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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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Green Run Modal Test of the NASA Space Launch System Core Stage

The Core Stage of the new NASA Space Launch System (SLS) is a 212-foot-tall rocket assembly—consisting primarily of two cryogenic propellant tanks, an engine section, and four RS-25 rocket engines—that will send crew and large payloads to the moon and beyond for NASA’s Artemis program. Prior to SLS assembly, the Core Stage completed a series of structural and functional tests in the B-2 Test Stand at Stennis Space Center, designated Green Run. The goal of Green Run was to verify analytical models, confirm proper subsystem operation, and test-fire all four RS-25 engines of the Core Stage. In January 2020, Green Run testing began with an experimental modal analysis test, performed by the Marshal Space Flight Center modal test team. A free-boundary test condition of the Core Stage was simulated as close as possible by suspending the massive launch vehicle from the B-2 Test Stand crane. Modal excitation was provided by a pair of 250-lb electro-dynamic shakers for multi-shaker random vibration testing, as well as a 12-pound instrumented hammer for impact testing. Modal response was measured with 550 accelerometer channels distributed on both the Core Stage and the B-2 Test Stand derrick crane. Following one very long day of testing, frequency response functions were calculated from the measured time histories in the target mode frequency range of 5 Hz to 15 Hz, and mode shapes, frequencies, and damping values were successfully estimated. The case-study presented in this paper will discuss Green Run, the SLS Core Stage, the modal test setup and execution, as well as a brief overview of the test results. Challenges associated with testing such a large, suspended structure in an outdoor environment will be discussed as well.

Space Launch System↗

DOE OSTI2024

First considerations on the supporting structures of FCC-ee booster and collider in the arc regions

In 2022, the FCC Feasibility Study management mandated a working group to analyse the best configuration of the FCC-ee tunnel in the arc regions, in view of the construction of a mock-up of the arc half-cell. One of the main and most challenging goals of the study, named FCC-ee Arc Half-Cell Mock-up Project, was to perform a preliminary investigation on the principles of supporting the Short-Straight Sections and dipoles of the half-cells, both for the booster and for the collider machines. This is an important input needed for the choice of the best configuration of the relative placement of the booster with respect to the collider. The structural stiffness, mass and stability of the supporting structures must be optimized to minimize the vibrations transmitted/transferred to the magnetic system of the accelerators by elements such as pumps, water cooling system, beam thermomechanical stresses, powering elements, etc. To perform the study, tools such as CAD software, FEM and analytical techniques were employed. This paper summarizes the preliminary design concepts and the results of the simulations performed.

Accelerator Subsystems and Technologies↗

DOE OSTI2020

Discrete Element Method Analysis for Metal Powders Used in Additive Manufacturing, and DEM Simulation Tutorial Using LIGGGHTS-PUBLIC [PowerPoint and paper]

Discrete Element Method (DEM) is a method of analysis to evaluate the dynamic interactions between granular particles. This method has been used in the pharmaceutical industry to improve the powder compaction process for tablet manufacturing. There are also applications in agriculture, food industry, and manufacturing. Direct energy deposition is an additive manufacturing technique which uses metallic powders fed through a nozzle, melted using a directed laser, and transformed into a solid object layer by layer. One way of feeding metal particles into the system involves the use of a vibrating hopper. Given a specified amplitude and frequency input, the hopper will enable the powder to travel up a path, and inject through the system with assistance from a stream of gas. The mechanical properties of a printed object can vary, depending on the characteristics of the powder flow and the particles’ as-received properties. Improved understanding of dynamic interactions of flowing powders could enable additive manufacturing components with 2D or 3D variations in mechanical properties, e.g., density. This work uses DEM simulation software to investigate the effects of particle cohesion, friction, and density on the quality of the flow by performing an angle of repose simulation, which is often used as a metric to evaluate the flowability of powders.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Three-Dimensional Aerodynamics and Vortex-Shedding Characteristics of Wind Turbine Airfoils over 360-Degree Angles of Attack

In this work, we present the first three-dimensional (3D) computational investigation of wind turbine airfoils over 360° angles of attack to predict unsteady aerodynamic loads and vortex-shedding characteristics. To this end, static–airfoil simulations are performed for the FFA-W3 airfoil family at a Reynolds number of 107 with the Improved Delayed Detached Eddy Simulation turbulence model. Aerodynamic forces reveal that the onset of boundary-layer instabilities and flow separation does not necessarily coincide with the onset of stall. In addition, a comparison with two-dimensional simulation data and flat plate theory extension of airfoil polars, suggest that, in the deep stall regime, 3D effects remain critical for predicting both the unsteady loads and the vortex-shedding dynamics. For all airfoils, the vortex-shedding frequencies are found to be inversely proportional to the wake width. In the case of slender airfoils, the frequencies are nearly independent of the airfoil thickness, and their corresponding Strouhal number St is approximately 0.15. Based on the calculated St, the potential for shedding frequencies to coincide with the natural frequencies of the International Energy Agency 15 MW reference wind turbine blades is investigated. The analysis shows that vortex-induced vibrations occur primarily at angles of attack of around ±90° for all airfoils.

17 WIND ENERGY↗

NASA NTRS1981

Vibrations of three-dimensional pipe systems with acoustic coupling

A general algorithm is developed to calculate the beam-type dynamic response of three dimensional multiplane finite length pipe systems, consisting of elbow and straight ducts with continuous interfaces. Emphasis is on secondary acoustic wave effects giving rise to coupling mechanisms; and the simulation accounts for one-dimensional elastoacoustic coupling from a plane acoustic wave and secondary loads resulting from wave asymmetries. The transfer matrix approach is adopted in modeling the elastodynamics of each duct, with allowance for distribution loads. Secondary loads from plane wave distortion are considered with a solution of the Helmholtz equation in an equivalent rigid waveguide, and effects of path imperfection are introduced as a perturbation from the hypothetical perfectly straight pipe. Computations indicate that the one-dimensional acoustic assumption is valid for frequencies below one-half the first cut-off frequency, and the three-dimensional acoustic effects produce an increase in response levels near and above cut-off.

El-Raheb, M.↗

DOE OSTI2020

Uncertainty evaluation for twist drilling stability model

This paper describes the first uncertainty analysis for drilling stability using a frequency-domain drilling stability model. The stability model inputs include: the modal parameters for the torsional-axial vibration mode from the twist drill-holder-spindle axial frequency response function; and the mechanistic coefficients that relate the torque and thrust force to chip area for the selected drill-workpiece material combination. Furthermore, Monte Carlo simulation is applied to propagate the input uncertainties to output uncertainty in the predicted stability map, which separates stable from unstable (chatter) zones in the spindle speed-chip width parameter space. Additionally, the mean stability boundary and its 95% confidence intervals are determined for five cases: varying all four inputs simultaneously and varying them individually. This enables the individual sensitivities to be compared. Experimental results from drilling tests are included for comparison to the prediction. Additionally, Matlab code is provided to implement the stability model and Monte Carlo uncertainty analysis.

42 ENGINEERING↗

DOE OSTI2021

Nanoscale hydration in layered manganese oxides

Birnessite is a layered MnO2 mineral with a nanoscale interlayer region that accommodates layers of intercalated water. Variable distributions of Mn sites with oxidation states of II, III and IV are responsible for the high catalytic reactivity of birnessite in nature and as a valuable candidate for energy storage solutions. We here report water loading capabilities and the vibrational spectral signatures of two forms of birnessite of strongly contrasting particle size. Using X-ray diffraction we find that potassium-birnessite accommodates no more than one monolayer (1W) of water in its interlayer region. Molecular simulations show that this is an energetically favorable hydration state where interlayer potassium-water and direct water-birnessite interactions are greater than at other hydration levels. Simulations also suggest a stable 2W state but that is not achieved experimentally by contact with water vapor. Finally, this work provides a means to predict the distribution of adsorbed and interlayer water molecules using a recently developed composite model.

Cheng, Wei↗

DOE OSTI2022

Enabling multiple intercavity polariton coherences by adding quantum confinement to cavity molecular polaritons

In this study, the “particle in a box” idea, which was broadly developed in semiconductor quantum dot research, was extended into mid-infrared (IR) cavity modes by applying lateral confinement in an optical cavity. The discrete cavity modes hybridized with molecular vibrational modes, resulting in a quartet of polariton states that can support multiple coherence states in the IR regime. We applied tailored pump pulse sequences to selectively prepare these coherences and verified the multi-coherence existence. The simulation based on Lindblad equation showed that because the quartet of polariton states resided in the same cavity, they were specifically robust toward decoherence caused by fluctuations in space. The multiple robust coherences paved the way for entangled states and coherent interactions between cavity polaritons, which would be critical for advancing polariton-based quantum information technology.

2D IR↗

NASA NTRS1987

Aeroelastic analysis of launch vehicles in transonic flight

A numerical study of the aeroelastic stability of launch vehicles in transonic flight is performed. The unsteady aerodynanic flowfield about the vehicle is simulated using the three dimensional Reynolds-Averaged Navier-Stokes equations with the account for turbulent mixing done by a two-layer algebraic eddy viscosity model. The structural-dynamic formulation considers free-free flexural vibration of an elongated beam with variable properties and the equations are cast in modal form. The two sets of equations are integrated simultaneously in time, after a initial perturbation, to ascertain the aeroelastic stability of a given configuration. The method propossed is described in detail, and results that illustrate its application are presented.

Azevedo, Joao Luiz F.↗

NASA NTRS1990

Rubbing Between Rotors And Stators

Report describes experimental and numerical-simulation studies of dynamical effects of rubbing between rotors and stators in turbomachinery. Purpose of study to gain improved understanding of such rubbing phenomena, with view toward: contributing to techniques for diagnosis of rubbing (e.g., via analysis of vibrations); predicting more accurately limiting operating conditions; and improving design criteria to prevent rubbing damage in high-performance rotating machinery.

Muszynska, Agnes↗

NASA NTRS1989

Numerical simulation of unsteady flows generated by dissociating nitrogen diffusion

An explicit time accurate predictor-corrector scheme, similar to MacCormack's, has been used to simulate unsteady nonequilibrium laminar chemically-reacting diffusion-reaction generated flows. A zonal approach, along with nonstructured boundaries, allows computation of internal and external flow with the same computer code. Results for equilibrium flows generated by dissociating, vibrationally relaxing nitrogen in a rectangular chamber are presented. The unsteady flows were generated strictly by the chemical reactions and concentration gradients.

Marraffa, Lionel↗

NASA NTRS2003

Small Particle Response to Fluid Motion Using Tethered Particles to Simulate Microgravity

This paper reports on ground based work conducted to support the Spaceflight Definition project SHIVA (Spaceflight Holography Investigation in a Virtual Apparatus). SHIVA will advance our understanding of the movement of a particle in a fluid. Gravity usually dominates the equations of motion, but in microgravity as well as on earth other terms can become important. Through an innovative application of fractional differential equations, two members of our team produced the first analytical solution of a fundamental equation of motion, which had only been solved numerically or by approximation before. The general solution predicts that the usually neglected history term becomes important in particle response to a sinusoidal fluid movement when the characteristic viscous time is in the same order as the fluid oscillation period and peaks when the two times are equal. In this case three force terms, the Stokes drag, the added mass, and the history drag must all be included in predicting particle movement. We have developed diagnostic recording methods using holography to save all of the particle field data, allowing the experiment to essentially be transferred from space back to earth in what we call the virtual apparatus for on-earth microgravity experimentation. We can quantify precisely the three-dimensional motion of sets of particles, allowing us to test and apply the new analytical solutions. We are examining the response of particles up to 2 mm radius to fluid oscillation at frequencies up to 80 Hz with amplitudes up to 200 microns. Ground studies to support the flight development program have employed various schemes to simulate microgravity. One of the most reliable and meaningful methods uses spheres tethered to a fine hair suspended in the fluid. We have also investigated particles with nearly neutral buoyancy. Recordings are made at the peak amplitudes of vibration of the cell providing a measure of the ratio of fluid to particle amplitude. The experiment requires precise location of the particle to within microns during recording, and techniques for achieving this are one of the project challenges. Focused microscopic images and diffraction patterns are used. To make the experiment more versatile, the spaceflight system will record holograms both on film and electronically. A cross correlation procedure enables sub pixel accuracies for electronic recordings, partially accommodating the lower spatial resolution of CCDs. The electronic holograms can be down linked providing real time data. Results of the ground experiments, the flight experiment design, and data analysis procedures are reported.

Trolinger, James↗

NASA NTRS2016

Boeing Smart Rotor Full-scale Wind Tunnel Test Data Report

A full-scale helicopter smart material actuated rotor technology (SMART) rotor test was conducted in the USAF National Full-Scale Aerodynamics Complex 40- by 80-Foot Wind Tunnel at NASA Ames. The SMART rotor system is a five-bladed MD 902 bearingless rotor with active trailing-edge flaps. The flaps are actuated using piezoelectric actuators. Rotor performance, structural loads, and acoustic data were obtained over a wide range of rotor shaft angles of attack, thrust, and airspeeds. The primary test objective was to acquire unique validation data for the high-performance computing analyses developed under the Defense Advanced Research Project Agency (DARPA) Helicopter Quieting Program (HQP). Other research objectives included quantifying the ability of the on-blade flaps to achieve vibration reduction, rotor smoothing, and performance improvements. This data set of rotor performance and structural loads can be used for analytical and experimental comparison studies with other full-scale rotor systems and for analytical validation of computer simulation models. The purpose of this final data report is to document a comprehensive, highquality data set that includes only data points where the flap was actively controlled and each of the five flaps behaved in a similar manner.

Full-Scale Wind Tunnel↗

NASA NTRS2019

In-Flight Line-Of-Sight Pointing Performance for the GOES-16 and GOES-17 Spacecraft

The Geostationary Operational Environmental Satellite-R program (GOES-R) has launched two of the next generation geostationary weather satellites, both of which are now fully operational. GOES-16 launched in November 2016, and GOES-17 launched in March 2017. In this paper, we present the pointing and pointing stability results of the two spacecraft, with specific focus on aspects of the design related to mitigating jitter. The flight instrument suite includes 6 seismic accelerometers sampled at approximately 2 kilohertz, allowing in-flight verification of pointing stability and comparison back to simulation predictions. This paper compares the observed flight results with the simulation predictions for acceleration and shock response spectrum (SRS) for various operational scenarios and instrument observation modes. Passive isolation of both the reaction wheels and the payload deck have proved to be effective in reducing jitter responses. Active Vibration Damping (AVD) of flexible-body modes attenuates the low frequency motion of the vehicle appendages, improving the low-frequency pointing performance. Knowledge of the instrument scan mirror motion is fed forward to the reaction wheel control, reducing disturbances on the spacecraft bus. Attitude knowledge and rate data are provided to the primary Earth-observing instrument with an accuracy defined by the Integrated Rate Error (IRE) requirements. The data are used to adjust instrument scanning. As we show in this paper, the in-flight performance of the GN&C (Guidance, Navigation and Control) design provides the necessary capabilities to achieve the demanding GOES-R mission objectives while its robustness enabled the simultaneous operation of the Advanced Baseline Imager (ABI) prime and redundant cryocoolers (CCs) to resolve an in-flight cooling anomaly on GOES-17.

Line-of-Sight↗

NASA NTRS2024

3D Scanning System to Assess Gravity-Dependent Body Shape Changes

The human body shows unique physiological and morphological changes when exposed to different gravity conditions, including muscle atrophy, fluid shift, spinal elongation, and body posture adjustments. Such changes need to be incorporated for human-system integration in the vehicle habitat, garment, and spacesuit designs, as inaccurate body measurements can result in suboptimal crew protection that can potentially decrease injury tolerance. However, the traditional linear measurements, such as stature, segment lengths or circumferences measured using a caliper or tape measure, often show limited consistency and are unable to capture the nonlinear characteristics of the human body. While 3D body scanning can provide significant advantages over linear measurements, the technologies have not been fully developed or customized for in-flight scanning. For ground laboratory use, several different scanner types are commercially available. However, in-flight scanning requires additional technical considerations, such as minimal scan time, simplified calibration, and sufficient capture volume. This work aims to develop a prototype 3-D body scanning system that is customized for in-flight use to scan crewmembers, with the configuration and performance optimized for detecting known gravity-dependent body shape and posture changes. A hardware system will be custom built using a network of commercial off-the-shelf 3D sensors. The sensor parameters and settings will be optimized to detect the targeted body shape changes, specifically using body manikins of which the shape and size are iteratively permuted to simulate the known changes by fluid shift and spinal elongation. The capture volume will be also matched for a range of body sizes from a 1st percentile female to 99th percentile male. Unintentional body motions or floating in microgravity will be also simulated and incorporated. A data acquisition software will be developed for efficient in-flight operations with minimal overhead and easy-to-use user interface. A simplified calibration procedure will be designed for robust scanning against frequent vibration or unexpected sensor position shifts. The system will be tested in the ground laboratory for accuracy and reliability against a reference scanning system. New anthropometry measurements will be also identified to sensitively capture the gravity dependent body shape changes, in addition to the traditional anthropometry measurements. A novel landmark-based technique will be tested for consistent anthropometry measurements across posture variations. If successfully developed and deployed, the new system is expected to provide previously unavailable body shape and size data from different gravitational environments, including 0-g, 1/6-g, and 1-g. Such data can improve suit fit, habitat design, exercise efficacy quantification and sizing of orthostatic intolerance garments.

K H Kim↗

NASA NTRS2024

3D Scanning System to Assess Gravity-Dependent Body Shape Changes

K H Kim↗

DOE OSTI2023

Numerical Analysis and Flow Induced Vibration Studies in Pressurized Helium Gas Cooling Channels

Los Alamos National Laboratory (LANL) is working with NorthStar Medical Radioisotopes (NMR) on their efforts to produce Mo-99 from the irradiation of Mo-100 targets. The NMR target consists of an Inconel window that allows the electron beam to penetrate and irradiate a stack of Mo-100 discs. The irradiation process generates large amounts of heat and is cooled using pressurized helium gas flowing at 400 g/s. LANL provides both numerical analysis support and experimental support. Computational fluid dynamics (CFD) simulations for both 300 g/s and 400 g/s are performed on the NMR target to analyze the helium flow through the NMR system. The pressure drop, the mass flow rate through each of the disc and window channels and the force applied on the first disc are some of the quantities estimated using CFD. These results will be combined with Monte Carlo N-Particle (MCNP) estimates of heat flux into the system from the electron beam to perform conjugate heat transfer analysis (CHT). The experiments presented in this report focus on the effect of the flow induced vibrations from helium flowing through the coolant gaps between the discs. There is concern that the flow induced vibrations may lead to excessive mass loss of the enriched Mo-100 discs, and the goal would be to mitigate the mass loss. This work presents benchtop tests of flow through a subset of the target stack which involves high speed imaging and displacement measurements used to estimate disc vibration, as well as mass loss.

42 ENGINEERING↗

NASA NTRS2005

Probabilistic Fracture Mechanics Analysis of the Orbiter's LH2 Feedline Flowliner

Work performed by Southwest Research Institute (SwRI) as part of an Independent Technical Assessment (ITA) for the NASA Engineering and Safety Center (NESC) is summarized. The ITA goal was to establish a flight rationale in light of a history of fatigue cracking due to flow induced vibrations in the feedline flowliners that supply liquid hydrogen to the space shuttle main engines. Prior deterministic analyses using worst-case assumptions predicted failure in a single flight. The current work formulated statistical models for dynamic loading and cryogenic fatigue crack growth properties, instead of using worst-case assumptions. Weight function solutions for bivariant stressing were developed to determine accurate crack "driving-forces". Monte Carlo simulations showed that low flowliner probabilities of failure (POF = 0.001 to 0.0001) are achievable, provided pre-flight inspections for cracks are performed with adequate probability of detection (POD)-specifically, 20/75 mils with 50%/99% POD. Measurements to confirm assumed POD curves are recommended. Since the computed POFs are very sensitive to the cyclic loads/stresses and the analysis of strain gage data revealed inconsistencies with the previous assumption of a single dominant vibrant mode, further work to reconcile this difference is recommended. It is possible that the unaccounted vibrational modes in the flight spectra could increase the computed POFs.

Bonacuse, Peter J.↗