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At least 829 records · Page 46

Toward a Generalizable Prediction Model of Molten Salt Mixture Density with Chemistry‐Informed Transfer Learning

Optimally designing applications of molten salts requires knowledge of their thermophysical properties over a wide range of temperatures and compositions. There exist significant gaps in existing databases and this data can be challenging to experimentally measure due to high temperatures, salt corrosivity, and salt hygroscopicity. Existing databases have been used to create Redlich–Kister (RK) models for mixture density showing improved accuracy with respect to ideal mixing assumptions, but these models require subcomponent data measurements for each new system, therefore lacking generality. In order to address generalizability and data sparsity, a transfer learning procedure is proposed to train deep neural networks (DNNs) using a combination of semi‐empirical relationships (RK), data from the thermophysical arm of the molten salt thermal properties database and universal ab initio properties of component mixtures taken from the joint automated repository for various integrated simulations (JARVIS) classical force‐field inspired descriptors database to predict density in molten salts. Herein, it is shown that DNNs predict molten salt density with an r 2 over 0.99 and a mean absolute percentage error under 1%, outperforming alternative methods.

inorganic materials↗

Constitutive model development of aluminum alloy 1100 for elevated temperature forming process

Commercially pure aluminum alloy, AA1100, presents good electrical and thermal conductivity, high formability, and low cost. Those favorable characteristics have the potential to enable bipolar plates with improved economics and enhanced performance compared to current stainless steel bipolar plates for proton exchange membrane fuel cells. An accurate constitutive model is essential to develop and optimize processing parameters and effectively control the forming process. Here, the objective of this work is to develop a constitutive model of AA1100 that is able to simulate stress-strain relation, formed geometry, and predict the onset of fracture strain to avoid forming failure. Initially, a set of tensile tests at temperature between 300 and 500°C and strain rate between 0.005 and 1.0/s were conducted to examine the deformation behavior. Then, a set of damage-based unified visco-plastic constitutive equations is proposed and calibrated based on the results of stress-strain data. A genetic algorithm optimization method is applied to search for best fitting material constants in constitutive equations. The proposed model shows good predictability of both the stress-strain relation and fracture strain at low strain rate and high temperature conditions. The accuracy of proposed model is also evaluated statistically. A comparison of the proposed model with three popular models (Arrhenius-type mode, Johnson-Cook model and Zerilli-Armstrong model) was made. The proposed model shows the best experimental agreement with correlation coefficient of 0.96 in contrast to 0.25, 0.38 and 0.75 for the popular models, respectively. The proposed model can help to optimize the elevated temperature forming process and guide die design to enable optimal geometric features in the formed components.

08 HYDROGEN↗

Additive manufacturing of two-phase lightweight, stiff and high damping carbon fiber reinforced polymer microlattices

Carbon fiber reinforced polymer (CFRP) composite is known for its high stiffness-to-weight ratio and hence is of great interest in several engineering fields such as aerospace, automotive, defense, etc. However, such a composite is not suitable for energy dissipation as failure occurs with very little or no plastic deformation. Herein, we present an extendable multi-material projection microstereolithography process capable of producing carbon-fiber-reinforced cellular materials that achieve simultaneously high specific stiffness and damping coefficient. Inspired by the upper bounds of stiffness-loss coefficient in a two-phase composite, we designed and additively manufactured CFRP microlattices with soft phases architected into selected stiff-phase struts. Our results, confirmed by experimental and analytical calculations, revealed that the damping performance can be significantly enhanced by the addition of only a small fraction of the soft phase. The presented design and additive manufacturing strategy allow for optimizing mutually exclusive properties. As a result, these CFRP microlattices achieved high specific stiffness comparable to commercial CFRP, technical ceramics, and composites, while being dissipative like elastomers.

36 MATERIALS SCIENCE↗

Integrated Design of Ultradurable, Low CO 2 Alternative Binder Systems via Machine Learning

This ARPA-E project developed a machine learning tool to use in formulation design of cementitious binders for concrete having 50% less embodied CO 2 and possessing twice the durability compared to concrete based on ordinary portland cement (OPC) binders. The technical focus was on limestone/calcined clay cement (LC3), the leading replacement for OPC. Here, hierarchical machine learning (HML) was used to model the flowability, set time, strength, and durability of LC3 concrete. This methodology identifies latent variables derived from domain knowledge and empirical models that develop an accurate model for a response surface from small datasets. For the flowability metric, particle packing was a dominant factor, while strength and durability were both strongly determined by the fraction of metakaolin and the water:solids ratio. Under constraints of water:binder ratio, material performance metrics, embodied CO 2 , and cost per tonne of OPC, multi-objective optimization was used to design binders parameterized by the mineral composition replacing OPC, particle size distributions, and water:solids ratio. The trained algorithm was able to predict multiple mixes met these performance criteria, and experimental testing validated the predictions. The model demonstrated here is relevant for North America, where pure kaolin deposits are found broadly. The approach is being taken forward into commercial application by Ansatz AI, a materials informatics company founded by PI Washburn and co-PI Poczos. Through collaborations with the cement and concrete industry, and funding from SBIR programs, a commercial software will be developed in future research.

36 MATERIALS SCIENCE↗

Investigation of Reaction Pathways and Temperature Inhibition in Methane DBD Plasmas at the Princeton Collaborative Research Facility (PCRF)

The overarching goal of this research is to advance the fundamental understanding of plasma-driven chemical conversion of light hydrocarbons using dielectric barrier discharges (DBDs). Using methane (CH 4 ) as a model system, the primary focus is to elucidate the influence of DBD plasma properties and environmental temperature on CH 4 plasma chemistry by studying decomposition products of the gas effluent across a broad range of conditions using experimental instrumentation at the Princeton Collaborative Research Facility (PCRF) located at the Princeton Plasma Physics Laboratory (PPPL). The insights obtained from this study are expected to form the mechanistic foundation for the design and optimization of plasma-catalytic reactions of light hydrocarbons for practical applications such as the recycling of production flare gas by transforming the uncaptured waste into value-added resources at the source of extraction, presenting a sustainable solution to a longstanding environmental challenge.

03 NATURAL GAS↗

Aircraft turbofan noise

Turbofan noise generation and suppression in aircraft engines are reviewed. The chain of physical processes which connect unsteady flow interactions with fan blades to far field noise is addressed. Mechanism identification and description, duct propagation, radiation and acoustic suppression are discussed. The experimental technique of fan inflow static tests are discussed. Rotor blade surface pressure and wake velocity measurements aid in the determination of the types and strengths of the generation mechanisms. Approaches to predicting or measuring acoustic mode content, optimizing treatment impedance to maximize attenuation, translating impedance into porous wall structure and interpreting far field directivity patterns are illustrated by comparisons of analytical and experimental results. The interdependence of source and acoustic treatment design to minimize far field noise is emphasized. Area requiring further research are discussed and the relevance of aircraft turbofan results to quieting other turbomachinery installations is addressed.

Groeneweg, J. F.↗

The performance of an annular vane swirler

In connection with the desirability of optimizing the design of a gas turbine combustion chamber, there exists a need for a more complete understanding of the fluid dynamics of the flow in such chambers. In order to satisfy this need, experimental and theoretical research is being conducted with the objective to study two-dimensional axisymmetric geometries under low speed, nonreacting, turbulent, swirling flow conditions. The flow enters the test section and proceeds into a larger chamber. Inlet swirl vanes are adjustable to a variety of vane angles. The present investigation concentrates on the time-mean flow characteristics which are generated by the upstream annular swirler. The investigation makes use of a five-hole pitot probe technique. A theoretical analysis of swirl numbers associated with several idealized exit velocity profiles is included, and values of the ratio of maximum swirl velocity to maximum axial velocity at different swirl strengths are given for each case.

Lilley, D. G.↗

Aircraft turbofan noise

Turbofan noise generation and suppression in aircraft engines are reviewed. The chain of physical processes which connect unsteady flow interactions with fan blades to far field noise is addressed. Mechanism identification and description, duct propagation, radiation, and acoustic suppression are discussed. The experimental techniques of fan inflow static tests are discussed. Rotor blade surface pressure and wake velocity measurements aid in the determination of the types and strengths of the generation mechanisms. Approaches to predicting or measuring acoustic mode content, optimizing treatment impedance to maximize attenuation, translating impedance into porous wall structure, and interpreting far field directivity patterns are illustrated by comparisons of analytical and experimental results. The interdependence of source and acoustic treatment design to minimize far field noise is emphasized. Areas requiring further research are discussed, and the relevance of aircraft turbofan results to quieting other turbomachinery installation is addressed.

Groeneweg, J. F.↗

A rule-based systems approach to spacecraft communications configuration optimization

An experimental rule-based system for optimizing user spacecraft communications configurations was developed at NASA to support mission planning for spacecraft that obtain telecommunications services through NASA's Tracking and Data Relay Satellite System. Designated Expert for Communications Configuration Optimization (ECCO), and implemented in the OPS5 production system language, the system has shown the validity of a rule-based systems approach to this optimization problem. The development of ECCO and the incremental optimization method on which it is based are discussed. A test case using hypothetical mission data is included to demonstrate the optimization concept.

Rash, James L.↗

Advances in computational design and analysis of airbreathing propulsion systems

The development of commercial and military aircraft depends, to a large extent, on engine manufacturers being able to achieve significant increases in propulsion capability through improved component aerodynamics, materials, and structures. The recent history of propulsion has been marked by efforts to develop computational techniques that can speed up the propulsion design process and produce superior designs. The availability of powerful supercomputers, such as the NASA Numerical Aerodynamic Simulator, and the potential for even higher performance offered by parallel computer architectures, have opened the door to the use of multi-dimensional simulations to study complex physical phenomena in propulsion systems that have previously defied analysis or experimental observation. An overview of several NASA Lewis research efforts is provided that are contributing toward the long-range goal of a numerical test-cell for the integrated, multidisciplinary design, analysis, and optimization of propulsion systems. Specific examples in Internal Computational Fluid Mechanics, Computational Structural Mechanics, Computational Materials Science, and High Performance Computing are cited and described in terms of current capabilities, technical challenges, and future research directions.

Klineberg, John M.↗

A rule-based systems approach to spacecraft communications configuration optimization

An experimental rule-based system for optimizing user spacecraft communications configurations was developed at NASA to support mission planning for spacecraft that obtain telecommunications services through NASA's Tracking and Data Relay Satellite System. Designated Expert for Communications Configuration Optimization (ECCO), and implemented in the OPS5 production system language, the system has shown the validity of a rule-based systems approach to this optimization problem. The development of ECCO and the incremental optimizatin method on which it is based are discussed. A test case using hypothetical mission data is included to demonstrate the optimization concept.

Rash, James L.↗

Advances in computational design and analysis of airbreathing propulsion systems

The development of commercial and military aircraft depends, to a large extent, on engine manufacturers being able to achieve significant increases in propulsion capability through improved component aerodynamics, materials, and structures. The recent history of propulsion has been marked by efforts to develop computational techniques that can speed up the propulsion design process and produce superior designs. The availability of powerful supercomputers, such as the NASA Numerical Aerodynamic Simulator, and the potential for even higher performance offered by parallel computer architectures, have opened the door to the use of multi-dimensional simulations to study complex physical phenomena in propulsion systems that have previously defied analysis or experimental observation. An overview of several NASA Lewis research efforts is provided that are contributing toward the long-range goal of a numerical test-cell for the integrated, multidisciplinary design, analysis, and optimization of propulsion systems. Specific examples in Internal Computational Fluid Mechanics, Computational Structural Mechanics, Computational Materials Science, and High Performance Computing are cited and described in terms of current capabilities, technical challenges, and future research directions.

Klineberg, John M.↗

Optimization of Orifice Geometry for Cross-Flow Mixing in a Cylindrical Duct

Mixing of gaseous jets in a cross-flow has significant applications in engineering, one example of which is the dilution zone of a gas turbine combustor. Despite years of study, the design of jet injection in combustors is largely based on practical experience. A series of experiments was undertaken to delineate the optimal mixer orifice geometry. A cross-flow to core-flow momentum-flux ratio of 40 and a mass flow ratio of 2.5 were selected as representative of an advanced design. An experimental test matrix was designed around three variables: the number of orifices, the orifice aspect ratio (long-to-short dimension), and the orifice angle. A regression analysis was performed on the data to arrive at an interpolating equation that predicted the mixing performance of orifice geometry combinations within the range of the test matrix parameters. Results indicate that mixture uniformity is a non-linear function of the number of orifices, the orifice aspect ratio, and the orifice angle. Optimum mixing occurs when the asymptotic mean jet trajectories are in the range of 0.35 less than r/R less than 0.5 (where r = 0 is at the mixer wall) at z/R = 1.0. At the optimum number of orifices, the difference between shallow-angled slots with large aspect ratios and round holes is minimal and either approach will lead to good mixing performance. At the optimum number of orifices, it appears possible to have two local optimums where one corresponds to an aspect ratio of 1.0 and the other to a high aspect ratio.

Sowa, W. A.↗

Optimization of Orifice Geometry for Cross-Flow Mixing in a Cylindrical Duct

Mixing of gaseous jets in a cross-flow has significant applications in engineering, one example of which is the dilution zone of a gas turbine combustor. Despite years of study, the design of the jet injection in combustors is largely based on practical experience. The emergence of NO(x) regulations for stationary gas turbines and the anticipation of aero-engine regulations requires an improved understanding of jet mixing as new combustor concepts are introduced. For example, the success of the staged combustor to reduce the emission of NO(x) is almost entirely dependent upon the rapid and complete dilution of the rich zone products within the mixing section. It is these mixing challenges to which the present study is directed. A series of experiments was undertaken to delineate the optimal mixer orifice geometry. A cross-flow to core-flow momentum-flux ratio of 40 and a mass flow ratio of 2.5 were selected as representative of a conventional design. An experimental test matrix was designed around three variables: the number of orifices, the orifice length-to- width ratio, and the orifice angle. A regression analysis was performed on the data to arrive at an interpolating equation that predicted the mixing performance of orifice geometry combinations within the range of the test matrix parameters. Results indicate that the best mixing orifice geometry tested involves eight orifices with a long-to-short side aspect ratio of 3.5 at a twenty-three degree inclination from the center-line of the mixing section.

Kroll, J. T.↗

Fluid Distribution for In-space Cryogenic Propulsion

The ultimate goal of this task is to enable the use of a single supply of cryogenic propellants for three distinct spacecraft propulsion missions: main propulsion, orbital maneuvering, and attitude control. A fluid distribution system is sought which allows large propellant flows during the first two missions while still allowing control of small propellant flows during attitude control. Existing research has identified the probable benefits of a combined thermal management/power/fluid distribution system based on the Solar Integrated Thermal Management and Power (SITMAP) cycle. Both a numerical model and an experimental model are constructed in order to predict the performance of such an integrated thermal management/propulsion system. This research task provides a numerical model and an experimental apparatus which will simulate an integrated thermal/power/fluid management system based on the SITMAP cycle, and assess its feasibility for various space missions. Various modifications are done to the cycle, such as the addition of a regeneration process that allows heat to be transferred into the working fluid prior to the solar collector, thereby reducing the collector size and weight. Fabri choking analysis was also accounted for. Finally the cycle is to be optimized for various space missions based on a mass based figure of merit, namely the System Mass Ratio (SMR). -. 1 he theoretical and experimental results from these models are be used to develop a design code (JETSIT code) which is able to provide design parameters for such a system, over a range of cooling loads, power generation, and attitude control thrust levels. The performance gains and mass savings will be compared to those of existing spacecraft systems.

Lear, William↗

High Performance Access to Archival Data Stored in HDF4 and HDF5 on Cloud Object Stores Without Reformatting the Files

Cloud computing offers numerous advantages for users of extensive Earth science data collections. These benefits encompass direct online access to data files and granules from any location, scalable access supporting parallel computing workflows, and flexible computing tools enabling innovative experimentation with processing techniques. However, older archival file formats designed for distinct computing systems hinder efficient access to decade-long time-series data when compared to data stored in modern cloud-optimized formats like Web Object Stores (WOS), exemplified by Amazon Web Services’ Simple Storage Service (S3). We describe DMR++ (Dataset Metadata Response plus plus), a technology facilitating efficient access to HDF5 (Hierarchical Data Format, version 5) and HDF4 files stored on WOS systems without requiring data reformatting. DMR++ achieves performance comparable to technologies like Zarr while preserving the original file structure, a substantial benefit considering the vast quantity of archival files held by organizations such as NASA. Moreover, DMR++ typically outperforms cloud-optimized versions of HDF5. Essentially an XML (Extensible Markup Language) document usually stored alongside the described data, DMR++ can also be generated on-the-fly but is generally created during data staging to the WOS. Archival files that use HDF4/5 often store large arrays of numerical data. The data in these files is often compressed, typically reducing their size by a factor of four or more. To achieve efficient access to portions of those arrays, they are 'chunked' into smaller sub-arrays, each individually compressed. The chunk size is a compromise, where spinning disks can efficiently access data in smaller chunks while S3 favors larger chunks. A simple optimization of aggregating smaller chunks that are stored adjacently, transferring them in a single access and then individually decompressing them will improve performance. NASA data pose an additional challenge: special Application Programmer Interface (API) libraries are often needed to compute some variables. These libraries are incompatible with WOS environments. Our solution involves storing computed values in the DMR++ document or a companion file, making them accessible like other variables and eliminating the need for specialized APIs. We outline specific optimizations for both satellite grid and swath data stored in HDF4-EOS2 (Earth Observing System).

James Gallagher↗

Design of Robust Adaptive Unbalance Response Controllers for Rotors with Magnetic Bearings

Experimental results have recently demonstrated that an adaptive open loop control strategy can be highly effective in the suppression of unbalance induced vibration on rotors supported in active magnetic bearings. This algorithm, however, relies upon a predetermined gain matrix. Typically, this matrix is determined by an optimal control formulation resulting in the choice of the pseudo-inverse of the nominal influence coefficient matrix as the gain matrix. This solution may result in problems with stability and performance robustness since the estimated influence coefficient matrix is not equal to the actual influence coefficient matrix. Recently, analysis tools have been developed to examine the robustness of this control algorithm with respect to structured uncertainty. Herein, these tools are extended to produce a design procedure for determining the adaptive law's gain matrix. The resulting control algorithm has a guaranteed convergence rate and steady state performance in spite of the uncertainty in the rotor system. Several examples are presented which demonstrate the effectiveness of this approach and its advantages over the standard optimal control formulation.

Knospe, Carl R.↗

Design of a High-Pressure Fuel System for Use with Dimethyl Ether

The paper documents the modeling and experimental work on a common rail fuel injection system for Dimethyl Ether, a potential diesel substitute with a low carbon intensity signature. The DME fuel system is deployed on a light duty 2.2L compression ignition engine. The paper describes the injector optimization to shift to higher flows to account for the lower heating value and density of the DME when compared to diesel. The type of the injection system used for the DME application is an advanced rendering of the Common rail noted for a one-piece piston-needle injector construction and a solenoid driven spill valve featuring a pressure balanced poppet. A dedicated high-pressure fuel pump designed to pressurize DME is used. The design results in a fast acting open and close injection event, reduced leakage, with reduced cavitation in the fuel injector volume. Design parameters for system optimization included fill and spill orifices, needle lift, bias spring, and injector hole size. The design model provides good correlation of the instantaneous rates of injection with experiments across a wide range of pressure and injection timings. Proposed performance milestones for the design included similar DME injection duration to the diesel counterpart for same fuel energy injected into the cylinder to retain high engine cycle efficiency. Here, the dedicated DME design provided reduced hydraulic delays of 50%. Tests demonstrated sustained operation at pressures of 1000 bar, with capability to reach 1500bar. Durability tests showed no cavitation-deterioration over a 200-hour test cycle by means of spray imaging and hardware inspection.

De Ojeda, William [WM International Engineering, L↗