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At least 937 records · Page 52
All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Reliability Quantification of the Flexure: A Critical Stirling Convertor Component

Uncertainties in the manufacturing, fabrication process, material behavior, loads, and boundary conditions results in the variation of the stresses and strains induced in the flexures and its fatigue life. Past experience and the test data at material coupon levels revealed a significant amount of scatter of the fatigue life. Owing to these facts, the design of the flexure, using conventional approaches based on safety factor or traditional reliability based on similar equipment considerations does not provide a direct measure of reliability. Additionally, it may not be feasible to run actual long term fatigue tests due to cost and time constraints. Therefore it is difficult to ascertain material fatigue strength limit. The objective of the paper is to present a methodology and quantified results of numerical simulation for the reliability of flexures used in the Stirling convertor for their structural performance. The proposed approach is based on application of finite element analysis method in combination with the random fatigue limit model, which includes uncertainties in material fatigue life. Additionally, sensitivity of fatigue life reliability to the design variables is quantified and its use to develop guidelines to improve design, manufacturing, quality control and inspection design process is described.

Shah, Ashwin R.↗
NASA NTRS2010

Vibration Response Predictions for Heavy Panel Mounted Components from Panel Acreage Environment Specifications

The development of new launch vehicles in the Aerospace industry often relies on response measurements taken from previously developed vehicles during various stages of liftoff and ascent, and from wind tunnel models. These measurements include sound pressure levels, dynamic pressures in turbulent boundary layers and accelerations. Rigorous statistical scaling methods are applied to the data to derive new environments and estimate the performance of new skin panel structures. Scaling methods have proven to be reliable, particularly for designs similar to the vehicles used as the basis for scaling, and especially in regions of smooth acreage without exterior protuberances or heavy components mounted to the panel. To account for response attenuation of a panel-mounted component due to its apparent mass at higher frequencies, the vibroacoustics engineer often reduces the acreage vibration according to a weight ratio first suggested by Barrett. The accuracy of the reduction is reduced with increased weight of the panel-mounted component, and does not account for low-frequency amplification of the component/panel response as a system. A method is proposed that combines acreage vibration from scaling methods with finite element analysis to account for the frequency-dependent dynamics of heavy panel-mounted components. Since the acreage and mass-loaded skins respond to the same dynamic input pressure, such pressure may be eliminated in favor of a frequency-dependent scaling function applied to the acreage vibration to predict the mass-loaded panel response. The scaling function replaces the Barrett weight ratio, and contains all of the dynamic character of the loaded and unloaded skin panels. The solution simplifies for spatially uncorrelated and fully correlated input pressures. Since the prediction uses finite element models of the loaded and unloaded skins, a rich suite of response data are available to the design engineer, including interface forces, stress and strain, as well as acceleration and displacement. An extension of the method is also developed to incorporate the effect of a local protuberance near a heavy component. Acreage environments from traditional scaling methods with and without protuberance effects serve as the basis for the extension. Authors:

Harrison, Phillip↗
NASA NTRS1991

Finite element computation of compressible flows with the SUPG formulation

Finite element computation of compressible Euler equations is presented in the context of the streamline-upwind/Petrov-Galerkin (SUPG) formulation. The SUPG formulation, which is based on adding stabilizing terms to the Galerkin formulation, is further supplemented with a shock capturing operator which addresses the difficulty in maintaining a satisfactory solution near discontinuities in the solution field. The shock capturing operator, which has been derived from work done in entropy variables for a similar operator, is shown to lead to an appropriate level of additional stabilization near shocks, without resulting in excessive numerical diffusion. An implicit treatment of the impermeable wall boundary condition is also presented. This treatment of the no-penetration condition offers increased stability for large Courant numbers, and accelerated convergence of the computations for both implicit and explicit applications. Several examples are presented to demonstrate the ability of this method to solve the equations governing compressible fluid flow.

Le Beau, G. J.↗
NASA NTRS1959

Vacuum-Induction, Vacuum-Arc, and Air-Induction Melting of a Complex Heat-Resistant Alloy

The relative hot-workability and creep-rupture properties at 1600 F of a complex 55Ni-20Cr-15Co-4Mo-3Ti-3Al alloy were evaluated for vacuum-induction, vacuum-arc, and air-induction melting. A limited study of the role of oxygen and nitrogen and the structural effects in the alloy associated with the melting process was carried out. The results showed that the level of boron and/or zirconium was far more influential on properties than the melting method. Vacuum melting did reduce corner cracking and improve surface during hot-rolling. It also resulted in more uniform properties within heats. The creep-rupture properties were slightly superior in vacuum heats at low boron plus zirconium or in heats with zirconium. There was little advantage at high boron levels and air heats were superior at high levels of boron plus zirconium. Vacuum heats also had fewer oxide and carbonitride inclusions although this was a function of the opportunity for separation of the inclusions from high oxygen plus nitrogen heats. The removal of phosphorous by vacuum melting was not found to be related to properties. Oxygen plus nitrogen appeared to increase ductility in creep-rupture tests suggesting that vacuum melting removes unidentified elements detrimental to ductility. Oxides and carbonitrides in themselves did not initiate microcracks. Carbonitrides in the grain boundaries of air heats did initiate microcracks. The role of microcracking from this source and as a function of oxygen and nitrogen content was not clear. Oxygen and nitrogen did intensify corner cracking during hot-rolling but were not responsible for poor surface which resulted from rolling heats melted in air.

Decker, R. F.↗
NASA NTRS1989

Acoustic wave propagation in heterogeneous structures including experimental validation

A finite element model was developed to solve for the acoustic pressure and energy fields in a heterogeneous suppressor. The derivations from the governing equations assumed that the material properties could vary with position resulting in a heterogeneous variable property two-dimensional wave equation. This eliminated the necessity of finding the boundary conditions between different materials. For a two media region consisting of part air and part bulk absorber, a model was used to describe the bulk absorber properties in two directions. Complex metallic structures inside the air duct are simulated by simply changing element properties from air to the structural material in a pattern to describe the desired shapes. To verify the numerical theory, experiments were conducted without flow in a rectangular duct with a single folded cavity mounted above the duct and absorbing material mounted inside a cavity. Changes in a nearly plane wave sound field were measured on the wall opposite the absorbing cavity. Fairly good agreement was found in the standing wave pattern upstream of the absorber and in the decay of pressure level opposite the absorber, as a function of distance along the duct. The finite element model provides a convenient method for evaluating the acoustic properties of bulk absorbers.

Baumeister, Kenneth J.↗
NASA NTRS1989

Acoustic wave propagation in heterogeneous structures including experimental validation

A finite element model was developed to solve for the acoustic pressure and energy fields in a heterogeneous suppressor. The derivations from the governing equations assumed that the material properties could vary with position resulting in a heterogeneous variable property two-dimensional wave equation. This eliminated the necessity of finding the boundary conditions between different materials. For a two-media region consisting of part air and part bulk absorber, a model was used to describe the bulk absorber properties in two directions. Complex metallic structures inside the air duct are simulated by simply changing element properties from air to the structural material in a pattern to describe the desired shapes. To verify the numerical theory, experiments were conducted without flow in a rectangular duct with a single folded cavity mounted above the duct and absorbing material mounted inside a cavity. Changes in a nearly plane wave sound field were measured on the wall opposite the absorbing cavity. Fairly good agreement was found in the standing wave pattern upstream of the absorber and in the decay of pressure level opposite the absorber, as a function of distance along the duct. The finite element model provides a convenient method for evaluating the acoustic properties of bulk absorbers.

Baumeister, Kenneth J.↗
NASA NTRSDate not supplied

Finite Element Modeling for Compression Strength Prediction of Honeycomb Cores with Geometric Imperfections Measured using X-ray CT Imaging

Aluminum honeycomb cores have been used extensively in composite sandwich panels due to having high bending rigidity while maintaining low density. During manufacturing of the aluminum honeycomb, the thin metal walls are susceptible to imperfections that deviate from an ideal honeycomb shape. Computational tools to quantify imperfections and investigate their effects on quasi-static compression and impact response can inform design criteria to construct safer and lighter launch vehicle structures. This paper presents the results of a study on finite element modeling of metallic honeycomb cores (HCC) with geometric imperfections measured using X-ray Computer Tomography (CT), to predict the compression response. Finite element (FE) models are constructed with measured imperfections with appropriate boundary conditions. It is shown that the average behavior of larger 10x11 cell models can be predicted by sampling single cell models from the larger domain. Amplification of imperfections for cells at the center of sampled specimens are mode switched from the larger out-of-plane imperfection to the mode shape of the adjacent cells resulting in strengthening of the center specimens.

aluminum honeycomb↗
NASA NTRS1975

Vertical velocity structure and geometry of clear air convective elements

The paper discusses observations of individual convective elements with a high-power narrow-beam scanning radar, an FM-CW radar, and an acoustic sounder, including the determination of the vertical air velocity patterns of convective structures with the FM-CW radar and acoustic sounder. Data are presented which link the observed velocity structure and geometrical patterns to previously proposed models of boundary layer convection. It is shown that the high-power radar provides a clear three-dimensional picture of convective cells and fields over a large area with a resolution of 150 m, where the convective cells are roughly spherical. Analysis of time-height records of the FM-CW radar and acoustic sounder confirms the downdraft-entrainment mechanism of the convective cell. The Doppler return of the acoustic sounder and the insect-trail slopes on FM-CW radar records are independent but redundant methods for obtaining the vertical velocity patterns of convective structures.

Rowland, J. R.↗
NASA NTRS2022

Multi-Scale Modelling of the Bound Metal Deposition Manufacturing of Ti6Al4V

Nonlinear shrinkage of the metal part during manufacturing by bound metal deposition, both on the ground and under microgravity, is considered. A multi-scale physics-based approach is developed to address the problem. It spans timescales from atomistic dynamics on the order of nanoseconds to full-part shrinkage on the order of hours. This approach enables estimation of the key parameters of the problem, including the widths of grain boundaries, the coefficient of surface diffusion, the initial redistribution of particles during the debinding stage, the evolution of the microstructure from round particles to densely-packed grains, the corresponding changes in the total and chemical free energies, and the sintering stress. The method has been used to predict shrinkage at the levels of two particles, of the filament cross-section, of the sub-model, and of the whole green, brown, and metal parts.

Nonlinear shrinkage↗
NASA NTRS1996

Coupled Structural, Thermal, Phase-change and Electromagnetic Analysis for Superconductors, Volume 2

Described are the theoretical development and computer implementation of reliable and efficient methods for the analysis of coupled mechanical problems that involve the interaction of mechanical, thermal, phase-change and electromag subproblems. The focus application has been the modeling of superconductivity and associated quantum-state phase change phenomena. In support of this objective the work has addressed the following issues: (1) development of variational principles for finite elements, (2) finite element modeling of the electromagnetic problem, (3) coupling of thermel and mechanical effects, and (4) computer implementation and solution of the superconductivity transition problem. The main accomplishments have been: (1) the development of the theory of parametrized and gauged variational principles, (2) the application of those principled to the construction of electromagnetic, thermal and mechanical finite elements, and (3) the coupling of electromagnetic finite elements with thermal and superconducting effects, and (4) the first detailed finite element simulations of bulk superconductors, in particular the Meissner effect and the nature of the normal conducting boundary layer. The theoretical development is described in two volumes. Volume 1 describes mostly formulation specific problems. Volume 2 describes generalization of those formulations.

Felippa, C. A.↗
NASA NTRS1996

Coupled Structural, Thermal, Phase-Change and Electromagnetic Analysis for Superconductors

Described are the theoretical development and computer implementation of reliable and efficient methods for the analysis of coupled mechanical problems that involve the interaction of mechanical, thermal, phase-change and electromagnetic subproblems. The focus application has been the modeling of superconductivity and associated quantum-state phase-change phenomena. In support of this objective the work has addressed the following issues: (1) development of variational principles for finite elements, (2) finite element modeling of the electromagnetic problem, (3) coupling of thermal and mechanical effects, and (4) computer implementation and solution of the superconductivity transition problem. The main accomplishments have been: (1) the development of the theory of parametrized and gauged variational principles, (2) the application of those principled to the construction of electromagnetic, thermal and mechanical finite elements, and (3) the coupling of electromagnetic finite elements with thermal and superconducting effects, and (4) the first detailed finite element simulations of bulk superconductors, in particular the Meissner effect and the nature of the normal conducting boundary layer. The theoretical development is described in two volumes. This volume, Volume 1, describes mostly formulations for specific problems. Volume 2 describes generalization of those formulations.

Felippa, C. A.↗
NASA NTRS2024

X-57 Cruise Motor GVT Using Fixed-Base Correction Technique

The National Aeronautics and Space Administration (NASA) Armstrong Flight Research Center (AFRC) completed a modal survey of the X-57 Maxwell aircraft cruise motor system to help inform cruise motor redesign efforts. X-57 Maxwell was an electric propulsion demonstrator aircraft developed by NASA to inform airworthiness standards for electrified-aircraft. The cruise motor system modal survey was completed in spring of 2023 utilizing the fixed-base correction (FBC) ground vibration test (GVT) technique developed by ATA Engineering, to decouple the motor modes from the aircraft modes. Previously during the full aircraft GVT, a detailed modal assessment of the cruise motors was not performed. Owing to the X-57 project’s phase in the aircraft development cycle when the motor redesign effort occurred, the cruise motor GVT could only be performed with the cruise motor system installed on the aircraft, with most of its installation hardware (wiring, baffling, sensors, etc.) attached. An impact hammer was used to provide excitation input at various locations within the tight confines of the cruise motor installation. To better support motor redesign efforts, the FBC methodology was utilized to fix, separate and de-couple the cruise motor modes from aircraft modal response. During the GVT, this required additional impact tap tests on candidate fixed-boundary points for each degree of freedom (DOF) to be fixed. Additional triaxial accelerometers installed at the candidate points were used to compute frequency response functions (FRFs) in X, Y, and Z directions to enable those DOFs to be numerically fixed. Test data was acquired using Hottinger Brüel & Kjær’s LAN-XI data acquisition hardware and BK Connect software. FBC post-test processing was performed using the Structural Modification Using Frequency Response Functions (SMURF) technique with ATA Engineering’s Interface between MATLAB, Analysis, Test (IMAT) software. Utilizing the FBC technique relieved test engineers from having to instrument the entire aircraft to identify and separate aircraft response from cruise motor modes of interest. The FBC technique also permitted structural analysis engineers to omit secondary components from their finite element model (FEM) of the cruise motor system. This FBC modal survey was successful, and the first time NASA AFRC utilized the FBC method on an aircraft rather than a test fixture, and also using an impact hammer rather than multiple shakers allowing significant project schedule and cost savings

Modal Survey↗
NASA NTRS2021

Analysis of Nonlinear Shrinkage for the Bound Metal Deposition Manufacturing using Multi-scale Approach

We consider problem of nonlinear shrinkage of the metal part during bound metal deposition manufacturing on the ground and in zero-G. To analyze this problem we developed multi-scale physics-based approach that spans atomistic dynamics at the scale of nanoseconds and the full part shrinkage at the time scale of hours. Using this approach we estimated the key parameters of the problem including grain boundary width, coefficient of surface diffusion, initial redistribution of particles during debinding stage, micro-structure evolution from round particles to densely packed grains and corresponding change of the total and chemical free energy, and sintering stress. The introduced method was used to predict shrinkage at the level of two particles, filament cross-section, sub-model, and the whole green, brown, and metal parts. To further improve accuracy and reliability of the shrinkage predictions we propose concept of intelligent additive manufacturing of metal powders in space that combines the strengths of both physics-based and data-driven methods of analysis of AM.

bound metal deposition↗
NASA NTRS2014

Multiscale Analysis of Structurally-Graded Microstructures Using Molecular Dynamics, Discrete Dislocation Dynamics and Continuum Crystal Plasticity

A multiscale modeling methodology is developed for structurally-graded material microstructures. Molecular dynamic (MD) simulations are performed at the nanoscale to determine fundamental failure mechanisms and quantify material constitutive parameters. These parameters are used to calibrate material processes at the mesoscale using discrete dislocation dynamics (DD). Different grain boundary interactions with dislocations are analyzed using DD to predict grain-size dependent stress-strain behavior. These relationships are mapped into crystal plasticity (CP) parameters to develop a computationally efficient finite element-based DD/CP model for continuum-level simulations and complete the multiscale analysis by predicting the behavior of macroscopic physical specimens. The present analysis is focused on simulating the behavior of a graded microstructure in which grain sizes are on the order of nanometers in the exterior region and transition to larger, multi-micron size in the interior domain. This microstructural configuration has been shown to offer improved mechanical properties over homogeneous coarse-grained materials by increasing yield stress while maintaining ductility. Various mesoscopic polycrystal models of structurally-graded microstructures are generated, analyzed and used as a benchmark for comparison between multiscale DD/CP model and DD predictions. A final series of simulations utilize the DD/CP analysis method exclusively to study macroscopic models that cannot be analyzed by MD or DD methods alone due to the model size.

Saether, Erik↗
NASA NTRS2015

Investigation of Micro-Scale Architectural Effects on Damage of Composites

This paper presents a three-dimensional, energy based, anisotropic, stiffness reduction, progressive damage model for composite materials and composite material constituents. The model has been implemented as a user-defined constitutive model within the Abaqus finite element software package and applied to simulate the nonlinear behavior of a damaging epoxy matrix within a unidirectional composite material. Three different composite microstructures were considered as finite element repeating unit cells, with appropriate periodicity conditions applied at the boundaries. Results representing predicted transverse tensile, longitudinal shear, and transverse shear stress-strain curves are presented, along with plots of the local fields indicating the damage progression within the microstructure. It is demonstrated that the damage model functions appropriately at the matrix scale, enabling localization of the damage to simulate failure of the composite material. The influence of the repeating unit cell geometry and the effect of the directionality of the applied loading are investigated and discussed.

damage↗
NASA NTRS1999

History of Ozone Research: From Schonbein to the Present

In 1840, C.F. Schonbein recognized that the smell generated in several different electrical and chemical processes was a single substance. He named this substance "ozein" from the Greek for "to smell". This substance we know today as ozone. Several periods can be distinguished in the continued development of our understanding of ozone. Throughout the late 19th century, the identity and properties of ozone were established and described. Ozone was recognized to be a constituent of normal air and tests were established to measure its concentration. Its disinfectant properties were recognized. New methods were developed for making ozone in the laboratory. In 1879, ultraviolet spectroscopic techniques were applied to the measurement of the solar spectrum and it was discovered by Comu that the spectrum was cut off at about 300 nm wavelength. Hartley suggested, based on laboratory measurements, that this cutoff was due to ozone in the atmosphere which he correctly asserted was somewhere in the upper atmosphere. This began the period of development of the amount and distribution of ozone throughout the atmosphere. In 1930, Chapman put forward the first theory of the formation and destruction of ozone. By the mid-1960s it was becoming obvious that the description of the chemical loss term was inadequate. By the early 1970s the chemical destruction of ozone by the oxides of hydrogen, nitrogen, chlorine, and bromine was recognized as an essential element in the chemical balance determining the ozone concentration. Today, ozone is a broad research project which crosses the boundaries of traditional disciplines. Stratospheric ozone loss due to chlorofluorocarbons is a newsworthy item. The Antarctic ozone hole opens up every spring. The provisions of the Montreal Protocol were agreed upon by countries around the world and promise to reduce the future levels of ozone-destroying chlorine in the stratosphere. Ozone concentrations in polluted cities are a subject of local and national regulations to limit its potential for causing health problems and corrosive effects on materials. A lot is known about ozone but many new questions are still being developed.

Stolarski, Richard S.↗
NASA NTRS1993

Coupled structural, thermal, phase-change and electromagnetic analysis for superconductors, volume 1

This research program has dealt with the theoretical development and computer implementation of reliable and efficient methods for the analysis of coupled mechanical problems that involve the interaction of mechanical, thermal, phase-change and electromagnetic subproblems. The focus application has been the modeling of superconductivity and associated quantum-state phase-change phenomena. In support of this objective the work has addressed the following issues: (1) development of variational principles for finite elements; (2) finite element modeling of the electromagnetic problem; (3) coupling of thermal and mechanical effects; and (4) computer implementation and solution of the superconductivity transition problem. The research was carried out over the period September 1988 through March 1993. The main accomplishments have been: (1) the development of the theory of parametrized and gauged variational principles; (2) the application of those principled to the construction of electromagnetic, thermal and mechanical finite elements; and (3) the coupling of electromagnetic finite elements with thermal and superconducting effects; and (4) the first detailed finite element simulations of bulk superconductors, in particular the Meissner effect and the nature of the normal conducting boundary layer. The grant has fully supported the thesis work of one doctoral student (James Schuler, who started on January 1989 and completed on January 1993), and partly supported another thesis (Carmelo Militello, who started graduate work on January 1988 completing on August 1991). Twenty-three publications have acknowledged full or part support from this grant, with 16 having appeared in archival journals and 3 in edited books or proceedings.

Felippa, Carlos A.↗
NASA NTRS1995

Verification of a three-dimensional resin transfer molding process simulation model

Experimental evidence was obtained to complete the verification of the parameters needed for input to a three-dimensional finite element model simulating the resin flow and cure through an orthotropic fabric preform. The material characterizations completed include resin kinetics and viscosity models, as well as preform permeability and compaction models. The steady-state and advancing front permeability measurement methods are compared. The results indicate that both methods yield similar permeabilities for a plain weave, bi-axial fiberglass fabric. Also, a method to determine principal directions and permeabilities is discussed and results are shown for a multi-axial warp knit preform. The flow of resin through a blade-stiffened preform was modeled and experiments were completed to verify the results. The predicted inlet pressure was approximately 65% of the measured value. A parametric study was performed to explain differences in measured and predicted flow front advancement and inlet pressures. Furthermore, PR-500 epoxy resin/IM7 8HS carbon fabric flat panels were fabricated by the Resin Transfer Molding process. Tests were completed utilizing both perimeter injection and center-port injection as resin inlet boundary conditions. The mold was instrumented with FDEMS sensors, pressure transducers, and thermocouples to monitor the process conditions. Results include a comparison of predicted and measured inlet pressures and flow front position. For the perimeter injection case, the measured inlet pressure and flow front results compared well to the predicted results. The results of the center-port injection case showed that the predicted inlet pressure was approximately 50% of the measured inlet pressure. Also, measured flow front position data did not agree well with the predicted results. Possible reasons for error include fiber deformation at the resin inlet and a lag in FDEMS sensor wet-out due to low mold pressures.

Fingerson, John C.↗