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At least 739 records · Page 41

Session on High Speed Civil Transport Design Capability Using MDO and High Performance Computing

Since the inception of CAS in 1992, NASA Langley has been conducting research into applying multidisciplinary optimization (MDO) and high performance computing toward reducing aircraft design cycle time. The focus of this research has been the development of a series of computational frameworks and associated applications that increased in capability, complexity, and performance over time. The culmination of this effort is an automated high-fidelity analysis capability for a high speed civil transport (HSCT) vehicle installed on a network of heterogeneous computers with a computational framework built using Common Object Request Broker Architecture (CORBA) and Java. The main focus of the research in the early years was the development of the Framework for Interdisciplinary Design Optimization (FIDO) and associated HSCT applications. While the FIDO effort was eventually halted, work continued on HSCT applications of ever increasing complexity. The current application, HSCT4.0, employs high fidelity CFD and FEM analysis codes. For each analysis cycle, the vehicle geometry and computational grids are updated using new values for design variables. Processes for aeroelastic trim, loads convergence, displacement transfer, stress and buckling, and performance have been developed. In all, a total of 70 processes are integrated in the analysis framework. Many of the key processes include automatic differentiation capabilities to provide sensitivity information that can be used in optimization. A software engineering process was developed to manage this large project. Defining the interactions among 70 processes turned out to be an enormous, but essential, task. A formal requirements document was prepared that defined data flow among processes and subprocesses. A design document was then developed that translated the requirements into actual software design. A validation program was defined and implemented to ensure that codes integrated into the framework produced the same results as their standalone counterparts. Finally, a Commercial Off the Shelf (COTS) configuration management system was used to organize the software development. A computational environment, CJOPT, based on the Common Object Request Broker Architecture, CORBA, and the Java programming language has been developed as a framework for multidisciplinary analysis and Optimization. The environment exploits the parallelisms inherent in the application and distributes the constituent disciplines on machines best suited to their needs. In CJOpt, a discipline code is "wrapped" as an object. An interface to the object identifies the functionality (services) provided by the discipline, defined in Interface Definition Language (IDL) and implemented using Java. The results of using the HSCT4.0 capability are described. A summary of lessons learned is also presented. The use of some of the processes, codes, and techniques by industry are highlighted. The application of the methodology developed in this research to other aircraft are described. Finally, we show how the experience gained is being applied to entirely new vehicles, such as the Reusable Space Transportation System. Additional information is contained in the original.

Rehder, Joe↗

Electronic Performance Support for Operational Systems: A Case Study of the Link Monitor and Control Operator Assistant

For complex operational systems, help needs to come from the inside out. It is often not realistic to call a help desk for problems that need immediate attention, especially for tasks that put a heavy cognitive load on the system operator. This session addresses the issues associated with providing electronic performance support for operational systems, including situations where the system is already fielded and can only change through evolution rather than revolution. We present a case study based on our experiences in developing the Link Monitor and Control Operator Assistant for NASA's Deep Space Network (DSN). The goals of the Operator Assistant are to improve the operability of the system and increase the efficiency of mission operations.

Hill, Randall W., Jr.↗

SSME Investment in Turbomachinery Inducer Impeller Design Tools and Methodology

Within the rocket engine industry, SSME turbomachines are the de facto standards of success with regard to meeting aggressive performance requirements under challenging operational environments. Over the Shuttle era, SSME has invested heavily in our national inducer impeller design infrastructure. While both low and high pressure turbopump failures/anomaly resolution efforts spurred some of these investments, the SSME program was a major benefactor of key areas of turbomachinery inducer-impeller research outside of flight manifest pressures. Over the past several decades, key turbopump internal environments have been interrogated via highly instrumented hot-fire and cold-flow testing. Likewise, SSME has sponsored the advancement of time accurate and cavitating inducer impeller computation fluid dynamics (CFD) tools. These investments together have led to a better understanding of the complex internal flow fields within aggressive high performing inducers and impellers. New design tools and methodologies have evolved which intend to provide confident blade designs which strike an appropriate balance between performance and self induced load management.

Zoladz, Thomas↗

Spray-On Foam Insulations for Launch Vehicle Cryogenic Tanks

Spray-on foam insulation (SOFI) has been developed for use on the cryogenic tanks of space launch vehicles beginning in the 1960s with the Apollo program. The use of SOFI was further developed for the Space Shuttle program. The External Tank (ET) of the Space Shuttle, consisting of a forward liquid oxygen tank in line with an aft liquid hydrogen tank, requires thermal insulation over its outer surface to prevent ice formation and avoid in-flight damage to the ceramic tile thermal protection system on the adjacent Orbiter. The insulation also provides system control and stability with throughout the lengthy process of cooldown, loading, and replenishing the tank. There are two main types of SOFI used on the ET: acreage (with the rind) and closeout (machined surface). The thermal performance of the seemingly simple SOFI system is a complex of many variables starting with the large temperature difference of from 200 to 260 K through the typical 25-mm thickness. Environmental factors include air temperature and humidity, wind speed, solar exposure, and aging or weathering history. Additional factors include manufacturing details, launch processing operations, and number of cryogenic thermal cycles. The study of the cryogenic thermal performance of SOFI under large temperature differentials is the subject of this article. The amount of moisture taken into the foam during the cold soak phase, termed Cryogenic Moisture Uptake, must also be considered. The heat leakage rates through these foams were measured under representative conditions using laboratory standard liquid nitrogen boiloff apparatus. Test articles included baseline, aged, and weathered specimens. Testing was performed over the entire pressure range from high vacuum to ambient pressure. Values for apparent thermal conductivity and heat flux were calculated and compared with prior data. As the prior data of record was obtained for small temperature differentials on non-weathered foams, analysis of the different methods is provided. Recent advancements and applications of SOFI systems on future launch vehicles and spacecraft are also addressed.

Fesmire, J. E.↗

Material Characterization and Geometric Segmentation of a Composite Structure Using Microfocus X-Ray Computed Tomography Image-Based Finite Element Modeling

This study utilizes microfocus x-ray computed tomography (CT) slice sets to model and characterize the damage locations and sizes in thermal protection system materials that underwent impact testing. ScanIP/FE software is used to visualize and process the slice sets, followed by mesh generation on the segmented volumetric rendering. Then, the local stress fields around several of the damaged regions are calculated for realistic mission profiles that subject the sample to extreme temperature and other severe environmental conditions. The resulting stress fields are used to quantify damage severity and make an assessment as to whether damage that did not penetrate to the base material can still result in catastrophic failure of the structure. It is expected that this study will demonstrate that finite element modeling based on an accurate three-dimensional rendered model from a series of CT slices is an essential tool to quantify the internal macroscopic defects and damage of a complex system made out of thermal protection material. Results obtained showing details of segmented images; three-dimensional volume-rendered models, finite element meshes generated, and the resulting thermomechanical stress state due to impact loading for the material are presented and discussed. Further, this study is conducted to exhibit certain high-caliber capabilities that the nondestructive evaluation (NDE) group at NASA Glenn Research Center can offer to assist in assessing the structural durability of such highly specialized materials so improvements in their performance and capacities to handle harsh operating conditions can be made.

Abdul-Aziz, Ali↗

NASA Phase2 Unlimited Rights Final Report Research and Technology for Aerospace Propulsion Systems (RTAPS) Task Order: ERA Advanced Core Compressor Technology Program

As part of the NASA Integrated Systems Research Program (ISRP), Environmentally Responsible Aviation (ERA) Project, NASA GRC and GE Aviation have partnered to investigate the technology barriers associated with improved fuel economy of large gas turbine engines. Crucial to improving fuel economy is the increase in pressure ratio (PR) of the core high pressure compressor (HPC). A key enabler to increasing HPC pressure ratios are new technology front stage airfoil designs that have higher efficiency, higher pressure ratios and improvements in front stage part-power operability. The purpose of this work is to design and test two high pressure ratio, high efficiency front block designs. The baseline design, hereafter referred to as Build 1, is similar to what would be found in a high efficiency 30:1 PR class HPC. A redesigned front block with improved blading will also be tested and hereafter be referred to as Build 2. The goal of Build 2 is to increase stage aero loading (increase stage pressure ratio) beyond Build 1 while maintaining equivalent efficiency and stall margin. The detailed inter-stage and traverse data from the two builds will be used to improve understanding of the complex flow physics at high-speed and part-speed conditions that impact performance and operability. By addressing, understanding and solving the challenges associated with aerodynamic losses and stage matching better design strategies can be incorporated in future core compressors with higher efficiency, thereby enabling improvement in mission fuel burn while still meeting operability requirements.

Axial Compressors↗

Monolithic Flexure Pre-Stressed Ultrasonic Horns

High-power ultrasonic actuators are generally assembled with a horn, backing, stress bolt, piezoelectric rings, and electrodes. The manufacturing process is complex, expensive, difficult, and time-consuming. The internal stress bolt needs to be insulated and presents a potential internal discharge point, which can decrease actuator life. Also, the introduction of a center hole for the bolt causes many failures, reducing the throughput of the manufactured actuators. A new design has been developed for producing ultrasonic horn actuators. This design consists of using flexures rather than stress bolts, allowing one to apply pre-load to the piezoelectric material. It also allows one to manufacture them from a single material/plate, rapid prototype them, or make an array in a plate or 3D structure. The actuator is easily assembled, and application of pre-stress greater than 25 MPa was demonstrated. The horn consists of external flexures that eliminate the need for the conventional stress bolt internal to the piezoelectric, and reduces the related complexity. The stress bolts are required in existing horns to provide prestress on piezoelectric stacks when driven at high power levels. In addition, the manufacturing process benefits from the amenability to produce horn structures with internal cavities. The removal of the pre-stress bolt removes a potential internal electric discharge point in the actuator. In addition, it significantly reduces the chances of mechanical failure in the piezoelectric stacks that result from the hole surface in conventional piezoelectric actuators. The novel features of this disclosure are: 1. A design that can be manufactured from a single piece of metal using EDM, precision machining, or rapid prototyping. 2. Increased electromechanical coupling of the horn actuator. 3. Higher energy density. 4. A monolithic structure of a horn that consists of an external flexure or flexures that can be used to pre-stress a solid piezoelectric structure rather than a bolt, which requires a through hole in the piezoelectric material. 5. A flexure system with low stiffness that accommodates mechanical creep with minor reduction in pre-stress.

Sherrit, Stewart↗

Accurate interlaminar stress recovery from finite element analysis

The accuracy and robustness of a two-dimensional smoothing methodology is examined for the problem of recovering accurate interlaminar shear stress distributions in laminated composite and sandwich plates. The smoothing methodology is based on a variational formulation which combines discrete least-squares and penalty-constraint functionals in a single variational form. The smoothing analysis utilizes optimal strains computed at discrete locations in a finite element analysis. These discrete strain data are smoothed with a smoothing element discretization, producing superior accuracy strains and their first gradients. The approach enables the resulting smooth strain field to be practically C1-continuous throughout the domain of smoothing, exhibiting superconvergent properties of the smoothed quantity. The continuous strain gradients are also obtained directly from the solution. The recovered strain gradients are subsequently employed in the integration o equilibrium equations to obtain accurate interlaminar shear stresses. The problem is a simply-supported rectangular plate under a doubly sinusoidal load. The problem has an exact analytic solution which serves as a measure of goodness of the recovered interlaminar shear stresses. The method has the versatility of being applicable to the analysis of rather general and complex structures built of distinct components and materials, such as found in aircraft design. For these types of structures, the smoothing is achieved with 'patches', each patch covering the domain in which the smoothed quantity is physically continuous.

Tessler, Alexander↗

Exploring Sustained Food Production in the Veggie Vegetable Production System

Since 2014, the Veggie vegetable production system on the International Space Station has intermittently supplied astronaut crews with fresh produce. To assess the potential for continuous crop production in Veggie and develop a baseline for future space crop production systems, a 120-day study was conducted to determine methodology for inputs, optimal yield, food safety standards, and crew involvement. ‘Amara’ mustard and ‘Red Russian’ kale were grown as initial crops, followed by ‘Extra Dwarf’ pakchoi and shungiku as final crops. Previous grow-outs in Veggie have included harvests at 28-35 days after initiation. In this study, a 56-day grow-out with multiple harvests from the same plants was compared to the conventional, single harvest Veggie schedule. Unlike previous Veggie studies which grew all plants simultaneously, this test staggered initiation and harvest, aiming for consistent and increased production. Plant pillows were initiated in pairs weekly and positioned to reduce shading. Completed pillows were immediately replaced with fresh ones. The multi-harvest scheme used fewer pillows, totaling 46% less pillow mass than the single harvest method. Yield varied by crop and harvest scheme, when compared as fresh edible biomass production across 56-day time increments. ‘Red Russian’ kale yielded similarly across harvest schemes. In the multiple-harvest schedule, ‘Amara’ mustard and shungiku yielded 23% to 25% higher, respectively, while ‘Extra Dwarf’ pakchoi had 43% lower yield. Microbial analysis of the plants indicated no culturable human pathogens. Microbial load of a given plant appeared to depend more on system age than plant age; across harvest methods, aerobic plate counts from final crops were higher than those of initial crops. This project also considered the complexity of crew involvement in a continuous production scenario. New crew procedures that periodically remove plant material from the Veggie root mat would be needed under continuous production to prevent potential pathogens and unpleasant odors. This study supports future space crop production scenarios and was funded by NASA’s Human Research Program.

Jess M Bunchek↗

Sustained Veggie: A Continuous Food Production Comparison

The International Space Station’s Veggie system intermittently supplies the crew with fresh produce. To assess the potential for continuous crop production in Veggie and develop a baseline for future space crop production systems, a 120-day study was conducted to determine methodology for inputs, optimal yield, and crew involvement. ‘Amara’ mustard and ‘Red Russian’ kale were grown as initial crops, followed by ‘Extra Dwarf’ pak choi and shungiku as final crops. Previous grow-outs in Veggie have included harvests at 28-35days after initiation. In this study, a 56-day grow-out with multiple harvests from the same plants was compared to the conventional, single harvest Veggie schedule. Unlike previous Veggie studies which grew all plants simultaneously, this test staggered initiation and harvest, aiming for consistent and increased production. Plant pillows were initiated in pairs weekly and positioned to reduce shading. Completed pillows were immediately replaced with fresh ones. The multi-harvest scheme used fewer pillows, totaling 46% less pillow mass than the single harvest method. Scaled to 56-day increments, yield varied by crop and harvest scheme. ‘Red Russian’ kale yielded similarly across harvest schemes. In the multiple-harvest schedule, ‘Amara’ mustard and shungiku yielded 23% to 25% higher, respectively, while ‘Extra Dwarf’ pak choi had43% lower yield. Microbial analysis of the plants indicated no culturable human pathogens. Microbial load of a given plant appears to depend more on system age than plant age. Across harvest methods, aerobic plate counts from final crops were higher than those of initial crops. This project also considered the complexity of crew involvement in a continuous production scenario. New crew procedures that periodically remove plant material from the Veggie root mat are needed under continuous production to prevent potential pathogens and unpleasant odors. This study supports future space crop production scenarios and was funded by NASA’s Human Research Program.

Jess M Bunchek↗

The Coupling Between Tropical Meteorology, Aerosol Lifecycle, Convection, and Radiation, During the Clouds, Aerosol and Monsoon Processes Philippines Experiment (CAMP2Ex)

The NASA Cloud, Aerosol, and Monsoon Processes Philippines Experiment (CAMP2Ex) employed the NASA P-3, Stratton Park Engineering Company (SPEC) Learjet 35, and a host of satellites and surface sensors to characterize the coupling of aerosol processes, cloud physics, and atmospheric radiation within the Maritime Continent’s complex southwest monsoonal environment. Conducted in the late summer of 2019 from Luzon Philippines in conjunction with the Office of Naval Research Propagation of Intraseasonal Tropical OscillatioNs (PISTON) experiment with its R/VSally Ride stationed in the North Western Tropical Pacific, CAMP2Ex documented diverse biomass burning, industrial and natural aerosol populations and their interactions with small to congestus convection. The 2019 season exhibited El Nino and associated drought, high biomass burning emissions, and an early monsoon transition allowing for observation of pristine to massively polluted environments as they advected through intricate diurnal mesoscale and radiative environments into the monsoonal trough. CAMP2Ex’s preliminary results indicate 1) increasing aerosol loadings tend to invigorate congestus convection in height and increase liquid water paths; 2) lidar, polarimetry, and geostationary Advanced Himawari Imager remote sensing sensors have skill in quantifying diverse aerosol and cloud properties and their interaction; and 3) high resolution remote sensing technologies are able to greatly improve our ability to evaluate the radiation budget in complex cloud systems. Through the development of innovative informatics technologies, CAMP2Ex provides a benchmark dataset of an environment of extremes for the study of aerosol, cloud and radiation processes as well as a crucible for the design of future observing systems.

CAMP2Ex↗

Investigation of Three-Dimensional Stress Fields and Slip Systems for FCC Single Crystal Superalloy Notched Specimens

Metals and their alloys, except for a few intermetallics, are inherently ductile, i.e. plastic deformation precedes fracture in these materials. Therefore, resistance to fracture is directly related to the development of the plastic zone at the crack tip. Recent studies indicate that the fracture toughness of single crystals depends on the crystallographic orientation of the notch as well as the loading direction. In general, the dependence of crack propagation resistance on crystallographic orientation arises from the anisotropy of (i) elastic constants, (ii) plastic deformation (or slip), and (iii) the weakest fracture planes (e.g. cleavage planes). Because of the triaxial stress state at the notch tips, many slip systems that otherwise would not be activated during uniaxial testing, become operational. The plastic zone formation in single crystals has been tackled theoretically by Rice and his co-workers and only limited experimental work has been conducted in this area. The study of the stresses and strains in the vicinity of a FCC single crystal notch tip is of relatively recent origin. We present experimental and numerical investigation of 3D stress fields and evolution of slip sector boundaries near notches in FCC single crystal tension test specimens, and demonstrate that a 3D linear elastic finite element model that includes the effect of material anisotropy is shown to predict active slip planes and sectors accurately. The slip sector boundaries are shown to have complex curved shapes with several slip systems active simultaneously near the notch. Results are presented for surface and mid-plane of the specimens. The results demonstrate that accounting for 3D elastic anisotropy is very important for accurate prediction of slip activation near FCC single crystal notches loaded in tension. Results from the study will help establish guidelines for fatigue damage near single crystal notches.

Arakere, Nagaraj K.↗

Acoustic emission monitoring of polymer composite materials

The techniques of acoustic emission monitoring of polymer composite materials is described. It is highly sensitive, quasi-nondestructive testing method that indicates the origin and behavior of flaws in such materials when submitted to different load exposures. With the use of sophisticated signal analysis methods it is possible the distinguish between different types of failure mechanisms, such as fiber fracture delamination or fiber pull-out. Imperfections can be detected while monitoring complex composite structures by acoustic emission measurements.

Bardenheier, R.↗

A finite element overlay technique for modeling pinned composite joints

A finite element technique using overlaid plane stress elements is presented for modeling a pinned composite joint. The technique allows for discrete modeling of the pin and web regions of the joint in a two-dimensional (2-D) finite element analysis. Thus, predictive capability is substantially increased without the added complexity of a three-dimensional (3-D) analysis. The overlay technique requires a thorough evaluation of the model constraints between the joint components. Bearing panels are used to account for a reduced compressive modulus under bearing loads. Application of the plane stress overlay technique to the Filament Wound Case (FWC) Program is discussed. The experimental approach to determine bearing panel moduli using a double lap shear test is detailed, and finite element results are correlated with full-scale FWC joint test results.

Colvin, G. E.↗

Impact of Tropospheric Aerosol Absorption on Ozone Retrieval from buv Measurements

The impact of tropospheric aerosols on the retrieval of column ozone amounts using spaceborne measurements of backscattered ultraviolet radiation is examined. Using radiative transfer calculations, we show that uv-absorbing desert dust may introduce errors as large as 10% in ozone column amount, depending on the aerosol layer height and optical depth. Smaller errors are produced by carbonaceous aerosols that result from biomass burning. Though the error is produced by complex interactions between ozone absorption (both stratospheric and tropospheric), aerosol scattering, and aerosol absorption, a surprisingly simple correction procedure reduces the error to about 1%, for a variety of aerosols and for a wide range of aerosol loading. Comparison of the corrected TOMS data with operational data indicates that though the zonal mean total ozone derived from TOMS are not significantly affected by these errors, localized affects in the tropics can be large enough to seriously affect the studies of tropospheric ozone that are currently undergoing using the TOMS data.

Torres, O.↗

Inviscid and Viscous CFD Analysis of Booster Separation for the Space Launch System Vehicle

This paper presents details of Computational Fluid Dynamic (CFD) simulations of the Space Launch System during solid-rocket booster separation using the Cart3D inviscid and Overflow viscous CFD codes. The discussion addresses the use of multiple data sources of computational aerodynamics, experimental aerodynamics, and trajectory simulations for this critical phase of flight. Comparisons are shown between Cart3D simulations and a wind tunnel test performed at NASA Langley Research Center's Unitary Plan Wind Tunnel, and further comparisons are shown between Cart3D and viscous Overflow solutions for the flight vehicle. The Space Launch System (SLS) is a new exploration-class launch vehicle currently in development that includes two Solid Rocket Boosters (SRBs) modified from Space Shuttle hardware. These SRBs must separate from the SLS core during a phase of flight where aerodynamic loads are nontrivial. The main challenges for creating a separation aerodynamic database are the large number of independent variables (including orientation of the core, relative position and orientation of the boosters, and rocket thrust levels) and the complex flow caused by exhaust plumes of the booster separation motors (BSMs), which are small rockets designed to push the boosters away from the core by firing partially in the direction opposite to the motion of the vehicle.

Viscous↗

Daily Kilometer-Scale MODIS Satellite Maps of PM2.5 Describe Wintertime Episodes

The San Joaquin Valley (SJV) suffers from severe health-endangering episodes of PM2.5 aerosol loadings in wintertime; episodes last approximately 5 days and differ in geographical distribution and composition. PM2.5 stations are scattered; consequently the use of remote sensing to map variable regional patterns of these varying respirable aerosol concentrations is desirable. High-precision AOT retrievals can capture column particulate loading. However,PM2.5 mapping is challenging due to several reasons: particularly thin mixed layers (ML) and thus relatively low aerosol optical thickness (AOT) close to current measurement limits, variable and a typical composition of the aerosols, and complex surface bidirectional reflectance. However, the West does present some advantages in analysis. Air basins are isolated from long-distance transport, and experience predominant strong meteorological subsidence. Thus these Western basin regions have fewer problematic cases of overriding aerosol layers detached from the surface. To counter such local overriding, Chu et al. have described an approach for the Eastern US, and He et al have described a synoptic classification approach useful in Shanghai. The Bay Area Air Quality Management District (BAAQMD) expands our experience with the use of AOT, with lower PM2.5 and several isolated sub-basins. We have prepared daily maps of episodes in each region. We present also a sequence of increasingly detailed statistical models, AOT initially appears to contribute little information; however, inclusion of weather information reveals its utility. Lyapustin and Wang's MultiAngle Implementation of Atmospheric Correction (MAIAC) retrieval for AOT provided the most useful operational remote sensing information for these regions. It provides high (1-km) spatial resolution maps and a high percentage of availability. Empirical regression methods have found that random effects regression models (aka mixed effects models, ME) employing AOT provide good estimates of ground PM2.5 concentrations.Here, we attempt to extend these methods and evaluate the usefulness of AOT with greater physical analysis, based on DISCOVER-AQ4 experience.

Chatfield, Robert B.↗

Fluid-Structure Interaction Simulations of the ASPIRE SR01 Supersonic Parachute

High-fidelity computational fluid dynamics (CFD) simulations have so far only played exploratory and supporting roles in the study and qualification of parachutes for planetary entry. The last few years have seen the maturation of coupled computational methods that are capable of modeling the complex fluid-structure interactions between a parachute canopy and the supersonic flow in the wake of an entry vehicle in flight conditions. One of the primary goals of these methods is to predict the peak opening load experienced by the parachute during inflation. The Launch, Ascent, and Vehicle Aerodynamics (LAVA)team is developing efficient, high-fidelity numerical methods to perform such challenging fluid-structure interaction simulations. A loose coupling approach is used to advance the solutions of a Cartesian ghost cell immersed boundary method CFD solver and a finite element computational structural dynamics (CSD) solver in space and time. The coupled solver is employed to simulate the ASPIRE SR01 flight test, where a build-to-print version of the Mars Science Laboratory parachute was inflated in supersonic conditions in the upper terrestrial atmosphere. The simulations conducted in the current paper predict a peak opening load that is within 10% of that from the flight test. Grid convergence with respect to the volume and structural domains is demonstrated, and less than 1% variation in the peak opening load is predicted between all grid resolutions.

ARMD↗