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Aerodynamic Design Optimization for Natural Laminar Flow Airfoils

Natural laminar flow technology is a passive laminar flow control (LFC) strategy that seeks to delay the onset of boundary-layer transition (BLT) through shape optimization to reduce the drag of the aerodynamic vehicle. Adjoint-based design optimization for LFC is proposed in an integrated multidisciplinary framework, which includes the computational fluid dynamics (CFD), geometry and grid deformation, and linear stability analysis (LSA) for transition prediction. In particular, the BLT location is predicted using the dual N-factor method that is based on a linear stability theory (LST) eigenvalue problem. The dual N-factor criterion accounts for the amplification of planar Tollmien-Schlichting (TS) and stationary crossflow (CF) boundary-layer instabilities to predict the transition location in three-dimensional boundary-layer flows. The adjoint-based shape optimization procedure is based on an iteratively coupled CFD and LSA methodology to converge the transition location and flow solutions, as well as to calculate the sensitivities of the aerodynamic metrics of interest with respect to the flow and shape design parameters. The RAE 2822 airfoil at 0 and 30 degrees yaw angles, an angle of attack of 0.72 degrees, and subsonic conditions (M∞ = 0.19, Rec = 5.6 × 106 ) are used as baseline configurations for design optimization. The angle of attack and the vertical displacement of free-form-deformation control points are used as design variables to reduce the drag coefficient while reaching a specified lift coefficient. The optimized unswept airfoil designs achieve a 30% drag reduction accompanied by a downstream shift of the transition locations over both suction and pressure sides of the airfoil. The initial design iterations for the swept case also show a favorable trend in the drag reduction with transition delay over both sides.

Transition↗

DOE OSTI2026

Graphical User Interface for a Biasing Board for the PSEC6

The PSEC6 is an application-specific integrated circuit (ASIC) designed for a readout system for a large area picosecond photodetector (LAPPD). The PSEC6 is currently in fabrication and pending testing. The testing system for the PSEC5, the previous iteration of the ASIC, required expensive and non-portable equipment, because the ASIC needs twelve adjustable reference voltages. The new testing system consists of an low-cost, open-source, cross-platform graphical user interface (GUI), a digital system, and a biasing board. The digital system is the interface between the GUI and biasing board, and can be implemented on a microcontroller or field-programmable gate array (FPGA). The biasing board contains twelve digital-to-analog converters (DACs) that are configurable via the GUI, which gives users the ability to write voltage values to all or specific DACs. The GUI was developed in C on Linux using the widget library GTK4 and cross-compiled for Windows compatibility. I2C and SPI protocols were implemented on an Adafruit Feather ESP32-S3 microcontroller to write commands to the DACs and PSEC6. A hardware implementation of the I2C protocol is in development on an FPGA. Since LAPPDs will be used by the Accelerator Neutrino Neutron Interaction Experiment (ANNIE) at Fermilab, the PSEC6 testing system in this internship project can potentially benefit future neutrino research. The project is relevant to the Department of Energy’s microelectronics mission, because the PSEC6 is an ASIC that will handle fast time signals arriving from the detector for readout. It also provided experience with building a cross-platform user interface, practicing digital design and implementation in hardware description language (HDL), and using simulations to inform new design iterations.

Guerrero, Sasha Camila [North Central Coll.]↗

DOE OSTI2026

Graphical User Interface for a Biasing Board for the PSEC6

Guerrero, Sasha Camila [North Central Coll.]↗

DOE OSTI2021

Vertical Septum Magnet Design for the APS Upgrade

The vertical injection scheme proposed for the APS Upgrade (APS-U) Project requires a challenging septum magnet that must meet stringent beam physics, magnetic field leakage, and vacuum requirements. The current iteration of this magnet design includes an enlarged stored-beam chamber aperture of 9 mm x 12 mm and a reduction of the septum thickness to 1.5 mm. The enlarged aperture accommodates a non-evaporable getter (NEG)-coated stored beam chamber to better achieve the required vacuum. A prototype septum magnet has been built and measurements confirm the cancellation of a peak leakage field even though the value is six times larger than the design. The leakage field measured at the upstream (US) end cancels the downstream (DS) end as was expected by design. The measured and simulated leakage field and the stored beam trajectories are reported.

43 PARTICLE ACCELERATORS↗

NASA NTRS1999

Ames Optimized TCA Configuration

Configuration design at Ames was carried out with the SYN87-SB (single block) Euler code using a 193 x 49 x 65 C-H grid. The Euler solver is coupled to the constrained (NPSOL) and the unconstrained (QNMDIF) optimization packages. Since the single block grid is able to model only wing-body configurations, the nacelle/diverter effects were included in the optimization process by SYN87's option to superimpose the nacelle/diverter interference pressures on the wing. These interference pressures were calculated using the AIRPLANE code. AIRPLANE is an Euler solver that uses a unstructured tetrahedral mesh and is capable of computations about arbitrary complete configurations. In addition, the buoyancy effects of the nacelle/diverters were also included in the design process by imposing the pressure field obtained during the design process onto the triangulated surfaces of the nacelle/diverter mesh generated by AIRPLANE. The interference pressures and nacelle buoyancy effects are added to the final forces after each flow field calculation. Full details of the (recently enhanced) ghost nacelle capability are given in a related talk. The pseudo nacelle corrections were greatly improved during this design cycle. During the Ref H and Cycle 1 design activities, the nacelles were only translated and pitched. In the cycle 2 design effort the nacelles can translate vertically, and pitch to accommodate the changes in the lower surface geometry. The diverter heights (between their leading and trailing edges) were modified during design as the shape of the lower wing changed, with the drag of the diverter changing accordingly. Both adjoint and finite difference gradients were used during optimization. The adjoint-based gradients were found to give good direction in the design space for configurations near the starting point, but as the design approached a minimum, the finite difference gradients were found to be more accurate. Use of finite difference gradients was limited by the CPU time limit available on the Cray machines. A typical optimization run using finite difference gradients can use only 30 to 40 design variables and one optimization iteration within the 8 hour queue limit for the chosen grid size and convergence level. The efficiency afforded by the adjoint method allowed for 50-120 design variables and 5-10 optimization iterations in the 8 hour queue. Geometric perturbations to the wing and fuselage were made using the Hicks/Henne (HH) shape functions. The HH functions were distributed uniformly along the chords of the wing defining sections and lofted linearly. During single-surface design, constraints on thickness and volume at selected wing stations were imposed. Both fuselage camber and cross-sectional area distributions were permitted to change during design. The major disadvantage to the use of these functions is the inherent surface waviness produced by repeated use of such functions. Many smoothing operations were required following optimization runs to produce a configuration with reasonable smoothness. Wagner functions were also used on the wing sections but were never used on the fuselage. The Wagner functions are a family of increasingly oscillatory functions that have also been used extensively in airfoil design. The leading and trailing edge regions of the wing were designed by use of polynomial and monomial functions respectively. Twist was attempted but was abandoned because of little performance improvement available from changing the baseline twist.

Cliff, Susan E.↗

DOE OSTI2022

Generative Design for Resilience of Interdependent Network Systems

Abstract Interconnected complex systems usually undergo disruptions due to internal uncertainties and external negative impacts such as those caused by harsh operating environments or regional natural disaster events. To maintain the operation of interconnected network systems under both internal and external challenges, design for resilience research has been conducted from both enhancing the reliability of the system through better designs and improving the failure recovery capabilities. As for enhancing the designs, challenges have arisen for designing a robust system due to the increasing scale of modern systems and the complicated underlying physical constraints. To tackle these challenges and design a resilient system efficiently, this study presents a generative design method that utilizes graph learning algorithms. The generative design framework contains a performance estimator and a candidate design generator. The generator can intelligently mine good properties from existing systems and output new designs that meet predefined performance criteria while the estimator can efficiently predict the performance of the generated design for a fast iterative learning process. Case studies results based on synthetic supply chain networks and power systems from the IEEE dataset have illustrated the applicability of the developed method for designing resilient interdependent network systems.

Engineering↗

NASA NTRS1966

The generalized forward iterator

Computer program for optimal design of Apollo missions

Moore, W. E.↗

NASA NTRS1973

Optimal design of structures with buckling constraints.

The paper presents an iterative, finite element method for minimum weight design of structures with respect to buckling constraints. The redesign equation is derived from the optimality criterion, as opposed to a numerical search procedure, and can handle problems that are characterized by the existence of two fundamental buckling modes at the optimal design. Application of the method is illustrated by beam and orthogonal frame design problems.

Kiusalaas, J.↗

NASA NTRS1996

Finite Difference Time Marching in the Frequency Domain: A Parabolic Formulation for Aircraft Acoustic Nacelle Design

An explicit finite difference iteration scheme is developed to study harmonic sound propagation in aircraft engine nacelles. To reduce storage requirements for large 3D problems, the time dependent potential form of the acoustic wave equation is used. To insure that the finite difference scheme is both explicit and stable, time is introduced into the Fourier transformed (steady-state) acoustic potential field as a parameter. Under a suitable transformation, the time dependent governing equation in frequency space is simplified to yield a parabolic partial differential equation, which is then marched through time to attain the steady-state solution. The input to the system is the amplitude of an incident harmonic sound source entering a quiescent duct at the input boundary, with standard impedance boundary conditions on the duct walls and duct exit. The introduction of the time parameter eliminates the large matrix storage requirements normally associated with frequency domain solutions, and time marching attains the steady-state quickly enough to make the method favorable when compared to frequency domain methods. For validation, this transient-frequency domain method is applied to sound propagation in a 2D hard wall duct with plug flow.

Baumeister, Kenneth J.↗

NASA NTRS2003

Science Issues Associated with the Use of a Microfluidic Chip Designed Specifically for Protein Crystallization

The Iterative Biological Crystallization team in partnership with Caliper Technologies has produced a prototype microfluidic chip for batch crystallization that has been designed and tested. The chip is designed for the mixing and dispensing of up to five solutions with possible variation of the recipe being delivered to two growth wells. Developments that have led to the successful on-chip crystallization of a few model proteins have required investigative insight into many different areas, including fluid mixing dynamics, surface treatments, quantification and fidelity of reagent delivery. This presentation will encompass the ongoing studies and data accumulated toward these efforts.

Holmes, Anna M.↗

NASA NTRS2015

A Path to Planetary Protection Requirements for Human Exploration: A Literature Review and Systems Engineering Approach

As systems, technologies, and plans for the human exploration of Mars and other destinations beyond low Earth orbit begin to coalesce, it is imperative that frequent and early consideration is given to how planetary protection practices and policy will be upheld. While the development of formal planetary protection requirements for future human space systems and operations may still be a few years from fruition, guidance to appropriately influence mission and system design will be needed soon to avoid costly design and operational changes. The path to constructing such requirements is a journey that espouses key systems engineering practices of understanding shared goals, objectives and concerns, identifying key stakeholders, and iterating a draft requirement set to gain community consensus. This paper traces through each of these practices, beginning with a literature review of nearly three decades of publications addressing planetary protection concerns with respect to human exploration. Key goals, objectives and concerns, particularly with respect to notional requirements, required studies and research, and technology development needs have been compiled and categorized to provide a current 'state of knowledge'. This information, combined with the identification of key stakeholders in upholding planetary protection concerns for human missions, has yielded a draft requirement set that might feed future iteration among space system designers, exploration scientists, and the mission operations community. Combining the information collected with a proposed forward path will hopefully yield a mutually agreeable set of timely, verifiable, and practical requirements for human space exploration that will uphold international commitment to planetary protection.

Johnson, James E.↗

NASA NTRS1989

The flexure assembly design for the SIRTF one-meter primary mirror

A titanium flexure assembly for the Space Infrared Telescope Facility (SIRTF) 1-m primary mirror has been designed to accommodate: (1) the cryogenic cool-down effect on the optical performance of the mirror, (2) the Shuttle launch-load environment, and (3) the support-baseplate manufacturing tolerances. Numerous iterations involving a multidimensional design space search led to an assembly design that provides the stiffness and strength in the vertical (optical axis) and tangential directions to accommodate launch loads, but is compliant radially to accommodate cryogenic cool down. A 'folded back' titanium flexure system was required because of the differential thermal contraction of the aluminum telescope baseplate support and the fused-silica mirror. This unique and innovative flexure assembly represents a totally passive mechanism for accommodating the design launch loads, cryogenic cool down, and out-of-plane baseplate effects.

Richard, R. M.↗

NASA NTRS1989

Application of numerical optimization techniques to control system design for nonlinear dynamic models of aircraft

Control system design for general nonlinear flight dynamic models is considered through numerical simulation. The design is accomplished through a numerical optimizer coupled with analysis of flight dynamic equations. The general flight dynamic equations are numerically integrated and dynamic characteristics are then identified from the dynamic response. The design variables are determined iteratively by the optimizer to optimize a prescribed objective function which is related to desired dynamic characteristics. Generality of the method allows nonlinear effects to aerodynamics and dynamic coupling to be considered in the design process. To demonstrate the method, nonlinear simulation models for an F-5A and an F-16 configurations are used to design dampers to satisfy specifications on flying qualities and control systems to prevent departure. The results indicate that the present method is simple in formulation and effective in satisfying the design objectives.

Lan, C. Edward↗

NASA NTRS1979

Improvements in surface singularity analysis and design methods

The coupling of the combined source vortex distribution of Green's potential flow function with contemporary numerical techniques is shown to provide accurate, efficient, and stable solutions to subsonic inviscid analysis and design problems for multi-element airfoils. The analysis problem is solved by direct calculation of the surface singularity distribution required to satisfy the flow tangency boundary condition. The design or inverse problem is solved by an iteration process. In this process, the geometry and the associated pressure distribution are iterated until the pressure distribution most nearly corresponding to the prescribed design distribution is obtained. Typically, five iteration cycles are required for convergence. A description of the analysis and design method is presented, along with supporting examples.

Bristow, D. R.↗

NASA NTRS2018

Conceptual Aerodynamic Design of a Tail-Cone Thruster System Under Axi-Symmetric Inlet Distortion

This paper presents a conceptual design of a tail-cone thruster system which is operating under an axisymmetric inlet distortion. An effort to realize the targeted fuel burn saving that was proposed in NASA's STARC_ABL aircraft design is made through a CFD (Computational Fluid Dynamics)-based design approach. This method employs three iterative steps to exploit the CFD tools until the design requirements are met: a quasi-2D through-flow model to design the fan/EGV (Exit Guide Vane), a 3-D RANS (Reynolds Averaging Navier-Stokes) simulation of the single blade row to account for the inlet/fan and the EGV/nozzle interaction, and a 3-D RANS simulation of the airframe with a propulsor installed - propulsion airframe integration (PAI). The design requirements which include the thrust, and shaft power of the propulsor are matched throughout the evaluations coming from two CFD domains, i.e., the turbo-machinery and the PAI. During the switch between these different computational domains, the inlet and exit profiles are matched via the correction factors of the body-force model. The present tail-cone thruster (TCT) aerodynamic design leverages a low-pressure ratio fan (FPR=1.2 to approximately 1.25) of which the camber-line angles are predicted by a quasi-2D through-flow model. The quasi-2D model is derived to analyze the radially distorted flow resulting from the ingested boundary layer at the inlet. It also estimates the appropriate velocity vectors of the metal angles of the fan and EGV which is subjected to different types of vortex at the fan exit. The baseline geometry is revisited and its internal flow-path and exhaust cone are redesigned to illustrate the strong correlation among the components of the propulsor in the PAI domain. The peak efficiency point of the fan/EGV with respect to the blade counts, also known as solidity, and rotational speed is chosen for the cruise condition via parametric studies. The corresponding performance maps are presented. The resulting performance metrics of the new conceptual design of the BLI (Boundary Layer Ingestion) propulsor are analyzed and compared with these of the baseline in the PAI aspect. Finally, ideas of the CFD based design of a BLI propulsor are discussed based on the observations drawn from the numerical results.

Inlet↗

DOE OSTI2024

Heterogeneous Integration Technologies for High-temperature, High-density, Low-profile Power Modules of Wide Bandgap Devices in Electric Drive Applications (Final Technical Report)

The goal of this project is to develop packaging technologies for making high-temperature, high-density, and low-profile wide-bandgap (WBG) power electronics modules for electric drives. These modules are aimed at enabling the DOE’s University Consortium to reach its 2025 inverter targets of ≥ 100 kW/L and ≤ 2.7 $/kW. The specific objectives are to: design and fabricate SiC half-bridge power modules with double-sided cooling and parasitic inductances < 5 nH, heat flux density > 400 W/cm 2 , and working junction temperature of 200 o C; design, fabricate, and deliver a gate driver with double-sided cooled modules for the construction of a 100 kW/L inverter at Oak Ridge National Lab; and design and prototype intelligent gate drivers with integrated current sensor and a low-profile DC-DC power supply with air-core transformer for testing power modules at 200 o C junction temperature. We followed an iterative technical approach of design, simulation, fabrication, and testing of various versions of modules, current sensors, and power supply. The state-of-the-art silicon carbide devices rated at 1.2 kV and 149 A were packaged by sintered-silver bonding on an aluminum nitride direct-bond-copper substrate for high thermal conductivity, high working temperature, and high joint reliability. Porous silver posts were used to interconnect the device’s source pads to the other direct-bond-copper substrate for low mechanical stresses, ease of manufacturing, and double-sided cooling. A current sensor based on package parasitic inductance was developed to measure switching current. A dynamic feedback scheme was developed to compensate the effect of parasitic resistance and temperature variation. A constant-current class-E dc-dc converter with air-core transformer was developed. Air-core transformer was used due to the unavailability of magnetic core at high temperatures. Gate driver and power supply were integrated with the double-side cooled, high temperature SiC power modules for testing the modules at 200 o C junction temperature. Double-pulse and continuous testing of the integrated technologies validated the design and fabrication of the three component technologies. Throughout the project, we overcame the challenge for design verification caused by low prototyping yield, which then helped train the graduate students, the future workforce, to learn the engineering know-how for low-cost manufacturing of reliable products. Below is a summary of the major accomplishments of this project: development of a prototyping process for fabricating double-side cooled (1200 V, 149 A) SiC phase-leg modules capable of working to 200 o C Tj; simulation and experimental verification of the improvement of thermo-mechanical reliability of the double-side cooled SiC phase-leg module by using rigid encapsulant; design and experimental validation of a current sensor based on package parasitic inductance and a compensation solution for eliminating the effect of parasitic resistance; design and experimental validation of a low-profile power supply with six-output air-core transformer for gate driver; functional demonstration of a SiC phase-leg module integrated with its gate driver, current sensor, and an air-core power supply at 200 o C Tj in a double-pulse switching test setup and Buck converter continuous test setup; successful completion of six PhD and two MS students who are or will work at Apple Inc., Tesla Inc., Wolfspeed Inc., Microchip Inc., Monolithic Power Systems Inc., and LG Magna Inc.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1973

A direct procedure for partitioning scanning workload in control display system design

Experimental eye scanning measurements were made from simulated instrument approaches in a flight-like cockpit representing a contemporary jet transport. The procedure for predicting the partition of the pilot's scanning workload required for monitoring and controlling a task with status displays and a flight director was simplified. When there is but a single director control display, iteration in the preliminary design computations is eliminated. The preliminary design computations are based on predictions of closed-loop input-correlated errors in displayed variables with respect to the trimmed flight values. Methods for predicting multiloop error coherence, and for correcting the predicted partition of scanning workload when the pilot's scanning remnant contribution is significant are included.

Clement, W. F.↗

NASA NTRS1999

Viscous Design of TCA Configuration

The goal in this effort is to redesign the baseline TCA configuration for improved performance at both supersonic and transonic cruise. Viscous analyses are conducted with OVERFLOW, a Navier-Stokes code for overset grids, using PEGSUS to compute the interpolations between overset grids. Viscous designs are conducted with OVERDISC, a script which couples OVERFLOW with the Constrained Direct Iterative Surface Curvature (CDISC) inverse design method. The successful execution of any computational fluid dynamics (CFD) based aerodynamic design method for complex configurations requires an efficient method for regenerating the computational grids to account for modifications to the configuration shape. The first section of this presentation deals with the automated regridding procedure used to generate overset grids for the fuselage/wing/diverter/nacelle configurations analysed in this effort. The second section outlines the procedures utilized to conduct OVERDISC inverse designs. The third section briefly covers the work conducted by Dick Campbell, in which a dual-point design at Mach 2.4 and 0.9 was attempted using OVERDISC; the initial configuration from which this design effort was started is an early version of the optimized shape for the TCA configuration developed by the Boeing Commercial Airplane Group (BCAG), which eventually evolved into the NCV design. The final section presents results from application of the Natural Flow Wing design philosophy to the TCA configuration.

Krist, Steven E.↗