Results for “Automated Testing” — Page 83

NASA NTRS2012

Multi-Beam Approach for Accelerating Alignment and Calibration of HyspIRI-Like Imaging Spectrometers

A paper describes an optical stimulus that produces more consistent results, and can be automated for unattended, routine generation of data analysis products needed by the integration and testing team assembling a high-fidelity imaging spectrometer system. One key attribute of the system is an arrangement of pick-off mirrors that provides multiple input beams (five in this implementation) to simultaneously provide stimulus light to several field angles along the field of view of the sensor under test, allowing one data set to contain all the information that previously required five data sets to be separately collected. This stimulus can also be fed by quickly reconfigured sources that ultimately provide three data set types that would previously be collected separately using three different setups: Spectral Response Function (SRF), Cross-track Response Function (CRF), and Along-track Response Function (ARF), respectively. This method also lends itself to expansion of the number of field points if less interpolation across the field of view is desirable. An absolute minimum of three is required at the beginning stages of imaging spectrometer alignment.

Eastwood, Michael L.↗

DOE OSTI2023

Automated Credibility Assessments of User Features in Scientific Software

Scientific software (SciSoft) is complex, often containing a mixture of production capabilities co-mingled with features under active research and development. Furthermore, SciSoft is often developed over decades by non-computer scientists who may not have a strong background in or prioritize software architecture design, testing, and quality (e.g., test coverage). These conditions lead to difficulty in understanding which software components or functions implement what user-facing features and therefore those features’ software quality pedigree. This lack of understanding poses challenges in assessing readiness and credibility of user features, and often relies on a SciSoft subject matter expert’s (SME) laborious investigation and assertion. This final report of a one-year Computing and Information Sciences Lab Directed Research and Development project presents a general framework for modeling SciSoft architecture as a direct relationship between user features and the software components/functions that implement them. Our approach leverages automated labeling of the SciSoft’s regression test suite and employs machine learning algorithms to construct the architecture model. We demonstrate this framework on the Solid Mechanics component of the SIERRA multi-physics engineering analysis suite developed at Sandia National Laboratories.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Practical Insights on Applying Simulation-Based Control Methods in Experimental Studies

Advanced nuclear reactors are crucial to the future of energy both in the United States and around the globe. In contrast to the current operating fleet, they are characterized as being deployable in remote locations and able to operate in semi-autonomous or autonomous fashion. This leap forward necessitates a new reactor control paradigm. Because advanced nuclear reactors are still under development in the United States, the creation of new control methods to achieve autonomous operations has been based on systems modeling and simulation. However, an important factor in successfully deploying these new control methods is the ability to seamlessly transition from simulation environments to real-world settings. Control methods tested in both simulation and experimental settings need to be investigated in the context of advanced reactor applications. This work developed a series of simple controllers for Idaho National Laboratory (INL)’s Microreactor Applications Research Validation and Evaluation (MARVEL) microreactor operating in load-following scenarios. These controllers were tested in both simulation and experimental settings, and a comparative performance analysis was performed. The simulation tests leveraged the Control and Optimization Modular Modeling Application for Nuclear Deployment (COMMAND) software developed in a previous stage of the current effort, along with the MARVEL Reactor Excursion and Leak Analysis Program (RELAP5-3D) and Monte Carlo N-Particle (MCNP) models. The experimental tests leveraged the COMMAND software, MARVEL models, and the U.S. Department of Energy Microreactor Program’s Microreactor Automated Control System (MACS). MACS was developed to serve as a control method testbed. It was customized to mirror the MARVEL microreactor, and COMMAND enabled MACS to emulate the physics of MARVEL. The load-following controller was developed using the simulation platform, with efforts to emulate real systems by introducing actuator saturation and noise. These factors were incrementally accounted for in the controller design. After finalizing the controller design, it was implemented with the experimental setup. The experimental conditions tested included an initial test under conditions similar to the final simulation test, and two additional scenarios. The first scenario introduced additional actuator saturation to account for equipment aging over time, which was unknown to the controller. The second scenario introduced sensor delay, a phenomenon anticipated with the use of remote operations or wireless communication in advanced reactors. These tests revealed several notable differences. While the controller performed well in simulation, it exhibited several limitations when transitioning to hardware. The main challenges involved maintaining the steady-state target power, as evidenced by larger error values between the true reactor power and setpoint power, as well as persistent oscillations in controlled reactor power. These issues could lead to unacceptable transient conditions in real reactor testing. Introducing actuator aging and stochastic delays in the experimental setup significantly impacted controller performance, resulting in increased overshoot and undershoot, and exacerbated error and oscillations previously mentioned. These findings underscore the importance of experimental testbeds for testing and validating control methods, as controllers developed using only theory and/or simulation may perform unexpectedly when applied to actual hardware. This research emphasizes the need for an experimental testbed for achieving such validation.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗

DOE OSTI2017

An Automated Microfluidic Assay for Photonic Crystal Enhanced Detection and Analysis of an Antiviral Antibody Cancer Biomarker in Serum

Here, we report on the implementation of an automated platform for detecting the presence of an antibody biomarker for human papillomavirus-associated oropharyngeal cancer from a single droplet of serum, in which a nanostructured photonic crystal surface is used to amplify the output of a fluorescence-linked immunosorbent assay. The platform is comprised of a microfluidic cartridge with integrated photonic crystal chips that interfaces with an assay instrument that automates the introduction of reagents, wash steps, and surface drying. Upon assay completion, the cartridge interfaces with a custom laser-scanning instrument that couples light into the photonic crystal at the optimal resonance condition for fluorescence enhancement. The instrument is used to measure the fluorescence intensity values of microarray spots corresponding to the biomarkers of interest, in addition to several experimental controls that verify correct functioning of the assay protocol. In this work, we report both dose-response characterization of the system using anti-E7 antibody introduced at known concentrations into serum and characterization of a set of clinical samples from which results were compared with a conventional enzyme-linked immunosorbent assay (ELISA) performed in microplate format. Finally, the demonstrated capability represents a simple, rapid, automated, and high-sensitivity method for multiplexed detection of protein biomarkers from a low-volume test sample.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS2008

Characterization of Piezoelectric Stacks for Space Applications

Future NASA missions are increasingly seeking to actuate mechanisms to precision levels in the nanometer range and below. Co-fired multilayer piezoelectric stacks offer the required actuation precision that is needed for such mechanisms. To obtain performance statistics and determine reliability for extended use, sets of commercial PZT stacks were tested in various AC and DC conditions at both nominal and high temperatures and voltages. In order to study the lifetime performance of these stacks, five actuators were driven sinusoidally for up to ten billion cycles. An automated data acquisition system was developed and implemented to monitor each stack's electrical current and voltage waveforms over the life of the test. As part of the monitoring tests, the displacement, impedance, capacitance and leakage current were measured to assess the operation degradation. This paper presents some of the results of this effort.

active mirrors↗

DOE OSTI2023

Final Technical Report Wireless Microsensors System for Monitoring Deep Subsurface Operations

This final technical report describes the main findings of the project Wireless Microsensors System for Monitoring Deep Subsurface Operations (FE0031850). The project was part of the U.S. Department of Energy National Energy Technology Laboratory FOA 1998 program to develop new sensor systems for direct observation of parameters associated with CO2 injection and to provide data collection without being disruptive to operations. The overall DOE program was aimed at developing and validating innovative transformational sensor systems, amenable for integration with autonomous intelligent monitoring systems, that are capable of being deployed within the casing annulus and do not have casing perforation or wires/cables in the annulus for installation, power supply, or data transmission needs. Project accomplishments included 1) design and fabrication of a wireless downhole sensor system to monitor parameters for CO2 storage, 2) field testing of the sensor system in two legacy oil & gas wells, and 3) development of an analysis approach that validates the measurements and demonstrates the application of the technology to depict CO2 movement in the subsurface. The project leveraged new sensor technologies along with specialized wellbore telemetry, deployment, and analysis methods designed to address the challenges and risks related to CO2 storage in the subsurface. Results from field testing were a mixture of successes and challenges. The temperature sensor rings, installation procedures in legacy oil & gas wells, wireless powering demonstration, automated data collection, and material compatibility were successful. The wireless data transfer through cement to the wellhead via the sensor relays was not functional beyond the first relay. Consequently, work in the last year of the project included some additional testing of data transmission through different materials along with modeling and analysis of field data for CO2 monitoring applications. This work suggested there are options like polymer cements and open hole annuli that may allow point-to-point transmission along the borehole. The techno-economic analysis suggests that the sensor system is ~40% less expensive than fiber optic distributed temperature system. Modeling of CO2 storage applications suggests temperature can provide an indicator of CO2 saturation but would be best combined with pressure sensors.

47 OTHER INSTRUMENTATION↗

DOE OSTI2021

Rapid Construction of Validated Chemistry Models for Advanced Biofuels (Co-Optima Final Report)

Computer methods were developed and demonstrated that make it possible to predict the combustion and pyrolysis chemistry of proposed biofuels, even before the biofuels are ever manufactured or experimentally tested. The methods are based on first-principles calculations of reaction rates and equilibria. A large number of complicated calculations are required, so we developed a computer workflow that automates many of the steps. With the chemical structure of the biofuel and the system conditions (temperature, pressure, compositions, etc.) as the input, the computer methods can construct a detailed kinetic model with refined parameters without intense human intervention. The automation of model construction makes it practical for a single engineer to make the predictions in a reasonable time period. The accuracy of the computer predictions was tested by measuring the time-profiles of various reaction intermediates (carbon monoxide, carbon dioxide, water, formaldehyde, methane, and ethylene) formed as the biofuels pyrolyze or ignite using sophisticated laser shock tube methods. Several biofuels, including methyl propyl ether, cyclopentanone, butyl acetate isomers, etc., were carefully studied to demonstrate the validity of the proposed computational and experimental methodology. This research project opens up the possibility for assessing some proposed biofuels on the computer without expensive experimental campaigns. The new computer methods are open source and well-documented, allowing a knowledgeable modeler to easily access the developed methods and implement them in their work routine. Moreover, they are also convenient and powerful, promising for developing the fuel chemistry models needed for use in engine simulators, facilitating co-optimization of new engine designs with new fuels.

09 BIOMASS FUELS↗

NASA NTRS1996

Welding rework data acquisition and automation

Aluminum-Lithium is a modern material that NASA MSFC is evaluating as an option for the aluminum alloys and other aerospace metals presently in use. The importance of aluminum-lithium is in it's superior weight to strength characteristics. However, aluminum-lithium has produced many challenges in regards to manufacturing and maintenance. The solution to these problems are vital to the future uses of the shuttle for delivering larger payloads into earth orbit and are equally important to future commercial applications of aluminum-lithium. The Metals Processes Branch at MSFC is conducting extensive tests on aluminum-lithium which includes the collection of large amounts of data. This report discusses the automation and data acquisition for two processes: the initial weld and the repair. The new approach reduces the time required to collect the data, increases the accuracy of the data, and eliminates several types of human errors during data collection and entry. The same material properties that enhance the weight to strength characteristics of aluminum-lithium contribute to the problems with cracks occurring during welding, especially during the repair/rework process. The repairs are required to remove flaws or defects discovered in the initial weld, either discovered by x-ray, visual inspection, or some other type of nondestructive evaluation. It has been observed that cracks typically appear as a result of or beyond the second repair. MSFC scientists have determined that residual mechanical stress introduced by the welding process is a primary cause of the cracking. Two obvious solutions are to either prevent or minimize the stress introduced during the welding process, or remove or reduce the stress after the welding process and MSFC is investigating both of these.

Romine, Peter L.↗

DOE OSTI2025

Development and flight-testing of modular autonomous cultivation systems for biological plastics upcycling aboard the ISS

Cultivation of microorganisms in space has enormous potential to enable in-situ resource utilization (ISRU) Here, we develop an autonomous payload with fully programmable serial passaging and sample preservation, termed the Modular Open Biological Platform (MOBP), and flight-test the MOBP aboard the International Space Station (ISS) by conducting enzymatic and microbial plastics upcycling experiments. The MOBP is a compact, modular bioreactor system that allows for sustained microbial growth via automated media transfers, such as those for sample collection and storage for terrestrial analyses, and precise data monitoring from integrated sensors. The MOBP was flight-tested with two experiments designed to evaluate biological upcycling of the plastic poly(ethylene terephthalate) (PET). The bioproduct βKA can be polymerized into a nylon-6,6 analog with improved properties for use in the production of a variety of materials. We posit the MOBP will aid in democratizing the execution of synthetic biology in spaceflight towards enabling ISRU.

09 BIOMASS FUELS↗

NASA NTRS1975

Manned systems utilization analysis (study 2.1). Volume 3: LOVES computer simulations, results, and analyses

The LOVES computer program was employed to analyze the geosynchronous portion of the NASA's 1973 automated satellite mission model from 1980 to 1990. The objectives of the analyses were: (1) to demonstrate the capability of the LOVES code to provide the depth and accuracy of data required to support the analyses; and (2) to tradeoff the concept of space servicing automated satellites composed of replaceable modules against the concept of replacing expendable satellites upon failure. The computer code proved to be an invaluable tool in analyzing the logistic requirements of the various test cases required in the tradeoff. It is indicated that the concept of space servicing offers the potential for substantial savings in the cost of operating automated satellite systems.

Stricker, L. T.↗

DOE OSTI2020

Building fault detection data to aid diagnostic algorithm creation and performance testing

It is estimated that approximately 4-5% of national energy consumption can be saved through corrections to existing commercial building controls infrastructure and resulting improvements to efficiency. Correspondingly, automated fault detection and diagnostics (FDD) algorithms are designed to identify the presence of operational faults and their root causes. A diversity of techniques is used for FDD spanning physical models, black box, and rule-based approaches. A persistent challenge has been the lack of common datasets and test methods to benchmark their performance accuracy. This article presents a first of its kind public dataset with ground-truth data on the presence and absence of building faults. This dataset spans a range of seasons and operational conditions and encompasses multiple building system types. It contains information on fault severity, as well as data points reflective of the measurements in building control systems that FDD algorithms typically have access to. The data were created using simulation models as well as experimental test facilities, and will be expanded over time.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2016

Design, fabrication and test of a pneumatically controlled, renewable, microfluidic bead trapping device for sequential injection analysis applications

This paper describes the design, fabrication, and testing of a pneumatically controlled,renewable, microfluidic device for conducting bead-based assays in an automated sequential injection analysis system. The device used a “brick wall”-like pillar array (pillar size: 20 μm length X 50 μm width X 45 μm height) with 5 μm gaps between the pillars serving as the micro filter. The flow channel where bead trapping occurred is 500 μm wide X 75 μm deep. An elastomeric membrane and an air chamber were located underneath the flow channel. By applying pressure to the air chamber, the membrane is deformed and pushed upward against the filter structure. This effectively traps beads larger than 5 μm and creates a “bed” or micro column of beads that can be perfused and washed with liquid samples and reagents. Upon completion of the assay process, the pressure is released and the beads are flushed out from underneath the filter structure to renew the device. Mouse IgG was used as a model analyte to test the feasibility of using the proposed device for immunoassay applications. Resulting microbeads from an on-chip fluorescent immunoassay were individually examined using flow cytometry. The results show that the fluorescence signal intensity distribution is fairly narrow indicating high chemical reaction uniformity among the beads population. Electrochemical onchip assay was also conducted. A detection limit of 0.1 ng/mL1 ppb was achieved and good device reliability and repeatability were demonstrated. The novel microfluidic-based beadstrapping device thus opens up a new pathway to design micro-bead based biosensor immunoassays for clinical and othervarious applications.

beads trapping↗

DOE OSTI2019

Applied Controls for sCO 2 Brayton Cycles

Sandia has a history of testing supercritical CO 2 Brayton Cycles to explore operation fundamentals and provide validation data for computer models. These systems have always had data acquisition and controls features. The Development Platform (DP) has been a flagship system for loop testing and operation but has been limited to manual control of many systems. Manual operation has increased operating complexity and reduced stability and repeatability. This work documents automated control development by linearizing otherwise non-linear valves, addition of closed-loop proportional-integral control software that has been tuned to the Sandia DP. It also describes testing of control methods that have improved test quality and reliability as shown in actual test data.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2016

MO-FG-202-04: Gantry-Resolved Linac QA for VMAT: A Comprehensive and Efficient System Using An Electronic Portal Imaging Device

Purpose: To automate gantry-resolved linear accelerator (linac) quality assurance (QA) for volumetric modulated arc therapy (VMAT) using an electronic portal imaging device (EPID). Methods: A QA system for VMAT was developed that uses an EPID, frame-grabber assembly and in-house developed image processing software. The system relies solely on the analysis of EPID image frames acquired without the presence of a phantom. Images were acquired at 8.41 frames per second using a frame grabber and ancillary acquisition computer. Each image frame was tagged with a gantry angle from the linac’s on-board gantry angle encoder. Arc-dynamic QA plans were designed to assess the performance of each individual linac component during VMAT. By analysing each image frame acquired during the QA deliveries the following eight machine performance characteristics were measured as a function of gantry angle: MLC positional accuracy, MLC speed constancy, MLC acceleration constancy, MLC-gantry synchronisation, beam profile constancy, dose rate constancy, gantry speed constancy, dose-gantry angle synchronisation and mechanical sag. All tests were performed on a Varian iX linear accelerator equipped with a 120 leaf Millennium MLC and an aS1000 EPID (Varian Medical Systems, Palo Alto, CA, USA). Results: Machine performance parameters were measured as a function of gantry angle using EPID imaging and compared to machine log files and the treatment plan. Data acquisition is currently underway at 3 centres, incorporating 7 treatment units, at 2 weekly measurement intervals. Conclusion: The proposed system can be applied for streamlined linac QA and commissioning for VMAT. The set of test plans developed can be used to assess the performance of each individual components of the treatment machine during VMAT deliveries as a function of gantry angle. The methodology does not require the setup of any additional phantom or measurement equipment and the analysis is fully automated to allow for regular routine testing.

60 APPLIED LIFE SCIENCES↗

NASA NTRSDate not supplied

Flight Deck Design of a Hybrid Turbine/Electric Passenger Aircraft

NASA is exploring the development of a 180-passenger subsonic single engine aft turbine aircraft, The aft turbine provides electric power in a hybrid design to wing mounted electric engines, creating a highly efficient, high-bypass-ratio fan equivalent. The SUbsonic Single Aft eNgine (SUSAN) aircraft is being developed as a sustainable subsonic regional aircraft that seeks to reduce emission levels by 50% in the next few decades. Pilot-in-the-loop studies were conducted at the NASA Langley Research Center in Hampton, Virginia, to explore the flight deck design for the hybrid electric aircraft. Following modern trends in commercial aircraft flight decks with full time augmented controls and a quiet and dark philosophy, single throttle and simplified engine displays were developed for the SUSAN aircraft. The aircraft includes a single aft mounted turbine engine and 16 wing mounted electric fans. The final design was developed from feedback received during an earlier pilot-in-the-loop study where one, two, and three throttles were tested in standard airline operations, including various failures of the turbine and electric engines. Current flight deck designs normally provide control inceptors for each propulsion engine and an engine display for all primary aircraft engine parameters. With full time augmentation expected, a single throttle control with autothrottle always engaged, even during failures, is desired. Augmentation of flight controls using distributed thrust also requires full time control of the electric engines using automation. Additionally, electric engine thrust is augmented during climb based on battery state of charge. Thrust augmentation changes faster than human reaction time and therefore requires full-time automation. A pilot-in-the-loop study was conducted at the NASA Langley Research Center in Hampton, Virginia, to test the final design of the single throttle with simplified engine displays. Fourteen airline pilots evaluated the single throttle and engine display concept. Electric engine failures included one, four symmetric, and eight non-symmetric electric engine failures. The turbine engine was evaluated for complete and partial failure during critical phases of flight to include takeoff as well as enroute. Unexpected go-arounds increase workload and require significant throttle manipulation. Go-arounds were included to ensure the single throttle was usable for all phases of flight. Failures during takeoff required a return to the departure field and failures enroute required a diversion except for one and four electric engine failures as these failures did not affect aircraft flyability or range. There are currently no Part 25 aircraft certified with hybrid systems or electric engines with batteries as emergency propulsion. For turbine engine failures in the SUSAN aircraft design, range is limited to 30 minutes at full power. Battery state of charge and battery health displays were developed and tested for usability and to determine how well they supported pilot decisions for alternate airports during emergency diversions. Novel displays using shape and color were developed to provide immediate feedback when state of charge became critical. This paper details the pilot study including pilot feedback supporting the potential for increased automation and a single throttle control. Detailed recommendations are provided for a novel single throttle control and additional pilot controls to support selection of engines during start, shutdown, and engine troubleshooting procedures. This design deviates significantly from current practice of providing throttles for each propulsion engine. Engine display recommendations are provided based on pilot feedback during a guided post-evaluation interview. Battery state of charge and battery health display recommendations were collected from all airline crews. The simplified engine displays design was rated excellent as measured with a usability scale. Quantitative metrics include airspeed tracking, time to complete checklists, time to make diversion decisions and the quality of the diversion decision. Recommendations for future studies are documented with supporting research and current observations about upcoming flight deck certifications.

autothrottle↗

NASA NTRSDate not supplied

Flight Deck Design of a Hybrid Turbine/Electric Passenger Aircraft

NASA is exploring the development of a 180-passenger subsonic single engine aft turbine aircraft, The aft turbine provides electric power in a hybrid design to wing mounted electric engines, creating a highly efficient, high-bypass-ratio fan equivalent. The SUbsonic Single Aft eNgine (SUSAN) aircraft is being developed as a sustainable subsonic regional aircraft that seeks to reduce emission levels by 50% in the next few decades. Pilot-in-the-loop studies were conducted at the NASA Langley Research Center in Hampton, Virginia, to explore the flight deck design for the hybrid electric aircraft. Following modern trends in commercial aircraft flight decks with full time augmented controls and a quiet and dark philosophy, single throttle and simplified engine displays were developed for the SUSAN aircraft. The aircraft includes a single aft mounted turbine engine and 16 wing mounted electric fans. The final design was developed from feedback received during an earlier pilot-in-the-loop study where one, two, and three throttles were tested in standard airline operations, including various failures of the turbine and electric engines. Current flight deck designs normally provide control inceptors for each propulsion engine and an engine display for all primary aircraft engine parameters. With full time augmentation expected, a single throttle control with autothrottle always engaged, even during failures, is desired. Augmentation of flight controls using distributed thrust also requires full time control of the electric engines using automation. Additionally, electric engine thrust is augmented during climb based on battery state of charge. Thrust augmentation changes faster than human reaction time and therefore requires full-time automation. A pilot-in-the-loop study was conducted at the NASA Langley Research Center in Hampton, Virginia, to test the final design of the single throttle with simplified engine displays. Fourteen airline pilots evaluated the single throttle and engine display concept. Electric engine failures included one, four symmetric, and eight non-symmetric electric engine failures. The turbine engine was evaluated for complete and partial failure during critical phases of flight to include takeoff as well as enroute. Unexpected go-arounds increase workload and require significant throttle manipulation. Go-arounds were included to ensure the single throttle was usable for all phases of flight. Failures during takeoff required a return to the departure field and failures enroute required a diversion except for one and four electric engine failures as these failures did not affect aircraft flyability or range. There are currently no Part 25 aircraft certified with hybrid systems or electric engines with batteries as emergency propulsion. For turbine engine failures in the SUSAN aircraft design, range is limited to 30 minutes at full power. Battery state of charge and battery health displays were developed and tested for usability and to determine how well they supported pilot decisions for alternate airports during emergency diversions. Novel displays using shape and color were developed to provide immediate feedback when state of charge became critical. This paper details the pilot study including pilot feedback supporting the potential for increased automation and a single throttle control. Detailed recommendations are provided for a novel single throttle control and additional pilot controls to support selection of engines during start, shutdown, and engine troubleshooting procedures. This design deviates significantly from current practice of providing throttles for each propulsion engine. Engine display recommendations are provided based on pilot feedback during a guided post-evaluation interview. Battery state of charge and battery health display recommendations were collected from all airline crews. The simplified engine displays design was rated excellent as measured with a usability scale. Quantitative metrics include airspeed tracking, time to complete checklists, time to make diversion decisions and the quality of the diversion decision. Recommendations for future studies are documented with supporting research and current observations about upcoming flight deck certifications.

autothrottle↗

NASA NTRS1994

Application of Self Nulling Eddy Current Probe Technique to the Detection of Fatigue Crack Initiation and Control of Test Procedures

A major part of fracture mechanics is concerned with studying the initiation and propagation of fatigue cracks. This typically requires constant monitoring of crack growth during fatigue cycles and the knowledge of the precise location of the crack tip at any given time. One technique currently available for measuring fatigue crack length is the Potential Drop method. The method, however, may be inaccurate if the direction of crack growth deviates considerably from what was assumed initially or the curvature of the crack becomes significant. Another popular approach is to optically view the crack using a high magnification microscope, but this entails a person constantly monitoring it. The present proposed technique uses an automated scheme, in order to eliminate the need for a person to constantly monitor the experiment. Another technique under development elsewhere is to digitize an optical image of the test specimen surface and then apply a pattern recognition algorithm to locate the crack tip. A previous publication showed that the self nulling eddy current probe successfully tracked a simulated crack in an aluminum sample. This was the impetus to develop an online real time crack monitoring system. An automated system has been developed which includes a two axis scanner mounted on the tensile testing machine, the probe and its instrumentation and a personal computer (PC) to communicate and control all the parameters. The system software controls the testing parameters as well as monitoring the fatigue crack as it propagates. This paper will discuss the experimental setup in detail and demonstrate its capabilities. A three dimensional finite element model is utilized to model the magnetic field distribution due to the probe and how the probe voltage changes as it scans the crack. Experimental data of the probe for different samples under zero load, static load and high cycle fatigue load will be discussed. The final section summarizes the major accomplishments of the present work, the elements of the future R&D needs and the advantages and disadvantages of using this system in the laboratory and field.

Namkung, M.↗

NASA NTRSDate not supplied

Numerical Simulation of the High-Speed Leg of the National Transonic Facility

Numerical simulations for the flow inside the high-speed leg of the National Transonic Facility was conducted. The NASA Tetrahedral Unstructured Software System (TetrUSS) with its USM3D_ME solver was used to perform the numerical simulations. USM3D_ME is developed and maintained by NASA Langley Research Center. Simulations were conducted for three configurations: empty tunnel, body of revolution installed, and NASA Common Research Model installed in the test section. Simulations were performed for a test section Mach number of 0.7 and 0.85 and a corresponding Reynolds number of 8 million per ft. A controller was developed that automated dynamic outflow boundary and streamlined the process of running multiple simulations. The use of a dynamic outflow boundary was the key parameter to drive simulation to the desired tunnel conditions. The numerical simulations captured expected flow features in NTF test section and in the tunnel plenum. The simulations depicted that separation of the flow inside the diffuser appears to be asymmetric and more extensive toward the top and bottom walls. Analysis of the flow field were conducted, and the computed drag coefficient compared to wind tunnel data.

NTF↗