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At least 1,369 records · Page 76

All sources NASA NTRS DOE OSTI

DOE OSTI2025

A detailed study of pre-heating effects in electron beam melting powder bed fusion process

Metal-based additive manufacturing processes, such as powder bed fusion with electron beam (PBF-EB) process, also referred to as electron beam melting (EBM), can produce high-density parts with minimal residual stresses due to the uniform and coherent preheating of the powder bed. However, understanding and controlling the multiple stages of preheating is required to enable the production of high-quality, consistent parts of various materials. This work presents a large-scale, multi-layer, three-dimensional numerical analysis focused on studying the preheating stages for predicting thermal history during the PBF-EB process. The model follows a continuous multi-stage cyclic process, that incorporates all the main stages of the PBF-EB process for 316 L stainless steel. This includes the gradual deposition of a new powder layer, the first and second preheating levels of the powder bed, and the energy deposition during melting (excluding the actual melt-pool behavior simulation). The model employs an adaptive time-scaling approach that automatically adjusts the energy deposition for each solution time-increment. This allows for localized changes in time-resolution over an otherwise computationally expensive multi-layer procedure. The material property variations are also taken into account, with an emphasis on the subtle irreversible changes in powder effective thermal conductivity after the two requisite preheating stages of the powder bed. This effect is studied using simplified conductivity models from the literature for partially sintered powder, validated by a dedicated experiment and numerical simulation. The large-scale model is then used to estimate the actual temperatures during first and second preheating levels for 316 L steel, which is not yet fully supported commercially for PBF-EB. Model predictions are corroborated by experiments, using and analyzing IR images, taken at the completion of each layer by the machine’s built-in infrared camera. The current model also incorporates a qualitative assessment for the effects of conductivity change during pre-heating, as well as evaluates the applicability of the time-scaling approach.

36 MATERIALS SCIENCE↗

DOE OSTI2024

DiscoFluxM version 1.x

DiscoFluxM is software for modeling the deformation behavior of crystalline materials within the third-party finite-element based software, MOOSE. The software enables full-field crystal plasticity finite element simulations of deformation processes of metals and other crystalline materials. DiscoFluxM is an implementation of the DiscoFlux theoretical and algorithmic framework for coupling single-crystal plasticity with dislocation transport. The continuum mesoscale modeling framework is founded upon a nonlocal dislocation-density based crystal plasticity theory. The nonlocal theory couples continuum dislocation transport with an otherwise spatially-local single-crystal model employing nonlinear thermoelasticity and crystallographic plasticity. Dislocation transport is modeled by enforcing dislocation conservation at a slip-system level through the solution of advection-diffusion equations. The configuration of geometrically necessary dislocation density gives rise to a back-stress that inhibits or accentuates the flow of dislocations.

Luscher, Darby↗

NASA NTRS1986

A model for the use of satellite remote sensing for the measurement of primary production in the ocean

A model of primary production based upon the responses of phytoplankton to differing light and nutrient fields is described. This model includes the effects on production of variations in surface pigment concentration, the mixed layer depth, and the dependence on the incident solar irradiance. The model has been tested using in situ data provided by the Southern California Bight Studies of Eppley, et al. (1979), the California Cooperative Fisheries Investigations, the Organization of Persistent Upwelling Structures, and other data sets. A synoptic measure of the distribution of surface pigments is derived from the West Coast Chlorophyll and Temperature Time Series. The features and behavior of the model are presented together with the results of the model verification.

Collins, Donald J.↗

NASA NTRS2001

Adjustable Autonomy Testbed

The Adjustable Autonomy Testbed (AAT) is a simulation-based testbed located in the Intelligent Systems Laboratory in the Automation, Robotics and Simulation Division at NASA Johnson Space Center. The purpose of the testbed is to support evaluation and validation of prototypes of adjustable autonomous agent software for control and fault management for complex systems. The AA T project has developed prototype adjustable autonomous agent software and human interfaces for cooperative fault management. This software builds on current autonomous agent technology by altering the architecture, components and interfaces for effective teamwork between autonomous systems and human experts. Autonomous agents include a planner, flexible executive, low level control and deductive model-based fault isolation. Adjustable autonomy is intended to increase the flexibility and effectiveness of fault management with an autonomous system. The test domain for this work is control of advanced life support systems for habitats for planetary exploration. The CONFIG hybrid discrete event simulation environment provides flexible and dynamically reconfigurable models of the behavior of components and fluids in the life support systems. Both discrete event and continuous (discrete time) simulation are supported, and flows and pressures are computed globally. This provides fast dynamic simulations of interacting hardware systems in closed loops that can be reconfigured during operations scenarios, producing complex cascading effects of operations and failures. Current object-oriented model libraries support modeling of fluid systems, and models have been developed of physico-chemical and biological subsystems for processing advanced life support gases. In FY01, water recovery system models will be developed.

Malin, Jane T.↗

NASA NTRS1988

The PAWS and STEM reliability analysis programs

The PAWS and STEM programs are new design/validation tools. These programs provide a flexible, user-friendly, language-based interface for the input of Markov models describing the behavior of fault-tolerant computer systems. These programs produce exact solutions of the probability of system failure and provide a conservative estimate of the number of significant digits in the solution. PAWS uses a Pade approximation as a solution technique; STEM uses a Taylor series as a solution technique. Both programs have the capability to solve numerically stiff models. PAWS and STEM possess complementary properties with regard to their input space; and, an additional strength of these programs is that they accept input compatible with the SURE program. If used in conjunction with SURE, PAWS and STEM provide a powerful suite of programs to analyze the reliability of fault-tolerant computer systems.

Butler, Ricky W.↗

DOE OSTI2021

The 3D printing and modeling of functionally graded Kelvin foams for controlling crushing performance

Mechanical impact protection is an important consideration in many applications, ranging from product transportation to sports. Cellular materials are typically used due to their desirable energy absorption properties and light weight. However, their large deformation and rate dependent responses (especially of polymer foams) are challenging to consider in design. Additionally, the use of foams with uniform properties, such as uniform density and uniform stiffness, often restricts the designed foams to only be suitable for a narrow range of mechanical impact conditions whereas real applications commonly face unpredictable situations. 3D printing offers fabrication flexibility and thus opens the door to create foams with tailored properties. In this work, we investigate the feasibility of using 3D printing for functionally graded foams (FGFs) that are optimal over a broad range of mechanical environments. The foams are fabricated by the recently developed grayscale digital light processing (g-DLP) method which can print parts with locally designed properties. These foams are tested under drop test conditions and with slower displacement control. We also model the large deformation behavior of FGFs using finite element analysis in which we account for the different viscoelastic behaviors of the distinct grayscale regions. We then use the model to examine the impact mitigation capabilities of FGFs in different loading scenarios. Finally, we show how FGFs can be used to satisfy real-world design goals using the case study of a motorcycle helmet. In contrast to prior work, we investigate continuous, functionally graded foams of a single density that differ in their viscoelastic responses. This work provides further insight into the benefits of viscoelastic properties and modulus graded foams and presents a manufacturing approach that can be used to produce the next generation of flexible lattice foams as mechanical absorbers.

3D printing↗

DOE OSTI2020

An extended moments model of quantum efficiency for metals and semiconductors

The complexity of photocathode designs and detector materials, and the need to model their performance for short pulse durations, response to high frequency photons, presence of coatings and/or thinness of the absorptive layer, necessitates modifications to three-step and moments models of photoemission that are used in simulation codes. Here, methods to include input from computationally intensive approaches, such as density functional theory to model optical properties and transfer matrix approaches to treat emission from the surface or transport past coatings, by means of parametric models are demonstrated. First, a technique to accurately represent optical behavior so as to model reflectivity and penetration depth is given. Second, modifications to bulk models arising from the usage of thin film architectures, and a means to rapidly calculate them, is provided. Third, a parameterization to model the impact of wells associated with coatings and surface layers on the transmission probably is given. In all cases, the methods are computationally efficient and designed to allow for including input from numerically intensive approaches that would otherwise be unavailable for simulations.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2022

Initial development of viscoplastic constitutive model of Alloy 800H in support of the use of inelastic analysis methods for ASME Section III, Division 5, Class A applications

This report describes the development of a preliminary inelastic constitutive model for the thermomechanical behavior of Alloy 800H. The objective is to develop a model suitable for incorporating into Nonmandatory Appendix Z to Section III, Division 5 of the ASME Boiler & Pressure Vessel Code, which provides guidance and reference constitutive models for the ASME design by inelastic analysis rules for Class A components. The report describes the process of collecting experimental data, developing a mathematical form for the model, and training the model against the test data. The initial version of the model captures most of the relevant material deformation mechanisms, including dynamic strain aging effects. However, further development of the model form will be required to develop a final model suitable for ASME use.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1989

Digital redesign of the control system for the Robotics Research Corporation model K-1607 robot

The analog control system for positioning each link of the Robotics Research Corporation Model K-1607 robot manipulator was redesigned for computer control. In order to accomplish the redesign, a linearized model of the dynamic behavior of the robot was developed. The parameters of the model were determined by examination of the input-output data collected in closed-loop operation of the analog control system. The robot manipulator possesses seven degrees of freedom in its motion. The analog control system installed by the manufacturer of the robot attempts to control the positioning of each link without feedback from other links. Constraints on the design of a digital control system include: the robot cannot be disassembled for measurement of parameters; the digital control system must not include filtering operations if possible, because of lack of computer capability; and criteria of goodness of control system performing is lacking. The resulting design employs sampled-data position and velocity feedback. The criteria of the design permits the control system gain margin and phase margin, measured at the same frequencies, to be the same as that provided by the analog control system.

Carroll, Robert L.↗

NASA NTRS1998

Modeling the Benchmark Active Control Technology Wind-Tunnel Model for Active Control Design Applications

This report describes the formulation of a model of the dynamic behavior of the Benchmark Active Controls Technology (BACT) wind tunnel model for active control design and analysis applications. The model is formed by combining the equations of motion for the BACT wind tunnel model with actuator models and a model of wind tunnel turbulence. The primary focus of this report is the development of the equations of motion from first principles by using Lagrange's equations and the principle of virtual work. A numerical form of the model is generated by making use of parameters obtained from both experiment and analysis. Comparisons between experimental and analytical data obtained from the numerical model show excellent agreement and suggest that simple coefficient-based aerodynamics are sufficient to accurately characterize the aeroelastic response of the BACT wind tunnel model. The equations of motion developed herein have been used to aid in the design and analysis of a number of flutter suppression controllers that have been successfully implemented.

Waszak, Martin R.↗

NASA NTRS1995

Computational Modeling of the Ames 11-Ft Transonic Wind Tunnel in Conjunction with IofNEWT

Technical advances in Computational Fluid Dynamics have now made it possible to simulate complex three-dimensional internal flows about models of various size placed in a Transonic Wind Tunnel. TWT wall interference effects have been a source of error in predicting flight data from actual wind tunnel measured data. An advantage of such internal CFD calculations is to directly compare numerical results with the actual tunnel data for code assessment and tunnel flow analysis. A CFD capability has recently been devised for flow analysis of the NASA/Ames 11-Ft TWT facility. The primary objectives of this work are to provide a CFD tool to study the NASA/Ames 11-Ft TWT flow characteristics, to understand the slotted wall interference effects, and to validate CFD codes. A secondary objective is to integrate the internal flowfield calculations with the Pressure Sensitive Paint data, a surface pressure distribution capability in Ames' production wind tunnels. The effort has been part of the Ames IofNEWT, Integration of Numerical and Experimental Wind Tunnels project, which is aimed at providing further analytical tools for industrial application. We used the NASA/Ames OVERFLOW code to solve the thin-layer Navier-Stokes equations. Viscosity effects near the model are captured by Baldwin-Lomax or Baldwin-Barth turbulence models. The solver was modified to model the flow behavior in the vicinity of the tunnel longitudinal slotted walls. A suitable porous type wall boundary condition was coded to account for the cross-flow through the test section. Viscous flow equations were solved in generalized coordinates with a three-factor implicit central difference scheme in conjunction with the Chimera grid procedure. The internal flow field about the model and the tunnel walls were descretized by the Chimera overset grid system. This approach allows the application of efficient grid generation codes about individual components of the configuration; separate minor grids were developed to resolve the model and overset onto a main grid which discretizes the interior of the tunnel test section. Individual grid components axe not required to have mesh boundaries joined in any special way to each other or to the main tunnel grid. Programs have been developed to rotate the model about the tunnel pivot point and rotation axis, similar to that of the tunnel turntable mechanism for adjusting the pitch of the physical model in the test section.

Djomehri, M. Jahed↗

NASA NTRS2004

Single Droplet Combustion of Decane in Microgravity: Experiments and Numerical Modeling

This paper presents experimental data on single droplet combustion of decane in microgravity and compares the results to a numerical model. The primary independent experiment variables are the ambient pressure and oxygen mole fraction, pressure, droplet size (over a relatively small range) and ignition energy. The droplet history (D(sup 2) history) is non-linear with the burning rate constant increasing throughout the test. The average burning rate constant, consistent with classical theory, increased with increasing ambient oxygen mole fraction and was nearly independent of pressure, initial droplet size and ignition energy. The flame typically increased in size initially, and then decreased in size, in response to the shrinking droplet. The flame standoff increased linearly for the majority of the droplet lifetime. The flame surrounding the droplet extinguished at a finite droplet size at lower ambient pressures and an oxygen mole fraction of 0.15. The extinction droplet size increased with decreasing pressure. The model is transient and assumes spherical symmetry, constant thermo-physical properties (specific heat, thermal conductivity and species Lewis number) and single step chemistry. The model includes gas-phase radiative loss and a spherically symmetric, transient liquid phase. The model accurately predicts the droplet and flame histories of the experiments. Good agreement requires that the ignition in the experiment be reasonably approximated in the model and that the model accurately predict the pre-ignition vaporization of the droplet. The model does not accurately predict the dependence of extinction droplet diameter on pressure, a result of the simplified chemistry in the model. The transient flame behavior suggests the potential importance of fuel vapor accumulation. The model results, however, show that the fractional mass consumption rate of fuel in the flame relative to fuel vaporized is close to 1.0 for all but the lowest ambient oxygen mole fractions.

Dietrich, D. L.↗

NASA NTRSDate not supplied

Probing Sensitivity of Discharge Characteristics to Model Selection using Uncertainty Quantification in an aprotic Li-Oxygen Battery

Currently, there are several models in the literature, such as kinetic models, microstructural models, and mass transport models that describe a Li-air battery's discharge behavior. Many of these models are calibrated and tested at low current densities and cannot be easily transferred to high current densities. Even at low current densities, there is no quantitative method for a researcher to choose a reaction kinetic model such as classical Butler-Volmer and its derivatives, and modified Marcus-Hush-Chidsey, a resistance model for lithium peroxide such as electron transport via tunneling or linear resistivity, a surface coverage model (lithium peroxide growth) such as partial coverage or full coverage, and mass transport model (discussed in Ref. [1]). Also, it is time-consuming to test different models at high current density (1C) due to a lack of well-tested models and well-calibrated model parameters. For this presentation, we will develop an analytical model, which acts as a surrogate model for a sophisticated finite element model to predict discharge time and discharge voltage. Next, we use an uncertainty quantifying technique called reduced-order stochastic optimization [2, 3] to determine the uncertainty in model parameters for rate kinetics, lithium peroxide resistivity, and parasitic resistance. Finally, a finite element simulation is performed to determine the error introduced by the surrogate model and its influence on the uncertainty in the model parameters.

M Mehta↗

NASA NTRS1991

Thermoviscoplastic response of Ti-15-3 under various loading conditions

The long term objective is to develop a combined experimental analytic methodology for predicting the thermoviscoplastic behavior of the neat (i.e., unreinforced) titanium matrix. Once a constitutive model which adequately describes the behavior of titanium has been identified, the viscoplastic behavior of unidirectional composites will be predicted through the use of the rule-of-mixtures. A crucial aspect of the study is the selection of a constitutive model to describe the thermoviscoplastic behavior of titanium.

Tuttle, M. E.↗

NASA NTRS1986

Temperature dependent nonlinear metal matrix laminae behavior

An analytical method is described for computing the nonlinear thermal and mechanical response of laminated plates. The material model focuses upon the behavior of metal matrix materials by relating the nonlinear composite response to plasticity effects in the matrix. The foundation of the analysis is the unidirectional material model which is used to compute the instantaneous properties of the lamina based upon the properties of the fibers and matrix. The unidirectional model assumes that the fibers properties are constant with temperature and assumes that the matrix can be modelled as a temperature dependent, bilinear, kinematically hardening material. An incremental approach is used to compute average stresses in the fibers and matrix caused by arbitrary mechanical and thermal loads. The layer model is incorporated in an incremental laminated plate theory to compute the nonlinear response of laminated metal matrix composites of general orientation and stacking sequence. The report includes comparisons of the method with other analytical approaches and compares theoretical calculations with measured experimental material behavior. A section is included which describes the limitations of the material model.

Barrett, D. J.↗

DOE OSTI2020

How Low Can You Go? Using Synthetic 3D Imagery to Drastically Reduce Real-World Training Data for Object Detection

Deep convolutional neural networks (DCNNs) currently provide state-of-the-art performance on image classification and object detection tasks, and there are many global security mission areas where such models could be extremely useful. Crucially, the success of these models is driven in large part by the widespread availability of high-quality open source data sets such as Image Net, Common Objects in Context (COCO), and KITTI, which contain millions of images with thousands of unique labels. However, global security relevant objects-of-interest can be difficult to obtain: relevant events are low frequency and high consequence; the content of relevant images is sensitive; and adversaries and proliferators seek to obscure their activities. For these cases where exemplar data is hard to come-by, even fine-tuning an existing model with available data can be effectively impossible. Recent work demonstrated that models can be trained using a combination of real-world and synthetic images generated from 3D representations; that such models can exceed the performance of models trained using real-world data alone; and that the generated images need not be perfectly realistic (Tremblay, et al., 2018). However, this approach still required hundreds to thousands of real-world images for training and fine tuning, which for sparse, global security-relevant datasets can be an unrealistic hurdle. In this research, we validate the performance and behavior of DCNN models as we drive the number of real-world images used for training object detection tasks down to a minimal set. We perform multiple experiments to identify the best approach to train DCNNs from an extremely small set of real-world images. In doing so, we: Develop state-of-the-art, parameterized 3D models based on real-world images and sample from their parameters to increase the variance in synthetic image training data; Use machine learning explainability techniques to highlight and correct through targeted training the biases that result from training using completely synthetic images; and Validate our results by comparing the performance of the models trained on synthetic data to one another, and to a control model created by fine-tuning an existing ImageNet-trained model with a limited number (hundreds) of real-world images.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS2000

Probabilistic Multi-Scale, Multi-Level, Multi-Disciplinary Analysis and Optimization of Engine Structures

Aircraft engines are assemblies of dynamically interacting components. Engine updates to keep present aircraft flying safely and engines for new aircraft are progressively required to operate in more demanding technological and environmental requirements. Designs to effectively meet those requirements are necessarily collections of multi-scale, multi-level, multi-disciplinary analysis and optimization methods and probabilistic methods are necessary to quantify respective uncertainties. These types of methods are the only ones that can formally evaluate advanced composite designs which satisfy those progressively demanding requirements while assuring minimum cost, maximum reliability and maximum durability. Recent research activities at NASA Glenn Research Center have focused on developing multi-scale, multi-level, multidisciplinary analysis and optimization methods. Multi-scale refers to formal methods which describe complex material behavior metal or composite; multi-level refers to integration of participating disciplines to describe a structural response at the scale of interest; multidisciplinary refers to open-ended for various existing and yet to be developed discipline constructs required to formally predict/describe a structural response in engine operating environments. For example, these include but are not limited to: multi-factor models for material behavior, multi-scale composite mechanics, general purpose structural analysis, progressive structural fracture for evaluating durability and integrity, noise and acoustic fatigue, emission requirements, hot fluid mechanics, heat-transfer and probabilistic simulations. Many of these, as well as others, are encompassed in an integrated computer code identified as Engine Structures Technology Benefits Estimator (EST/BEST) or Multi-faceted/Engine Structures Optimization (MP/ESTOP). The discipline modules integrated in MP/ESTOP include: engine cycle (thermodynamics), engine weights, internal fluid mechanics, cost, mission and coupled structural/thermal, various composite property simulators and probabilistic methods to evaluate uncertainty effects (scatter ranges) in all the design parameters. The objective of the proposed paper is to briefly describe a multi-faceted design analysis and optimization capability for coupled multi-discipline engine structures optimization. Results are presented for engine and aircraft type metrics to illustrate the versatility of that capability. Results are also presented for reliability, noise and fatigue to illustrate its inclusiveness. For example, replacing metal rotors with composites reduces the engine weight by 20 percent, 15 percent noise reduction, and an order of magnitude improvement in reliability. Composite designs exist to increase fatigue life by at least two orders of magnitude compared to state-of-the-art metals.

Chamis, Christos C.↗

DOE OSTI2022

Data-Driven Dynamic Modeling in Power Systems: A Fresh Look on Inverter-Based Resource Modeling

Here, this article introduces ways to identify dynamic system models using measurement data. In power system analysis, a static model represents the time-invariant input-output relationship of a system, while a dynamic model describes the behavior of the system over time. For example, how will a system transit from one steady-state operation point to another?

24 POWER TRANSMISSION AND DISTRIBUTION↗