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DOE OSTI2026

Mechanical Characterization of the NIF Ignition Target TMPSA Bonding Flexure

The Thermo-Mechanical Package Sub-Assembly (TMPSA) provides a critical mechanical, thermal, and electrical interface between a silicon arm and a TMP aluminum can in a NIF ignition target. During assembly, sixteen silicon pads are bonded to the aluminum using a fixture that positions the components and applies a repeatable prescribed displacement through a compliant flexure. The flexure converts fixture interference into displacement and reaction force. Because bondline thickness variation must be maintained within +/-4 µm, consistent flexure behavior is important to the assembly process. With a recent string of TMPSAs exhibiting low bond strength, the flexures were inspected. Despite being manufactured to the same specifications, flexures were found to exhibit variation in measured stiffness. Additionally, the measured stiffness values did not always follow the presumed beam mechanics model. This work addresses two questions: whether the bonding fixture is working as intended, and whether the previously made stiffness measurements are accurate representations of the use case. The flexures are analyzed using Euler-Bernoulli beam theory, measured beam dimensions, finite element analysis, and tolerance stack-up calculations. The analysis shows that the fixed-guided beam mechanics model appropriately represents the flexure during TMPSA bonding, but the chisel-tip stiffness measurement method introduces a deformation to the inner ring of the flexure that is not represented during use. The measured stiffness values should therefore be interpreted as test-condition stiffness values rather than direct measurements of operational flexure stiffness. The discrepancy is therefore attributed primarily to the measurement boundary condition rather than to failure of the fixed-guided beam model. Recommendations are provided for GD&T, dimensional inspection, and a representative stiffness testing method to better control bondline variation.

42 ENGINEERING↗

NASA NTRS1980

Vortex methods for two- and three-dimensional flow simulations

The point vortex and vortex blob methods for two dimensional flows are presented. Several results are discussed concerning the numerical analysis of the latter scheme, e.g., the preservation of globally conserved quantities and the analysis of the spatial discretization error resulting from the convection of fixed blobs of vorticity. An application to the two dimensional mixing layer is briefly described. The contour dynamics method is also discussed. The simulation of three dimensional flows with vortex methods is discussed. A natural way to represent the vorticity is in the form of closed tubes of filaments of vorticity, although other schemes are examined. Applications to aircraft trailing vortices and to a turbulent spot in a laminar boundary layer are presented. Hybrid schemes that use an Eulerian mesh to solve the Poisson equation for the velocity field are discussed. The goal of these schemes is to avoid the high cost of the Biot-Savart integration if many vortex elements are used while enjoying most of the advantages of pure Lagrangian schemes.

Leonard, A.↗

NASA NTRS2000

Resin Film Infusion (RFI) Process Modeling for Large Transport Aircraft Wing Structures

This investigation completed the verification of a three-dimensional resin transfer molding/resin film infusion (RTM/RFI) process simulation model. The model incorporates resin flow through an anisotropic carbon fiber preform, cure kinetics of the resin, and heat transfer within the preform/tool assembly. The computer model can predict the flow front location, resin pressure distribution, and thermal profiles in the modeled part. The formulation for the flow model is given using the finite element/control volume (FE/CV) technique based on Darcy's Law of creeping flow through a porous media. The FE/CV technique is a numerically efficient method for finding the flow front location and the fluid pressure. The heat transfer model is based on the three-dimensional, transient heat conduction equation, including heat generation. Boundary conditions include specified temperature and convection. The code was designed with a modular approach so the flow and/or the thermal module may be turned on or off as desired. Both models are solved sequentially in a quasi-steady state fashion. A mesh refinement study was completed on a one-element thick model to determine the recommended size of elements that would result in a converged model for a typical RFI analysis. Guidelines are established for checking the convergence of a model, and the recommended element sizes are listed. Several experiments were conducted and computer simulations of the experiments were run to verify the simulation model. Isothermal, non-reacting flow in a T-stiffened section was simulated to verify the flow module. Predicted infiltration times were within 12-20% of measured times. The predicted pressures were approximately 50% of the measured pressures. A study was performed to attempt to explain the difference in pressures. Non-isothermal experiments with a reactive resin were modeled to verify the thermal module and the resin model. Two panels were manufactured using the RFI process. One was a stepped panel and the other was a panel with two 'T' stiffeners. The difference between the predicted infiltration times and the experimental times was 4% to 23%.

Loos, Alfred C.↗

DOE OSTI2020

A numerical-homogenization based phase-field fracture modeling of linear elastic heterogeneous porous media

Most porous media, such as geomaterials and biomaterials are highly heterogeneous in nature, and they contain large variations of microscopic pore structures, such as pore sizes, pore distribution, and pore shapes. The oscillation of microscopic structures is a substantial challenge in theoretical characterization and is usually ignored in continuous modeling. However, mechanical behavior of porous media such as deformation and failure, are essentially impacted by the microscopic heterogeneity which needs to be considered in modeling a porous media. Here, this research proposes a numerical modeling framework with a capability to investigate the effect of microscopic heterogeneity on the macroscopic fracture behavior in porous media by using a numerical homogenization technique, combined with the phase-field fracture modeling method. This numerical modeling strategy computes a homogenized elasticity tensor based on microscopic heterogeneous pore structures heterogenous porous domain by solving boundary value problems at microscopic domain. The strain energy and subsequent propagation of macroscopic fractures will be updated using homogenized stiffness information. Using this numerical scheme, the microscopic pore structure’s impact on the fracture behavior through the homogenized elastic tensor will be taken into account. This multiscale technique is benchmarked against classical problems. Finally, the results highlight the importance of the underlying pore structure and reveal that both fracture strength and propagation path can be influenced by the microscopic heterogeneity.

36 MATERIALS SCIENCE↗

NASA NTRS1987

Dynamic testing of a two-dimensional box truss beam

Testing to determine the effects of joint freeplay and pretensioning of diagonal members on the dynamic characteristics of a two-dimensional box truss beam was conducted. The test article was ten bays of planar truss suspended by long wires at each joint. Each bay measured 2 meters per side. Pins of varying size were used to simulate various joint freeplay conditions. Single-point random excitation was the primary method of test. The rational fraction polynomial method was used to extract modal characteristics from test data. A finite element model of the test article was generated from which modal characteristics were predicted. These were compared with those obtained from tests. With the exception of the fundamental mode, correlation of theoretical and experimental results was poor, caused by the resonant coupling of local truss member bending modes with global truss beam modes. This coupling introduced many modes in the frequency range of interest whose frequencies were sensitive to joint boundary conditions. It was concluded that local/global coupling must be avoided in the frequency range where accurate modal characteristics are required.

White, Charles W.↗

NASA NTRS1998

Simulation of Conformal Spiral Slot Antennas on Composite Platforms

During the course of the grant, we wrote and distributed about 12 reports and an equal number of journal papers supported fully or in part by this grant. The list of reports (title & abstract) and papers are given in Appendices A and B. This grant has indeed been instrumental in developing a robust hybrid finite element method for the analysis of complex broadband antennas on doubly curved platforms. Previous to the grant, our capability was limited to simple printed patch antennas on mostly planar platforms. More specifically: (1) mixed element formulations were developed and new edge-based prisms were introduced; (2) these elements were important in permitting flexibility in geometry gridding for most antennas of interest; (3) new perfectly matched absorbers were introduced for mesh truncations associated with highly curved surfaces; (4) fast integral algorithms were introduced for boundary integral truncations reducing CPU time from O(N-2) down to O(N-1.5) or less; (5) frequency extrapolation schemes were developed for efficient broadband performance evaluations. This activity has been successfully continued by NASA researchers; (6) computer codes were developed and extensively tested for several broadband configurations. These include FEMA-CYL, FEMA-PRISM and FEMA-TETRA written by L. Kempel, T. Ozdemir and J. Gong, respectively; (7) a new infinite balun feed was designed nearly constant impedance over the 800-3000 MHz operational band; (8) a complete slot spiral antenna was developed, fabricated and tested at NASA Langley. This new design is a culmination of the projects goals and integrates the computational and experimental efforts. this antenna design resulted in a U.S. patent and was revised three times to achieve the desired bandwidth and gain requirements from 800-3000 MHz.

Volakis, J. L.↗

DOE OSTI2025

Modeling low cycle fatigue (LCF) of additively manufactured Hastelloy X using An accelerated crystal plasticity fatigue damage model

This paper presents a microstructure-based model for low cycle fatigue (LCF) behavior and life of Nickel-based alloy Hastelloy X manufactured using laser-powder bed fusion (L-PBF) additive manufacturing (AM). AM Hastelloy X, a solution-strengthened alloy, is tested at elevated temperature under fully reversed LCF conditions at different strain levels. A generalized plane strain finite element model is generated from electron backscatter diffraction (EBSD) characterization. The constitutive behavior of the material under fatigue is modeled using crystal plasticity and calibrated with both monotonic tensile and cyclic stress–strain data. The fatigue micro-crack initiation and propagation in the microstructure is modeled using a modified Chaboche fatigue damage model. An embedded boundary condition with a homogenous medium is used to apply the cyclic deformation and prevent numerically introduced over-constraints during fatigue simulation. A ‘cycle-jump’ method is used to accelerate the fatigue simulation and reduce the computational cost. The simulation results are compared to LCF experiments, showing satisfactory matches in cyclic stress behavior and number of cycles to macro-crack initiation for all applied strain ranges. In addition, the model illustrates the potential for quantifying microscale fatigue life impacting factors such as microstructure and surface roughness, which is needed to accurately quantify the reliability of AM components in service.

36 MATERIALS SCIENCE↗

NASA NTRS1989

A two-layer multiple-time-scale turbulence model and grid independence study

A two-layer multiple-time-scale turbulence model is presented. The near-wall model is based on the classical Kolmogorov-Prandtl turbulence hypothesis and the semi-empirical logarithmic law of the wall. In the two-layer model presented, the computational domain of the conservation of mass equation and the mean momentum equation penetrated up to the wall, where no slip boundary condition has been prescribed; and the near wall boundary of the turbulence equations has been located at the fully turbulent region, yet very close to the wall, where the standard wall function method has been applied. Thus, the conservation of mass constraint can be satisfied more rigorously in the two-layer model than in the standard wall function method. In most of the two-layer turbulence models, the number of grid points to be used inside the near-wall layer posed the issue of computational efficiency. The present finite element computational results showed that the grid independent solutions were obtained with as small as two grid points, i.e., one quadratic element, inside the near wall layer. Comparison of the computational results obtained by using the two-layer model and those obtained by using the wall function method is also presented.

Kim, S.-W.↗

NASA NTRS1989

Group-kinetic theory and modeling of atmospheric turbulence

A group kinetic method is developed for analyzing eddy transport properties and relaxation to equilibrium. The purpose is to derive the spectral structure of turbulence in incompressible and compressible media. Of particular interest are: direct and inverse cascade, boundary layer turbulence, Rossby wave turbulence, two phase turbulence; compressible turbulence, and soliton turbulence. Soliton turbulence can be found in large scale turbulence, turbulence connected with surface gravity waves and nonlinear propagation of acoustical and optical waves. By letting the pressure gradient represent the elementary interaction among fluid elements and by raising the Navier-Stokes equation to higher dimensionality, the master equation was obtained for the description of the microdynamical state of turbulence.

Tchen, C. M.↗

NASA NTRS2014

Advanced Modeling and Uncertainty Quantification for Flight Dynamics; Interim Results and Challenges

As part of the NASA Vehicle Systems Safety Technologies (VSST), Assuring Safe and Effective Aircraft Control Under Hazardous Conditions (Technical Challenge #3), an effort is underway within Boeing Research and Technology (BR&T) to address Advanced Modeling and Uncertainty Quantification for Flight Dynamics (VSST1-7). The scope of the effort is to develop and evaluate advanced multidisciplinary flight dynamics modeling techniques, including integrated uncertainties, to facilitate higher fidelity response characterization of current and future aircraft configurations approaching and during loss-of-control conditions. This approach is to incorporate multiple flight dynamics modeling methods for aerodynamics, structures, and propulsion, including experimental, computational, and analytical. Also to be included are techniques for data integration and uncertainty characterization and quantification. This research shall introduce new and updated multidisciplinary modeling and simulation technologies designed to improve the ability to characterize airplane response in off-nominal flight conditions. The research shall also introduce new techniques for uncertainty modeling that will provide a unified database model comprised of multiple sources, as well as an uncertainty bounds database for each data source such that a full vehicle uncertainty analysis is possible even when approaching or beyond Loss of Control boundaries. Methodologies developed as part of this research shall be instrumental in predicting and mitigating loss of control precursors and events directly linked to causal and contributing factors, such as stall, failures, damage, or icing. The tasks will include utilizing the BR&T Water Tunnel to collect static and dynamic data to be compared to the GTM extended WT database, characterizing flight dynamics in off-nominal conditions, developing tools for structural load estimation under dynamic conditions, devising methods for integrating various modeling elements into a real-time simulation capability, generating techniques for uncertainty modeling that draw data from multiple modeling sources, and providing a unified database model that includes nominal plus increments for each flight condition. This paper presents status of testing in the BR&T water tunnel and analysis of the resulting data and efforts to characterize these data using alternative modeling methods. Program challenges and issues are also presented.

Hyde, David C.↗

DOE OSTI2022

Tunable phononic bandgap materials designed via topology optimization

Topology optimization is used to design phononic bandgap materials that are tunable by mechanical deformation. A periodic media is considered, which due to the assumption of length scale separation, allows the dispersion relations to be obtained by analyzing a single unit cell subjected to Floquet–Bloch boundary conditions. A finite macroscopic deformation is applied to the unit cell to affect its geometry and hence dispersion. We tune the dispersion–deformation relation to our liking by solving a topology optimization problem using nonlinear programming. The adjoint method is employed to compute the sensitivities, and the non-differentiability of degenerate eigenvalues is avoided using symmetric polynomials. Several tunable phononic crystal designs are presented. Also, a verification analysis is performed, wherein the optimized design is interpreted and analyzed using a conforming finite element mesh.

42 ENGINEERING↗

NASA NTRS1985

On the Computation of Structural Vibrations Induced by a Low-speed Turbulent Flow

A method for numerical evaluation of the vibrations of a cylindrical shell structure induced by a low speed external turbulent flow is discussed. The direction of flow is along the axis of revolution of the shell, and the source of excitation is the pressure fluctuations in the turbulent boundary layer. For the investigation of vibration and noise problems it is usually more desirable to utilize the modal expansion approach. The axisymmetric shell structure can be modeled by the assemblage of conical-shell finite-elements. This modeling allows the eigenfunction psi sub mn (x,theta) to be represented in a rectangular product of a longitudinal modal function f sub mn (x) and a circular harmonic function cos m theta (or sin m theta).

Hwang, Y. F.↗

NASA NTRS1993

High accuracy computation of fluid-structure interaction in transonic cascades

A coupling strategy for simulating fluid-structure interaction phenomena is formulated and applied to the prediction of flutter in transonic cascades. The flow is governed by the Euler equations and discretized using a finite volume flux-splitting scheme. The structure is modeled using an isoparametric finite element formulation. The coupling strategy successfully reconciles these two formulations at the fluid-structure interface by enforcing both kinematic and kinetic boundary conditions. In particular, the conservation laws applicable to the combined fluid-structure system are preserved across the interface. Since the primary mechanism driving aeroelastic phenomena involves energy exchange occurring at the interface, this highly accurate coupling mechanism is believed to improve the predictive capability of the scheme. The coupled equations are advanced simultaneously in time using an implicit time integration method. Results obtained using the coupling method are presented for cascade geometries operating in transonic flow.

Boschitsch, Alexander↗

NASA NTRS1994

Discretized energy minimization in a wave guide with point sources

An anti-noise problem on a finite time interval is solved by minimization of a quadratic functional on the Hilbert space of square integrable controls. To this end, the one-dimensional wave equation with point sources and pointwise reflecting boundary conditions is decomposed into a system for the two propagating components of waves. Wellposedness of this system is proved for a class of data that includes piecewise linear initial conditions and piecewise constant forcing functions. It is shown that for such data the optimal piecewise constant control is the solution of a sparse linear system. Methods for its computational treatment are presented as well as examples of their applicability. The convergence of discrete approximations to the general optimization problem is demonstrated by finite element methods.

Propst, G.↗

NASA NTRS1995

Implementation of Combined Feather and Surface-Normal Ice Growth Models in LEWICE/X

Experimental observations have shown that discrete rime ice growths called feathers, which grow in approximately the direction of water droplet impingement, play an important role in the growth of ice on accreting surfaces for some thermodynamic conditions. An improved physical model of ice accretion has been implemented in the LEWICE 2D panel-based ice accretion code maintained by the NASA Lewis Research Center. The LEWICE/X model of ice accretion explicitly simulates regions of feather growth within the framework of the LEWICE model. Water droplets impinging on an accreting surface are withheld from the normal LEWICE mass/energy balance and handled in a separate routine; ice growth resulting from these droplets is performed with enhanced convective heat transfer approximately along droplet impingement directions. An independent underlying ice shape is grown along surface normals using the unmodified LEWICE method. The resulting dual-surface ice shape models roughness-induced feather growth observed in icing wind tunnel tests. Experiments indicate that the exact direction of feather growth is dependent on external conditions. Data is presented to support a linear variation of growth direction with temperature and cloud water content. Test runs of LEWICE/X indicate that the sizes of surface regions containing feathers are influenced by initial roughness element height. This suggests that a previous argument that feather region size is determined by boundary layer transition may be incorrect. Simulation results for two typical test cases give improved shape agreement over unmodified LEWICE.

Matthew T Velazquez↗

NASA NTRS2000

Prediction of Sound Waves Propagating Through a Nozzle Without/With a Shock Wave Using the Space-Time CE/SE Method

The benchmark problems in Category 1 (Internal Propagation) of the third Computational Aeroacoustics (CAA) Work-shop sponsored by NASA Glenn Research Center are solved using the space-time conservation element and solution element (CE/SE) method. The first problem addresses the propagation of sound waves through a nearly choked transonic nozzle. The second one concerns shock-sound interaction in a supersonic nozzle. A quasi one-dimension CE/SE Euler solver for a nonuniform mesh is developed and employed to solve both problems. Numerical solutions are compared with the analytical solution for both problems. It is demonstrated that the CE/SE method is capable of solving aeroacoustic problems with/without shock waves in a simple way. Furthermore, the simple nonreflecting boundary condition used in the CE/SE method which is not based on the characteristic theory works very well.

Wang, Xiao-Yen↗

NASA NTRSDate not supplied

Advancing xEMU Lunar Dust Mitigation Devices

Fine, electrically charged, glass like dust particles caused significant damage to the Apollo EMU9 during lunar EVAs, identified as one of the greatest challenges to future exploration. Passive Lunar Dust Mitigation Devices (LDMD) were developed, within a SBIR Phase II, to prohibit this dust from interrupting venting space suit component operation. A Computational Fluid-Dynamics and Discrete Element Method (CFD-DEM) Simulation Tool was developed at the University of Colorado, Boulder to predict venting gas flow ability to self-clean adhered dust particles from LDMD surfaces. Lunar dust properties (i.e., adhesion and cohesion strengths) required to complete Simulation Tool analysis are relatively unknown due to considerable differences between the Earth and the Moon (i.e., gravity, humidity) and due to an absence of dust particles in their native state. Analytically determining gas flow velocity, density and direction within the fluid Boundary Layer, microns from LDMD surfaces presented a second challenge. Dusty Plasma Chamber testing is being performed at Auburn University, Auburn to observe electrostatically charged dust behavior as it adheres to LDMD prototypes and specific geometry and is then blown away by metered gas flow. Test articles were developed to offer insight into the impact of different flow geometries, surface roughness and dust removal within the gas Boundary-Layer. Observed dust behavior is currently being developed to support the CFD-DEM analysis. Many Simulation Tool analytical cases have been processed to support the intention of completing sensitivity studies to assess how different dust adherence values and Boundary Layer fluid properties impact LDMD self-cleaning effectivity.

Thomas J Stapleton↗

DOE OSTI2022

Chemical order transitions within extended interfacial segregation zones in NbMoTaW

Interfacial segregation and chemical short-range ordering influence the behavior of grain boundaries in complex concentrated alloys. In this study, we use atomistic modeling of a NbMoTaW refractory complex concentrated alloy to provide insight into the interplay between these two phenomena. Hybrid Monte Carlo and molecular dynamics simulations are performed on columnar grain models to identify equilibrium grain boundary structures. Here our results reveal extended near-boundary segregation zones that are much larger than traditional segregation regions, which also exhibit chemical patterning that bridges the interfacial and grain interior regions. Furthermore, structural transitions pertaining to an A2-to-B2 transformation are observed within these extended segregation zones. Both grain size and temperature are found to significantly alter the widths of these regions. An analysis of chemical short-range order indicates that not all pairwise elemental interactions are affected by the presence of a grain boundary equally, as only a subset of elemental clustering types are more likely to reside near certain boundaries. The results emphasize the increased chemical complexity that is associated with near-boundary segregation zones and demonstrate the unique nature of interfacial segregation in complex concentrated alloys.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗