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At least 1,117 records · Page 62

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DOE OSTI2023

Accelerating Additive Manufacturing Process Design for Energy Conversion Materials using In-situ Sensing and Machine Learning

One promising candidate for manufacturing of the bismuth Telluride thermoelectric legs is laser powder bed fusion (LPBF) additive Manufacturing (AM). AM processing parameters highly influence the material properties, however current processing parameter development methods in AM are costly and time consuming. In-situ sensors allow for the capture of physically relevant process information on a layer-by-layer basis and will be used to aide process development. To optimize the AM process for the best thermoelectric performance, process variables, in-situ process sensor data and ex-situ material characterization data are collected. Several different interpretable machine learning (ML) approaches are used, and the performance of each method are assessed. Significant input process variables include laser focus, hatch spacing and laser power. The best performing models are used to determine the manufacturing parameters that maximize the power factor. AM of bismuth telluride material provides the ability to create complex geometries enabling more efficient energy conversion.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2025

Installation and Demonstration of CNC Machining for Mechanical Test Specimens in the IFEL Hot Cell

This report documents the installation and demonstration of computer numerical control (CNC) machining capabilities in the Irradiated Fuels Examination Laboratory hot cell facility at Oak Ridge National Laboratory (ORNL). A modified Tormach PCNC 440 mill was integrated into the hot cell with custom fixturing, fines management, and manipulator-compatible interfaces to enable the fabrication of axial tension test (ATT) and ring tension test (RTT) specimens from irradiated cladding. The first irradiated specimens machined included ATT and RTT geometries harvested from the high-burnup 6XV fuel rod. Dimensional inspections confirmed that machined specimens met the ±0.025 mm tolerance envelope established in prior development; deviations were consistent with expected measurement scatter and inherent specimen variability, such as wall thickness gradients and eccentricity. Comparisons with out-of-cell metrology confirmed that in-cell machining performance aligns with baseline scatter observed under ideal conditions. This work establishes reproducible, end-to-end specimen preparation at ORNL, directly supporting the US Department of Energy’s Accident-Tolerant Fuel program by enabling reliable, traceable mechanical testing of irradiated cladding.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1979

Applications of velocity potential function to acoustic duct propagation and radiation from inlets using finite element theory

A finite element velocity potential program was developed to study acoustic wave propagation in complex geometries. For irrotational flows, relatively low sound frequencies, and plane wave input, the finite element solutions showed significant effects of inlet curvature and flow gradients on the attenuation of a given acoustic liner in a realistic variable area turbofan inlet. The velocity potential approach can not be used to estimate the effects of rotational flow on acoustic propagation, since the potential acoustic disturbances propagate at the speed of the media in sheared flow. Approaches are discussed that are being considered for extending the finite element solution to include the far field, as well as the internal portion of the duct. A new matrix partitioning approach is presented that can be incorporated in previously developed programs to allow the finite element calculation to be marched into the far field. The partitioning approach provided a large reduction in computer storage and running times.

Baumeister, K. J.↗

NASA NTRS1979

Applications of velocity potential function to acoustic duct propagation and radiation from inlets using finite element theory

A finite element velocity potential program has been developed to study acoustic wave propagation in complex geometries. For irrotational flows, relatively low sound frequencies, and plane wave input, the finite element solutions show significant effects of inlet curvature and flow gradients on the attenuation of a given acoustic liner in a realistic variable area turbofan inlet. In addition, as shown in the paper, the velocity potential approach can not be used to estimate the effects of rotational flow on acoustic propagation since the potential acoustic disturbances propagate at the speed of the media in sheared flow. Approaches are discussed that are being considered for extending the finite element solution to include the far field as well as the internal portion of the duct. A new matrix partitioning approach is presented that can be incorporated in previously developed programs to allow the finite element calculation to be marched into the far field. The partitioning approach provides a large reduction in computer storage and running times.

Baumeister, K. J.↗

NASA NTRS1989

A rocket engine design expert system

The overall structure and capabilities of an expert system designed to evaluate rocket engine performance are described. The expert system incorporates a JANNAF standard reference computer code to determine rocket engine performance and a state-of-the-art finite element computer code to calculate the interactions between propellant injection, energy release in the combustion chamber, and regenerative cooling heat transfer. Rule-of-thumb heuristics were incorporated for the hydrogen-oxygen coaxial injector design, including a minimum gap size constraint on the total number of injector elements. One-dimensional equilibrium chemistry was employed in the energy release analysis of the combustion chamber and three-dimensional finite-difference analysis of the regenerative cooling channels was used to calculate the pressure drop along the channels and the coolant temperature as it exits the coolant circuit. Inputting values to describe the geometry and state properties of the entire system is done directly from the computer keyboard. Graphical display of all output results from the computer code analyses is facilitated by menu selection of up to five dependent variables per plot.

Davidian, Kenneth J.↗

NASA NTRS1989

A Rocket Engine Design Expert System

The overall structure and capabilities of an expert system designed to evaluate rocket engine performance are described. The expert system incorporates a JANNAF standard reference computer code to determine rocket engine performance and a state of the art finite element computer code to calculate the interactions between propellant injection, energy release in the combustion chamber, and regenerative cooling heat transfer. Rule-of-thumb heuristics were incorporated for the H2-O2 coaxial injector design, including a minimum gap size constraint on the total number of injector elements. One dimensional equilibrium chemistry was used in the energy release analysis of the combustion chamber. A 3-D conduction and/or 1-D advection analysis is used to predict heat transfer and coolant channel wall temperature distributions, in addition to coolant temperature and pressure drop. Inputting values to describe the geometry and state properties of the entire system is done directly from the computer keyboard. Graphical display of all output results from the computer code analyses is facilitated by menu selection of up to five dependent variables per plot.

Davidian, Kenneth J.↗

NASA NTRS1991

A generalized scheme for three-dimensional hyperbolic grid generation

A hyperbolic grid generation scheme formulated from grid orthogonality and cell volume specification is generalized such that high quality three-dimensional grids can be obtained for a wide variety of geometries. The speed of the scheme is one to two orders of magnitude faster than typical elliptic grid generation methods. The robustness of the scheme is significantly enhanced by several new techniques. By using a spatially variable smoothing coefficient, orthogonality and smoothness of the grid are maintained around complex concave and convex surface topologies. A metric correction procedure is employed to guarantee that the grid marches out of a corner by bisecting the angles subtended by the neighboring points. Extra robustness at severe convex corners is achieved by special local treatments. Different extrapolation methods are used to provide smoothness at floating edges and axis regions. The versatility of the new hyperbolic grid generation scheme is demonstrated by three-dimensional grids generated for external components of the intergrated Space Shuttle vehicle and the SOFIA telescope.

Chan, William M.↗

NASA NTRS1995

Rapid deceleration mode evaluation

Aircraft with flight capability above 1.4 normally have an RPM lockup or similar feature to prevent inlet buzz that would occur at low engine airflows. This RPM lockup has the effect of holding the engine thrust level at the intermediate power (maximum non-afterburning). For aircraft such as military fighters or supersonic transports, the need exists to be able to rapidly slow from supersonic to subsonic speeds. For example, a supersonic transport that experiences a cabin decompression needs to be able to slow/descend rapidly, and this requirement may size the cabin environmental control system. For a fighter, there may be a desire to slow/descend rapidly, and while doing so to minimize fuel usage and engine exhaust temperature. Both of these needs can be aided by achieving the minimum possible overall net propulsive force. As the intermediate power thrust levels of engines increase, it becomes even more difficult to slow rapidly from supersonic speeds. Therefore, a mode of the performance seeking control (PSC) system to minimize overall propulsion system thrust has been developed and tested. The rapid deceleration mode reduces the engine airflow consistent with avoiding inlet buzz. The engine controls are trimmed to minimize the thrust produced by this reduced airflow, and moves the inlet geometry to degrade the inlet performance. As in the case of the other PSC modes, the best overall performance (in this case the least net propulsive force) requires an integrated optimization of inlet, engine, and nozzle variables. This paper presents the predicted and measured results for the supersonic minimum thrust mode, including the overall effects on aircraft deceleration.

Conners, Timothy R.↗

NASA NTRS2012

Adaptive Aft Signature Shaping of a Low-Boom Supersonic Aircraft Using Off-Body Pressures

The design and optimization of a low-boom supersonic aircraft using the state-of-the- art o -body aerodynamics and sonic boom analysis has long been a challenging problem. The focus of this paper is to demonstrate an e ective geometry parameterization scheme and a numerical optimization approach for the aft shaping of a low-boom supersonic aircraft using o -body pressure calculations. A gradient-based numerical optimization algorithm that models the objective and constraints as response surface equations is used to drive the aft ground signature toward a ramp shape. The design objective is the minimization of the variation between the ground signature and the target signature subject to several geometric and signature constraints. The target signature is computed by using a least-squares regression of the aft portion of the ground signature. The parameterization and the deformation of the geometry is performed with a NASA in- house shaping tool. The optimization algorithm uses the shaping tool to drive the geometric deformation of a horizontal tail with a parameterization scheme that consists of seven camber design variables and an additional design variable that describes the spanwise location of the midspan section. The demonstration cases show that numerical optimization using the state-of-the-art o -body aerodynamic calculations is not only feasible and repeatable but also allows the exploration of complex design spaces for which a knowledge-based design method becomes less effective.

Ordaz, Irian↗

NASA NTRS2022

Unique Observational Constraints on the Seasonal and Longitudinal Variability of the Earth’s Planetary Albedo and Cloud Distribution Inferred From EPIC Measurements

Thorough comparison to observations is key to developing a credible climate model forecasting capability. Deep Space Climate Observatory (DSCOVR) measurements of Earth’s reflected solar and emitted thermal radiation provide a unique observational perspective that permits a more reliable model/data comparison than is possible with the otherwise available satellite data. The uniqueness is in the DSCOVR satellite’s viewing geometry, which enables continuous viewing of the Earth’s sunlit hemisphere from its Lissajous orbit around the Lagrangian L1 point. The key instrument is the Earth Polychromatic Imaging Camera (EPIC), which views the Earth’s sunlit hemisphere with 1024-by-1024-pixel imagery in 10 narrow spectral bands from 317 to 780 nm, acquiring up to 22 high spatial resolution images per day. The additional feature is that the frequency of EPIC image acquisition is nearly identical to that of the climate GCM data generation scheme where climate data for the entire globe are ‘instantaneously’ calculated at 1-h radiation time-step intervals. Implementation of the SHS (Sunlit Hemisphere Sampling) EPIC-view geometry for the in-line GCM output data sampling establishes a precise self-consistency in the space-time data sampling between EPIC observational and GCM output data generation and sampling. The remaining problem is that the GCM generated data are radiative fluxes, while the EPIC measurements are backscatter-dependent radiances. Radiance to flux conversion is a complex problem with no simple way to convert GCM radiative fluxes into spectral radiances. The more expedient approach is to convert the EPIC spectral radiances into broadband radiances by MODIS/CERES-based regression relationships and then into solar radiative fluxes using the CERES angular distribution models. Averaging over the sunlit hemisphere suppresses the meteorological weather noise, but preserves the intra-seasonal larger scale variability. Longitudinal slicing by the Earth’s rotation permits a self-consistent model/data comparison of the longitudinal model/data differences in the variability of the reflected solar radiation. Ancillary EPIC Composite data provide additional cloud property information for climate model diagnostics. Comparison of EPIC-derived seasonal and longitudinal variability of the Earth’s planetary albedo with the GISS ModelE2 results shows systematic overestimate of cloud reflectivity over the Pacific Ocean with corresponding underestimates over continental land areas.

DSCOVR↗

NASA NTRS2007

HST/ACS Coronagraphic Observations of the HD 163296 Circumstellar Disk: Evidence of Time-Variable Self-Shadowing?

We present Hubble Space Telescope Advanced Camera for Surveys (HST/ACS) coronagraphic observations of the Herbig Ae star HD 163296. HD 163296's scattered light disk was resolved in the F606W and F814W filters in observations obtained In 2003 and in the F435W filter in observations obtained in 2004. Analysis of single-epoch data indicates that the disk (V-I) color is redder than the observed stellar (V-I) color. This spatially uniform red disk color might be indicative of either an evolution in the grain size distribution (i.e. grain growth) and/or composition. Both of these processes would be consistent with the observed flat geometry of the outer disk, as diagnosed by the observed r$(exp -3)$ power law behavior of its median azimuthally averaged disk surface brightness, which suggest that grain evolution is occurring. Comparison of ACS and STIS epoch scattered light data reveals differences in the observed disk surface brightnesses, of order 1 mag arcsec$(exp -2)$, in both V and white-light filter bandpasses. Along with the observed variability in the visibility and surface brightness of the ansa(e) in the disk, and spectropolarimetric variability of the system, these results suggest that the resolved scattered light disk is variable, a phenomenon not previously observed in any other Herbig protoplanetary system We speculate that the observed behavior might be attributable to the variable inflation of the scale height of the inner disk wall, which results in variable self-shadowing of the outer disk.

Wisniewski, J.↗

NASA NTRS1979

Effect of lip and centerbody geometry on aerodynamic performance of inlets for tilting-nacelle VTOL aircraft

Inlets for tilt-nacelle VTOL aircraft must operate over a wide range of incidence angles and engine weight flows without internal flow separation. Wind tunnel tests of scale model inlets were conducted to evaluate the effectiveness of three geometric variables to provide this capability. Increasing the lip contraction ratio increased the separation angle at all engine weight flows. The optimum axial location of the centerbody occurred when its leading edge was located just downstream of the inlet lip. Compared with a short centerbody, the optimum location of the centerbody resulted in an increase in separation angle at all engine weight flows. Decreasing the lip major-to-minor-axis ratio increased the separation angle at the lower engine weight flows.

Burley, R. R.↗

NASA NTRS1979

Effect of lip and centerbody geometry on aerodynamic performance of inlets for tilting-nacelle VTOL aircraft

Burley, R. R.↗

DOE OSTI2024

Evaluation and development of flow condensation correlations using the data from low GWP refrigerants in an axial micro-fin aluminum tube

To mitigate global warming, the world is transitioning to refrigerants with low global warming potential (GWP). Supporting this shift requires a model that can accurately predict the heat transfer and pressure drop of new refrigerants, crucial for designing efficient heat exchangers. Existing models, however, are largely based on currently deployed refrigerants and primarily developed for unexpanded micro-fin tubes with spiral angles of 6° to 30°. Their applicability to new refrigerants, especially in expanded micro-fin tubes, is uncertain. This study assesses the performance of four well-known condensation models for six emerging refrigerants—R-32, R-454B, R-454C, R-455A, R-1234yf, and R-1234ze(E)—against experimental data. Initially, the Han and Lee (2005) model shows the best prediction accuracy with a mean absolute deviation (MAD) of 22.1 %. To enhance the accuracy of heat transfer models for new refrigerants and geometries with large temperature glides, two approaches are proposed. Here, the first approach applies a simple correction factor, reducing the MAD of the Cavallini et al. (2009) model from 68.2 % to 15.4 %. The second approach uses the variable metric method for minimization, fitting new constants to the data. This optimization results in the Kedzierski and Goncalves (1997) model achieving the highest accuracy, with a MAD of 13.1 %. For pressure drop models, the Cavallini et al. (1997) model is the most accurate with a MAD of 6.4 %, followed by the Haraguchi et al. (1993) model with a MAD of 9.4 %. Due to its simplicity, the Haraguchi et al. (1993) model is a practical option for predicting frictional pressure drop.

Axial micro-fin tubes↗

NASA NTRS1988

Numerical simulation of axisymmetric turbulent flow in combustors and diffusors

A method for predicting turbulent flow in combustors and diffusers is developed. The Navier-Stokes equations, incorporating a turbulence kappa-epsilon model equation, were solved in a nonorthogonal curvilinear coordinate system. The solution applied the finite volume method to discretize the differential equations and utilized the SIMPLE algorithm iteratively to solve the differenced equations. A zonal grid method, wherein the flow field was divided into several subsections, was developed. This approach permitted different computational schemes to be used in the various zones. In addition, grid generation was made a more simple task. However, treatment of the zonal boundaries required special handling. Boundary overlap and interpolating techniques were used and an adjustment of the flow variables was required to assure conservation of mass, momentum and energy fluxes. The numerical accuracy was assessed using different finite differencing methods, i.e., hybrid, quadratic upwind and skew upwind, to represent the convection terms. Flows in different geometries of combustors and diffusers were simulated and results compared with experimental data and good agreement was obtained.

Yung, Chain Nan↗

NASA NTRS1990

Three-dimensional solutions for antisymmetrically laminated anisotropic plates

Analytic three-dimensional elasticity solutions are presented for the stress and free vibration problems of multilayered anisotropic plates. The plates are assumed to have rectangular geometry and antisymmetric lamination with respect to the middle plane. A mixed formulation is used with the fundamental unknowns consisting of the six stress components and the three displacement components of the plate. Each of the plate variables is decomposed into symmetric and antisymmetric components in the thickness direction, and is expressed in terms of a double Fourier series in the Cartesian surface coordinates. Extensive numerical results are presented showing the effects of variation in the lamination and geometric parameters of composite plates on the importance of the transverse stress and strain components.

Noor, Ahmed K.↗

NASA NTRS1991

Linear and nonlinear dynamic analysis by boundary element method

An advanced implementation of the direct boundary element method (BEM) applicable to free-vibration, periodic (steady-state) vibration and linear and nonlinear transient dynamic problems involving two and three-dimensional isotropic solids of arbitrary shape is presented. Interior, exterior, and half-space problems can all be solved by the present formulation. For the free-vibration analysis, a new real variable BEM formulation is presented which solves the free-vibration problem in the form of algebraic equations (formed from the static kernels) and needs only surface discretization. In the area of time-domain transient analysis, the BEM is well suited because it gives an implicit formulation. Although the integral formulations are elegant, because of the complexity of the formulation it has never been implemented in exact form. In the present work, linear and nonlinear time domain transient analysis for three-dimensional solids has been implemented in a general and complete manner. The formulation and implementation of the nonlinear, transient, dynamic analysis presented here is the first ever in the field of boundary element analysis. Almost all the existing formulation of BEM in dynamics use the constant variation of the variables in space and time which is very unrealistic for engineering problems and, in some cases, it leads to unacceptably inaccurate results. In the present work, linear and quadratic isoparametric boundary elements are used for discretization of geometry and functional variations in space. In addition, higher order variations in time are used. These methods of analysis are applicable to piecewise-homogeneous materials, such that not only problems of the layered media and the soil-structure interaction can be analyzed but also a large problem can be solved by the usual sub-structuring technique. The analyses have been incorporated in a versatile, general-purpose computer program. Some numerical problems are solved and, through comparisons with available analytical and numerical results, the stability and high accuracy of these dynamic analysis techniques are established.

Ahmad, Shahid↗

NASA NTRS1992

Heat flow in variable polarity plasma arc welds

The space shuttle external tank and the space station Freedom are fabricated by the variable polarity plasma arc (VPPA) welding. Heat sink effects (taper) are observed when there are irregularities in the work-piece configuration especially if these irregularities are close to the weld bead. These heat sinks affect the geometry of the weld bead, and in extreme cases they could cause defects such as incomplete fusion. Also, different fixtures seem to have varying heat sink effects. The objective of the previous, present, and consecutive research studies is to investigate the effect of irregularities in the work-piece configuration and fixture differences on the weld bead geometry with the ultimate objective to compensate automatically for the heat sink effects and achieve a perfect weld.

Abdelmessih, Amanie N.↗