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At least 1,351 records · Page 75

All sources NASA NTRS DOE OSTI

NASA NTRS2008

An Approach to Assess Delamination Propagation Simulation Capabilities in Commercial Finite Element Codes

An approach for assessing the delamination propagation simulation capabilities in commercial finite element codes is presented and demonstrated. For this investigation, the Double Cantilever Beam (DCB) specimen and the Single Leg Bending (SLB) specimen were chosen for full three-dimensional finite element simulations. First, benchmark results were created for both specimens. Second, starting from an initially straight front, the delamination was allowed to propagate. The load-displacement relationship and the total strain energy obtained from the propagation analysis results and the benchmark results were compared and good agreements could be achieved by selecting the appropriate input parameters. Selecting the appropriate input parameters, however, was not straightforward and often required an iterative procedure. Qualitatively, the delamination front computed for the DCB specimen did not take the shape of a curved front as expected. However, the analysis of the SLB specimen yielded a curved front as was expected from the distribution of the energy release rate and the failure index across the width of the specimen. Overall, the results are encouraging but further assessment on a structural level is required.

Krueger, Ronald↗

NASA NTRS2014

A Morphing Radiator for High-Turndown Thermal Control of Crewed Space Exploration Vehicles

Spacecraft designed for missions beyond low earth orbit (LEO) face a difficult thermal control challenge, particularly in the case of crewed vehicles where the thermal control system (TCS) must maintain a relatively constant internal environment temperature despite a vastly varying external thermal environment and despite heat rejection needs that are contrary to the potential of the environment. A thermal control system may be required to reject a higher heat load to warm environments and a lower heat load to cold environments, necessitating a relatively high turndown ratio. A modern thermal control system is capable of a turndown ratio of on the order of 12:1, but crew safety and environment compatibility have constrained these solutions to massive multi-loop fluid systems. This paper discusses the analysis of a unique radiator design that employs the behavior of shape memory alloys (SMAs) to vary the turndown of, and thus enable, a single-loop vehicle thermal control system for space exploration vehicles. This design, a morphing radiator, varies its shape in response to facesheet temperature to control view of space and primary surface emissivity. Because temperature dependence is inherent to SMA behavior, the design requires no accommodation for control, instrumentation, or power supply in order to operate. Thermal and radiation modeling of the morphing radiator predict a turndown ranging from 11.9:1 to 35:1 independent of TCS configuration. Coupled thermal-stress analyses predict that the desired morphing behavior of the concept is attainable. A system level mass analysis shows that by enabling a single loop architecture this design could reduce the TCS mass by between 139 kg and 225 kg. The concept has been demonstrated in proof-of-concept benchtop tests.

Cognata, Thomas J.↗

DOE OSTI2023

Abnormal grain growth of 68Cu–16Al–16Zn alloys for elastocaloric cooling via cyclical heat treatments

Abstract Cu-based superelastic shape memory alloys are promising for low-stress elastocaloric cooling. We have synthesized bulk alloys of 68Cu–16Al–16Zn under different conditions in order to promote its grain growth and enhance its elastocaloric properties. High-temperature x-ray diffraction of untreated 68Cu–16Al–16Zn alloy showed that the phase boundary between the α + β mixed phases and the high temperature phase ( β phase) was between 973 K and 1023 K. Based on this result, the 68Cu–16Al–16Zn alloy was heated and cooled in a furnace repeatedly between 773 K and 1173 K. The maximum grain size after heat treatment of the ingot rolled to 67% reached 11.1 mm. The latent heat of the martensitic transformation after grain growth was 6.3 J g −1 , which is higher than the previously reported value for the compound. The stress–strain curve of 68Cu–16Al–16Zn rolled to 67% rolling with cyclical heat treatments showed a maximum stress of 106 MPa at 4.5% strain, with adiabatic temperature change of 5.9 K in heating during stress loading and 5.6 K in cooling in stress removal. Furthermore, no fatigue in the stress–strain behavior was observed up to at least 60 000 mechanical cycles at 2% strain.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Module-Level Thermal Interface Material Degradation in HALT

Abstract In this study, thermal interface material (TIM) degradation is driven through highly accelerated life test (HALT) using temperature cycling with a prescribed vibrational acceleration for two commercially available materials having thermal conductivities of 6.0 and 8.5 W/m K. HALT specimens were prepared by applying TIM through a 4-mil stencil over AlSiC baseplates in the shape of those used in Wolfspeed CAS325M12HM2 power electronics modules. Baseplates were mounted onto aluminum carrier blocks with embedded thermocouples to characterize the thermal resistance across the baseplate and TIM layer. Thermal dissipation into the top of the baseplates was provided by a custom heating block, which mimics the size and placement of the die junctions in CAS325 modules, applying power loads of 200, 300, and 400 W. After initial characterization, samples were transferred to the HALT chamber with one set of samples exposed to temperature cycling only (TCO) and the other temperature cycling and vibration (TCV). Both sample sets were cycled between temperature extremes of −40 °C and 180 °C with vibrations applied at a peak acceleration of 3.21 Grms. After hundreds of cycles, samples were reevaluated to assess changes in thermal resistance to provide an accelerated measure of TIM degradation. This allows for reliability prediction of useful lifetime (illustrated in a solar inverter case study herein), as well as to provide a basis for developing an accelerated testing method to related temperature cycling to faster methods of degradation. Such techniques provide a means to develop maintenance schedules for power modules for ensuring sufficient thermal performance over the operating lifetime.

Engineering↗

NASA NTRS1972

Nonapplicability of linear finite element programs to the stress analysis of tires

A static finite element stress analysis of an inflated radial car tire was carried out. The deformed shape of the sidewall presents outward bulging. The analysis of a homogeneous isotropic toroidal shell shows that the problem is common to all solids of this type. The study suggests that the geometric stiffness due to the inflation pressure has to be taken into account. Also, the resulting large displacements make it necessary for the geometry to be updated at each load step.

Durand, M.↗

NASA NTRS1973

Finite element stress analysis of polymers at high strains

A numerical analysis is presented for the problem of a flat rectangular rubber membrane with a circular rigid inclusion undergoing high strains due to the action of an axial load. The neo-hookean constitutive equations are introduced into the general purpose TITUS program by means of equivalent hookean constants and initial strains. The convergence is achieved after a few iterations. The method is not limited to any specific program. The results are in good agreement with those of a company sponsored photoelastic stress analysis. The theoretical and experimental deformed shapes also agree very closely with one another. For high strains it is demonstrated that using the conventional HOOKE law the stress concentration factor obtained is unreliable in the case of rubberlike material.

Durand, M.↗

NASA NTRS1977

Design charts for arbitrarily pivoted, liquid-lubricated flat-sector-pad thrust bearing

A flat, sector-shaped geometry for a liquid-lubricated thrust bearing is analyzed considering both the pitch and roll of the pad. Results are presented in design charts that enable a direct approach to the design of point- and line-pivoted, tilting pad bearings. A comparison is made with the Mitchell bearing approximation and it is found that this approximation always overestimates load capacity.

Etsion, I.↗

NASA NTRS1981

Elastohydrodynamic lubrication of elliptical contacts

The determination of the minimum film thickness within contact is considered for both fully flooded and starved conditions. A fully flooded conjunction is one in which the film thickness is not significantly changed when the amount of lubricant is increased. The fully flooded results presented show the influence of contact geometry on minimum film thickness as expressed by the ellipticity parameter and the dimensionless speed, load, and materials parameters. These results are applied to materials of high elastic modulus (hard EHL), such as metal, and to materials of low elastic modulus(soft EHL), such as rubber. In addition to the film thickness equations that are developed, contour plots of pressure and film thickness are given which show the essential features of elastohydrodynamically lubricated conjunctions. The crescent shaped region of minimum film thickness, with its side lobes in which the separation between the solids is a minimum, clearly emerges in the numerical solutions. In addition to the 3 presented for the fully flooded results, 15 more cases are used for hard EHL contacts and 18 cases are used for soft EHL contacts in a theoretical study of the influence of lubricant starvation on film thickness and pressure. From the starved results for both hard and soft EHL contacts, a simple and important dimensionless inlet boundary distance is specified. This inlet boundary distance defines whether a fully flooded or a starved condition exists in the contact. Contour plots of pressure and film thickness in and around the contact are shown for conditions.

Hamrock, B. J.↗

NASA NTRS1986

An overview of some investigations of pressure and thermal distributions induced by trailing edge controls on hypersonic aircraft

Detailed surface heat transfer and pressure distributions have been obtained in three-dimensional shock-wave boundary-layer interactions flow regions. The data described were obtained on fundamental shapes: planar wings with trailing edge flaps or spoilers and planar or cylindrical center bodies, representative of the aft portion of hypersonic aircraft. An overview of the work is presented; details of the projects are available in many reports in the open literature. Analytic, empiric methods are advanced for predicting the extent of separation and the increased heat transfer and pressure loads in three-dimensional separated flow regions.

Kaufman, Louis G., II↗

NASA NTRS1943

Large-deflection theory of curved sheet

Equations are given for the elastic behavior of initially curved sheets in which the deflections are not small in comparison with the thickness, but at the same time small enough to justify the use of simplified formulas for curvature. These equations are solved for the case of a sheet with circular cylindrical shape simply supported along two edges parallel to the axis of the generating cylinder. Numerical results are given for three values of the curvature and for three ratios of buckle length to buckle width. The computations are carried to buckle deflections of about twice the sheet thickness. It was concluded that initial curvature may cause an appreciable increase in the buckling load but that, for edge strains which are several times the buckling strain, the initial curvature causes a negligibly small change in the effective width.

Levy, Samuel↗

NASA NTRS2013

A Particle-in-Cell Simulation for the Traveling Wave Direct Energy Converter (TWDEC) for Fusion Propulsion

A Particle-in-cell simulation model has been developed to study the physics of the Traveling Wave Direct Energy Converter (TWDEC) applied to the conversion of charged fusion products into electricity. In this model the availability of a beam of collimated fusion products is assumed; the simulation is focused on the conversion of the beam kinetic energy into alternating current (AC) electric power. The model is electrostatic, as the electro-dynamics of the relatively slow ions can be treated in the quasistatic approximation. A two-dimensional, axisymmetric (radial-axial coordinates) geometry is considered. Ion beam particles are injected on one end and travel along the axis through ring-shaped electrodes with externally applied time-varying voltages, thus modulating the beam by forming a sinusoidal pattern in the beam density. Further downstream, the modulated beam passes through another set of ring electrodes, now electrically oating. The modulated beam induces a time alternating potential di erence between adjacent electrodes. Power can be drawn from the electrodes by connecting a resistive load. As energy is dissipated in the load, a corresponding drop in beam energy is measured. The simulation encapsulates the TWDEC process by reproducing the time-dependent transfer of energy and the particle deceleration due to the electric eld phase time variations.

Chap, Andrew↗

NASA NTRS2015

Subsonic Ultra Green Aircraft Research: Truss Braced Wing Design Exploration - Phase II - Volume I

This report summarizes the Truss Braced Wing (TBW) work accomplished by the Boeing Subsonic Ultra Green Aircraft Research (SUGAR) team, consisting of Boeing Research and Technology, Boeing Commercial Airplanes, General Electric, Georgia Tech, Virginia Tech, NextGen Aeronautics, and Microcraft. A multi-disciplinary optimization (MDO) environment defined the geometry that was further refined for the updated SUGAR High TBW configuration. Airfoil shapes were tested in the NASA TCT facility, and an aeroelastic model was tested in the NASA TDT facility. Flutter suppression was successfully demonstrated using control laws derived from test system ID data and analysis models. Aeroelastic impacts for the TBW design are manageable and smaller than assumed in Phase I. Flutter analysis of TBW designs need to include pre-load and large displacement non-linear effects to obtain a reasonable match to test data. With the updated performance and sizing, fuel burn and energy use is reduced by 54% compared to the SUGAR Free current technology Baseline (Goal 60%). Use of the unducted fan version of the engine reduces fuel burn and energy by 56% compared to the Baseline. Technology development roadmaps were updated, and an airport compatibility analysis established feasibility of a folding wing aircraft at existing airports.

Bradley, Marty K.↗

NASA NTRS2024

Shape Memory Alloy Material Maturation (SMA)

The Shape Memory Alloy (SMA) project will evaluate, process, and refine 3 SMA materials that have the potential to provide the properties needed to enable various technologies for human exploration missions on the Moon and Mars. The work will focus on the development and identification of a new SMA alloy targeted at enabling compliant rover tires capable of the extreme demands (high loads, faster drive speeds, extreme cold temperatures and exceedingly long mission durations). The necessary work will include the development of key material testing capabilities that will enable material properties development from 40K – 400K for all properties needed to qualify space flight hardware (Tensile, Fatigue/Durability, etc.). The SMA wire properties will be input into a database and model, ultimately to disseminate material property design data (for 1 alloy only) as parameters for finite element modeling of a tire structure.

Andrea Marchica↗

NASA NTRSDate not supplied

Wall-Modeled Large-Eddy Simulations of a Swept Wing with Leading-Edge Ice

The aerodynamic performance of a swept wing derived from the Common Research Model wing with high-fidelity and smooth leading-edge ice shapes is evaluated using wall-modeled large-eddy simulations. Two mesh paradigms are considered within the Launch, Ascent, and Vehicle Aerodynamics framework: structured hybrid curvilinear body-fitted/immersed-boundary and unstructured Voronoi. The curvilinear approach models the effect of the ice on the flow through penalty terms and the Voronoi strategy includes the ice representation directly in the mesh.Aerodynamic loads, surface pressure profiles, and skin-friction streamlines are compared against experimental results collected at the Wichita State University wind tunnel at a Mach number of 0.18 and a Reynolds number per mean aerodynamic chord of 1.6 million. For the curvilinear simulations with high-fidelity ice, results are sensitive to spanwise mesh resolution near the leading edge, where insufficient spanwise resolution leads to a spanwise running vortexaft of the high-fidelity ice, which is partially removed with increasing spanwise resolution. For the Voronoi simulations with high-fidelity ice, refining the mesh led to good convergence towards the experimental results with the best case demonstrating a maximum discrepancy of three lift counts relative to the experiment across a range of angles of attack from about 5 to 24 degrees, validating the shrink-wrapping procedure used for the ice. For the smooth ice, the curvilinear approach consistently under-predicted the upper surface suction leading to an under-prediction in lift, but did not demonstrate the pronounced over-prediction in upper surface suction near the leading edge observed in the Voronoi simulations.

AATT↗

DOE OSTI2021

Direct ink writing of boron carbide monoliths

Direct ink writing – an extrusion-based additive manufacturing process – followed by pressureless sintering was investigated to produce boron carbide monoliths. The effects of ceramic powder loading and Pluronic binder concentration on the rheology of boron carbide pastes were studied and linked to both processing behaviour and final outcome in terms of sintered density and hardness. The effects of printing parameters, in particular orifice diameter and printing speed, were also investigated. Reducing the size of the extrusion nozzle from 584 μm to 406 μm led to significantly better shape retention, lower surface roughness, as well as higher density and hardness. A 203 μm printing orifice was also trialled but was unsuccessful due to faster drying kinetics that occurred with smaller ceramic struts resulting in rapid warping and nozzle clogging. Carbon-black – 8 wt% relative to B 4 C – acted as an effective sintering aid to increase both density and hardness. After optimisation of feedstock and printing parameters, few-layer samples (3–5 layers) had a density as high as ~ 97 % TD and a hardness of ~ 30 GPa. On the other hand, 18-layer specimens had a sintered density of ~ 87 % TD, despite a fully dense microstructure, due to the formation of a 3D array of inter-strut pores. Nevertheless, several issues that arose during manufacturing and post-processing were detrimental to the density and structural integrity of printed specimens; these issues were identified, discussed, and suggestions for future work are provided in this report.

36 MATERIALS SCIENCE↗

NASA NTRS1983

Double arch mirror study. Part 1: Preliminary engineering report

In the proposed design, the NASA AMES 20-in double arch mirror is supported by three clamp and flexure assemblies. The mirror clamp consists of a T-shaped Invar-36 member that goes into a similarly shaped socket in the back of the mirror. The mirror socket is made oversize and contacts the clamp only along the conical surface. The clamp is preloaded by a spring washer and pulls the mirror into contact with the flexure. The clamp is then inserted into the mirror socket through a cutout, is rotated 90 deg, and is then pinned in place. Loading conditions considered in socket design are discussed as well as stress in the socket and clamp. Flexure geometry and stress are examined as well as the effects of flexure error and of mirror cell error.

Vukobratovich, D.↗

NASA NTRS1984

Ground vibration test of F-16 airplane with initial decoupler pylon

A ground vibration test was conducted on an F-16 airplane loaded on each wing with a 370-gal tank mounted on a standard pylon, a GBU-8 store mounted on a decoupler pylon, and an AIM-9J missile mounted on a wing-tip launcher. The decoupler pylon is a passive wing/store flutter-suppression device. The test was conducted prior to initial flight tests to determine the modal frequencies, mode shapes, and structural damping coefficients. The data presented include frequency response plots, force effect plots, and limited mode shape data.

Cazier, F. W., Jr.↗

NASA NTRS2022

Finite Element Modeling of Rigid-Flex PCB Robotic Structures for Dynamic Environments

Rigid-flex circuit boards are becoming moreprevalent as the limits are pushed on the size, mass, and geometryof electronic systems. A key aspect of designing a rigid-flexprinted circuit boards (PCB) system is an assessment of thedynamic properties of the PCB and predicting system perfor-mance under dynamic loading. Among current modeling method-ologies for rigid-flex PCB, a simplified modeling methodology thatadequately captures the system dynamics does not exist. This arti-cle presents a novel, computationally efficient approach formodeling rigid-flex PCB systems and the calibration of the mate-rial models via modal testing. The resulting simplified model isable to capture system frequencies, mode shapes, and representa-tive force-displacement behavior. The proposed methodology isused to model NASA Jet Propulsion Laboratory’s Pop-Up FlatFolding Explorer Robot (PUFFER) and assess the sensitivity of asystem model to input parameters.

John Bell↗