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NASA NTRS2019

Design Optimization for X-Ray Telescopes

The capability of future X-ray telescopes depends on the quality of their Point Spread Function (PSF) and the size of their field of view. Traditional designs, such as Wolter, and Wolter-Schwarzschild telescopes are stigmatic on the optical axis but their PSF degrades rapidly off-axis. At the optimal focal surface, their PSFs can be significantly improved. We present a simple optimization process for Wolter (W), Wolter-Schwarzschild (WS) and Hyperboloid-Hyperboloid (HH) telescopes that substantially improves the off-axis PSF for either narrow or wide field of view applications. In this paper, we will compare the optical performance of conventional and optimized W-, WS-, and HH-telescopes for a wide range of telescope diameters that can be used to build up future x-ray telescopes.

Saha, Timo T.↗
NASA NTRS2019

Design Optimization for X-ray Telescopes

The capability of future X-ray telescopes depends on the quality of their Point Spread Function (PSF) and the size of their field of view. Traditional designs, such as Wolter, and Wolter-Schwarzschild telescopes are stigmatic on the optical axis but their PSF degrades rapidly off-axis. At the optimal focal surface, their PSFs can be significantly improved. We present a simple optimization process for Wolter (W), Wolter-Schwarzschild (WS) and Hyperboloid-Hyperboloid (HH) telescopes that substantially improves the off-axis PSF for either narrow or wide field of view applications. In this paper, we will compare the optical performance of conventional and optimized W-, WS-, and HH-telescopes for a wide range of telescope diameters that can be used to build up future x-ray telescopes.

Timo T Saha↗
NASA NTRSDate not supplied

Open-source Numerical Modeling of Solidification Cracking Susceptibility: Application to Refractory Alloy Systems

Introduction. Alloys such as aluminum, nickel-base, and austenitic stainless steels are susceptible to solidification cracking during welding and 3D printing. Compositional optimization is one method used to effectively mitigate solidification cracking of those alloy systems. With the surge in hypersonic and in-space propulsion activities, refractory metals (Nb, Mo, Ta, W, and Re) and their alloy derivatives are increasing in importance due to their extreme high melting point and retention of high-temperature strength; however, their chemistry was most typically optimized to promote ductility during mechanical operations such as drawing and forming. Welding of such alloys has been a challenge due to a number of issues including solidification cracking, atmospheric contamination (O, C, and N), as well as a shift in ductile-to-brittle transition to higher temperature following grain growth induced by welding. Compositional optimization of refractory alloys for solidification cracking resistance in particular is desirable as their usage increases with the advent of advanced manufacturing methods such as 3D printing. This work evaluates the effect of compositional variation in refractory metal systems on the solidification cracking susceptibility with the goals of optimizing existing alloys and joining process techniques, and formulating new alloys with increased solidification cracking resistance. Experimental Procedures. A python code was developed in a Jupyter notebook environment (Michael and Sowards, 2023) to facilitate the calculation of crack susceptibility index proposed by Kou (2015). Composition is entered as a single point, or as a 1-D or 2-D array. The notebook calls pycalphad (Otis and Liu, 2017 and Bocklund et al, 2020) to calculate the evolution of fraction solid as a function of temperature (under either Scheil or equilibrium assumptions) and then evaluates steepness of the fraction solid curve near the terminal stage of solidification to predict solidification cracking resistance. Open source thermodynamic databases available at online repositories are used (van de Walle). The process is setup in an automated fashion to generate plots that show variation in solidification cracking susceptibility according to composition on 1-D line plots or 2-D contour plots. The Jupyter notebook and crack susceptibility algorithm was also integrated with a widely used commercial CALPHAD code for validation and alloy exploration. Results and Discussion. The crack susceptibility model was first validated against a series of refractory alloy compositions evaluated in past work which utilized a specialized Varestraint test built inside a vacuum chamber environment (Lessman and Gold, 1971). The alloys tested in the Varestraint apparatus included T-111 (Ta-8W-2Hf), ASTAR-811C (Ta-8W-1Re-0.7Hf-0.025C), FS-85 (Nb-27Ta-10W-1Zr), T-222 (Ta-9.6W-2.4Hf-0.01C), Ta-10W, B-66 (Nb-5Mo-5V-1Zr), and SCb-291 (Nb-10W-10Ta). The initial test of the model showed a strong correlation with empirical Varestraint data, i.e., a Spearman rank correlation between model predictions and hot cracking measurements was observed to be greater than 0.8. Following the validation, a set of refractory metal binary mixtures was investigated to evaluate sensitivity of Nb, Mo, W, and Ta to C, N, and O content. A series of plots were produced that suggest ppmw ranges of C, N, and O where solidification cracking increases significantly and reaches a maximum. Also comparative ranking of each primary refractory metal to each interstitial was produced. For example C produces greater cracking response in Mo whereas O produces greater cracking response in Ta and Nb. Such compositional values have utility in setting limits on pickup of these interstitial elements during welding and printing rather than using a one-size-fits-all approach. Furthermore, the results have use in determining additive powder recycling requirements, which is especially pertinent for refractory metal powders due to their high cost compared to conventional alloys. Another application created thousands of hypothetical alloys within the nominal specified composition range of two widely used refractory alloys C103 (Nb-10Hf-1Ti) and TZM (Mo-0.5Ti-0.1Zr). The cracking index was calculated for the alloys and results were fed into machine learning regression techniques including Multiple Linear Regression, Ridge Regression, and Lasso Regression to determine relative potency each alloying element had on computed solidification cracking index. A series of linear equations were produced that relate composition of C103 and TZM to solidification cracking index. The crack susceptibility of C103 for example is described by an equation of the form: cracking index ~ O + 0.667*C + 0.635*N + 0.00037*Ta – 0.0008*Hf (in wt.%) From that equation, it is clear that O has strong propensity to induce solidification cracking. Interestingly, Hf is shown to reduce calculated cracking response. Finally, realizing the potential of this method to discover new refractory alloy formulations across the period table that have low solidification cracking sensitivity, the code was applied to new untested alloy systems including W-Zr-C, W-Ta-C, and others. Conclusions. In summary, an open source numerical method has been developed using Python code to calculate Kou’s crack susceptibility index. The method was applied to refractory metals which are inherently difficult to study from a weldability testing standpoint since inert shielding gas is not sufficient and welding is typically done in vacuum, especially in light of findings presented here where oxygen has profound influence on solidification cracking. This work revealed the effect of compositional variations on a series of refractory metals and showed the framework defined here will be useful in 1) the development of new alloys that have improved weldability and 3D printability, 2) placing compositional limits on existing alloys, and 3) ensuring adequate controls of manufacturing processes such as 3D printing where powder reuse is critical. Keywords. pycalphad; Python; refractory metals; solidification cracking. References. B. Bocklund et. al. (2020) http://doi.org/10.5281/zenodo.3630657. S. Kou. (2015) https://doi.org/10.1016/j.actamat.2015.01.034. G.G. Lessmann and R.E. Gold. Welding Journal, issue 1, pp. 1-s – 8-s (1971). F.N. Michael and J.W. Sowards. NASA/TM-20230002218 (2023). R. Otis and Z.-K. Liu. (2017) http://doi.org/10.5334/jors.140. A. Van de Wallle et. al. (2018) https://doi.org/10.1016/j.calphad.2018.04.003.

pycalphad↗
DOE OSTI2026

Adaptive Sampling-Based Bi-Fidelity Stochastic Trust Region Method for Stochastic Derivative-Free Optimization

Bi-fidelity stochastic optimization has gained increasing attention as an efficient approach to reduce computational costs by leveraging a low-fidelity (LF) model to optimize an expensive high-fidelity (HF) objective. In this paper, we propose ASTRO-BFDF, an adaptive sampling trust-region method specifically designed for unconstrained bi-fidelity stochastic derivative-free optimization problems. In ASTRO-BFDF, the LF function serves two purposes: (i) to identify better iterates for the HF function when the optimization process indicates a high correlation between them and (ii) to reduce the variance of the HF function estimates using bi-fidelity Monte Carlo (BFMC). The algorithm dynamically determines sample sizes while adaptively choosing between crude Monte Carlo and BFMC to balance the trade-off between optimization and sampling errors. We prove that the iterates generated by ASTRO-BFDF converge to a first-order stationary point almost surely. Additionally, we demonstrate the effectiveness of the proposed algorithm through numerical experiments on synthetic benchmarks and simulation optimization problems involving discrete event systems.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Follow the power—pathways to steady-state tokamak reactors

Abstract Diagramming pathways of dimensionless power is a potent method for extrapolating between operating points on present-day tokamaks and future burning plasma devices. The heat transport power, current drive power, H-mode threshold power and other ‘plasma physics’ powers can be expressed in dimensionally correct (or normalized) form as Pa 3/4 , where P is the power and a is the plasma minor radius, with the relative gyroradius ( ρ * ) dependence ranging from gyro-Bohm-like for transport ( P a 3 / 4 ∝ ρ * − 3 / 2 ), Bohm-like for current drive ( P a 3 / 4 ∝ ρ * − 5 / 2 ) and worse than Bohm-like for H-mode threshold ( P a 3 / 4 ∝ ρ * − 3 ). The D–T fusion power cannot be normalized in the same fashion since it is governed by nuclear physics, but at fixed B T it scales like P a 3 / 4 ∝ ρ * − 9 / 2 . Other ‘mixed physics’ powers can be incorporated into the dimensionless power framework by holding B T fixed in the same manner. Diagramming these dimensionless powers vs ρ * shows how the pathway to a steady-state reactor can be optimized relative to various operational boundaries. Using a steady-state hybrid discharge with β N = 3.2 from DIII-D as the starting point, a multi-parameter optimization finds an attractive pathway to steady-state operation on ITER using 76 MW of current drive power (fusion gain of Q fus = 8), along with a pathway to Q fus = 20 in a JET-sized steady-state reactor with B T = 10 T.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2011

Enhanced Fuel-Optimal Trajectory-Generation Algorithm for Planetary Pinpoint Landing

An enhanced algorithm is developed that builds on a previous innovation of fuel-optimal powered-descent guidance (PDG) for planetary pinpoint landing. The PDG problem is to compute constrained, fuel-optimal trajectories to land a craft at a prescribed target on a planetary surface, starting from a parachute cut-off point and using a throttleable descent engine. The previous innovation showed the minimal-fuel PDG problem can be posed as a convex optimization problem, in particular, as a Second-Order Cone Program, which can be solved to global optimality with deterministic convergence properties, and hence is a candidate for onboard implementation. To increase the speed and robustness of this convex PDG algorithm for possible onboard implementation, the following enhancements are incorporated: 1) Fast detection of infeasibility (i.e., control authority is not sufficient for soft-landing) for subsequent fault response. 2) The use of a piecewise-linear control parameterization, providing smooth solution trajectories and increasing computational efficiency. 3) An enhanced line-search algorithm for optimal time-of-flight, providing quicker convergence and bounding the number of path-planning iterations needed. 4) An additional constraint that analytically guarantees inter-sample satisfaction of glide-slope and non-sub-surface flight constraints, allowing larger discretizations and, hence, faster optimization. 5) Explicit incorporation of Mars rotation rate into the trajectory computation for improved targeting accuracy. These enhancements allow faster convergence to the fuel-optimal solution and, more importantly, remove the need for a "human-in-the-loop," as constraints will be satisfied over the entire path-planning interval independent of step-size (as opposed to just at the discrete time points) and infeasible initial conditions are immediately detected. Finally, while the PDG stage is typically only a few minutes, ignoring the rotation rate of Mars can introduce 10s of meters of error. By incorporating it, the enhanced PDG algorithm becomes capable of pinpoint targeting.

Acikmese, Behcet↗
NASA NTRS2004

Aerodynamic Optimization of Rocket Control Surface Geometry Using Cartesian Methods and CAD Geometry

Aerodynamic design is an iterative process involving geometry manipulation and complex computational analysis subject to physical constraints and aerodynamic objectives. A design cycle consists of first establishing the performance of a baseline design, which is usually created with low-fidelity engineering tools, and then progressively optimizing the design to maximize its performance. Optimization techniques have evolved from relying exclusively on designer intuition and insight in traditional trial and error methods, to sophisticated local and global search methods. Recent attempts at automating the search through a large design space with formal optimization methods include both database driven and direct evaluation schemes. Databases are being used in conjunction with surrogate and neural network models as a basis on which to run optimization algorithms. Optimization algorithms are also being driven by the direct evaluation of objectives and constraints using high-fidelity simulations. Surrogate methods use data points obtained from simulations, and possibly gradients evaluated at the data points, to create mathematical approximations of a database. Neural network models work in a similar fashion, using a number of high-fidelity database calculations as training iterations to create a database model. Optimal designs are obtained by coupling an optimization algorithm to the database model. Evaluation of the current best design then gives either a new local optima and/or increases the fidelity of the approximation model for the next iteration. Surrogate methods have also been developed that iterate on the selection of data points to decrease the uncertainty of the approximation model prior to searching for an optimal design. The database approximation models for each of these cases, however, become computationally expensive with increase in dimensionality. Thus the method of using optimization algorithms to search a database model becomes problematic as the number of design variables is increased.

Nelson, Andrea↗
NASA NTRS2003

Experimental Performance Evaluation of a Supersonic Turbine for Rocket Engine Applications

In order to mitigate the risk of rocket propulsion development, efficient, accurate, detailed fluid dynamics analysis and testing of the turbomachinery is necessary. To support this requirement, a task was developed at NASA Marshall Space Flight Center (MSFC) to improve turbine aerodynamic performance through the application of advanced design and analysis tools. These tools were applied to optimize a supersonic turbine design suitable for a reusable launch vehicle (RLV). The hot gas path and blading were redesigned-to obtain an increased efficiency. The goal of the demonstration was to increase the total-to- static efficiency of the turbine by eight points over the baseline design. A sub-scale, cold flow test article modeling the final optimized turbine was designed, manufactured, and tested in air at MSFC s Turbine Airflow Facility. Extensive on- and off- design point performance data, steady-state data, and unsteady blade loading data were collected during testing.

Snellgrove, Lauren M.↗
NASA NTRS1996

System Synthesis in Preliminary Aircraft Design using Statistical Methods

This paper documents an approach to conceptual and preliminary aircraft design in which system synthesis is achieved using statistical methods, specifically design of experiments (DOE) and response surface methodology (RSM). These methods are employed in order to more efficiently search the design space for optimum configurations. In particular, a methodology incorporating three uses of these techniques is presented. First, response surface equations are formed which represent aerodynamic analyses, in the form of regression polynomials, which are more sophisticated than generally available in early design stages. Next, a regression equation for an overall evaluation criterion is constructed for the purpose of constrained optimization at the system level. This optimization, though achieved in a innovative way, is still traditional in that it is a point design solution. The methodology put forward here remedies this by introducing uncertainty into the problem, resulting a solutions which are probabilistic in nature. DOE/RSM is used for the third time in this setting. The process is demonstrated through a detailed aero-propulsion optimization of a high speed civil transport. Fundamental goals of the methodology, then, are to introduce higher fidelity disciplinary analyses to the conceptual aircraft synthesis and provide a roadmap for transitioning from point solutions to probabalistic designs (and eventually robust ones).

DeLaurentis, Daniel↗
NASA NTRS1996

System Synthesis in Preliminary Aircraft Design Using Statistical Methods

This paper documents an approach to conceptual and early preliminary aircraft design in which system synthesis is achieved using statistical methods, specifically Design of Experiments (DOE) and Response Surface Methodology (RSM). These methods are employed in order to more efficiently search the design space for optimum configurations. In particular, a methodology incorporating three uses of these techniques is presented. First, response surface equations are formed which represent aerodynamic analyses, in the form of regression polynomials, which are more sophisticated than generally available in early design stages. Next, a regression equation for an Overall Evaluation Criterion is constructed for the purpose of constrained optimization at the system level. This optimization, though achieved in an innovative way, is still traditional in that it is a point design solution. The methodology put forward here remedies this by introducing uncertainty into the problem, resulting in solutions which are probabilistic in nature. DOE/RSM is used for the third time in this setting. The process is demonstrated through a detailed aero-propulsion optimization of a High Speed Civil Transport. Fundamental goals of the methodology, then, are to introduce higher fidelity disciplinary analyses to the conceptual aircraft synthesis and provide a roadmap for transitioning from point solutions to probabilistic designs (and eventually robust ones).

DeLaurentis, Daniel↗
DOE OSTI2023

Performance, Combustion and Emissions Evaluation of Liquid Phase Port-Injected LPG on a Single Cylinder Heavy-Duty Spark Ignited Engine

Liquefied petroleum gas (LPG), like many other alternative fuels, has witnessed increased adoption in the last decade, and its use is projected to rise as stricter emissions regulations continue to be applied. However, much of its use is limited to dual fuel applications, gaseous phase injection, light-duty passenger vehicle applications, or scenarios that require conversion from gasoline engines. Therefore, to address these limitations and discover the most efficient means of harnessing its full potential, more research is required in the development of optimized fuel injection equipment for liquid port and direct injection, along with the implementation of advanced combustion strategies that will improve its thermal efficiency to the levels of conventional fuels. This paper focuses on the development of a liquid phase port-injection system for LPG, the design of a reference piston, and the baseline evaluation of the performance, combustion, and emissions characteristics of a single cylinder research engine to establish a benchmark comparable to existing LPG engines. A sweep of start of injection (SOI) timing is performed by injecting liquid LPG at several closed and open intake valve timings, which demonstrates no significant variation in engine performance, but accounts for a 10% reduction in bsCO with the optimal SOI timing. Spark timing sweep demonstrates the 50% burn crank angle location related to maximum brake torque (MBT) point with a brake thermal efficiency (BTE) of ~34% for the tested load case. The effect of equivalence ratio is also presented with optimal SOI timing at MBT condition. The engine starts exhibiting knocking combustion at 140kPa intake manifold air pressure (IMAP) with a peak torque of 253Nm and a 5% reduction in brake specific fuel consumption compared to the naturally aspirated scenario.

Fosudo, Toluwalase↗
NASA NTRS1992

Computational fluid dynamic design of rocket engine pump components

Integration of computational fluid dynamics (CFD) for design and analysis of turbomachinery components is needed as the requirements of pump performance and reliability become more stringent for the new generation of rocket engine. A fast grid generator, designed specially for centrifugal pump impeller, which allows a turbomachinery designer to use CFD to optimize the component design will be presented. The CFD grid is directly generated from the impeller blade G-H blade coordinates. The grid points are first generated on the meridional plane with the desired clustering near the end walls. This is followed by the marching of grid points from the pressure side of one blade to the suction side of a neighboring blade. This fast grid generator has been used to optimize the consortium pump impeller design. A grid dependency study has been conducted for the consortium pump impeller. Two different grid sizes, one with 10,000 grid points and one with 80,000 grid points were used for the grid dependency study. The effects of grid resolution on the turnaround time, including the grid generation and completion of the CFD analysis, is discussed. The impeller overall mass average performance is compared for different designs. Optimum design is achieved through systematic change of the design parameters. In conclusion, it is demonstrated that CFD can be effectively used not only for flow analysis but also for design and optimization of turbomachinery components.

Chen, Wei-Chung↗
NASA NTRS1999

A Comparative Study of Interferometric Regridding Algorithms

THe paper discusses regridding options: (1) The problem of interpolating data that is not sampled on a uniform grid, that is noisy, and contains gaps is a difficult problem. (2) Several interpolation algorithms have been implemented: (a) Nearest neighbor - Fast and easy but shows some artifacts in shaded relief images. (b) Simplical interpolator - uses plane going through three points containing point where interpolation is required. Reasonably fast and accurate. (c) Convolutional - uses a windowed Gaussian approximating the optimal prolate spheroidal weighting function for a specified bandwidth. (d) First or second order surface fitting - Uses the height data centered in a box about a given point and does a weighted least squares surface fit.

Hensley, Scott↗
DOE OSTI2026

Control co-design under uncertainty for offshore wind farms: Optimizing grid integration, energy storage, and market participation

Offshore wind farms (OWFs) are set to significantly contribute to global decarbonization efforts. Developers often use a sequential approach to optimize design variables and market participation for grid-integrated offshore wind farms. However, this method can lead to sub-optimal system performance, and uncertainties associated with renewable resources are often overlooked in decision-making. Here, this paper proposes a control co-design approach, optimizing design and control decisions for integrating OWFs into the power grid while considering energy market and primary frequency market participation. Additionally, we introduce optimal sizing solutions for energy storage systems deployed onshore to enhance revenue for OWF developers over time. This framework addresses uncertainties related to wind resources and energy prices. We analyze five U.S. west-coast offshore wind farm locations and potential interconnection points, as identified by the Bureau of Ocean Energy Management (BOEM). Results show that optimized control co-design solutions can increase market revenue by 3.2% and provide flexibility in managing wind resource uncertainties.

Control Co-design↗
DOE OSTI2023

Empirically Optimized One-Electron Pseudopotential for the Hydrated Electron: A Proof-of-Concept Study

Mixed quantum-classical molecular dynamics simulations have been important tools for studying the hydrated electron. They generally use a one-electron pseudopotential to describe the interactions of an electron with the water molecules. Furthermore, this approximation shows both the strength and weakness of the approach. On the one hand, it enables extensive statistical sampling and large system sizes that are not possible with more accurate ab initio molecular dynamics methods. On the other hand, there has (justifiably) been much debate about the ability of pseudopotentials to accurately and quantitatively describe the hydrated electron properties. These pseudopotentials have largely been derived by fitting them to ab initio calculations of an electron interacting with a single water molecule. In this paper, we present a proof-of-concept demonstration of an alternative approach in which the pseudopotential parameters are determined by optimizing them to reproduce key experimental properties. Specifically, we develop a new pseudopotential, using the existing TBOpt model as a starting point, which correctly describes the hydrated electron vertical detachment energy and radius of gyration. In addition to these properties, this empirically optimized model displays a significantly modified solvation structure, which improves, for example, the prediction of the partial molar volume.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
NASA NTRS1970

Global search algorithm for optimal control

Random-search algorithm employs local and global properties to solve two-point boundary value problem in Pontryagin maximum principle for either fixed or variable end-time problems. Mixed boundary value problem is transformed to an initial value problem. Mapping between initial and terminal values utilizes hybrid computer.

Brocker, D. H.↗
NASA NTRS1978

Computational wing optimization and wind tunnel test of semi-span model

A computational transonic wing design procedure has been developed and verified by a wind tunnel test of a variable camber semi-span wing model. The Bailey-Ballhaus transonic potential flow analysis code linked to Vanderplaat's constrained minimization routine was used to optimize test configurations at 0.9 Mach number. Based on wind tunnel test results, computationally optimized designs were as efficient as the best configurations determined by previous parametric testing and performed better at off-design points. Wind tunnel wing pressures agreed well with predictions from the improved Bailey-Ballhaus code at moderate CL's. Computational optimization was shown to be an effective transonic wing design tool.

Haney, H. P.↗