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NASA NTRSDate not supplied

NDE Methods and Capabilities Handbook – Resources for the Composites NDE Community

Composite structures are often difficult to inspect due to the anisotropic nature of the material systems and the range of flaws and defects that can arise in the manufacturing process. NASA’s Advanced Composites Project, a public-private partnership between government, universities and industry, sought to address improved methods, tools, and protocols to reduce the development and certification timeline for composite materials and structures. The rapid inspection of composites was one of the three focused research areas of the project. One deliverable of the project was to develop an NDE Methods and Capabilities Handbook. This Handbook provides a publicly available guidance document that facilitates the selection of appropriate NDE techniques and provides recommended protocols for detecting and characterizing common flaw types in solid laminate carbon fiber reinforced polymer composite (CFRP) structures. The Handbook seeks to reduce the time required to develop qualified inspection processes for composite aircraft structures during the development, certification, and manufacturing phases by providing a reference that helps minimize trial and error and provides guidance on best practices, techniques, and settings, for specific flaw types and geometries. NDE techniques include, but are not limited to ultrasound, laser based ultrasound, infrared thermography, and x-ray CT. Flaw types include, but are not limited to porosity, delamination, voids, AFP defects and impact damage. The Handbook contains details such as inspection parameters, data analysis techniques, inspection efficiency (speed & cost), and limitations. This presentation will describe key Handbook activities with examples of the techniques and flaw types examined by the Advanced Composite Consortium members. Availability of the fabricated NDE standards as well as the raw data collected on the standards by the Consortium members to the NDE community is discussed.

Patricia A Howell↗

NASA NTRSDate not supplied

NDE Methods and Capabilities Handbook - Resources for the Composites NDE Community

Composite structures are often difficult to inspect due to the anisotropic nature of the material systems and the range of flaws and defects that can arise in the manufacturing process. NASA’s Advanced Composites Project, a public-private partnership between government, universities and industry, sought to address improved methods, tools, and protocols to reduce the development and certification timeline for composite materials and structures. The rapid inspection of composites was one of the three focused research areas of the project. One deliverable of the project was to develop an NDE Methods and Capabilities Handbook. This Handbook provides a publicly available guidance document that facilitates the selection of appropriate NDE techniques and provides recommended protocols for detecting and characterizing common flaw types in solid laminate carbon fiber reinforced polymer composite (CFRP) structures. The Handbook seeks to reduce the time required to develop qualified inspection processes for composite aircraft structures during the development, certification, and manufacturing phases by providing a reference that helps minimize trial and error and provides guidance on best practices, techniques, and settings, for specific flaw types and geometries. Techniques include, but are not limited to ultrasound, laser based ultrasound, infrared thermography, and x-ray CT. Flaw types include, but are not limited to porosity, delaminations, voids, Automated Fiber Placement (AFP) defects and impact damage. The Handbook contains details such as inspection parameters, data analysis techniques, inspection efficiency and limitations. This presentation will describe key Handbook activities with examples of the techniques and flaw types examined by the Advanced Composite Consortium members. Availability to the NDE community of the fabricated NDE standards as well as the raw data collected on the standards by the Consortium members is discussed.

Nondestructive Evaluation↗

NASA NTRSDate not supplied

NDE Methods and Capabilities Handbook - Resources for the Composites NDE Community

Composite structures are often difficult to inspect due to the anisotropic nature of the material systems and the range of flaws and defects that can arise in the manufacturing process. NASA’s Advanced Composites Project, a public-private partnership between government, universities and industry, sought to address improved methods, tools, and protocols to reduce the development and certification timeline for composite materials and structures. The rapid inspection of composites was one of the three focused research areas of the project. One deliverable of the project was to develop an NDE Methods and Capabilities Handbook. This Handbook provides a publicly available guidance document that facilitates the selection of appropriate NDE techniques and provides recommended protocols for detecting and characterizing common flaw types in solid laminate carbon fiber reinforced polymer composite (CFRP) structures. The Handbook seeks to reduce the time required to develop qualified inspection processes for composite aircraft structures during the development, certification, and manufacturing phases by providing a reference that helps minimize trial and error and provides guidance on best practices, techniques, and settings, for specific flaw types and geometries. Techniques include, but are not limited to ultrasound, laser based ultrasound, infrared thermography, and x-ray CT. Flaw types include, but are not limited to porosity, delaminations, voids, Automated Fiber Placement (AFP) defects and impact damage. The Handbook contains details such as inspection parameters, data analysis techniques, inspection efficiency and limitations. This paper describes key Handbook activities with examples of the techniques and flaw types examined by the Advanced Composite Consortium members. Availability to the NDE community of the fabricated NDE standards as well as the raw data collected on the standards by the Consortium members is discussed.

nondestructive evaluation↗

NASA NTRSDate not supplied

Probabalistic Risk Analysis and Thermal Margin Process for an Inflatable Aeroshell

Uncertainties always exist in atmospheric entry aeroheating environments and the thermal response of thermal protection system (TPS) material. These uncertainties are mitigated in the design by ap-plying margin and factors of safety to the TPS. Entry vehicle TPS is often conservatively over-sized for the heat loads that are experienced along the entry trajectory by stacking worst-case scenarios together. Additionally, the current TPS design and margin process used by NASA offers very little insight into the risk of over-temperature during flight and the reliability of the heat shield performance [1,3]. A probabilistic margin process can be used to calculate the amount of TPS margin necessary to survive a given entry heat load at a specified level of risk [2,3,4]. The vehicle’s initial entry state (entry velocity, flight path angle, and entry mass) determines the expected atmospheric entry environmental conditions and resulting heat load that the entry vehicle will experience. If there is flexibility in the entry state, then this process can be used to select an appropriate combination of entry state parameters and TPS size to target a desired reentry reliability. This probabilistic margin process allows engineers to make informed aeroshell design, entry-trajectory design, and TPS performance risk trades while preventing excessive TPS margin from being applied. The probabilistic TPS margin process has been performed to determine TPS thickness and entry heating constraints given an acceptable risk level for the Low Earth Orbit Flight Experiment of an Inflatable Decelerator (LOFTID) flight project. The process is used in a manner to size the entry heat load for a given flexible TPS (FTPS) thickness so that it meets project reliability standards while allowing the FTPS and the underlying inflatable structure (IS) to be pushed to adequately high temperatures. Since the LOFTID project is an experimental flight demonstration, it is de-sired to drive the FTPS and IS to temperatures that cover a large range of their thermal response models’ applicability. This will allow the thermal response models to be better improved and validated post-flight using LOFTID’s extensive instrumentation embedded within the aeroshell. The presentation demonstrates how uncertainty analysis is carried out using an end-to-end Monte Carlo process where three separate Monte Carlo simulations are run in sequence. The first Monte Carlo simulation operates on the entry trajectory model to generate trajectory parameter dispersions that are fed into the second Monte Carlo simulation. The second Monte Carlo simulation operates on the aerothermodynamics model to generate aeroheating parameter dispersions that are fed into the third Monte Carlo simulation. The third Monte Carlo simulation operates on the FTPS material thermal response model to generate the final FTPS/IS thermal response dispersions. The end-to-end Monte Carlo simulation propagates the uncertainties of each model into the next to quantify the resulting uncertainty of the FTPS/IS thermal response. The fractional contributions of the uncertain parameters in the trajectory, aerothermal, and thermal response models to the variance in the FTPS/IS thermal response is determined as a byproduct of the Monte Carlo analysis. The structural uncertainty of the FTPS thermal response model is evaluated by flight relevant ground testing and model error analysis using test measurements. This probabilistic TPS margin process had never been applied to an entry vehicle and it is one of the LOFTID project’s goals to demonstrate its merits.

Steven A. Tobin↗

DOE OSTI2024

Delocalization error poisons the density-functional many-body expansion

The many-body expansion is a fragment-based approach to large-scale quantum chemistry that partitions a single monolithic calculation into manageable subsystems. This technique is increasingly being used as a basis for fitting classical force fields to electronic structure data, especially for water and aqueous ions, and for machine learning. Here, we show that the many-body expansion based on semilocal density functional theory affords wild oscillations and runaway error accumulation for ion–water interactions, typified by F − (H 2 O) N with N ≳ 15. We attribute these oscillations to self-interaction error in the density-functional approximation. The effect is minor or negligible in small water clusters, explaining why it has not been noticed previously, but grows to catastrophic proportion in clusters that are only moderately larger. This behavior can be counteracted with hybrid functionals but only if the fraction of exact exchange is ≳50%, whereas modern meta-generalized gradient approximations including ωB97X-V, SCAN, and SCAN0 are insufficient to eliminate divergent behavior. Other mitigation strategies including counterpoise correction, density correction (i.e., exchange–correlation functionals evaluated atop Hartree–Fock densities), and dielectric continuum boundary conditions do little to curtail the problematic oscillations. In contrast, energy-based screening to cull unimportant subsystems can successfully forestall divergent behavior. These results suggest that extreme caution is warranted when the many-body expansion is combined with density functional theory.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1993

A comparison of refined models for flexible subassemblies

Interactions between structure response and control of large flexible space systems have challenged current modeling techniques and have prompted development of new techniques for model improvement. Due to the geometric complexity of envisioned large flexible space structures, finite element models (FEM's) will be used to predict the dynamic characteristics of structural components. It is widely accepted that these models must be experimentally 'validated' before their acceptance as the basis for final design analysis. However, predictions of modal properties (natural frequencies, mode shapes, and damping ratios) are often in error when compared to those obtained from Experimental Modal Analysis (EMA). Recent research efforts have resulted in the development of algorithmic approaches for model improvement, also referred to as system or structure identification.

Smith, Suzanne Weaver↗

NASA NTRS2002

Fundamental Studies of Crystal Growth of Microporous Materials

Microporous materials are framework structures with well-defined porosity, often of molecular dimensions. Zeolites contain aluminum and silicon atoms in their framework and are the most extensively studied amongst all microporous materials. Framework structures with P, Ga, Fe, Co, Zn, B, Ti and a host of other elements have also been made. Typical synthesis of microporous materials involve mixing the framework elements (or compounds, thereof) in a basic solution, followed by aging in some cases and then heating at elevated temperatures. This process is termed hydrothermal synthesis, and involves complex chemical and physical changes. Because of a limited understanding of this process, most synthesis advancements happen by a trial and error approach. There is considerable interest in understanding the synthesis process at a molecular level with the expectation that eventually new framework structures will be built by design. The basic issues in the microporous materials crystallization process include: (1) Nature of the molecular units responsible for the crystal nuclei formation; (2) Nature of the nuclei and nucleation process; (3) Growth process of the nuclei into crystal; (4) Morphological control and size of the resulting crystal; (5) Surface structure of the resulting crystals; (6) Transformation of frameworks into other frameworks or condensed structures. The NASA-funded research described in this report focuses to varying degrees on all of the above issues and has been described in several publications. Following is the presentation of the highlights of our current research program. The report is divided into five sections: (1) Fundamental aspects of the crystal growth process; (2) Morphological and Surface properties of crystals; (3) Crystal dissolution and transformations; (4) Modeling of Crystal Growth; (5) Relevant Microgravity Experiments.

Dutta, P.↗

NASA NTRS2003

Fundamental Studies of Crystal Growth of Microporous Materials

Microporous materials are framework structures with well-defined porosity, often of molecular dimensions. Zeolites contain aluminum and silicon atoms in their framework and are the most extensively studied amongst all microporous materials. Framework structures with P, Ga, Fe, Co, Zn, B, Ti and a host of other elements have also been made. Typical synthesis of microporous materials involve mixing the framework elements (or compounds, thereof) in a basic solution, followed by aging in some cases and then heating at elevated temperatures. This process is termed hydrothermal synthesis, and involves complex chemical and physical changes. Because of a limited understanding of this process, most synthesis advancements happen by a trial and error approach. There is considerable interest in understanding the synthesis process at a molecular level with the expectation that eventually new framework structures will be built by design. The basic issues in the microporous materials crystallization process include: (a) Nature of the molecular units responsible for the crystal nuclei formation; (b) Nature of the nuclei and nucleation process; (c) Growth process of the nuclei into crystal; (d) Morphological control and size of the resulting crystal; (e) Surface structure of the resulting crystals; and (f) Transformation of frameworks into other frameworks or condensed structures.

Singh, Ramsharan↗

NASA NTRS2003

A Comparison of Solar p-Mode Parameters from MDI and Gong: Mode Frequencies and Structure Inversions

Helioseismic analysis of solar global oscillations allows investigation of the internal structure of the Sun. One important test of the reliability of the inferences from helioseismology is that the results from independent sets of contemporaneous data are consistent with one another. Here we compare mode frequencies from the Global Oscillation Network Group and Michelson Doppler Imager on board SOHO and resulting inversion results on the Sun's internal structure. The average relative differences between the data sets are typically less than 1 x 10(exp -5) substantially smaller than the formal errors in the differences; however, in some cases the frequency differences show a systematic behavior that might nonetheless influence the inversion results. We find that the differences in frequencies are not a result of instrumental effects but are almost entirely related to the data pipeline software. Inversion of the frequencies shows that their differences do not result in any significant effects on the resulting inferences on solar structure. We have also experimented with fitting asymmetric profiles to the oscillation power spectra and find that, compared with the symmetric fits, this causes no significant change in the inversion results.

Basu, S.↗

NASA NTRS1992

Control-structure interaction/mirror motion compensation

Space Systems/Loral (formerly Ford Aerospace, Space Systems Division) has implemented a rigid-body Mirror Motion Compensation (MMC) scheme for the GOES-I/M spacecraft currently being built for NASA and NOAA. This has resulted in a factor of 15 reduction in pointing error due to rigid-body spacecraft motion induced by the periodic black-body calibration maneuvers required for the instruments. For GOES the spacecraft and the payload mirrors are considered as rigid bodies. The structural flexibility effects are small and are included in the total pointing budget as a separate item. This paper extends the MMC technique to include structural flexibility. For large multi-payload platforms, the structural flexibility effects can be more important in sensor pointing jitter as the result of payload motion. Sensitivity results are included to show the importance of the dynamic model fidelity.

Mclaren, Mark↗

NASA NTRS2011

Negative Stress Margins - Are They Real?

Advances in modeling and simulation, new finite element software, modeling engines and powerful computers are providing opportunities to interrogate designs in a very different manner and in a more detailed approach than ever before. Margins of safety are also often evaluated using local stresses for various design concepts and design parameters quickly once analysis models are defined and developed. This paper suggests that not all the negative margins of safety evaluated are real. The structural areas where negative margins are frequently encountered are often near stress concentrations, point loads and load discontinuities, near locations of stress singularities, in areas having large gradients but with insufficient mesh density, in areas with modeling issues and modeling errors, and in areas with connections and interfaces, in two-dimensional (2D) and three-dimensional (3D) transitions, bolts and bolt modeling, and boundary conditions. Now, more than ever, structural analysts need to examine and interrogate their analysis results and perform basic sanity checks to determine if these negative margins are real.

Raju, Ivatury S.↗

NASA NTRS2011

Negative stress margins – are they real?

Raju, Ivatury S.↗

NASA NTRS1985

A comparison of measured and calculated thermal stresses in a hybrid metal matrix composite spar cap element

A hybrid spar of titanium with an integrally brazed composite, consisting of an aluminum matrix reinforced with boron-carbide-coated fibers, was heated in an oven and the resulting thermal stresses were measured. Uniform heating of the spar in an oven resulted in thermal stresses arising from the effects of dissimilar materials and anisotropy of the metal matrix composite. Thermal stresses were calculated from a finite element structural model using anisotropic material properties deduced from constituent properties and rules of mixtures. Comparisons of calculated thermal stresses with measured thermal stresses on the spar are presented. It was shown that failure to account for anisotropy in the metal matrix composite elements would result in large errors in correlating measured and calculated thermal stresses. It was concluded that very strong material characterization efforts are required to predict accurate thermal stresses in anisotropic composite structures.

Jenkins, J. M.↗

DOE OSTI2017

Artificial neural network based predictions of cetane number for furanic biofuel additives

The next generation of alternative fuels is being explored through advanced chemical and biological production techniques for the purpose of finding suitable replacements for diesel and gasoline while lowering production costs and increasing process yields. Chemical conversion of biomass to fuels offers a plethora of pathways with a variety of fuel molecules, both novel and traditional, which may be targeted. In the search for new fuels, an initial, intuition-driven evaluation of fuel compounds with desired properties is required. Due to the high cost and significant production time needed to synthesize these materials at a scale sufficient for exhaustive testing, a predictive model would allow chemists to preemptively screen fuel properties of potentially desirable fuel candidates. Current work has shown that predictive models, in this case artificial neural networks (ANN's) analyzing quantitative structure property relationships (QSPR's), can predict the cetane number (CN) of a proposed fuel molecule with relatively small error. A fuel's CN is a measure of its ignition quality, typically defined using prescribed ASTM standards and a cetane testing engine. Alternatively, the analogous derived cetane number (DCN), obtained using an Ignition Quality Tester (IQT), is a direct measurement alternative to the CN that uses an empirical inverse relationship to the ignition delay found in the constant volume combustion chamber apparatus. DCN data points acquired using an IQT were utilized for model validation and expansion of the experimental database used in this study. The present report improves on an existing model by optimizing the model architecture along with the key learning variables of the ANN and by making the model more generalizable to a wider variety of fuel candidate types, specifically the class of furans and furan derivatives, by including specific molecules for the model to incorporate. The new molecules considered include tetrahydrofuran, 2-methylfuran, 2-methyltetrahydrofuran, 5,5'-(furan-2-ylmethylene)bis(2-methylfuran), 5,5'-((tetrahydrofuran-2-yl)methylene)bis(2-methyltetrahydrofuran), tris(5-methylfuran-2-yl)methane, and tris(5-methyltetrahydrofuran-2-yl)methane. Model architecture adjustments improved the overall root-mean-square error (RMSE) of the base database predictions by 5.54%. Additionally, through the targeted database expansion, it is shown that the predicted cetane number of the furan-based molecules improves on average by 49.21% (3.74 CN units) and significantly for a few of the individual molecules. This indicates that a selected subset of representative molecules can be used to extend the model's predictive accuracy to new molecular classes. The approach, bolstered by the improvements presented in this paper, enables chemists to focus on promising molecules by eliminating less favorable candidates in relation to their ignition quality.

09 BIOMASS FUELS↗

DOE OSTI2017

Development of performance specifications for hybrid modeling of floating wind turbines in wave basin tests

Hybrid modeling—combining physical testing and numerical simulation in real time$-$opens new opportunities in floating wind turbine research. Wave basin testing is an important validation step for floating support structure design, but the conventional approaches that use physical wind above the basin are limited by scaling problems in the aerodynamics. Applying wind turbine loads with an actuation system that is controlled by a simulation responding to the basin test in real time offers a way to avoid scaling problems and reduce cost barriers for floating wind turbine design validation in realistic coupled wind and wave conditions. This paper demonstrates the development of performance specifications for a system that couples a wave basin experiment with a wind turbine simulation. Two different points for the hybrid coupling are considered: the tower-base interface and the aero-rotor interface (the boundary between aerodynamics and the rotor structure). Analyzing simulations of three floating wind turbine designs across seven load cases reveals the motion and force requirements of the coupling system. By simulating errors in the hybrid coupling system, the sensitivity of the floating wind turbine response to coupling quality can be quantified. The sensitivity results can then be used to determine tolerances for motion tracking errors, force actuation errors, bandwidth limitations, and latency in the hybrid coupling system. These tolerances can guide the design of hybrid coupling systems to achieve desired levels of accuracy. An example demonstrates how the developed methods can be used to generate performance specifications for a system at 1:50 scale. Results show that sensitivities vary significantly between support structure designs and that coupling at the aero-rotor interface has less stringent requirements than those for coupling at the tower base. As a result, the methods and results presented here can inform design of future hybrid coupling systems and enhance understanding of how test results are affected by hybrid coupling quality.

16 TIDAL AND WAVE POWER↗

NASA NTRS1984

Digital image processing of Seabeam bathymetric data for structural studies of seamounts near the East Pacific Rise

The problem of displaying information on the seafloor morphology is attacked by utilizing digital image processing techniques to generate images for Seabeam data covering three young seamounts on the eastern flank of the East Pacific Rise. Errors in locations between crossing tracks are corrected by interactively identifying features and translating tracks relative to a control track. Spatial interpolation techniques using moving averages are used to interpolate between gridded depth values to produce images in shaded relief and color-coded forms. The digitally processed images clarify the structural control on seamount growth and clearly show the lateral extent of volcanic materials, including the distribution and fault control of subsidiary volcanic constructional features. The image presentations also clearly show artifacts related to both residual navigational errors and to depth or location differences that depend on ship heading relative to slope orientation in regions with steep slopes.

Edwards, M. H.↗

NASA NTRS1995

(abstract) Characterization of Structural Response for Systems with Loose Joints

This paper describes a technique to locate and characterize loose joints in a large truss structure to generate an accurate structural model. The joint looseness is modeled as a gap in the member that opens and closes depending on the loading. Arbitrarily placed actuators are used to prestress the structure to first linearize the response. Next the actuator displacements are systematically reduced while monitoring the displacement response. The gap locations are determined by comparing the measured displacements with sets of calculated displacements and the sizes are estimated by monitoring the gap member length changes using the appropriate linear force-displacement relationship for the load level. The effect of measurement error in the truss displacements and the actuator length changes are investigated.

truss structures loose joints displacements actuat↗

DOE OSTI2024

KiDS-1000 cosmology: Combined second- and third-order shear statistics

Aims.In this work, we perform the first cosmological parameter analysis of the fourth release of Kilo Degree Survey (KiDS-1000) data with second- and third-order shear statistics. This paper builds on a series of studies aimed at describing the roadmap to third-order shear statistics. Methods.We derived and tested a combined model of the second-order shear statistic, namely, the COSEBIs and the third-order aperture mass statistics 〈ℳ ap 3 〉 in a tomographic set-up. We validated our pipeline withN-body mock simulations of the KiDS-1000 data release. To model the second- and third-order statistics, we used the latest version of HMCODE2020 for the power spectrum and BIHALOFITfor the bispectrum. Furthermore, we used an analytic description to model intrinsic alignments and hydro-dynamical simulations to model the effect of baryonic feedback processes. Lastly, we decreased the dimension of the data vector significantly by considering only equal smoothing radii for the 〈ℳ ap 3 〉 part of the data vector. This makes it possible to carry out a data analysis of the KiDS-1000 data release using a combined analysis of COSEBIs and third-order shear statistics. Results.We first validated the accuracy of our modelling by analysing a noise-free mock data vector, assuming the KiDS-1000 error budget, finding a shift in the maximum of the posterior distribution of the matter density parameter, ΔΩ m < 0.02 σ Ω m , and of the structure growth parameter, ΔS 8 < 0.05 σ S 8 . Lastly, we performed the first KiDS-1000 cosmological analysis using a combined analysis of second- and third-order shear statistics, where we constrained Ω m = 0.248 −0.055 +0.062 andS 8 = σ 8 √(Ω m /0.3 )= 0.772 ± 0.022. The geometric average on the errors of Ω m andS 8 of the combined statistics decreases, compared to the second-order statistic, by a factor of 2.2.

Astronomy & Astrophysics↗