Material extrusion additive manufacturing (AM) has enabled an elegant fabrication pathway for a vast material library. Nonetheless, each material requires optimization of printing parameters generally determined through significant trial-and-error testing. To eliminate arduous, iteration-based optimization approaches, many researchers have used machine learning (ML) algorithms which provide opportunities for automated process optimization. Here, in this work, we demonstrate the use of an ML-driven approach for real-time material extrusion print-parameter optimization through in-situ monitoring of printed line geometry. To do this, we use deep invertible neural networks (INNs) which can solve both forward and inverse, or optimization, problems using a single network. By combining in-situ computer vision and deep INNs, the printing parameters can be autonomously optimized to print a target line width in 1.2 s. Furthermore, defects that occur during printing can be rapidly identified and corrected autonomously. The methods developed and presented in this work eliminate user-intensive, time-consuming, and iterative parameter discovery approaches that currently limit accelerated implementation of extrusion-based AM processes. Furthermore, the presented approach can be generalized to provide real-time monitoring and optimization pathways for increasingly complex AM environments.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Multi-state Catalysts Modulated by Mechanical Force (Final Report)

The development of more efficient catalytic processes and new approaches to control catalytic activity and selectivity are central to the realization of more selective, atom economic, and energy efficient routes to value added chemicals and polymers. The reactivity and selectivity of a transition metal catalyst is intimately related to the ligand-sphere geometry and, in many cases, the ideal ligand geometry for one step of a catalytic cycle is poorly matched to the ideal ligand geometry for another, resulting in sub-optimal efficiency. Macroscopic mechanical forces are both large, potentially much larger than interatomic forces, and are directional and localized to an extent that differentiates them from other forms of energy input such as heat or light. As such, mechanical force represents a heretofore untapped approach to modulate catalyst geometry, with the potential to reversibly modulate catalyst geometry on the timescale of catalytic turnover or monomer enchainment. This project has addressed the fundamental challenges in material-to-molecule strain coupling associated with the development of a new class of mechanically responsive catalysts (mechanocatalysts) in which active organotransition metal catalysts are strategically embedded in a flexible polymer network such that application of external mechanical force (stretching or deformation) leads to modulation of catalyst geometry, and hence reactivity and selectivity. Our efforts during the tenure of this grant were directed toward the elucidation of force-reactivity relationships of elementary transformations that occur within the first coordination sphere of a transition metal complex employing stiff stilbene photoswitches tethered to a flexible bidentate phosphine ligand derived from MeOBiphep as molecular force probes which provide a range of compressive and extension forces to the coupled transition metal complex depending on the geometry of the stiff stilbene and length of the tethering chains. During the tenure of this grant, we have quantified the rate of C(sp 2 )-C(sp 2 ) reductive elimination from platinum(II) diaryl complexes containing bis(phosphine) force probe ligands as a function of mechanical force; compressive forces decreased the rate of reductive elimination whereas extension forces increased the rate relative to the strain-free MeOBiphep complex with a 3.4-fold change in rate over a ~290 pN range of restoring forces. In a similar manner, we have quantified the rate of oxidative addition of bromobenzene to low-ligated palladium(0) complexes containing force probe ligands as a function of mechanical force; compressive forces increase the rate of oxidative addition, whereas tensile forces decrease the rate with a ~6 fold change in rate across ~340 pN of force applied to the complexes. In both cases, experimental and computational analyses argue strongly against any significant force-induced perturbation of ground state geometry within the first coordination sphere of the reactant complexes. Rather, the force/rate behavior observed for these transformations across these ranges of forces is attributed to the coupling of force to the nuclear motion comprising the reaction coordinates for reductive elimination and oxidative addition. These results together inform the development of catalysts whose activity can be tuned by an external force that is adjusted within a catalytic cycle and suggest opportunities to experimentally map geometry changes associated with reactions in transition metal complexes and potential strategies for force-modulated catalysis.

99 GENERAL AND MISCELLANEOUS↗

NASA NTRS2020

Communication-Aware Orbit Design for Small Spacecraft Swarms around Small Bodies

Exploration of small Solar System bodies has traditionally been performed by single monolithic spacecraft carrying a number of science instruments. However, science instruments typically cannot be operated simultaneously due to the instrument requirements including optimal viewing angle, surface illumination, altitude and ground resolution, power, and data constraints. This observation has motivated interest in multi-spacecraft architectures where a swarm of small spacecraft, each carrying a single science instrument, studies a small body after being deployed by a carrier spacecraft, which then collects data from the vehicles and relays it to Earth. Such architectures hold promise to yield significant improvements in mission efficiency, increases in data quality, and shorter mission duration. A key difficulty in the design of such missions is the selection of orbits for the small spacecraft, which must satisfy not only instrument requirements, but also strict inter-spacecraft communication and on-board storage constraints. To address this, in this paper, we present a novel computationally-efficient optimization algorithm for \emph{communication-aware design} of the orbits of a small spacecraft swarm orbiting a small body. The proposed approach captures constraints including instrument requirements, inter-spacecraft communication bandwidths, and on-board memory usage, and it can accommodate highly irregular gravity field models and surface geometries. We propose an efficient algorithm for optimization of instrument observations and inter-spacecraft communications; we then leverage the differentiable nature of the proposed algorithm to accelerate a gradient-based global search algorithm. Numerical simulations of a six-spacecraft swarm studying 433 Eros show that the proposed approach successfully identifies high-quality orbits, and significantly outperform communication-agnostic optimization techniques, resulting in a 10% increase in scientific returns and a 30% increase in the quality of the collected data.

Rahmani, Amir↗

DOE OSTI2026

Optimized matching conditions for self-guided laser wakefield accelerators

We revisit the matching conditions for self-guided laser pulse propagation in plasma and refine their formulation to maximize the energy of electrons produced via laser wakefield acceleration. Bayesian optimization, combined with particle-in-cell simulations carried out in a quasi-three-dimensional geometry and a Lorentz-boosted frame, is employed. The optimization identifies the maximum electron energy that a self-guided laser wakefield accelerator, driven by a laser of a given energy, can produce, together with the corresponding acceleration distance. Our results further demonstrate that electrons with energies close to the maximum value can be obtained across a relatively wide range of input parameters and without the need for their precise tuning. This provides substantial flexibility for experimental implementation and significantly relaxes the operational constraints associated with self-guided laser wakefield accelerators.

43 PARTICLE ACCELERATORS↗

NASA NTRS1991

Least-squares/parabolized Navier-Stokes procedure for optimizing hypersonic wind tunnel nozzles

A new procedure is demonstrated for optimizing hypersonic wind-tunnel-nozzle contours. The procedure couples a CFD computer code to an optimization algorithm, and is applied to both conical and contoured hypersonic nozzles for the purpose of determining an optimal set of parameters to describe the surface geometry. A design-objective function is specified based on the deviation from the desired test-section flow-field conditions. The objective function is minimized by optimizing the parameters used to describe the nozzle contour based on the solution to a nonlinear least-squares problem. The effect of the changes in the nozzle wall parameters are evaluated by computing the nozzle flow using the parabolized Navier-Stokes equations. The advantage of the new procedure is that it directly takes into account the displacement effect of the boundary layer on the wall contour. The new procedure provides a method for optimizing hypersonic nozzles of high Mach numbers which have been designed by classical procedures, but are shown to produce poor flow quality due to the large boundary layers present in the test section. The procedure is demonstrated by finding the optimum design parameters for a Mach 10 conical nozzle and a Mach 6 and a Mach 15 contoured nozzle.

Korte, John J.↗