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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 109 records · Page 6

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NASA NTRS1983

The optimal design of standard gearsets

A design procedure for sizing standard involute spur gearsets is presented. The procedure is applied to find the optimal design for two examples - an external gear mesh with a ratio of 5:1 and an internal gear mesh with a ratio of 5:1. In the procedure, the gear mesh is designed to minimize the center distance for a given gear ratio, pressure angle, pinion torque, and allowable tooth strengths. From the methodology presented, a design space may be formulated for either external gear contact or for internal contact. The design space includes kinematics considerations of involute interference, tip fouling, and contact ratio. Also included are design constraints based on bending fatigue in the pinion fillet and Hertzian contact pressure in the full load region and at the gear tip where scoring is possible. This design space is two dimensional, giving the gear mesh center distance as a function of diametral pitch and the number of pinion teeth. The constraint equations were identified for kinematic interference, fillet bending fatigue, pitting fatigue, and scoring pressure, which define the optimal design space for a given gear design. The locus of equal size optimum designs was identified as the straight line through the origin which has the least slope in the design region.

Savage, M.↗

DOE OSTI2025

Gaussian integral method for void fraction

Here, a novel method, the Gaussian Integral Method (GIM), is presented for calculating void fractions in Computational Fluid Dynamics–Discrete Element Method (CFD-DEM) simulations. GIM is versatile and applicable to various grid types, including structured and unstructured polyhedral meshes, without requiring special boundary treatments. An optimization technique is introduced to make GIM independent of grid resolution and type. The method is validated against experimental data from a fluidized bed, demonstrating that GIM produces realistic simulations closely resembling experimental observations. Additionally, unstructured polyhedral grids using GIM outperform structured grids of equivalent resolution, yielding results more aligned with experimental data. The gradient of the void fraction is computed in the CFD solver and utilized in the DEM solver for precise estimation at particle locations. Overall, GIM provides an effective solution for void fraction calculations in particulate media simulations with complex geometries, enhancing the accuracy and applicability of CFD-DEM simulations for industrial processes.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1993

H-P adaptive methods for finite element analysis of aerothermal loads in high-speed flows

The commitment to develop the National Aerospace Plane and Maneuvering Reentry Vehicles has generated resurgent interest in the technology required to design structures for hypersonic flight. The principal objective of this research and development effort has been to formulate and implement a new class of computational methodologies for accurately predicting fine scale phenomena associated with this class of problems. The initial focus of this effort was to develop optimal h-refinement and p-enrichment adaptive finite element methods which utilize a-posteriori estimates of the local errors to drive the adaptive methodology. Over the past year this work has specifically focused on two issues which are related to overall performance of a flow solver. These issues include the formulation and implementation (in two dimensions) of an implicit/explicit flow solver compatible with the hp-adaptive methodology, and the design and implementation of computational algorithm for automatically selecting optimal directions in which to enrich the mesh. These concepts and algorithms have been implemented in a two-dimensional finite element code and used to solve three hypersonic flow benchmark problems (Holden Mach 14.1, Edney shock on shock interaction Mach 8.03, and the viscous backstep Mach 4.08).

Chang, H. J.↗

NASA NTRS2005

X-ray Polarimetry with a Micro-Pattern Gas Detector

Topics covered include: Science drivers for X-ray polarimetry; Previous X-ray polarimetry designs; The photoelectric effect and imaging tracks; Micro-pattern gas polarimeter design concept. Further work includes: Verify results against simulator; Optimize pressure and characterize different gases for a given energy band; Optimize voltages for resolution and sensitivity; Test meshes with 80 micron pitch; Characterize ASIC operation; and Quantify quantum efficiency for optimum polarization sensitivity.

Hill, Joe↗

DOE OSTI2024

Development of a Method for Shape Optimization for a Gas Turbine Fuel Injector Design Using Metal-Additive Manufacturing

Adjoint shape optimization has enabled physics-based optimal designs for aerodynamic surfaces. Additive manufacturing (AM) makes it possible to manufacture complex shapes. However, there has been a gap between optimal and manufacturable surfaces due to the inherent limitations of commercial computational fluid dynamics (CFD) codes to implement geometric constraints during adjoint computation. In such cases, the design sensitivities are exported and used to perform constrained shape modifications using parametric information stored in computer aided design (CAD) files to satisfy manufacturability constraints. However, modifying the design using adjoint methods in CFD solvers and performing constrained shape modification in CAD can lead to inconsistencies due to different shape parameterization schemes. This paper describes a method to enable the simultaneous optimization of the fluid domain and impose AM manufacturability constraints, resolving one of the key issues of geometry definition for isogeometric analysis. Similar to a grid convergence study, the proposed method verifies the consistencies between shape parameterization techniques present within commercial CAD and CFD software during mesh movement as a part of the adjoint shape optimization routine. By identifying the appropriate parameters essential to a shape optimization study, the error metric between the different parameterization techniques converges to demonstrate sufficient consistencies for justifiable exchange of data between CAD and CFD. For the identified shape optimization parameters, the error metric to measure the deviation between the two parameterization schemes lies within the AM laser-powder bed fusion (L-PBF) process tolerance. Additionally, comparison for subsequent objective function calculations between iterations of the optimization loop showed acceptable differences within 1% variation between the modified geometries obtained using the two parameterization schemes. This method provides justification for the use of multiphysics guided adjoint design sensitivities computed in CFD software to perform shape modifications in CAD to incorporate AM manufacturability constraints during the shape optimization loop such that optimal designs are also additively manufacturable.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2015

Aerodynamic Shape Optimization of a Dual-Stream Supersonic Plug Nozzle

Aerodynamic shape optimization was performed on an isolated axisymmetric plug nozzle sized for a supersonic business jet. The dual-stream concept was tailored to attenuate nearfield pressure disturbances without compromising nozzle performance. Adjoint-based anisotropic mesh refinement was applied to resolve nearfield compression and expansion features in the baseline viscous grid. Deformed versions of the adapted grid were used for subsequent adjoint-driven shape optimization. For design, a nonlinear gradient-based optimizer was coupled to the discrete adjoint formulation of the Reynolds-averaged Navier- Stokes equations. All nozzle surfaces were parameterized using 3rd order B-spline interpolants and perturbed axisymmetrically via free-form deformation. Geometry deformations were performed using 20 design variables shared between the outer cowl, shroud and centerbody nozzle surfaces. Interior volume grid deformation during design was accomplished using linear elastic mesh morphing. The nozzle optimization was performed at a design cruise speed of Mach 1.6, assuming core and bypass pressure ratios of 6.19 and 3.24, respectively. Ambient flight conditions at design were commensurate with 45,000-ft standard day atmosphere.

shape optimization↗

NASA NTRS2006

Ion Thruster Discharge Performance Per Magnetic Field Topography

DC-ION is a detailed computational model for predicting the plasma characteristics of rain-cusp ion thrusters. The advanced magnetic field meshing algorithm used by DC-ION allows precise treatment of the secondary electron flow. This capability allows self-consistent estimates of plasma potential that improves the overall consistency of the results of the discharge model described in Reference [refJPC05mod1]. Plasma potential estimates allow the model to predict the onset of plasma instabilities, and important shortcoming of the previous model for optimizing the design of discharge chambers. A magnetic field mesh simplifies the plasma flow calculations, for both the ions and the secondary electrons, and significantly reduces numerical diffusion that can occur with meshes not aligned with the magnetic field. Comparing the results of this model to experimental data shows that the behavior of the primary electrons, and the precise manner of their confinement, dictates the fundamental efficiency of ring-cusp. This correlation is evident in simulations of the conventionally sized NSTAR thruster (30 cm diameter) and the miniature MiXI thruster (3 cm diameter).

plasma processes↗

DOE OSTI2025

A framework for discrete optimization of stellarator coils

Designing magnets for three-dimensional plasma confinement is a key task for advancing the stellarator as a fusion reactor concept. Stellarator magnets must produce an accurate field while leaving adequate room for other components and being reasonably simple to construct and assemble. In this paper, a framework for coil design and optimization is introduced that enables the attainment of sparse magnet solutions with arbitrary restrictions on where coils may be located. The solution space is formulated as a 'wireframe' consisting of a mesh of interconnected wire segments enclosing the plasma. Two methods are developed for optimizing the current distribution on a wireframe: Regularized Constrained Least Squares, which uses a linear least-squares approach to optimize the currents in each segment, and Greedy Stellarator Coil Optimization, a fully discrete procedure in which loops of current are added to the mesh one by one to achieve the desired magnetic field on the plasma boundary. Examples are presented of solutions obtainable with each method, some of which achieve high field accuracy while obeying spatial constraints that permit easy assembly.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

A Framework for Compressing Unstructured Scientific Data via Serialization

We present a general framework for compressing unstructured scientific data with known local connectivity. A common application is simulation data defined on arbitrary finite element meshes. The framework employs a greedy topology preserving reordering of original nodes which allows for seamless integration into existing data processing pipelines. This reordering process depends solely on mesh connectivity and can be performed offline for optimal efficiency. However, the algorithm’s greedy nature also supports on-the-fly implementation. The proposed method is compatible with any compression algorithm that leverages spatial correlations within the data. The effectiveness of this approach is demonstrated on a large-scale real dataset using several compression methods, including MGARD, SZ, and ZFP.

Reshniak, Viktor [ORNL] (ORCID:0000000315454462)↗

NASA NTRS2014

Optimization of a Lunar Pallet Lander Reinforcement Structure Using a Genetic Algorithm

This paper presents a design automation process using optimization via a genetic algorithm to design the conceptual structure of a Lunar Pallet Lander. The goal is to determine a design that will have the primary natural frequencies at or above a target value as well as minimize the total mass. Several iterations of the process are presented. First, a concept optimization is performed to determine what class of structure would produce suitable candidate designs. From this a stiffened sheet metal approach was selected leading to optimization of beam placement through generating a two-dimensional mesh and varying the physical location of reinforcing beams. Finally, the design space is reformulated as a binary problem using 1-dimensional beam elements to truncate the design space to allow faster convergence and additional mechanical failure criteria to be included in the optimization responses. Results are presented for each design space configuration. The final flight design was derived from these results.

Burt, Adam O.↗

NASA NTRS2006

Adjoint-Based Algorithms for Adaptation and Design Optimizations on Unstructured Grids

Schemes based on discrete adjoint algorithms present several exciting opportunities for significantly advancing the current state of the art in computational fluid dynamics. Such methods provide an extremely efficient means for obtaining discretely consistent sensitivity information for hundreds of design variables, opening the door to rigorous, automated design optimization of complex aerospace configuration using the Navier-Stokes equation. Moreover, the discrete adjoint formulation provides a mathematically rigorous foundation for mesh adaptation and systematic reduction of spatial discretization error. Error estimates are also an inherent by-product of an adjoint-based approach, valuable information that is virtually non-existent in today's large-scale CFD simulations. An overview of the adjoint-based algorithm work at NASA Langley Research Center is presented, with examples demonstrating the potential impact on complex computational problems related to design optimization as well as mesh adaptation.

Nielsen, Eric J.↗

NASA NTRS1990

The 'optimum' upwind advection on a triangular mesh

For advection schemes based on fluctuation splitting, a design criterion of optimizing the time step leads to linear schemes that coincide with those designed for least truncation error. A further stage of optimizing the time step using a nonlinear positivity criterion, leads to considerable further gains in resolution.

Roe, P. L.↗

NASA NTRS2011

Actuator Grouping Optimization on Flexible Space Reflectors

With the rapid advances in deployable membrane and mesh antenna technologies, the feasibility of developing large, lightweight reflectors has greatly improved. In order to achieve the required surface accuracy, precision surface control is needed on these lightweight reflectors. For this study, an analytical model is shown which combines a flexible Kapton reflector with Polyvinylidene fluoride (PVDF) actuators for surface control. Surface errors are introduced that are similar to real world scenarios, and a least squares control algorithm is developed for surface control. Experimental results on a 2.4 meter reflector show that while the analytical reflector model is generally correct, due to idiosyncrasies in the reflector it cannot be used for online control. A new method called the En Mass Elimination algorithm is used to determine the optimal grouping of actuators when the number of actuators in the system exceeds the number of power supplies available.

en masse elimination (EME) algorithm↗

NASA NTRS2024

Usage of ChatGPT for Engineering Design and Analysis Tool Development

ChatGPT, a generative AI large language model, has recently captured significant attention in both the computer science community and the broader public domain. It has demonstrated a wide range of capabilities, from answering simple questions to writing fully functional computer code. This study spotlights both the capabilities and limitations of ChatGPT when addressing engineering problems. The model's capacity to generate practical engineering tools is highlighted through an example of a prompt that leads to an interactive plotting tool, enabling the examination of the fluid boundary layer around a fan blade. Subsequently, the paper also uncovers potential pitfalls in ChatGPT’s application, shown through an unsuccessful attempt to use ChatGPT to automate a process in Ansys Workbench through scripting. The research further investigates ChatGPT's proficiency in addressing inquiries and providing explanations about the functionalities of OpenMDAO, an open-source, multidisciplinary design, analysis, and optimization tool developed at NASA Glenn Research Center. Finally, an optimization methodology, developed with ChatGPT’s help, is applied to the structural optimization of a fan blade. The developed optimization method utilizes T-Blade3 for geometry generation, Ansys Mechanical for meshing and finite element analysis, and sci-kit learn’s MLPRegressor method to generate a trained neural network model of the design space. OpenMDAO is then used to find the optimal point within the design space. The outcome is a significant reduction in stress in the optimized model—less than one-fifth of the stress value in the baseline model.

Design↗

NASA NTRSDate not supplied

Usage of ChatGPT for Engineering Design and Analysis Tool Development

Design↗

NASA NTRS2002

Multilevel Error Estimation and Adaptive h-Refinement for Cartesian Meshes with Embedded Boundaries

This paper presents the development of a mesh adaptation module for a multilevel Cartesian solver. While the module allows mesh refinement to be driven by a variety of different refinement parameters, a central feature in its design is the incorporation of a multilevel error estimator based upon direct estimates of the local truncation error using tau-extrapolation. This error indicator exploits the fact that in regions of uniform Cartesian mesh, the spatial operator is exactly the same on the fine and coarse grids, and local truncation error estimates can be constructed by evaluating the residual on the coarse grid of the restricted solution from the fine grid. A new strategy for adaptive h-refinement is also developed to prevent errors in smooth regions of the flow from being masked by shocks and other discontinuous features. For certain classes of error histograms, this strategy is optimal for achieving equidistribution of the refinement parameters on hierarchical meshes, and therefore ensures grid converged solutions will be achieved for appropriately chosen refinement parameters. The robustness and accuracy of the adaptation module is demonstrated using both simple model problems and complex three dimensional examples using meshes with from 10(exp 6), to 10(exp 7) cells.

Aftosmis, M. J.↗

DOE OSTI2025

Coupled beam-target-moderator optimization for the Second Target Station

To support the design of the Second Target Station, that aims to provide the world’s highest peak brightness of cold neutrons, studies that optimize the dimensions of the target and moderators are invaluable. In this work, we investigate the influence of the target dimensions and beam profile on the performance and optimal size of the moderators. We perform optimization runs with detailed MCNP6.2 simulations using high-fidelity unstructured mesh geometries generated from parametrized CAD models. We demonstrate that small changes in target height do not influence the moderator performance if the beam dimensions are chosen adequately. We quantify the effect of beam footprint and target width on the moderator performance and show that the optimal moderator dimensions are insensitive to limited changes in target and beam profile.

Dakota↗

DOE OSTI2025

Fuel performance analysis of fully-resolved TRISO compact

The TRi-structural ISOtropic (TRISO) fuel multilayered coating structure offers multiple barriers to fission product release, enhancing safety and performance. The heterogeneous nature of TRISO fuel compacts, comprising thousands of randomly distributed coated fuel particles embedded in a graphite matrix, creates intricate stress fields and thermal gradients that cannot be accurately modeled using simplified one-dimensional or homogenized approaches. Consequently, three-dimensional modeling enables the prediction of fuel compact dimensional changes, internal pressure buildup, and fission product transport pathways under diverse irradiation and thermal conditions. This capability facilitates detailed analysis of particle-to-particle interactions, matrix cracking mechanisms, and the statistical distribution of coating failures, which directly impact fuel performance and safety margins. This capability is particularly critical for advanced reactors, such as high-temperature gas-cooled reactors and other Generation IV reactor designs where TRISO fuel operates at elevated temperatures and burn-up levels. This work introduces a novel method to generate an optimized packing of TRISO compacts and a complete 3D mesh with random distribution of TRISO particles, which are discretized into each coating component layer.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗