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NASA NTRS2024

Transfer-AE: A novel autoencoder-based impact detection model for structural digital twin

Accurately detecting the location and intensity of impacts is crucial for ensuring structural safety. Currently, AI-based structural impact detection methods are widely used for their excellent detection accuracy. However, their generalization capability is limited by the scenarios present in the training data. Many complex and dangerous impact scenarios are difficult to conduct real-world experiments on to collect sufficient samples. To capture all impact scenarios and fully leverage the advantages of AI-based detection technologies, advanced methods involve combining real-world structural monitoring data with corresponding numerical models to construct digital twins. These methods continuously refine the created numerical models with limited real-world data and provide diverse impact scenarios through numerical model simulations. However, there are inevitable differences between digital models and physical models that are challenging to correct through mechanical means. This discrepancy in data distribution between the two models significantly hinders the application of digital twin technology in impact/event identification tasks. To address this challenge, this study proposes a novel model based on autoencoders, named Transfer-AE. Transfer-AE encodes the common features of digital twins in the latent space to bridge the uncertainty gap at a macro scale between numerical models and physical models and synchronously fits the magnitude and location of the impact load in the decoder. This enables consistent detection results for the same impact event, whether the sample comes from the numerical model or the physical model. Transfer-AE includes two operating modes: Mode 1 has a fixed computational complexity with stable inference speed, but the training cost and difficulty increase with data distribution. Mode 2's computational complexity increases with data distribution, but it has a fixed training cost and speed. In both cases involving the geodesic dome structure simulating a deep space habitat and the IASC-ASCE benchmark structure, Transfer-AE demonstrated the best performance in impact localization and quantification tasks compared to mainstream domain-adaptive transfer models.

Chengjia Han↗

NASA NTRSDate not supplied

Integrated Process-Structure-Property Simulations for Additive Manufacturing Using the Open-Source Materialite Package

The microstructure and properties of additively manufactured (AM) metals are strongly dependent on process conditions. Therefore, process-structure-property (PSP) simulations are a useful tool for exploring process parameter space, studying process variations, and quantifying uncertainty in material properties. However, integrating process-structure and structure-property simulations often involves connecting multiple software packages. Each package may use unique data structures and require substantial domain knowledge. This presentation demonstrates PSP simulation capabilities of Materialite, an open-source package developed at NASA Langley Research Center. Materialite simplifies model linkages by using a common data structure and model interface, enabling straightforward simulation across a PSP model chain. Physics-based models, including kinetic Monte Carlo and crystal plasticity, are implemented within the package. The model interface is also intended to simplify implementation of new models and enable integration with external simulation tools. Example use cases include uncertainty quantification with PSP models and GPU-accelerated powder bed fusion AM process models.

additive manufacturing↗

NASA NTRS2003

Crystal structures of pinoresinol-lariciresinol and phenylcoumaran benzylic ether reductases and their relationship to isoflavone reductases

Despite the importance of plant lignans and isoflavonoids in human health protection (e.g. for both treatment and prevention of onset of various cancers) as well as in plant biology (e.g. in defense functions and in heartwood development), systematic studies on the enzymes involved in their biosynthesis have only recently begun. In this investigation, three NADPH-dependent aromatic alcohol reductases were comprehensively studied, namely pinoresinol-lariciresinol reductase (PLR), phenylcoumaran benzylic ether reductase (PCBER), and isoflavone reductase (IFR), which are involved in central steps to the various important bioactive lignans and isoflavonoids. Of particular interest was in determining how differing regio- and enantiospecificities are achieved with the different enzymes, despite each apparently going through similar enone intermediates. Initially, the three-dimensional x-ray crystal structures of both PLR_Tp1 and PCBER_Pt1 were solved and refined to 2.5 and 2.2 A resolutions, respectively. Not only do they share high gene sequence similarity, but their structures are similar, having a continuous alpha/beta NADPH-binding domain and a smaller substrate-binding domain. IFR (whose crystal structure is not yet obtained) was also compared (modeled) with PLR and PCBER and was deduced to have the same overall basic structure. The basis for the distinct enantio-specific and regio-specific reactions of PCBER, PLR, and IFR, as well as the reaction mechanism and participating residues involved (as identified by site-directed mutagenesis), are discussed.

NASA Discipline Plant Biology↗

NASA NTRSDate not supplied

Multiscale Simulation of Deployable Composite Structures

In this paper, a multiscale simulation method for analyzing deployable composite structures is presented. Effective shell properties of the composites are obtained based on Mechanics of Structure Genome (MSG) homogenization, and then implemented into a user-subroutine UGENS for structural simulation with shell elements in Abaqus. The column bending test(CBT) of a flat thin flexure and lenticular composite boom in a simplified deployer structure are studied for demonstration. A viscoelastic material model with direct integration is adopted in this paper. The CBT simulation shows good agreement with experiments during relaxation, while errors are observed when comparing residual deformation. It is shown that this CBT model can be calibrated to CBT test results. For the lenticular boom analysis, the complete process of flattening, coiling, stowage, deployment and recovery is simulated with the viscoelastic shell model.

Finite element analysis↗

NASA NTRSDate not supplied

Cavitation Effects on the Structural Dynamics of Turbomachinery Components

The structural integrity of inducer and impeller blades in rocket engine turbomachinery must be evaluated in the face of complex excitation mechanisms including fluctuating pressures due to cavitation. Cavitation occurs when the local fluid pressure drops below the vapor pressure, causing the formation of vapor-filled bubbles. Cavitation can exist to various extents within the typical operating range of rocket engine turbopumps. Despite recent progress towards reducing uncertainties in structural dynamic models of turbomachinery components, the extent to which pump cavitation affects the structural dynamic properties (i.e., natural frequencies, damping, and mode shapes) of inducer and impeller blades remains largely unknown. To study the structural dynamic effects of cavitating flows, experiments are conducted in a high-speed water tunnel. The test article is a low aspect ratio cantilevered plate, thus mimicing a single inducer blade that is unwrapped from its hub. The test article is oriented at zero angle of attack and has a triangular trip at its leading edge to induce cavitation. To change the extent of cavitation, the static pressure of the water tunnel is controlled. A high-speed camera is used to quantify the coverage of the cavitation sheet.

Fluid-Structure Interaction↗

NASA NTRS1991

Performance of fuselage pressure structure

There are currently more than 1,000 Boeing airplanes around the world over 20 years old. That number is expected to double by the year 1995. With these statistics comes the reality that structural airworthiness will be in the forefront of aviation issues well into the next century. The results of previous and recent test programs Boeing has implemented to study the structural performance of older airplanes relative to pressurized fuselage sections are described. Included in testing were flat panels with multiple site damage (MSD), a full-scale 737 and 2 747s as well as panels representing a 737 and 777, and a generic aircraft in large pressure-test fixtures. Because damage is a normal part of aging, focus is on the degree to which structural integrity is maintained after failure or partial failure of any structural element, including multiple site damage (MSD), and multiple element damage (MED).

Aging Aircraft↗

NASA NTRS1989

From non-random molecular structure to life and mind

The evolutionary hierarchy molecular structure-->macromolecular structure-->protobiological structure-->biological structure-->biological functions has been traced by experiments. The sequence always moves through protein. Extension of the experiments traces the formation of nucleic acids instructed by proteins. The proteins themselves were, in this picture, instructed by the self-sequencing of precursor amino acids. While the sequence indicated explains the thread of the emergence of life, protein in cellular membrane also provides the only known material basis for the emergence of mind in the context of emergence of life.

Non-NASA Center↗

NASA NTRS1994

High Fidelity Modeling of Evolutionary Structures in IMOS

A methodology is proposed for testing, modal identification, and model correlation of structures which are assembled in an evolutionary manner. The methodology prescribes initial testing of a base structure without any attached components. The experimental modal properties are used to update the physical properties of the base structure finite element model using a Bayesian Estimation Technique (BET). The BET is implemented in METLAB using IMOS functions. As components are added to the base structure, additional tests are performed. Three testing options are proposed, all of which enable estimation of the physical parameters of the components alone. Furthermore, improvements to the original BET implementation have been made, which contribute to higher fidelity models and more efficient computational times.

structures testing assembling modeling BET Bayesia↗

NASA NTRS1993

Adaptive Space Structures

The term adaptive structures refers to a structural control approach in which sensors, actuators, electronics, materials, structures, structural concepts, and system-performance-validation strategies are integrated to achieve specific objectives.

adaptive structures response to external stimulati↗

NASA NTRS2014

Integrated Aeromechanics with Three-Dimensional Solid-Multibody Structures

A full three-dimensional finite element-multibody structural dynamic solver is coupled to a three-dimensional Reynolds-averaged Navier-Stokes solver for the prediction of integrated aeromechanical stresses and strains on a rotor blade in forward flight. The objective is to lay the foundations of all major pieces of an integrated three-dimensional rotor dynamic analysis - from model construction to aeromechanical solution to stress/strain calculation. The primary focus is on the aeromechanical solution. Two types of three-dimensional CFD/CSD interfaces are constructed for this purpose with an emphasis on resolving errors from geometry mis-match so that initial-stage approximate structural geometries can also be effectively analyzed. A three-dimensional structural model is constructed as an approximation to a UH-60A-like fully articulated rotor. The aerodynamic model is identical to the UH-60A rotor. For preliminary validation measurements from a UH-60A high speed flight is used where CFD coupling is essential to capture the advancing side tip transonic effects. The key conclusion is that an integrated aeromechanical analysis is indeed possible with three-dimensional structural dynamics but requires a careful description of its geometry and discretization of its parts.

Three-Dimensional↗

NASA NTRS2014

Creating a Test Validated Structural Dynamic Finite Element Model of the Multi-Utility Technology Test Bed Aircraft

Small modeling errors in the finite element model will eventually induce errors in the structural flexibility and mass, thus propagating into unpredictable errors in the unsteady aerodynamics and the control law design. One of the primary objectives of Multi Utility Technology Test Bed, X-56A, aircraft is the flight demonstration of active flutter suppression, and therefore in this study, the identification of the primary and secondary modes for the structural model tuning based on the flutter analysis of X-56A. The ground vibration test validated structural dynamic finite element model of the X-56A is created in this study. The structural dynamic finite element model of the X-56A is improved using a model tuning tool. In this study, two different weight configurations of the X-56A have been improved in a single optimization run.

structural dynamic model tuning↗

NASA NTRS2015

Finite Element Estimation of Meteorite Structural Properties

The goal of the project titled Asteroid Threat Assessment at NASA Ames Research Center is to develop risk assessment tools. The expertise in atmospheric entry in the Entry Systems and Technology Division is being used to describe the complex physics of meteor breakup in the atmosphere. The breakup of a meteor is dependent on its structural properties, including homogeneity of the material. The present work describes an 11-week effort in which a literature survey was carried for structural properties of meteoritic material. In addition, the effect of scale on homogeneity isotropy was studied using a Monte Carlo approach in Nastran. The properties were then in a static structural response simulation of an irregularly-shape meteor (138-scale version of Asteroid Itokawa). Finally, an early plan was developed for doctoral research work at Georgia Tech. in the structural failure fragmentation of meteors.

Structural Properties↗

NASA NTRS2016

Solving Fluid Structure Interaction Problems with an Immersed Boundary Method

An immersed boundary method for the compressible Navier-Stokes equations can be used for moving boundary problems as well as fully coupled fluid-structure interaction is presented. The underlying Cartesian immersed boundary method of the Launch Ascent and Vehicle Aerodynamics (LAVA) framework, based on the locally stabilized immersed boundary method previously presented by the authors, is extended to account for unsteady boundary motion and coupled to linear and geometrically nonlinear structural finite element solvers. The approach is validated for moving boundary problems with prescribed body motion and fully coupled fluid structure interaction problems. Keywords: Immersed Boundary Method, Higher-Order Finite Difference Method, Fluid Structure Interaction.

Structure Interactions↗

NASA NTRS2016

Stochastic-Strength-Based Damage Simulation Tool for Ceramic Matrix and Polymer Matrix Composite Structures

Stochastic-based, discrete-event progressive damage simulations of ceramic-matrix composite and polymer matrix composite material structures have been enabled through the development of a unique multiscale modeling tool. This effort involves coupling three independently developed software programs: (1) the Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC), (2) the Ceramics Analysis and Reliability Evaluation of Structures Life Prediction Program (CARES/ Life), and (3) the Abaqus finite element analysis (FEA) program. MAC/GMC contributes multiscale modeling capabilities and micromechanics relations to determine stresses and deformations at the microscale of the composite material repeating unit cell (RUC). CARES/Life contributes statistical multiaxial failure criteria that can be applied to the individual brittle-material constituents of the RUC. Abaqus is used at the global scale to model the overall composite structure. An Abaqus user-defined material (UMAT) interface, referred to here as "FEAMAC/CARES," was developed that enables MAC/GMC and CARES/Life to operate seamlessly with the Abaqus FEA code. For each FEAMAC/CARES simulation trial, the stochastic nature of brittle material strength results in random, discrete damage events, which incrementally progress and lead to ultimate structural failure. This report describes the FEAMAC/CARES methodology and discusses examples that illustrate the performance of the tool. A comprehensive example problem, simulating the progressive damage of laminated ceramic matrix composites under various off-axis loading conditions and including a double notched tensile specimen geometry, is described in a separate report.

composite structures↗

NASA NTRS2017

Robotically Assembled Aerospace Structures: Digital Material Assembly using a Gantry-Type Assembler

This paper evaluates the development of automated assembly techniques for discrete lattice structures using a multi-axis gantry type CNC machine. These lattices are made of discrete components called digital materials. We present the development of a specialized end effector that works in conjunction with the CNC machine to assemble these lattices. With this configuration we are able to place voxels at a rate of 1.5 per minute. The scalability of digital material structures due to the incremental modular assembly is one of its key traits and an important metric of interest. We investigate the build times of a 5x5 beam structure on the scale of 1 meter (325 parts), 10 meters (3,250 parts), and 30 meters (9,750 parts). Utilizing the current configuration with a single end effector, performing serial assembly with a globally fixed feed station at the edge of the build volume, the build time increases according to a scaling law of n4, where n is the build scale. Build times can be reduced significantly by integrating feed systems into the gantry itself, resulting in a scaling law of n3. A completely serial assembly process will encounter time limitations as build scale increases. Automated assembly for digital materials can assemble high performance structures from discrete parts, and techniques such as built in feed systems, parallelization, and optimization of the fastening process will yield much higher throughput.

Mechanical Structure↗

NASA NTRS2018

Wide-field Infrared Survey Telescope (WFIRST): Composite Structure Verification for Operational Temperatures

The Wide-Field Infrared Survey Telescope (WFIRST) mission is the next large astrophysics observatory for NASA after the James Webb Space Telescope and is the top priority mission from the 2010 National Academy of Sciences' decadal survey. The WFIRST Optical Telescope Assembly (OTA) includes inherited composite support structures that were originally designed and tested for room temperature operation; however, the WFIRST mission will require operation at colder temperatures to achieve sufficient sensitivity for the infrared wavelengths. We will present the results and conclusions of testing completed at the coupon and engineering model level to verify that the inherited composite structures will maintain mechanical integrity and performance over the required temperature range. The testing included: (1) characterization testing of constituent material coupons, (2) thermal cycling and static load testing of a representative aft metering structure (AMS) and forward metering structure (FMS), and (3) thermal cycling and dynamic testing of a representative secondary mirror assembly (SMA).

metering↗

NASA NTRS2019

Inflatable Technology: Using Flexible Materials to Make Large Structures

Space structures are one of the most critical components for any spacecraft, as they must provide the maximum amount of livable volume with the minimum amount of mass. Deployable structures can be used to gain additional space that would not normally fit under a launch vehicle shroud. This expansion capability allows it to be packed in a small launch volume for launch, and deploy into its fully open volume once in space. Inflatable, deployable structures in particular, have been investigated by NASA since the early 1950’s and used in a number of spaceflight applications. Inflatable satellites, booms, and antennas can be used in low-Earth orbit applications. Inflatable heatshields, decelerators, and airbags can be used for entry, descent and landing applications. Inflatable habitats, airlocks, and space stations can be used for in-space living spaces and surface exploration missions. Inflatable blimps and rovers can be used for advanced missions to other worlds. These applications are just a few of the possible uses for inflatable structures that will continued to be studied as we look to expand our presence throughout the solar system.

structures↗

NASA NTRS2020

A Computer Program to Generate Tri-Truss Structures for On- and Off-Axis Telescope Dishes

The size of traditional space telescopes has been limited by the size of the launch vehicle shroud size. Designs of space telescopes with larger apertures and greater resolving power can be achieved with multiple launches incorporating modular elements and in-space assembly techniques. The modular elements of an in-space assembled telescope include segmented reflectors supported on an assembled truss structure. The modular truss structures are most commonly based on a tessellation of triangles across a reflector’s surface, and in some cases utilize deployable trusses to simplify in-space assembly. One design effort, the in-Space Assembled Telescope (iSAT), proposes the use of deployable “tri-truss” modules to form an off-set parabolic reflector. In support of the iSAT, a computer program was developed to tesselate tri-truss modules over a parabolic surface. Based on several user-defined variables, the program renders a tri-truss structure and generates a stereolithography file of the generated truss structure for three dimensional (3D) printing. In addition, due to the importance of packing efficiency for space launch, the program attempts to minimize unnecessary differences in strut lengths using a grade parameter based on previous work.

Structures↗