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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 685 records · Page 38
All sourcesNASA NTRSDOE OSTI
NASA NTRS1992

An optical study of grain formation: Casting and solidification technology (2-IML-1)

By studying the unidirectional growth of a metal-model material in microgravity, an attempt is made to characterize alloy solidification. Using holograms and supporting temperature measurements obtained during processing in the Fluids Experiment System (FES), the solute and thermal fields associated with the dendrite growth front and extraneous nucleation will be measured and compared to a theoretical (computational) model. Ground based supporting experiments include particle tracking to measure the velocity fields, and optical phase shift techniques (confocal optical signal processing, interferometry, and Schlieren) to study thermal and solutal fields.

Mccay, Mary H.↗
NASA NTRSDate not supplied

The Porous Microstructure Analysis (PuMA) software

The open-source Porous Microstructure Analysis (PuMA) software was implemented to offer an efficient framework for determining material characteristics from 3D microstructures. Its development was inspired by progress in X-ray microtomography, an imaging technology that captures the internal structure of materials in 3D, and even in a 4D temporal context. Over recent years, this method has transformed the domain of materials science due to its capability to non-destructively examine material microstructures while presenting digital data about their geometrical details. It has provided insights into materials relevant to several NASA missions, including heatshields, parachute fabrics, meteorites, and other advanced composites. PuMA, in its current version 3, delivers an array of features, spanning from basic geometric insights of a microstructure to intricate anisotropic thermo-elastic and chemical behavior. Specifically, the software evaluates morphological attributes (specific surface area, volume fractions, mean intercept lengths, orientation) and physical characteristics (conductivity, elasticity, permeability, and tortuosity). Additionally, it can model material degradation processes, such as oxidation and surface chemistry interactions. The software can generate synthetic microstructures, from straightforward geometrical designs to intricate woven and non-woven geometries. Coupling material generation and characterization enable parametric studies and sensitivity analysis to optimize the microstructural performance and inform design decisions and reliability assessment based on uncertainty quantification. A recent addition to PuMA includes the TomoSAM plugin, devised to incorporate the cutting-edge Segment Anything Model (SAM). SAM is a promptable deep learning model that can identify objects and create image masks in a zero-shot manner, based only on a few user clicks. The synergy between these tools aids in the segmentation of complex 3D datasets from tomography or other imaging techniques, which would otherwise require a laborious manual segmentation process.

Tomography↗
NASA NTRSDate not supplied

The Porous Microstructure Analysis (PuMA) software

The open-source Porous Microstructure Analysis (PuMA) software was created to offer an efficient framework for determining material properties from 3D microstructures. Its development was inspired by progress in X-ray microtomography, an imaging technology that captures the internal structure of materials in 3D, and even in a 4D temporal context. Over recent years, this method has transformed the domain of materials science due to its capability to non-destructively examine material microstructures while presenting digital data about their geometrical details. It has provided insights into materials relevant to several NASA missions, including heatshields, parachute fabrics, meteorites, and other advanced composites. PuMA, in its current version 3, delivers an array of features, spanning from basic geometric insights of a microstructure to intricate anisotropic thermo-elastic and chemical behavior. Specifically, the software evaluates morphological attributes (specific surface area, volume fractions, mean intercept lengths, orientation) and physical characteristics (conductivity, elasticity, permeability, and tortuosity). Additionally, it can model material degradation processes, such as oxidation and surface chemistry interactions. The software can generate synthetic microstructures, from straightforward geometrical designs to intricate woven and non-woven geometries. Coupling material generation and characterization enables parametric studies and sensitivity analysis to optimize the microstructural performance and inform design decisions and reliability assessment based on uncertainty quantification. A recent addition to PuMA includes the TomoSAM plugin, devised to incorporate the cutting-edge Segment Anything Model (SAM) into our image segmentation workflow. SAM is a promptable deep learning model that can identify objects and create image masks in a zero-shot manner, based only on a few user clicks. The synergy between these tools aids in the segmentation of complex 3D datasets from tomography and other imaging techniques, which would otherwise require a laborious manual segmentation process.

Tomography↗
DOE OSTI2022

Benchmarking and Exploring Parameter Space of the 2-Phase Bubble Tracking Model for Liquid Mercury Target Simulation

High intensity proton pulses strike the Spallation Neutron Source (SNS)’s mercury target to provide bright neutron beams. These strikes deposit extensive energy into the mercury and its steel vessel. Prediction of the resultant loading on the target is difficult when helium gas is intentionally injected into the mercury to reduce the loading and to mitigate the pitting damage on the vessel. A 2-phase material model that incorporates the Rayleigh-Plesset (R-P) model is expected to address this complex multi-physics dynamics problem by including the bubble dynamics in the liquid mercury. We present a study comparing the measured target strains in the SNS target station with the simulation results of the solid mechanics simulation framework. We investigate a wide range of various physical model parameters, including the number of bubble families, bubble size distribution, viscosity, surface tension, etc. to understand their impact on simulation accuracy. Our initial findings reveal that using 8-10 bubble families in the model renders a simulation strain envelope that covers the experimental ones. Further optimization studies are planned to predict the strain response more accurately.

Lin, Lianshan↗
NASA NTRS2012

Crystallographic Stability of Metastable Phase Formed by Containerless Processing in REFeO3 (RE: Rare-Earth Element)

Undercooling a melt often facilitates a metastable phase to nucleate preferentially. Although the classical nucleation theory shows that the most critical factor for forming a metastable phase is the interface free energy, the crystallographic stability is also indispensable for the phase to be frozen at ambient temperature. In compound materials such as oxides, authors have suggested that the decisive factors for forming a critical nucleus are not only the free energy difference but also the difference of the entropy of fusion between stable and metastable phases. In the present study, using REFeO3 (RE: rare-earth element) as a model material, we investigate the formation of a metastable phase from undercooled melts with respect to the competitive nucleation and crystallographical stabilities of both phases.

Kuribayashi, Kazuhiko↗
DOE OSTI2020

Improvements to the New CTH Code Verification & Validation Test Suite (FY2020)

The CTH multiphysics hydrocode, which is used for a wide range of important calculations, has undertaken in recent years to overhaul its software quality and testing processes. A key part of this effort entailed building a new, robust V&V test suite made up of traditional hydrocode verification problems, such as those listed in the ASC Tri-Lab Test Suite and the Enhanced Tri-Lab Test Suite, as well as validation problems for some of CTHs most frequently used equations of state, materials models, and other key capabilities. Substantial progress towards this goal was made in FY19. In FY20, this test suite has been expanded to include verification and validation tests of the Sesame and JWL equation of state models as well as the Mader verification problem from the Tri-Lab Test Suite and the Blake verification problem - a linear elastic analog to the Hunter problem from the Enhanced Tri-Lab Test Suite. This report documents CTH performance on the new test suite problems. Verification test results are compared to analytic solutions and, for most tests, convergence results are presented. Validation test results are compared to experimental data and mesh refinement studies are included. CTH performs well overall on the new test problems. Convergence rates for the Blake and Mader problems are comparable to those for similar ASC codes. The JWL and Sesame verification tests show good agreement with analytic solutions. Likewise, CTH simulation results show good agreement with experimental validation data for the Sesame and JWL equations of state for the materials tested. Future V&V work will focus on adding tests for other key capabilities like fracture and high explosive models.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2023

Benchmarking Microscale Ductility Measurements (Final Report of the Project DE-NE0008799)

Conventional macroscale experimentation is generally considered to be straightforward with few limitations. Conversely, micro/nanoscale experimentation presents numerous challenges in loading device design, sample preparation and handling, as well as accurate understanding of grain size and local texture effects on recorded measurements. Despite these challenges, nanopillar compression, MEMs based micro-tension, and nanoindentation approaches have been able to provide fundamental contributions to the understanding of material behavior at small lengthscales. However, the overarching shortcoming of these micro/nanoscale experimentation approaches, is the inability to directly translate measurements evaluated at the nm and µm length scales (e.g., hardness) to macroscale tensile material behavior (i.e., elastic modulus, yield strength, and ductility). The objectives of the proposed study are, 1) to establish best practices for obtaining tensile microscale ductility measurements, and 2) to validate methodologies to for comparing microscale ductility measurements to macroscale ductility measurements. In order to achieve these objectives, a multi-lengthscale, multi-temperature testing protocol and simulation framework are executed first on copper as a model material to validate the following approach, and second on reactor grade Zircaloy-2. Experiments are conducted on specimens extracted from the same test piece to ensure nominally identical grain size and texture from specimens to specimen. Motivated by the need to isolate the contribution of size-effects on obtained mechanical property measurements, specimens are manufactured with thicknesses at the micro- (1-10 µm), meso- (10-100's µm), and macroscales (sub-sized ASTM E8). In-situ full-field deformation techniques (scanning electron microscopy (SEM) grid methods and optical DIC) are incorporated into testing at each specimen length-scale to capture plasticity localization and evolution. Experimental testing for all specimens is conducted at both room temperature and elevated temperatures to probe the role of thermal activation on plastic deformation accommodation processes. Simulation efforts focus on examining the mechanical behavior of microscale specimens using a finite element approach with explicitly resolved grain morphologies, and an embedded crystal plasticity model. The cost-efficient implementation method allows for the modeling of a statistically significant number of both real (i.e., digital twin) and generated microstructures to obtain an understanding of the interrelationships between specimen microstructure and geometric variables (grain size, texture, specimen geometry, etc.) on microscale mechanical behavior.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

New Developments In NASA’s Entry Systems Modeling Project

This paper describes recent developments for modeling entry, descent, and landing (EDL)of spacecraft in support of NASA’s exploration missions. Mission-specific research and model development for entry systems occurs across the Agency (e.g., within flight programs like Artemis/Orion and Mars Sample Return), however the aim of this paper is to discuss the research conducted by NASA’s Entry Systems Modeling (ESM) Project, which serves as the Agency’s only effort dedicated to advancing modeling capabilities that cross-cut multiple technical disciplines, missions and destinations. The ESM portfolio is developed to address the specific needs expressed by a cross-section of NASA stakeholders, including flight and research projects, technical leadership, and subject matter experts. Technology development in ESM is organized and prioritized from a system-level perspective, resulting in four broad technical areas of investment: (1) Thermal Protection System (TPS) material modeling, (2) Shock layer kinetics and radiation, (3) Aerosciences, and (4) Guidance, navigation, and control. In addition to the core technical areas, special topics are rolled into the project portfolio as specific demands arise. Current special topics include TPS Certification by Analysis, improving understanding of woven TPS material performance; Hypersonic Wake Flows, assessing and improving predictions of base flows; and the MEDLI2 Deep Dive, furthering analysis of data obtained during Mars2020 mission’s entry and descent at Mars. Key results from each of these areas are presented in this paper, along with associated references to serve as a roadmap for other EDL researchers to access NASA’s publications.

Aaron M Brandis↗
DOE OSTI2025

Failure Strain and Related Triaxiality of Aluminum 6061-T6, A36 Carbon Steel, 304 Stainless Steel, and Nitronic 60 Metals, Part I: Experimental Investigation

The objective of this study is to develop failure-limit material models for Aluminum 6061-T6, A36 Carbon Steel, 304 Stainless Steel, and Nitronic 60 metals, based on parameters of plastic equivalent strain (failure strain) and stress triaxiality. The research is conducted in two parts. This paper presents Part One of the study. In Part One, custom-designed test specimens undergo controlled uniaxial tension and compression testing at ambient temperature. These tests are performed at quasi-static speeds using Universal Testing Machines (UTMs) in accordance with ASTM E8 and ASTM E9 standards. Experimental data, specifically engineering stress–strain and force–displacement curves, are recorded from the onset of loading until specimen fracture, or in the case of compression tests, until the capacity of the testing machine is reached. In Part Two, the emphasis shifts to the calibration of Finite Element Analysis (FEA) models of the custom-designed test specimens. Plastic equivalent strain and the corresponding stress triaxiality values at failure are extracted from each test specimen for the given metal. These values are then systematically plotted onto a single graph to construct the failure-limit curve, which delineates the boundary conditions for material failure. This approach will facilitate the development of a comprehensive material property definition that correlates plastic equivalent strain with stress triaxiality at failure for Aluminum 6061-T6, A36 Carbon Steel, 304 Stainless Steel, and Nitronic 60 metals.

Harwell, Ron↗
NASA NTRS2022

Validation of a High-Fidelity Supersonic Parachute Inflation Dynamics Model and Best Practice

The parachute inflation dynamics (PID) of a Disk-Gap-Band (DGB) parachute system travelling at supersonic velocities in the high-altitude Earth atmosphere is simulated using a high-fidelity, multiphysics, massively-parallel computational framework. The sensitivity of the simulation results with respect to critical modelling and simulation parameters, including the fluid mechanical governing equations (Euler vs Navier-Stokes with RANS turbulence closure vs Navier-Stokes with LES turbulence closer), the interaction between the flow and the suspension lines (accounted for vs not accounted for), the dynamics of the payload (restrained vs free), and the material model of the heterogeneous fabric canopy (Saint-Venant Kirchoff vs mechanics-informed multiscale neural network), is extensively investigated. The parameter investigation is enabled by advancements to the state-of-the-art in the modelling and simulation of the supersonic parachute inflation process, which are presented as part of the computational framework. The predictive quality of the computational framework in the context of supersonic PID is validated by comparison of the simulation results with the experimental results from NASA’s Advanced Supersonic Parachute Research (ASPIRE) project. Through the validation, best practices for the modelling and simulation of supersonic PID are developed and proposed.

Rabinovitch, Jason↗
NASA NTRS2024

Mechanical Testing of Soils from the South Range of the Utah Test and Training Range: Derivation of Soil Properties to Support the Earth Entry System Landing for Mars Sample Return

This report summarizes results from laboratory tests conducted by Applied Research Associates, Inc. (ARA) on soil samples collected from multiple sites within the South Range of the U.S. Air Force Utah Test and Training Range (UTTR). The goal of the laboratory tests was to establish soil constitutive properties and develop computational soil models enabling NASA to simulate impact landings of the Earth Entry System (EES) for the Mars Sample Return (MSR) mission. Test methods and results are presented describing the strength, compressibility, and stiffness of soils in the UTTR South Range including methods to incorporate the measured properties into Ansys LS-DYNAÒ constitutive material models for EES landing simulations.

Soil↗
DOE OSTI2020

Accelerating Ab Initio Simulation via Nested Monte Carlo and Machine Learned Reference Potentials

As a corollary of the rapid advances in computing, ab initio simulation is playing an increasingly important role in modeling materials at the atomic scale. Two strategies are possible, ab initio Monte Carlo (AIMC) and molecular dynamics (AIMD) simulation. The former benefits from exact sampling from the correct thermodynamic distribution, while the latter is typically more efficient with its collective all-atom coordinate updates. In this study, using a relatively simple test model comprised of helium and argon, we show that AIMC can be brought up to, and even above, the performance levels of AIMD via a hybrid nested sampling/machine learning (ML) strategy. Here, ML provides an accurate classical reference potential (up to three-body explicit interactions) that can pilot long collective Monte Carlo moves that are accepted or rejected in toto à la nested Monte Carlo (NMC); this is in contrast to the single move nature of a naive implementation. Our proposed method only requires a small up front expense from evaluating the ab initio energies and forces of (100) random configurations for training. Importantly, our method does not totally rely on the trained, assuredly imperfect, interaction. We show that high performance and exact sampling at the desired level of theory can be realized even when the trained interaction has appreciable differences from the ab initio potential. Remarkably, at the highest levels of performance realized via our approach, a pair of statistically uncorrelated atomic configurations can be generated with (1) ab initio calculations.

74 ATOMIC AND MOLECULAR PHYSICS↗
NASA NTRS2006

Quasi-Static 3-Point Reinforced Carbon-Carbon Bend Test and Analysis for Shuttle Orbiter Wing Leading Edge Impact Damage Thresholds

Static 3-point bend tests of Reinforced Carbon-Carbon (RCC) were conducted to failure to provide data for additional validation of an LS-DYNA RCC model suitable for predicting the threshold of impact damage to shuttle orbiter wing leading edges. LS-DYNA predictions correlated well with the average RCC failure load, and were good in matching the load vs. deflection. However, correlating the detectable damage using NDE methods with the cumulative damage parameter in LS-DYNA material model 58 was not readily achievable. The difficulty of finding internal RCC damage with NDE and the high sensitivity of the mat58 damage parameter to the load near failure made the task very challenging. In addition, damage mechanisms for RCC due to dynamic impact of debris such as foam and ice and damage mechanisms due to a static loading were, as expected, not equivalent.

Fasanella, Edwin L.↗
DOE OSTI2026

Fast and accurate calculation of EXAFS Debye-Waller factors in U⁢O2 using the dynamical matrix method

Theoretical modeling of bonding dynamics in metal oxides is required for predicting their thermal conductivity, catalytic activity, and mechanical properties. A primary challenge is the scarcity of experimental methods for validating theoretical predictions of these atomic-scale dynamics. This work presents a workflow that uses experimental extended x-ray absorption fine structure (EXAFS) data collected at high temperatures to validate an interatomic force field for uranium dioxide (UO2), an important model material. The validated force field is then used to drive computationally intensive molecular dynamics (MD) simulations and as input for the much faster dynamical matrix Debye-Waller (DMDW) method. The predicted values of the Debye-Waller factors from the DMDW calculations are in good agreement with those obtained from the MD simulations, with residual pair-specific differences attributable to quantum zero-point motion at low temperatures and lattice anharmonicity at high temperatures. We further show that theoretical EXAFS spectra constructed directly from DMDW-derived Debye-Waller factors reproduce the experimental data (at relatively low temperatures) with accuracy comparable to full MD-EXAFS, providing an additional validation of the choice of the potential. This study establishes a validated, rapid computational pathway for modeling bond dynamics, naturally incorporating quantum nuclear\\\\r\\\\nstatistics absent in classical simulations, which are essential for the mechanistic understanding of complex oxide materials.

58 GEOSCIENCES↗
NASA NTRS1988

Life assessment of combustor liner using unified constitutive models

Hot section components of gas turbine engines are subject to severe thermomechanical loads during each mission cycle. Inelastic deformation can be induced in localized regions leading to eventual fatigue cracking. Assessment of durability requires reasonably accurate calculation of the structural response at the critical location for crack initiation. In recent years nonlinear finite element computer codes have become available for calculating inelastic structural response under cyclic loading. NASA-Lewis sponsored the development of unified constitutive material models and their implementation in nonlinear finite element computer codes for the structural analysis of hot section components. These unified models were evaluated with regard to their effect on the life prediction of a hot section component. The component considered was a gas turbine engine combustor liner. A typical engine mission cycle was used for the thermal and structural analyses. The analyses were performed on a CRAY computer using the MARC finite element code. The results were compared with laboratory test results, in terms of crack initiation lives.

Tong, M. T.↗
DOE OSTI2025

Automated Redox Titrations via Interdigitated Electrode Arrays: Application to the Mediated Electron Transfer Interrogation of Charge and Rate on Electrodeposited Polymers

Mediated electron transfer (MET) plays a crucial role in energy storage and conversion technologies such as redox targeting flow batteries (RTFBs), yet its experimental investigation often requires labor-intensive and low-throughput setups. To address this, we developed a microfabricated interdigitated electrode array (IDA) platform that enables automated, high-throughput electrochemical redox titration measurement to be performed to study the MET process. Our redox titration method enables simultaneous measurement of the charge capacity and rate of MET processes on a material or surface. Automated redox titration (ART) facilitates systematic investigation of the MET process across a broad parameter space, exemplified through the study of polypyrrole (PPy) and a pyrene-4,5,9,10-tetrone azo group-based polymer (PTAP), both redox-active polymers relevant to various energy storage applications. Using PPy as a model material, 500 redox titration measurements were conducted within 50 h, varying the electrode gap widths, polymer charging potentials, voltammetric scan rates, and electrolyte concentrations. Finite-element simulations confirmed the electrochemical responses and elucidated the kinetics of the MET reactions. Our automated methodology was further tested with PTAP, revealing a surprising charging potential dependence on the rate of MET. The automation, flexibility, and scalability of our redox titration platform pave the way not only for advanced studies of MET processes relevant to RTFBs, but also with implications in the understanding of next-generation energy storage materials, molecular electrocatalysis, and biosensing.

electrochemical analysis↗
DOE OSTI2026

Finite deformation implementation of a mixed-mode single-integral type cohesive zone with reorienting surfaces of separation

To model material ductile failure and crack propagation, cohesive zone elements can be embedded along potential fracture paths in a finite element simulation. When damage criteria are met, elements in the mesh decohere, simulating the formation and propagation of a crack. In this paper, we present a novel computational algorithm based on finite deformation theory, essential to modeling crack initiation and growth in solids undergoing large deformations. This new algorithm was formulated within a Lagrangian frame of reference to extend previous cohesive zone algorithms to include modeling crack growth in finite deformation contexts. The local coordinate system, necessary for defining an embedded cohesive zone, is constructed based upon the current configuration and is updated within the nonlinear iteration process, thereby resulting in the convergence of the solution for a growing crack in a large deformation quasi-static setting. The model’s accuracy was demonstrated by comparing finite element model simulation results with the analytic case of a constant surface separation, as shown in the verification examples. The power and efficacy of the algorithm to capture large deformations during crack growth were then demonstrated with a double cantilever beam example case. It indicates that the model can be applied to a variety of physical circumstances for predicting crack initiation and growth with delamination and fracture.

42 ENGINEERING↗