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At least 1,009 records · Page 56

Lateral Load Testing of the Advanced Stirling Convertor (ASC-E2) Heater Head

Free-piston Stirling convertors are fundamental to the development of NASA s next generation of radioisotope power system, the Advanced Stirling Radioisotope Generator (ASRG). The ASRG will use General Purpose Heat Source (GPHS) modules as the energy source and Advanced Stirling Convertors (ASCs) to convert heat into electrical energy, and is being developed by Lockheed Martin under contract to the Department of Energy. Achieving flight status mandates that the ASCs satisfy design as well as flight requirements to ensure reliable operation during launch. To meet these launch requirements, GRC performed a series of quasi-static mechanical tests simulating the pressure, thermal, and external loading conditions that will be experienced by an ASC-E2 heater head assembly. These mechanical tests were collectively referred to as "lateral load tests" since a primary external load lateral to the heater head longitudinal axis was applied in combination with the other loading conditions. The heater head was subjected to the operational pressure, axial mounting force, thermal conditions, and axial and lateral launch vehicle acceleration loadings. To permit reliable prediction of the heater head s structural performance, GRC completed Finite Element Analysis (FEA) computer modeling for the stress, strain, and deformation that will result during launch. The heater head lateral load test directly supported evaluation of the analysis and validation of the design to meet launch requirements. This paper provides an overview of each element within the test and presents assessment of the modeling as well as experimental results of this task.

Cornell, Peggy A.↗

Face Sheet/Core Disbond Growth in Honeycomb Sandwich Panels Subjected to Ground-Air-Ground Pressurization and In-Plane Loading

Typical damage modes in light honeycomb sandwich structures include face sheet/core disbonding and core fracture, both of which can pose a threat to the structural integrity of a component. These damage modes are of particular interest to aviation certification authorities since several in-service occurrences, such as rudder structural failure and other control surface malfunctions, have been attributed to face sheet/core disbonding. Extensive studies have shown that face sheet/core disbonding and core fracture can lead to damage propagation caused by internal pressure changes in the core. The increasing use of composite sandwich construction in aircraft applications makes it vitally important to understand the effect of ground-air-ground (GAG) cycles and conditions such as maneuver and gust loads on face sheet/core disbonding. The objective of the present study was to use a fracture mechanics based approach developed earlier to evaluate the loading at the disbond front caused by ground-air-ground pressurization and in-plane loading. A honeycomb sandwich panel containing a circular disbond at one face sheet/core interface was modeled with three-dimensional (3D) solid finite elements. The disbond was modeled as a discrete discontinuity and the strain energy release rate along the disbond front was computed using the Virtual Crack Closure Technique (VCCT). Special attention was paid to the pressure-deformation coupling which can decrease the pressure load within the disbonded sandwich section significantly when the structure is highly deformed. The commercial finite element analysis software, Abaqus/Standard, was used for the analyses. The recursive pressure-deformation coupling problem was solved by representing the entrapped air in the honeycomb cells as filled cavities in Abaqus/Standard. The results show that disbond size, face sheet thickness and core thickness are important parameters that determine crack tip loading at the disbond front. Further, the pressure-deformation coupling was found to have an important load decreasing effect [6]. In this paper, a detailed problem description is provided first. Second, the analysis methodology is presented. The fracture mechanics approach used is described and the specifics of the finite element model, including the fluid-filled cavities, are introduced. Third, the initial model verification and validation are discussed. Fourth, the findings from a closely related earlier study [6] are summarized. These findings provided the basis for the current investigation. Fifth, an aircraft ascent scenario from 0 to 12192 m (0 to 40000 ft) is considered and the resulting crack tip loading at the disbond front is determined. In-plane loading to simulate maneuvers and gust conditions are also considered. Sixth, the results are shown for a curved panel, which was used to simulate potential fuselage applications. Finally, a brief summary of observations is presented and recommendations for improvement are provided.

Chen, Zhi M.↗

Fourier Analysis Method for Wireless Power Transfer Coil Design

Wireless power transfer (WPT) systems for Electric Vehicles (EVs) are designed to meet specifications such as stray field, power transfer, efficiency, and ground clearance. Typical design approaches include iterative analysis of predetermined coil geometries to identify candidates that meet these constraints. This work instead directly generates WPT coil shapes and magnetic fields to meet specifications and constraints through the optimization of Fourier basis function coefficients. The proposed Fourier Analysis Method (FAM) applies to arbitrary planar coil geometries and does not rely on iterative finite-element analysis (FEA) simulations. This flexibility allows for rapid design evaluation across a larger range of coil geometries and design specifications. A prototype coil is built to compare FAM outputs to experimental measurements and FEA simulations. The FAM is then used to illustrate the tradeoff of coil current and stray field for a given power level showing that the method is capable of generating optimized coil shapes to meet arbitrary field constraints.

Foote, Andrew↗

P-Finite-Element Program For Analysis Of Plates

BUCKY is p-finite-element computer program for highly accurate analysis of structures. Used to analyze buckling, bending, and in-plane stress-and-strain behaviors of plates. Provides elastic-plastic solutions for isotropic plates in states of plane stress, and axisymmetric solution sequence used to treat three-dimensional problems. Computes response of plate to variety of loading and boundary conditions by use of higher-order displacement function in p-finite-element method. Enables user to obtain results more accurate than obtained by use of traditional h-finite elements. Written in FORTRAN 77.

Smith, James P.↗

The 15 meter hoop-column antenna dynamics: Test and analysis

A 15 meter model of the hoop-column antenna concept has been vibration tested for model characterization and analytical model verification. Linear finite element analysis predicted the global vibration frequencies accurately. Good agreement between analysis and test data was obtained only after the analytical model was refined using static test data. As structures become more flexible, structural properties determined from static data become more accurate and should be used to update analytical models. Global vibration modes are not significantly affected by the surface mesh which permits simplified analytical models to be used for prediction of global behavior. These reduced models are believed sufficient for preliminary design and controls simulations where only global behavior is desired. The mesh modes were highly damped due to the knit mesh used for the reflector surface. These modes were also highly coupled and very difficult to measure in the laboratory. The inability to fully characterize the antenna mesh modes in the laboratory indicates robust methods for active surface vibration suppression will be needed. Fortunately, the surface mesh exhibits high passive damping which should be beneficial to active control systems.

Belvin, W. Keith↗

Analysis of delamination onset and growth in curved laminates

Delamination onset and growth from a matrix crack in a curved composite laminate are studied. Finite element analysis is used to determine values of G which can be compared to the interlaminar fracture toughness of the composite for delamination predictions. The delamination is assumed to grow from the matrix crack and to remain straight and perpendicular to the edge. G is larger at the free edge than in the center and increases with delamination growth. Thus, once delamination begins from the matrix crack it should continue around the curved section with no increase in applied load. In the local vicinity of the matrix crack the rate of change of G decreases initially and then begins to increase with a point of inflection in between. Measured failure loads and the interlaminar fracture toughness of the composite are used to show that the point of inflection corresponds to the critical value of G.

Martin, Roderick H.↗

A Thermostructural Analysis of a Diboride Composite Leading Edge

In an effort to support the design of zirconium diboride composite leading edges for hypersonic vehicles, a finite element model (FEM) of a prototype leading edge was created and finite element analysis (FEA) was employed to assess its thermal and structural response to aerothermal boundary conditions. Unidirectional material properties for the structural components of the leading edge, a continuous fiber reinforced diboride composite, were computed with COSTAR. These properties agree well with those experimentally measured. To verify the analytical approach taken with COSMOS/M, an independent FEA of one of the leading edge assembly components was also done with COSTAR. Good agreement was obtained between the two codes. Both showed that a unidirectional lay-up had the best margin of safety for a simple loading case. Both located the maximum stress in the same region and ply. The magnitudes agreed within 4 percent. Trajectory based aerothermal heating was then applied to the leading edge assembly FEM created with COSMOS/M to determine steady state temperature response, displacement, stresses, and contact forces due to thermal expansion and thermal strains. Results show that the leading edge stagnation line temperature reached 4700 F. The maximum computed failure index for the laminated composite components peaks at 4.2, and is located at the bolt flange in layer 2 of the side bracket. The temperature gradient in the tip causes a compressive stress of 279 ksi along its width and substantial tensile stresses within its depth.

Kowalski, Tom↗

Software Performs Complex Design Analysis

Designers use computational fluid dynamics (CFD) to gain greater understanding of the fluid flow phenomena involved in components being designed. They also use finite element analysis (FEA) as a tool to help gain greater understanding of the structural response of components to loads, stresses and strains, and the prediction of failure modes. Automated CFD and FEA engineering design has centered on shape optimization, which has been hindered by two major problems: 1) inadequate shape parameterization algorithms, and 2) inadequate algorithms for CFD and FEA grid modification. Working with software engineers at Stennis Space Center, a NASA commercial partner, Optimal Solutions Software LLC, was able to utilize its revolutionary, one-of-a-kind arbitrary shape deformation (ASD) capability-a major advancement in solving these two aforementioned problems-to optimize the shapes of complex pipe components that transport highly sensitive fluids. The ASD technology solves the problem of inadequate shape parameterization algorithms by allowing the CFD designers to freely create their own shape parameters, therefore eliminating the restriction of only being able to use the computer-aided design (CAD) parameters. The problem of inadequate algorithms for CFD grid modification is solved by the fact that the new software performs a smooth volumetric deformation. This eliminates the extremely costly process of having to remesh the grid for every shape change desired. The program can perform a design change in a markedly reduced amount of time, a process that would traditionally involve the designer returning to the CAD model to reshape and then remesh the shapes, something that has been known to take hours, days-even weeks or months-depending upon the size of the model.

Source record↗

Dynamic response and sonic fatigue analysis at NASA Langley for hypersonic vehicle structures

This paper presents an overview of three research topics being pursued at the NASA Langley Research Center for dynamic response prediction and sonic fatigue analysis of hypersonic vehicle structures. The first is the development of a numerical simulation procedure within the framework of a finite element analysis for the prediction of the large deflection random response of simple panels. The second topic is an implementation of the equivalent linearization technique in a commercial finite element code for the prediction of large deflection random response of complicated panels. The last area is the calculation of a dynamic stress intensity factor in the frequency domain for use in sonic fatigue crack growth prediction.

Rizzi, Stephen A.↗

Initial dynamic load estimates during configuration design

This analysis includes the structural response to shock and vibration and evaluates the maximum deflections and material stresses and the potential for the occurrence of elastic instability, fatigue and fracture. The required computations are often performed by means of finite element analysis (FEA) computer programs in which the structure is simulated by a finite element model which may contain thousands of elements. The formulation of a finite element model can be time consuming, and substantial additional modeling effort may be necessary if the structure requires significant changes after initial analysis. Rapid methods for obtaining rough estimates of the structural response to shock and vibration are presented for the purpose of providing guidance during the initial mechanical design configuration stage.

Schiff, Daniel↗

VEG-05 Tomato Crop Testing on the International Space Station

Production of fresh, nutritious, and tasty produce for astronauts during spaceflight may provide health-promoting, bioavailable nutrients, enhance the dietary experience, and reduce menu fatigue as we move into longer-duration missions. Growing and caring for plants may also reduce the psychological stresses associated with spaceflight and enhance connection to Earth. A diversity of crops will be required to provide nutrition, variety, and resiliency, however requirements for consistent growth under spaceflight environmental conditions remain unclear. VEG-05 is part of a series of experiments with pick-and-eat salad crops to better define best practices for crop production in space. VEG-05 and predecessor experiments VEG-04A and VEG-04B, grew salad crops in the Veggie vegetable production facilities on the International Space Station using different lighting treatments. In VEG-05 we grew ‘Red Robin’ dwarf cherry tomatoes under two different red: blue lighting spectra. Light can impact the growth habit, yield, nutritional composition, microbial levels, and even flavor attributes within crops, and our goal was to assess these characteristics in ‘Red Robin’ tomatoes during VEG-05. Considerable pre-flight verification testing was performed prior to launch in Nov. 2022. Prior to the flight and ground experiments, lighting in both Veggie units on ISS was measured and lights were standardized between flight and ground hardware. VEG-05 flight operations ran between December 2022 and March 2023, with a ground control initially 48 hours delayed. Due to environmental challenges of very low humidity during the first week of the experiment, seed germination was low for both flight and ground plants. The flight experiment ultimately had 4 - 5 plants per treatment out of the planned 6 plants, but the initial ground control had only three plants in one treatment and none in the other, so this ground control was restarted at the beginning of Feb. 2023 and ran through May, with successful growth of all 12 plants. Both flight and ground control ran 100 days, with harvests of fruit at day 83, day 90, and day 100. Flight plants had uneven growth, and following the early drying events, excess water was frequently observed, which led to a variety of plant stress responses including uneven plant growth, excess adventitious root formation, flower and fruit abortion, and visible microbial growth. In total, from the five surviving red-rich lighted plants, only 5 ripe fruit were produced, and from the four surviving blue-rich lighted plants, 10 fruit were produced with only 6 of these ripe by day 100. Because of the small fruit number and the unsatisfactory growth, crew members were not allowed to consume the tomatoes, and all fruit, as well as large branches with leaves, samples of the adventitious roots, two plant rooting pillows from each treatment, microbial sampling swabs, and some water samples were returned for analysis. Because of the small sample sizes and factors affecting growth on the ISS, objectives of assessing light quality effect (red: blue light treatments) will not be achieved. Revised objectives of this study include to compare stressed flight plants with normal ground plants to determine the impact of plant overwatering stress in space on food safety and the plant microbial community, to determine nutrient content changes in fruit and leaves from stressed plants, and to evaluate stress metabolism changes in returned tissue by transcriptomic analysis. Postflight analysis is underway with the following analyses being conducted: A. culturable microbiology and food safety as well as molecular microbial community analysis of 1. ripe fruit, 2. leaves, stems, and adventitious roots, 3. pillow components (roots, wicks, and substrates), 4. swabs, and 5. water samples from root mats before and after growth. B. transcriptomics of leaf tissue and adventitious roots, and C. elemental analysis of leaf tissue. If sufficient tissue remains elemental analyses will also be conducted on fruit. While not generating the desired information on spaceflight growth responses of healthy crops, our team is hopeful that these analyses will shed light on tomato responses to stress in this environment as plant overwatering stress is a mission-relevant condition that could occur in future space crop growth systems. This research was co-funded by the Human Research Program and Space Biology (MTL#1075) in the ILSRA 2015 NRA call.

Gioia D. Massa↗

Fluid structural interaction simulation of the MP-1 plate performance irradiated in the advanced test reactor

Due to the high neutron fluxes they generate and increased heat transfer performance, plate type fuels are used in the U.S. high-performance research reactors. During irradiation, a significant amount of fission energy (i.e., ~200 MeV per atom) is released by the U-235 chain reaction that is carried away by the coolant. Through thermal hydraulic analysis, the coolant’s heat transfer capability is investigated to ensure that the desired fuel temperature can be maintained. At high temperatures, the plate undergoes elastic/plastic deformation, creep, and swelling as a result of both the temperature gradients and the fission gas production within the fuel. These effects are studied via fuel performance analysis. When the plate deformation is small enough that the coolant flow remains relatively unchanged, conducting these two types of analyses independently will suffice. But at high fuel burnups, the swollen plates may encroach into the coolant channels that separate the fuel plates from each other and cause these channels to narrow. Large reductions in channel gap size imperil cooling performance, causing fuel temperatures to rise. Further, if the plate deformation is asymmetric, the fuel centerline will shift toward one side of the channel, causing an uneven reduction in coolability. In addition, a boehmite (oxide) layer will, over time, grow on the plate surface, further obstructing the heat transfer process. To precisely predict fuel temperatures/deformation, a complete coupled analysis that considers coolant flow, heat transfer, oxide growth, elastic/plastic deformation, creep, and swelling is needed; however, this type of analysis method is not available in the literature. To fill the gap, this research developed a fluid structure interaction (FSI) approach to the fuel plate analysis, then successfully applied it to the Mini-Plate (MP)-1 experiment, which was irradiated in the Advanced Test Reactor (ATR) for both one and two cycles. The complete analysis coupled STAR-CCM+, a computational fluid dynamic (CFD) software for calculating flow, with Abaqus, a finite element analysis code for calculating plate deformation. Improvements in the results were found when comparing the fully coupled analysis to the independently conducted analyses but they were not significant due to the miniature size of the plates and the relatively short irradiation time. In the future, the fully coupled approach presented herein will be applied to full-size fuel plates with longer irradiation cycles once additional experiments become available.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Modeling the hydrodynamic impact on the tool influence function during hemispherical subaperture optical polishing

To fabricate high-precision and accurate optics relative to the optical design surface, a high level of deterministic control of material removal (i.e., the tool influence function, TIF) during subaperture tool polishing is required. In this study, a detailed analysis of the pressure distribution, which is a key component of the TIF, has been performed using finite element analysis to couple together solid mechanics and fluid dynamics. Modeling experimental parameters of recently published work reveals that, when considering tool deformation, which in turn influences the fluid film thickness between the tool and workpiece, the effective pressure profile has a flat-top distribution. This flat-top pressure profile differs from the parabolic pressure distributions predicted by Hertzian mechanics. Furthermore, the shear contribution is shown here to be a key contributor to material removal, inducing the removal at the periphery of the contact edge and even outside the generally accepted contact area. Finally, the simulated fluid velocities provide evidence of mixed-mode contact polishing, supporting recent experimental findings that also suggest that onset of hydroplaning contributions lead to material removal drop-off.

36 MATERIALS SCIENCE↗

Technology Demonstration of a High-Pressure Swirl Oxy-Coal Combustor

This technical report presents the exploration of the design and prototyping of a High-Pressure Swirl Oxy-coal Combustor. Pressurized oxy-coal combustion systems have the potential to improve efficiency along with an increased carbon capture rate. Reduction of flue gas at higher pressure, smaller system size, and capital cost reductions render high-pressure oxy-coal systems particularly attractive as next-generation energy-producing systems. High-pressure oxy-coal combustion systems are a recent concept, and thus operability issues of combustor designs for such systems are not fully understood. Significant challenges exist to maintain oxy-coal combustion stability at elevated pressure and a high CO 2 diluent environment. Although a body of knowledge exists for high-pressure oxygen combustion in rocket engines (or similar applications), it is yet to be strategized how these fundamental concepts can be translated to low-temperature CO 2 diluent combustion regimes. The realization of the pressurized oxy-coal based systems requires combustor components to be designed and demonstrated for an operating pressure over 10 bar. However, pressurized oxy-coal combustor design information at this pressure range and scale relevant to validate those proposed systems is currently limited. Experimental data from MWth scale oxy-coal combustors are needed to identify the optimal trade-off between net efficiency and systems size. The proposed effort is aimed at demonstrating a 1 MWth down-fired swirl Oxy-Coal combustor and investigate the interrelation between combustor operating conditions (pressure; flame stability; flue gas recirculation ratio) and conversion efficiencies to minimize oxygen requirements. One of the key challenges is to configure burner design (i.e., swirl number and injector) and operating conditions for high-pressure oxy-coal combustion systems. These experiments differ from current systems partly due to the high theoretical flame temperature and related burner operability issues associated with oxy-combustion. An ASPEN PLUS® model study for 550 MWe TIPS and ENEL pressurized oxy-coal systems with CO 2 recirculation was performed to evaluate system design, subsystems sizing, and operating condition determination. The system analysis effort included TRL and technology gap determination of subsystems and critical components. This information was scaled to develop design requirements (design pressure and flue gas recirculation: RR Flue Gas = $\frac{m_{flue}}{m_{total}}$) for the 1 MWth combustor. The effects of a wide range of carbon dioxide recirculation ratios on the thermal efficiency of ENEL and TIPS cycles are studied. The pressure of 10 bar and 80 bar are used for ENEL and TIPS cycles, respectively. The thermal efficiency of ENEL is significantly higher than the efficiency of TIPS at a pressure of less than 10 bar. The insights from system analysis were then used to design a 1 MWth swirl oxy-coal combustor. Flame temperature analysis and material strength analysis was performed to determine the combustor thickness. The structural integrity of the combustor was validated by finite element analysis using Abacus® and Hypermesh®. Feasibility of igniters and secondary burners are investigated in successful high-pressure oxy-methane combustion. The secondary burners are designed in such a way that it can operate between 100 to 500 kW firing input. Three generations of the pintle injector were designed based on swirl numbers (S=0, 0.9, and 1.2). Key pintle injector parameters such as pintle size, pintle orifice size, spray pattern were investigated by cold flow tests. Information from these tests was used to modify injector design for smooth and successful operation. A 5 mm pintle orifice size was decided upon as the optimum size for oxy-coal operation for the combustor. Shadow sizing experiments were performed to identify the atomization rate of each injector. Different coal water slurry mixtures (30 – 50% coal by wt% in the mixture) at various total momentum ratios (TMR) were investigated for this purpose. These experiments provided decisive information to choose the best design of the injector. The injector with 1.2 swirl provided higher atomization in all cases than other designs. The mean equivalent droplet size of the jet was similar at different TMR and mixture ratios using this injector, thus making it suitable for use in most cases. Therefore, the 1.2 swirl-pintle injector was chosen for the shakedown test. The combustor and other sub-systems, including feed systems and control and data acquisition, have been manufactured, assembled, and integrated. The total system integration and installation began on July 1, 2020. The shake-down tests and initial operational capability demonstration are expected to be completed by September 30, 2020.

01 COAL, LIGNITE, AND PEAT↗

Specialists Meeting on Rotorcraft Dynamics, Moffett Field, Calif., February 13-15, 1974, Proceedings

Analysis of specific problems in rotorcraft dynamics. Topics include hingeless rotor theory, dynamic stall modelling, periodic systems identification, analysis of complex systems with phasing matrices, flapping stability, flap-lag dynamics at high advance ratios, finite element analysis and fuselage free-vibration characteristics, coupled rotor/frame vibration methods, gust response characteristics with unsteady stall effects, antiresonance theory, cyclic feathering motions and dynamic loads, control load envelope shaping, rotor aeroelasticity, use of Floquet theory, theory of proprotors and tilt-rotors, two-bladed teetering rotors, stability of air and ground resonance, vertical-plane pendulum absorbers, multicyclic jet-flap control, engine/frame interface dynamics, and others. The minutes of the question and answer periods following the presentations are presented in the supplement. Individual items are announced in this issue.

Source record↗

A fundamental approach to adhesion: Synthesis, surface analysis, thermodynamics and mechanics

Several techniques were used to study pretreated Ti 6-4 surfaces including scanning electron microscopy (SEM), electron spectroscopy of chemical analysis (ESCA), and, reflectance visible spectroscopy. Each pretreatment type gave a characteristic surface morphology as seen by SEM. Elemental analysis of the Ti 6-4 surfaces was done using ESCA. Trace residual contaminants from particular chemical pretreatments were identified readily. Results indicate that reflectance visible spectroscopy using indicator dyes placed on Ti 6-4 surfaces appears to be a feasible approach to establish surface acidity. Differences in surface acidity were observed using bromthymol blue on Ti 6-4 surfaces pretreated by two different methods.

Beck, B.↗

Spectroscopic characterization of titanium 6-4 surfaces after chemical pretreatments

Several techniques have been used to study pretreated Ti 6-4 surfaces including scanning electron microscopy (SEM), electron spectroscopy of chemical analysis (ESCA), and, reflectance visibile spectroscopy. Each pretreatment type gives a characteristic surface morphology as seen by SEM. Elemental analysis of the Ti 6-4 surfaces was done using ESCA. Trace residual contaminants from particular chemical pretreatments are identified readily. Reflectance visible spectroscopy using indicator dyes placed on Ti 6-4 surfaces appears to be a feasible approach to establish surface acidity. Differences in surface acidity have been observed using bromthymol blue on Ti 6-4 surfaces pretreated by two different methods.

Chen, W.↗