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Structural Dynamics Observations in Space Launch System Green Run Hot Fire Testing

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of eight mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Green Run Hot Fire (GRHF) of the SLS Core Stage provided a flight-like ground test environment for verification of integrated vehicle TVC performance. A TVC model coupled to a vehicle structural dynamic model has been developed previously and incrementally validated in subsystem tests and simulations. Still, some aspects of TVC performance in GRHF were not anticipated. The ensuing investigation demonstrated the need for well-instrumented test environments, various levels of modeling fidelity, test-representative structural models, and caution in reuse of legacy components. This paper is the sixth installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. It introduces the salient structural dynamic phenomena uncovered in ambient and hot fire testing. During the Green Run test campaign, a comparison of ambient and hot fire step responses showed a significant change in apparent damping due to the presence of friction, challenging long standing assumptions that friction could be neglected. Additionally, the characteristic response of the engine and thrust structure during GRHF proved to be more complex than anticipated, as evidenced by the available actuator, thrust structure, and engine measurements. While the string-potentiometer based test instrumentation was intended to allow for reconstruction of the engine angles along the two control axes, the geometric placement, location uncertainty, and responses in overlapping frequency spectra revealed additional phenomena requiring further analysis and post-processing. The observations from both modal and frequency response testing during the Green Run ambient and hot fire configurations led to Engine and Core Stage FEM (finite element model) updates. When evidence of unexpected engine motion was found in engine section accelerometer data, the authors pursued additional structural analysis leading to FEM updates associated with the TVC gimbal and thrust structure. Through collaboration between structures, TVC, and flight control disciplines, the test-informed models and root-cause analysis led to confident flight rationale for the first flight of the SLS launch vehicle.

Richard K. Moore↗

DOE OSTI2022

A Machine Learning-Assisted Framework to Control Thermally Anisotropic Building Envelopes in Residential Buildings

To curb the energy consumption of buildings and their related CO2 emissions, Oak Ridge National Laboratory (ORNL) has developed the thermally anisotropic building envelope (TABE) —a multi-layer design comprising insulation materials and metal foils connected to thermal loops. In this study, a machine learning-assisted framework was developed to control the TABE in residential buildings to reduce the computation load for future optimal rule-based control and application. First, a 2D finite element model was established in COMSOL to calculate the hourly heat flux through exterior walls installed with the TABE. Then, TABE wall heat fluxes were simulated for various given indoor and outdoor boundary conditions, as well as thermal loops fluid temperatures and flow rates. Since the finite element simulations are computationally expensive, an artificial neural network (ANN) was then trained to use as a proxy of the finite element (COMSOL) modeling. Finally, the trained ANN model was coupled with the EnergyPlus model to predict the energy consumption of a US Department of Energy prototype single-family house installed with the TABE. An optimal simple rule-based control was determined from predefined rules for a case study. The results demonstrate that the developed machine learning–assisted framework can reduce 99.9% of the computation time while efficiently managing residential building energy for installed TABE walls.

Shen, Zhenglai↗

NASA NTRS1938

Experimental Study of Ignition by Hot Spot in Internal Combustion Engines

In order to carry out the contemplated study, it was first necessary to provide hot spots in the combustion chamber, which could be measured and whose temperature could be changed. It seemed difficult to realize both conditions working solely on the temperature of the cooling water in a way so as to produce hot spots on the cylinder wall capable of provoking autoignition. Moreover, in the majority of practical cases, autoignition is produced by the spark plug, one of the least cooled parts in the engine. The first procedure therefore did not resemble that which most generally occurs in actual engine operation. All of these considerations caused us to reproduce similar hot spots at the spark plugs. The hot spots produced were of two kinds and designated with the name of thermo-electric spark plug and of metallic hot spot.

Serruys, Max↗

NASA NTRS1993

Liquid hydrogen and liquid oxygen feedline passive recirculation analysis

The primary goal of the National Launch System (NLS) program was to design an operationally efficient, highly reliable vehicle with minimal recurring launch costs. To achieve this goal, trade studies of key main propulsion subsystems were performed to specify vehicle design requirements. These requirements include the use of passive recirculation to thermally condition the liquid hydrogen (LH2) and liquid oxygen (LO2) propellant feed systems and Space Transportation Main Engine (STME) fuel pumps. Rockwell International (RI) proposed a joint independent research and development (JIRAD) program with Marshall Space Flight Center (MSFC) to study the LH2 feed system passive recirculation concept. The testing was started in July 1992 and completed in November 1992. Vertical and sloped feedline designs were used. An engine simulator was attached at the bottom of the feedline. This simulator had strip heaters that were set to equal the corresponding heat input from different engines. A computer program is currently being used to analyze the passive recirculation concept in the LH2 vertical feedline tests. Four tests, where the heater setting is the independent variable, were chosen. While the JIRAD with RI was underway, General Dynamics Space Systems (GDSS) proposed a JIRAD with MSFC to explore passive recirculation in the LO2 feed system. Liquid nitrogen (LN2) is being used instead of LO2 for safety and economic concerns. To date, three sets of calibration tests have been completed on the sloped LN2 test article. The environmental heat was calculated from the calibration tests in which the strip heaters were turned off. During the LH2 testing, the environmental heat was assumed to be constant. Therefore, the total heat was equal to the environmental heat flux plus the heater input. However, the first two sets of LN2 calibration tests have shown that the environmental heat flux varies with heater input. A Systems Improved Numerical Differencing Analyzer and Fluid Integrator (SINDA/FLUINT) model is currently being built to determine if this variation in environmental heat is due to a change in the wall temperature. During the third set of calibration tests, a faulty reference junction was found. Based on this anomaly with the reference junction, the heat flux calculations from the first two calibration sets are now considered questionable.

Holt, Kimberly Ann↗

NASA NTRS2008

Computational Analyses in Support of Sub-scale Diffuser Testing for the A-3 Facility: Steady Predictions - Part 1

Simulation technology can play an important role in rocket engine test facility design and development by assessing risks, providing analysis of dynamic pressure and thermal loads, identifying failure modes and predicting anomalous behavior of critical systems. Advanced numerical tools assume greater significance in supporting testing and design of high altitude testing facilities and plume induced testing environments of high thrust engines because of the greater inter-dependence and synergy in the functioning of the different sub-systems. This is especially true for facilities such as the proposed A-3 facility at NASA SSC because of a challenging operating envelope linked to variable throttle conditions at relatively low chamber pressures. Facility designs in this case will require a complex network of diffuser ducts, steam ejector trains, fast operating valves, cooling water systems and flow diverters that need to be characterized for steady state performance. In this paper, we will demonstrate with the use of CFD analyses s advanced capability to evaluate supersonic diffuser and steam ejector performance in a sub-scale A-3 facility at NASA Stennis Space Center (SSC) where extensive testing was performed. Furthermore, the focus in this paper relates to modeling of critical sub-systems and components used in facilities such as the A-3 facility. The work here will address deficiencies in empirical models and current CFD analyses that are used for design of supersonic diffusers/turning vanes/ejectors as well as analyses for confined plumes and venting processes. The primary areas that will be addressed are: (1) supersonic diffuser performance including analyses of thermal loads (2) accurate shock capturing in the diffuser duct; (3) effect of turning duct on the performance of the facility (4) prediction of mass flow rates and performance classification for steam ejectors (5) comparisons with test data from sub-scale diffuser testing and assessment of confidence levels in CFD based flowpath modeling of the facility. The analyses tools used here expand on the multi-element unstructured CFD which has been tailored and validated for impingement dynamics of dry plumes, complex valve/feed systems, and high pressure propellant delivery systems used in engine and component test stands at NASA SSC. The analyses performed in the evaluation of the sub-scale diffuser facility explored several important factors that influence modeling and understanding of facility operation such as (a) importance of modeling the facility with Real Gas approximation, (b) approximating the cluster of steam ejector nozzles as a single annular nozzle, (c) existence of mixed subsonic/supersonic flow downstream of the turning duct, and (d) inadequacy of two-equation turbulence models in predicting the correct pressurization in the turning duct and expansion of the second stage steam ejectors. The procedure used for modeling the facility was as follows: (i) The engine, test cell and first stage ejectors were simulated with an axisymmetric approximation (ii) the turning duct, second stage ejectors and the piping downstream of the second stage ejectors were analyzed with a three-dimensional simulation utilizing a half-plane symmetry approximation. The solution i.e. primitive variables such as pressure, velocity components, temperature and turbulence quantities were passed from the first computational domain and specified as a supersonic boundary condition for the second simulation. (iii) The third domain comprised of the exit diffuser and the region in the vicinity of the facility (primary included to get the correct shock structure at the exit of the facility and entrainment characteristics). The first set of simulations comprising the engine, test cell and first stage ejectors was carried out both as a turbulent real gas calculation as well as a turbulent perfect gas calculation. A comparison for the two cases (Real Turbulent and Perfect gas turbulent) of the Ma Number distribution and temperature distributions are shown in Figures 1 and 2 respectively. The Mach Number distribution shows small yet distinct differences between the two cases such as locations of shocks/shock reflections and a slightly different impingement point on the wall of the diffuser from the expansion at the exit of the nozzle. Similarly the temperature distribution indicates different flow recirculation patterns in the test cell. Both cases capture all the essential flow phenomena such as the shock-boundary layer interaction, plume expansion, expansion of the first stage ejectors, mixing between the engine plume and the first stage ejector flow and pressurization due to the first stage ejectors. The final paper will discuss thermal loads on the walls of the diffuser and cooling mechanisms investigated.

Allgood, Daniel C.↗

NASA NTRS2018

Hollow-Wall Heat Shield for Fuel Injector Component

A fuel injector component includes a body, an elongate void and a plurality of bores. The body has a first surface and a second surface. The elongate void is enclosed by the body and is integrally formed between portions of the body defining the first surface and the second surface. The plurality of bores extends into the second surface to intersect the elongate void. A process for making a fuel injector component includes building an injector component body having a void and a plurality of ports connected to the void using an additive manufacturing process that utilizes a powdered building material, and removing residual powdered building material from void through the plurality of ports.

Hanson, Russell B.↗

DOE OSTI2023

Iodine Vacancies do not Cause Nonradiative Recombination in Halide Perovskites

The iodine vacancy (V I ) has frequently been discussed as a strong nonradiative recombination center in halide perovskites. This proposition was mainly based on the presence of charge-state transition levels in the band gap, as found in early first-principles calculations. In this work, we perform accurate hybrid-density-functional calculations for V I in CsPbI 3 , CsSnI 3 , and CsGeI 3 and find that V I does not have any transition levels in the band gap in CsPbI 3 , in contrast to the results from calculations based on semilocal functionals. The iodine vacancy V I does introduce levels in the band gap in CsSnI 3 and CsGeI 3 , but our explicitly computed nonradiative capture coefficients demonstrate that V I has a negligible impact on nonradiative recombination. Our study corrects a misunderstanding of the role of V I in the iodide-based perovskites, and shifts the focus toward identifying and mitigating actual recombination centers in order to further improve the optoelectronic performance.

14 SOLAR ENERGY↗

NASA NTRS1972

Analysis and comparison of wall cooling schemes for advanced gas turbine applications

The relative performance of (1) counterflow film cooling, (2) parallel-flow film cooling, (3) convection cooling, (4) adiabatic film cooling, (5) transpiration cooling, and (6) full-coverage film cooling was investigated for heat loading conditions expected in future gas turbine engines. Assumed in the analysis were hot-gas conditions of 2200 K (3500 F) recovery temperature, 5 to 40 atmospheres total pressure, and 0.6 gas Mach number and a cooling air supply temperature of 811 K (1000 F). The first three cooling methods involve film cooling from slots. Counterflow and parallel flow describe the direction of convection cooling air along the inside surface of the wall relative to the main gas flow direction. The importance of utilizing the heat sink available in the coolant for convection cooling prior to film injection is illustrated.

Colladay, R. S.↗

DOE OSTI2022

A 1D–0D–3D coupled model for simulating blood flow and transport processes in breast tissue

In this work, we present mixed dimensional models for simulating blood flow and transport processes in breast tissue and the vascular tree supplying it. These processes are considered, to start from the aortic inlet to the capillaries and tissue of the breast. Large variations in biophysical properties and flow conditions exist in this system necessitating the use of different flow models for different geometries and flow regimes. In total, we consider four different model types. First, a system of 1D nonlinear hyperbolic partial differential equations (PDEs) is considered to simulate blood flow in larger arteries with highly elastic vessel walls. Second, we assign 1D linearized hyperbolic PDEs to model the smaller arteries with stiffer vessel walls. The third model type consists of ODE systems (0D models). It is used to model the arterioles and peripheral circulation. Finally, homogenized 3D porous media models are considered to simulate flow and transport in capillaries and tissue within the breast volume. Sink terms are used to account for the influence of the venous and lymphatic systems. Combining the four model types, we obtain two different 1D–0D–3D coupled models for simulating blood flow and transport processes: The first model results in a fully coupled 1D–0D–3D model covering the complete path from the aorta to the breast combining a generic arterial network with a patient specific breast network and geometry. The second model is a reduced one based on the separation of the generic and patient specific parts. The information from a calibrated fully coupled model is used as inflow condition for the patient specific sub-model allowing a significant computational cost reduction. Several numerical experiments are conducted to calibrate the generic model parameters and to demonstrate realistic flow simulations compared to existing data on blood flow in the human breast and vascular system. Moreover, we use two different breast vasculature and tissue data sets to illustrate the robustness of our reduced sub-model approach.

multiscale blood flow models↗

NASA NTRS1972

Numerical and Experimental Studies of the Natural Convection Flow Within a Horizontal Cylinder Subjected to a Uniformly Cold Wall Boundary Condition

Numberical solutions are obtained for the quasi-compressible Navier-Stokes equations governing the time dependent natural convection flow within a horizontal cylinder. The early time flow development and wall heat transfer is obtained after imposing a uniformly cold wall boundary condition on the cylinder. Solutions are also obtained for the case of a time varying cold wall boundary condition. Windware explicit differ-encing is used for the numerical solutions. The viscous truncation error associated with this scheme is controlled so that first order accuracy is maintained in time and space. The results encompass a range of Grashof numbers from 8.34 times 10,000 to 7 times 10 to the 7th power which is within the laminar flow regime for gravitationally driven fluid flows. Experiments within a small scale instrumented horizontal cylinder revealed the time development of the temperature distribution across the boundary layer and also the decay of wall heat transfer with time.

Stewart, R. B.↗

NASA NTRS1987

An engineering study of hybrid adaptation of wind tunnel walls for three-dimensional testing

Solid wall tunnels having only upper and lower walls flexing are described. An algorithm for selecting the wall contours for both 2 and 3 dimensional wall flexure is presented and numerical experiments are used to validate its applicability to the general test case of 3 dimensional lifting aircraft models in rectangular cross section wind tunnels. The method requires an initial approximate representation of the model flow field at a given lift with wallls absent. The numerical methods utilized are derived by use of Green's source solutions obtained using the method of images; first order linearized flow theory is employed with Prandtl-Glauert compressibility transformations. Equations are derived for the flexed shape of a simple constant thickness plate wall under the influence of a finite number of jacks in an axial row along the plate centerline. The Green's source methods are developed to provide estimations of residual flow distortion (interferences) with measured wall pressures and wall flow inclinations as inputs.

Brown, Clinton↗

DOE OSTI2021

An LES study of secondary motion and wall shear stresses in a pipe bend

In this study, large-eddy simulations (LES) of a single-phase, turbulent flow in a 90 ° pipe bend are performed at three Reynolds numbers (5300, 27 000, and 45 000) to investigate the correlation between secondary flow motion and wall shear stresses, which is suspected to be a potential mechanism responsible for material erosion. The isothermal flows are validated against available experimental and numerical data first. The snapshot proper orthogonal decomposition (POD) is applied for the medium and high Reynolds number flows to identify the secondary flow motions and the oscillation of the Dean vortices that are found to cause swirl-switching. Distinguished frequencies of the POD time coefficients at Strouhal numbers of 0.25 and 0.28 are identified for Reynolds numbers at 27 000 and 45 000, respectively. Moreover, shear stress on the pipe wall and the associated power spectral density are obtained and shown to have the same oscillating frequency as the swirl-switching.

42 ENGINEERING↗

DOE OSTI2022

INGRID: An interactive grid generator for 2D edge plasma modeling

A fusion boundary-plasma domain is defined by axisymmetric magnetic surfaces where the geometry is often complicated by the presence of one or more X-points; and modeling boundary plasmas usually relies on computational grids that account for the magnetic field geometry. The new grid generator INGRID (Interactive Grid Generator) presented in this work is a Python-based code for calculating grids for fusion boundary plasma modeling, for a variety of configurations with one or two X-points in the domain. INGRID first performs partitioning over the domain consisting of a small number of patches conforming to the magnetic field and wall geometry; then it generates a subgrid on each of the patches and joins them into a global grid. This domain partitioning strategy makes possible a uniform treatment of various configurations with one or two X-points in the domain. This includes single-null, double-null, and other configurations with two X-points in the domain. The INGRID design allows generating grids either interactively, via a parameter-file driven GUI, or using a non-interactive script-controlled workflow. Results of testing demonstrate that INGRID is a flexible, robust, and user-friendly grid-generation tool for fusion boundary-plasma modeling.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

3D Nanomagnetism in Low Density Interconnected Nanowire Networks

Free-standing, interconnected metallic nanowire networks with densities as low as 40 mg/cm 3 have been achieved over centimeter-scale areas, using electrodeposition into polycarbonate membranes that have been ion-tracked at multiple angles. Networks of interconnected magnetic nanowires further provide an exciting platform to explore 3-dimensional nanomagnetism, where their structure, topology, and frustration may be used as additional degrees of freedom to tailor the materials properties. New magnetization reversal mechanisms in cobalt networks are captured by the first-order reversal curve method, which demonstrate the evolution from strong demagnetizing dipolar interactions to intersection-mediated domain wall pinning and propagation, and eventually to shape-anisotropy dominated magnetization reversal. These findings open up new possibilities for 3-dimensional integrated magnetic devices for memory, complex computation, and neuromorphics.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Magnetic-Field Diffusion Effects in Beam Position Monitors II: Application to Calibration Single-Pulse Data

Beam position monitors (BPMs) provide time-resolved measurements of the current and centroid position of high-current electron beams in linear induction accelerators (LIAs). One of the types of detectors used in BPMs is the B-dot loop, which generates a signal from the EMF due to the time varying magnetic flux through the loop. If some of the boundaries of the loop are composed of thick metal walls with finite conductivity, the resulting signal must be corrected for the magnetic field diffusion into the metal. From first principles, we have derived the perturbation to BPM measurements due to this effect. The theoretical framework was used to design an algorithm for signal correction that does not require knowledge of the time history of the magnetic flux being measured. Corrected signals based on that process compared favorably with the know reference signals in a laboratory calibration test sequence.

43 PARTICLE ACCELERATORS↗

DOE OSTI2022

INGRID: An interactive grid generator for 2D edge plasma modeling

A fusion boundary-plasma domain is defined by axisymmetric magnetic surfaces where the geometry is often complicated by the presence of one or more X-points; and modeling boundary plasmas usually relies on computational grids that account for the magnetic field geometry. The new grid generator INGRID (Interactive Grid Generator) presented here is a Python-based code for calculating grids for fusion boundary plasma modeling, for a variety of configurations with one or two X-points in the domain. INGRID first performs partitioning over the domain consisting of a small number of patches conforming to the magnetic field and wall geometry; then it generates a subgrid on each of the patches and joins them into a global grid. This domain partitioning strategy makes possible a uniform treatment of various configurations with one or two X-points in the domain. This includes single-null, double-null, and other configurations with two X-points in the domain. The INGRID design allows generating grids either interactively, via a parameterfile driven GUI, or using a non-interactive script-controlled workflow. Results of testing demonstrate that INGRID is a flexible, robust, and user-friendly grid-generation tool for fusion boundary-plasma modeling.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Defining and Measuring Forest Dependence in the United States: Operationalization and Sensitivity Analysis

This manuscript helps bridge a gap between theoretical work that advocates for a broad view of forest dependence, and empirical work that has focused narrowly on economic measures. Background: Forest dependence has been widely recognized as a valuable concept for understanding human communities’ well-being and vulnerability to shocks and changes. Past theoretical literature has highlighted the importance of recognizing various types of dependence—environmental, economic, and social—yet past empirical literature on the topic in the United States has almost exclusively relied on measures of economic dependence such as employment and earnings from the traditional forest products sector. Objective and Methods: As a first step to bridge the gap between the theoretical and empirical, we reviewed the existing, publicly available, reliable, wall-to-wall data sources to identify alternate proxy measures for forest dependence. Data availability made the analysis feasible only at the county level—the administrative subdivisions of the state—or higher. Results and Conclusions: We created environmental, economic, and social criteria based on threshold levels of the following proxy variables: forest area, earnings, employment, and indigenous population. Using these criteria, we identified 524 counties to be potentially forest-dependent of 3140 total counties in the United States. The largest concentration was in the Pacific Northwest and Southeast regions, and a higher proportion were non-metro counties than metro. Varying the threshold levels significantly changes the number of counties identified but does not alter the overall geographic trends.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1985

Analytical study of flow phenomena in SSME turnaround duct geometries

The SSME fuel turbopump hot gas manifold was identified as a source of loss and flow distortion which significantly affects the performance and durability of both the drive turbine and the LOX injector area of the main combustion chamber. Two current SSME geometries were studied, the full power level (FPL) and the first manned orbital flight (FMOF) configuration. The effects of turnaround duct geometry on flow losses and distortions, by varying wall curvature and flow area variation in the 180 deg turnaround region were examined. The effects of the duct inlet flow phenomena such as the radial distortion of the inlet flow and inlet swirl level on turnaround duct performance were also investigated. It is shown that of the two current geometries, the FMOF configuration had lower pressure losses and generated less flow distortion, but had a small flow separation bubble at the 180 deg turnaround exit. It is found that by optimizing wall curvature and flow diffusion in the turnaround, improved duct performance can be achieved.

Mclallin, K. L.↗