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The mathematical models embodied in the simulation are described in considerable detail and with supporting evidence for the model forms chosen. In addition the trimming and linearization algorithms used in the simulation are described. Appendices to the manual identify reference material for estimating the needed coefficients for the input data and provide example simulation results.
Improved nonlinear mathematical model developed to fit experimental data on relaxation of stresses in viscoelastic materials. Developed specifically to study shear moduli of rubbery solid rocket propellants, also used to characterize polymers in general, other viscoelastic materials, and composites of viscoelastic materials. Facilitates and improves accuracy of analysis and numerical simulation of mechanical behavior of structural components (for example, tires) made of such materials.
Rocket-nozzle environment simulation with DC arc- plasma generator noting graphite and phenolic material test results
This material is for presentation at the annual meeting of the NASA Engineering and Safety Center (NESC) Guidance, Navigation, and Control (GNC) Technical Discipline Team (TDT), on 22 July 2020. The briefing is entitled “Vertical Motion Simulator – A Unique Facility for Piloted GNC Research.” It provides a technical description of key VMS features and a high-level overview of some large bodies of work conducted in the VMS over the past 40 years.
Efforts to build a Predictive Material Modeling (PMM) framework from the micro-scale to the macro-scale are presented in this abstract. To reduce the need for extensive testing, accelerate the design cycle process, and reduce uncertainty margins applied to final designs, NASA is developing simulation and modeling tools that enable characterization of material properties and response to high-enthalpy environments. The Porous Microstructure Analysis (PuMA) code has been developed for computing macroscale (volume averaged) properties of porous materials using microscale images from micro-computed tomography (micro-CT). Microscale modeling requires a realistic representation of a material microstructure; these are obtained either synthetically during the design of the material or through X-ray micro-CT. Volume averaged properties are then used to inform macroscale material response models, such as those implemented in the Porous-material Analysis Toolbox based on OpenFOAM (PATO) software, also actively developed by NASA. The computational model in PATO is a generic heat and mass transfer model for porous reactive materials containing several solid phases and a single gas phase. The detailed chemical interactions occurring between the solid phases and the gas phase are modeled at the pore scale assuming local thermal equilibrium. These tools were developed to efficiently interface with other pre-existing codes such as SPARTA (direct simulation Monte Carlo), DPLR (hypersonic CFD), NEQAIR (radiative transport) and DAKOTA (uncertainty quantification and optimization). Detailed flight data (Mars Science Laboratory [MSL] Entry Descent and Landing Instrument [MEDLI]) is critical for validating these computational tools for NASA applications. Examples of modeling ablative material response using these codes will be presented including 3D simulations of the full-scale heatshield of the MSL capsule. The simulations demonstrate the ability of the modern material response code, PATO, to handle the material response of geometrically complex and large domains, through the use of massively parallel computations.
Efforts to build a Predictive Material Modeling (PMM) framework from the micro-scale to the macro-scale are presented in this abstract. To reduce the need for extensive testing, accelerate the design cycle process, and reduce uncertainty margins applied to final designs, NASA is developing simulation and modeling tools that enable characterization of material properties and response to high-enthalpy environments. The Porous Microstructure Analysis (PuMA) code has been developed for computing macroscale (volume averaged) properties of porous materials using microscale images from micro-computed tomography (micro-CT). Microscale modeling requires a realistic representation of a material microstructure; these are obtained either synthetically during the design of the material or through X-ray micro-CT. Volume averaged properties are then used to inform macroscale material response models, such as those implemented in the Porous-material Analysis Toolbox based on OpenFOAM (PATO) software, also actively developed by NASA. The computational model in PATO is a generic heat and mass transfer model for porous reactive materials containing several solid phases and a single gas phase. The detailed chemical interactions occurring between the solid phases and the gas phase are modeled at the pore scale assuming local thermal equilibrium. These tools were developed to efficiently interface with other pre-existing codes such as SPARTA (direct simulation Monte Carlo), DPLR (hypersonic CFD), NEQAIR (radiative transport) and DAKOTA (uncertainty quantification and optimization). Detailed flight data (Mars Science Laboratory [MSL] Entry Descent and Landing Instrument [MEDLI]) is critical for validating these computational tools for NASA applications. Examples of modeling ablative material response using these codes will be presented including 3D simulations of the full-scale heatshield of the MSL capsule. The simulations demonstrate the ability of the modern material response code, PATO, to handle the material response of geometrically complex and large domains, through the use of massively parallel computations.
Spectra or similar Ultra-high-molecular-weight polyethylene (UHMWPE) fabric is the likely choice for future structural space suit restraint materials due to its high strength-to-weight ratio, abrasion resistance, and dimensional stability. During long duration space missions, space suits will be subjected to significant amounts of high-energy radiation from several different sources. To insure that pressure garment designs properly account for effects of radiation, it is important to characterize the mechanical changes to structural materials after they have been irradiated. White Sands Test Facility (WSFTF) collaborated with the Crew and Thermal Systems Division at the Johnson Space Center (JSC) to irradiate and test various space suit materials by examining their tensile properties through blunt probe puncture testing and single fiber tensile testing after the materials had been dosed at various levels of simulated GCR and SPE Iron and Proton beams at Brookhaven National Laboratories. The dosages were chosen based on a simulation developed by the Structural Engineering Division at JSC for the expected radiation dosages seen by space suit softgoods seen on a Mars reference mission. Spectra fabric tested in the effort saw equivalent dosages at 2x, 10x, and 20x the predicted dose as well as a simulated 50 year exposure to examine the range of effects on the material and examine whether any degradation due to GCR would be present if the suit softgoods were stored in deep space for a long period of time. This paper presents the results of this work and outlines the impact on space suit pressure garment design for long duration deep space missions.
Etching of silicon microstructures for semiconductor manufacturing in chlorine plasmas has been well characterized. The etching proceeds in a two-part process, where the chlorine neutrals passivate the Si surface and then the ions etch away SiClx. However, etching in more complicated gas mixtures and materials, such as etching of SiO2 in Ar/C4F8, requires knowledge of the ion and neutral distribution functions as a function of angle and velocity, in addition to modeling the gas surface reactions. In order to address these needs, we have developed and integrated a suite of models to simulate the etching process from the plasma reactor level to the feature profile evolution level. This arrangement allows for a better understanding, control, and prediction of the influence of equipment level process parameters on feature profile evolution. We are currently using the HPEM (Hybrid Plasma Equipment Model) and PCMCM (Plasma Chemistry Monte Carlo Model) to generate plasma properties and ion and neutral distribution functions for argon/fluorocarbon discharges in a GEC Reference Cell. These quantities are then input to the feature scale model, Simulation of Profile Evolution by Level Sets (SPELS). A surface chemistry model is used to determine the interaction of the incoming species with the substrate material and simulate the evolution of the trench profile. The impact of change of gas pressure and inductive power on the relative flux of CFx and F to the wafer, the etch and polymerization rates, and feature profiles will be examined. Comparisons to experimental profiles will also be presented.
Recent successes in Integrated Computational Materials Engineering (ICME) have demonstrated the potential in designing ‘fit-for-purpose’ materials for a given application in a cost and time efficient manner. However, the material design process must contain a level of judicious automation in the material decision process; that is implementing some optimization algorithms to truly enable the benefits of ICME, particularly when considering materials at multiple length and time scales. Furthermore, the ability to effectively store developed material models, experimental data used for validation, and link models at multiple length and time scales must be implemented to ensure traceability across the material design process, such that the data gathered can be leveraged towards efficient material design. To enable such an optimization scheme a robust framework must exist: (1) that can capture changes made at a given length scale, (2) automatically propagate changes upstream to the highest scale, and (3) evaluate the material’s performance at the structural level. In this work, a developed framework for tracking material changes, automatically running the necessary simulations to determine the properties at the next highest scale, and saving each iteration of the design process to maintain the application’s digital thread is presented for polymer matrix composites (PMCs). The Automated Information Management Across Organizations and Scales (AIMAOS) program offers users an interactive graphical user interface (GUI) for defining constituent materials, building lamina and laminates, and applying effective laminate properties to finite element and composite optimization third party software. At each length scale, the necessary input files are automatically written, and subsequent analysis tools are called to solve for effective properties at the next scale, which are then read by the AIMAOS tool and displayed to the user. As changes are made to the material at lower length scales, information is automatically propagated upstream to higher length scales, and changes made are automatically tracked and versioned to maintain traceability during the design process. The AIMAOS tools serves as the first step in enabling optimized design of composites from the nano to the macroscale for a given application.
The NASA Ames COsmic SImulation Chamber (COSmIC) is a unique experimental facility that can be used, among many applications, to produce solid particles from gas phase molecular precursors at low temperature (150 K) using a plasma discharge to induce the chemistry in the stream of a free jet expansion. The choice of the initial gas mixture used to produce the solid sample allows the simulation of either cold planetary atmospheres like Titan or Pluto (with N2/CH4-based initial mixtures), or circumstellar environments (with Ar/CxHy-based initial mixtures). The Ames Optical Constants Facility (OCF) allows the determination of optical constants covering a broad wavelength range with high spectral resolution for solid materials, analogs of organic refractory materials formed in planetary and astrophysical environments. The core of the OCF is a Fourier transform infrared (FTIR) spectrometer that allows the continuous characterization of solid samples in the visible to far-infrared (FIR) range (0.59–200 μm, 16,950–50 cm−1). Modeling of the laboratory measurements conducted with the OCF allows the determination of accurate optical constants, n and k, over the full vis-FIR range. Here we present the latest results of two studies that combined (1) experiments performed with COSmIC to produce analogs of aerosols forming in Titan’s atmosphere and analogs of cosmic grains forming in circumstellar envelops, and (2) the characterization of these analogs with the OCF to provide the real and imaginary parts of their refractive indices, n + ik, to the community, from the visible to the FIR. These optical constants can be used as critical input parameters in radiative transfer, atmospheric and reflectance models to interpret observational data of, e.g., Titan’s atmosphere and protoplanetary disks. Providing optical constants for various materials of different compositions allows to explore a broad range of composition by simulating mixtures of materials. We also present a new project to produce analogs of Pluto’s atmospheric aerosols with COSmIC and determine their optical constants with OCF, to be used in reflectance spectra models for the interpretation of New Horizons observations of Lowell Regio, Sputnik Planitia and Cthulhu.
NASA and Ames is conducting ongoing research in lower density reusable TPS material for future reentry vehicles. Ceramic foams from pre ceramic polymer routes have potential for use in both acreage TPS and as tile leading edges for reentry vehicles. One of the key factors to investigate, when developing new materials for reentry applications, is their oxidation behavior in the appropriate reentry environment whrch can be simulated using ground based arc jet (plasma jet) testing. Studies have shown that oxidation rates of materials will differ when exposed to either monatomatic or molecular oxygen and the amount of monoatomic oxygen depends on the conditions particular to a given test situation. Monoatomic oxygen is always present in reentry environment, therefore arc jet testing is required to provide the appropriate conditions (stagnation pressures, heat fluxes, enthalpies, heat loads and atmospheres) encountered during flight. This preliminary work looks at the response of ceramic foams (Si systems) exposed to simulated reentry environments and investigates the influence of microstructure and composition on the materials response.
A study is undertaken to develop a methodology for determining the suitability of various high-cycle fatigue models for metallic structures subjected to combined thermal-acoustic loadings. Two features of this problem differentiate it from the fatigue of structures subject to acoustic loading alone. Potentially large mean stresses associated with the thermally pre- and post-buckled states require models capable of handling those conditions. Snap-through motion between multiple post-buckled equilibrium positions introduces very high alternating stress. The thermal-acoustic time history response of a clamped aluminum beam structure with geometric and material nonlinearities is determined via numerical simulation. A cumulative damage model is employed using a rainflow cycle counting scheme and fatigue estimates are made for 2024-T3 aluminum using various non-zero mean fatigue models, including Walker, Morrow, Morrow with true fracture strength, and MMPDS. A baseline zero-mean model is additionally considered. It is shown that for this material, the Walker model produces the most conservative fatigue estimates when the stress response has a tensile mean introduced by geometric nonlinearity, but remains in the linear elastic range. However, when the loading level is sufficiently high to produce plasticity, the response becomes more fully reversed and the baseline, Morrow, and Morrow with true fracture strength models produce the most conservative fatigue estimates.
Researchers at NASA Ames in California have built a new facility that uses multiple 50-kW continuous wave lasers to add the capability for simulating radiative heating on thermal protection materials. The new facility, the Laser Enhanced Arc-jet Facility (LEAF-Lite), was added to NASA Ames’s Interaction Heating Facility arc-jet and now allows for test articles to be heated by both convective and radiative heat flux, making the facility more like flight. Using this new system, researchers can now simulate radiant heating with the laser and convective heating with the arc-jet simultaneously on a single test article. During its initial test in October 2017, the lasers radiatively heated a 6” x 6” Avcoat wedge sample to 405 W/sq.cm while the arc-jet simultaneously provided 160 W/sq.cm of convective heat, resulting in a total heat flux of 565 W/sq.cm. Radiative heating is more prevalent in missions with higher atmospheric entry speeds like the Orion space capsule or interplanetary scientific probes. Later this year, scientists will expand the spot size to cover 17” x 17” to test an Orion TPS panel.
The key objectives of this study are to investigate, both computationally and experimentally, which forms, compositions, and layerings of hydrogen, boron, and nitrogen containing materials will offer the greatest shielding in the most structurally robust combination against galactic cosmic radiation (GCR), secondary neutrons, and solar energetic particles (SEP). The objectives and expected significance of this research are to develop a space radiation shielding materials system that has high efficacy for shielding radiation and that also has high strength for load bearing primary structures. Such a materials system does not yet exist. The boron nitride nanotube (BNNT) can theoretically be processed into structural BNNT and used for load bearing structures. Furthermore, the BNNT can be incorporated into high hydrogen polymers and the combination used as matrix reinforcement for structural composites. BNNT's molecular structure is attractive for hydrogen storage and hydrogenation. There are two methods or techniques for introducing hydrogen into BNNT: (1) hydrogen storage in BNNT, and (2) hydrogenation of BNNT (hydrogenated BNNT). In the hydrogen storage method, nanotubes are favored to store hydrogen over particles and sheets because they have much larger surface areas and higher hydrogen binding energy. The carbon nanotube (CNT) and BNNT have been studied as potentially outstanding hydrogen storage materials since 1997. Our study of hydrogen storage in BNNT - as a function of temperature, pressure, and hydrogen gas concentration - will be performed with a hydrogen storage chamber equipped with a hydrogen generator. The second method of introducing hydrogen into BNNT is hydrogenation of BNNT, where hydrogen is covalently bonded onto boron, nitrogen, or both. Hydrogenation of BN and BNNT has been studied theoretically. Hyper-hydrogenated BNNT has been theoretically predicted with hydrogen coverage up to 100% of the individual atoms. This is a higher hydrogen content than possible with hydrogen storage; however, a systematic experimental hydrogenation study has not been reported. A combination of the two approaches may be explored to provide yet higher hydrogen content. The hydrogen containing BNNT produced in our study will be characterized for hydrogen content and thermal stability in simulated space service environments. These new materials systems will be tested for their radiation shielding effectiveness against high energy protons and high energy heavy ions at the HIMAC facility in Japan, or a comparable facility. These high energy particles simulate exposure to SEP and GCR environments. They will also be tested in the LaRC Neutron Exposure Laboratory for their neutron shielding effectiveness, an attribute that determines their capability to shield against the secondary neutrons found inside structures and on lunar and planetary surfaces. The potential significance is to produce a radiation protection enabling technology for future exploration missions. Crew on deep space human exploration missions greater than approximately 90 days cannot remain below current crew Permissible Exposure Limits without shielding and/or biological countermeasures. The intent of this research is to bring the Agency closer to extending space missions beyond the 90-day limit, with 1 year as a long-term goal. We are advocating a systems solution with a structural materials component. Our intent is to develop the best materials system for that materials component. In this Phase I study, we have shown, computationally, that hydrogen containing BNNT is effective for shielding against GCR, SEP, and neutrons over a wide range of energies. This is why we are focusing on hydrogen containing BNNT as an innovative advanced concept. In our future work, we plan to demonstrate, experimentally, that hydrogen, boron, and nitrogen based materials can provide mechanically strong, thermally stable, structural materials with effective radiation shielding against GCR, SEP, and neutrons.
Some experimental and analytical studies of plasma sprayed ZrO2-Y2O3 thick seal thermoprotective materials over NiCrAlY bond coats with testing to 1040 deg C in a Mach 0.3 burner flame are reviewed. These results indicate the need for material to have both compliance and sufficient strength to function successfully as a thick thermoprotective seal material. Fibrous materials may satisfy many of these requirements. A preliminary analysis simulating the simplified behavior of a 25 mm cylindrical SiO2-fiber material indicated significant radial temperature gradients, a relatively cool interface and generally acceptable stresses over the initial portion of the thermal cycle. Subsequent testing of these fiberlike materials in a Mach 0.3 Jet A/air burner flame confirmed these results.
A major long-term goal of the Materials Division at the NASA Langley Research Center is the characterization of new high-performance materials that have potential applications in the aircraft industry, and in space. The materials used for space applications are often subjected to a harsh and potentially damaging radiation environment. The present study constitutes the application of a novel technique to obtain reliable data for ascertaining the molecular basis for the resilience and durability of materials that have been exposed to simulated space radiations. The radiations of greatest concern are energetic electrons and protons, as well as galactic cosmic rays. Presently, the effects of such radiation on matter are not understood in their entirety. It is clear however, that electron radiation causes ionization and homolytic bond rupture, resulting in the formation of paramagnetic spin centers in the polymer matrices of the structural materials. Since the detection and structure elucidation of paramagnetic species are most readily accomplished using Electron Paramagnetic Resonance (EPR) Spectroscopy, the NASA LaRC EPR system was brought back on-line during the 1991 ASEE term. The subsequent 1992 ASEE term was devoted to the adaptation of the EPR core system to meet the requirements for EPR Imaging (EPRI), which provides detailed information on the spatial distribution of paramagnetic species in bulk media. The present (1994) ASEE term was devoted to the calibration of this EPR Imaging system, as well as to the application of this technology to study the effects of electron irradiation on Ultem(exp R), a high performance polymer which is a candidate for applications in aerospace. The Ultem was exposed to a dose of 2.4 x 10(exp 9) Rads (1-MeV energy/electron) at the LaRC electron accelerator facility. Subsequently, the exposed specimens were stored in liquid nitrogen, until immediately prior to analyses by EPRI. The intensity and dimensions of the EPR Images that were generated for the irradiated specimens showed that the electrons penetrated the material to a depth of approximately 0.125 inch. These data show a very high degree of correlation to the energy deposition profile as predicted by the Tiger Code, a Monte Carlo code that provides guidelines for the transport of electrons in matter. Subsequent efforts will focus on delineating the transport properties of energetic protons in Ultem(R).
A simplified inelastic analysis computer program was developed for predicting the stress-strain history of a thermomechanically cycled structure from an elastic solution. The program uses an iterative and incremental procedure to estimate the plastic strains from the material stress-strain properties and a simulated plasticity hardening model. The simplified method was exercised on a number of problems involving uniaxial and multiaxial loading, isothermal and nonisothermal conditions, and different materials and plasticity models. Good agreement was found between these analytical results and nonlinear finite element solutions for these problems. The simplified analysis program used less than 1 percent of the CPU time required for a nonlinear finite element analysis.
Problems involving mesh motion-which should not be mistakenly associated with moving mesh methods, a class of adaptive mesh redistribution techniques-are of critical importance in numerical simulations of the thermal response of melting and ablative materials. Ablation is the process by which material vaporizes or otherwise erodes due to strong heating. Accurate modeling of such materials is of the utmost importance in design of passive thermal protection systems ("heatshields") for spacecraft, the layer of the vehicle that ensures survival of crew and craft during re-entry. In an explicit mesh motion approach, a complete thermal solve is first performed. Afterwards, the thermal response is used to determine surface recession rates. These values are then used to generate boundary conditions for an a posteriori correction designed to update the location of the mesh nodes. Most often, linear elastic or biharmonic equations are used to model this material response, traditionally in a finite element framework so that complex geometries can be simulated. A simple scheme for moving the boundary nodes involves receding along the surface normals. However, for all but the simplest problem geometries, evolution in time following such a scheme will eventually bring the mesh to intersect and "tangle" with itself, inducing failure. This presentation demonstrates a comprehensive and sophisticated scheme that analyzes the local geometry of each node with help from user-provided clues to eliminate the tangle and enable simulations on a wide-class of difficult problem geometries. The method developed is demonstrated for linear elastic equations but is general enough that it may be adapted to other modeling equations. The presentation will explicate the inner workings of the tangle-free mesh motion algorithm for both two and three-dimensional meshes. It will show abstract examples of the method's success, including a verification problem that demonstrates its accuracy and correctness. The focus of the presentation will be on the algorithm; specifics on how the techniques may be used in spacecraft design will be not discussed.