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NASA NTRSDate not supplied

Improved Benchmarking of Cohesive Elements in Abaqus Standard for Predicting Disbond and Delamination in Composite Structures

Traditional approaches for aircraft certification require the assumption of an initial flaw condition, either represented as barely visible impact damage (BVID) or through inclusion of a Teflon insert to serve as surrogate damage. Based on the initial composite damage state, the structure must be shown to demonstrate structural durability and damage tolerance (DaDT) according to the following criteria: a. Damage displays no detrimental growth under cyclic loading. The structure is able to sustain design limit load (DLL). Currently, the only available manner for validating structural performance is through test. Since damage can occur over a wide variety of areas within a structure, this approach has proven to be increasingly expensive and time consuming for composite airframes and acreage structure within the design-test-certification building block. A further complicating factor is the requirement to accurately capture the most critical damage morphologies as a starting condition. To understand the severity of the damage, it is either required to experimentally determine the most critical areas at tremendous expense or rely on legacy data of similar structural testing, which limits design space expansion. A preferred solution is to use advanced analysis to provide improved understanding of load margins for critical locations based on a wide variety of potential starting damage conditions.

Eric M. Roberts↗

NASA NTRS2019

Early Lessons on Combining Lidar and Multi‑baseline SAR Measurements for Forest Structure Characterization

The estimation and monitoring of 3D forest structure at large scales strongly rely on the use of remote sensing techniques. Today, two of them are able to provide 3D forest structure estimates: lidar and synthetic aperture radar (SAR) configurations. The differences in wavelength, imaging geometry, and technical implementation make the measurements pro-vided by the two configurations different and, when it comes to the sensitivity to individual 3D forest structure components, complementary. Accordingly, the potential of combining lidar and SAR measurements toward an improved 3D forest structure estimation has been recognised from the very beginning. However, until today there is no established frame-work for this combination. This paper attempts to review differences, commonalities, and complementarities of lidar and SAR measurements. First, vertical lidar reflectance and SAR reflectivity profiles at different wavelengths are compared in different forest types. Then, current perspectives on their combination for the generation of enhanced structure products are discussed. Two promising frameworks for combining lidar and SAR measurements are reviewed. The first one is a model-based framework where lidar-derived parameters are used to initialize SAR scattering models, and relies on both the validity of the models and on the physical equivalence of the used lidar and SAR parameters. The second one is a structure-based framework based on the ability of lidar and SAR measurements to express physical forest structure by means of appropriate indices. These indices can then be used to establish a link between the two kind of measurements. The review is supported by experimental results achieved using space- and airborne data acquired in recent relevant mission and campaigns.

Matteo Pardini↗

NASA NTRS2023

MMIC-I: A Robotic Platform for Assembly Integration and Internal Locomotion through Mechanical Meta-Material Structures

In-space assembly is crucial to creating large-scale space structures and enabling long term space missions. Natural limitations in the size of transportation vehicles and ISRU production facilities necessitate an additive strategy with the size of the typical structural unit being essentially fixed and inversely proportional to the final assembly size. In prior robotic and space assembly examples, reversible mechanical integration of structural modules is typically achieved with actuated alignment and fastening mechanisms onboard every structural module. Additive assembly or manufacturing planning approaches often feature a “build front” that receives new materials or parts and progresses gradually across the target geometry. The system we describe here places much of the alignment and fastener actuation systems onboard a mobile robot that can operate at a build front while companion robots (Scaling Omni-directional Lattice Locomoting Explorer, SOLLE) provide part or material transportation. The design and evaluation of this Mobile Meta-Material Interior Co-Integrator (MMIC-I), an inchworm-style locomoting robotic assembler, is described here with an emphasis on ease of assembly and a low number of unique parts for a simple design. It is designed to assist in alignment of cuboctahedron structural unit cells with captive fasteners, defining the build front in operation. Adjacent structural unit cells are locked together with specified axial and rotational actuation of the fasteners. Hardware prototypes show that the robot is able to successfully locomote to any indexed location within a lattice structure and bolt together each set of fasteners on any interface.

Robotics↗

NASA NTRSDate not supplied

Scaling Climbing Collaborative Mobile Manipulators (C2M2) for Outfitting a Tall Lunar Tower (TLT) and Truss Structures

In-space and planetary truss structures like the Tall Lunar Tower (TLT) can greatly benefit from truss climbing collaborative mobile manipulators (C-CMMs) for outfitting and other servicing tasks. Mobile robotic systems traversing these structures will allow for improved access to the structure for placing equipment and routing cables after the structure has been assembled. The robotic system described in the proposed paper is designed to provide access to the structure through collaborative mobile robotics. The paper will provide a method to constrain the design of such a robot via the geometry of the truss structure and the controlling joint torques across various gaits. The focus of the design is on a six-degree of freedom (DOF) robot arranged with two-DOF at each end and at the center. The variable features of this system are the actuators and the length of the links connecting the two-DOF modules. The result of the analysis is a link sizing range which the robot can be designed within to ensure functionality on the truss structure. A C-CMM will be designed using the scaling utility and several constructed to demonstrate operating both independently and collaboratively.

in-space assembly↗

NASA NTRSDate not supplied

History of Structural Stitching Development for Aerospace Applications

Layered composite structures are a commonly used, lightweight option for aerospace vehicles today. However, these structures are prone to delamination between plies as well as separation between co-cured sections such as skins and flanges. In addition, delamination can easily be induced by impact damage from events such as tool drops and hailstones. Since such delaminations are often not visible from the external surface of the structure, additional material or fasteners must be included in the design to ensure the structure will maintain the required load-carrying ability through its lifetime. However, adding extra material increases weight and reduces structural efficiency and adding fasteners and their associated holes reduces manufacturing efficiency and adds the requirement to inspect the holes since they could become crack initiation points. Alternate means to reduce delaminations could be beneficial. An alternative to these options is to build the structure with through-thickness reinforcement, such as using stitching threads, to limit delamination, increase out-of-plane strength, and provide a method to join structural elements together without fasteners. The history of through-thickness stitching as it could be applied to aerospace vehicles is described in this paper.

carbon-epoxy↗

NASA NTRSDate not supplied

Analysis of a Landing System for Planetary Payloads Utilizing Passive Energy Absorbing Composite Structure

Delivery of a payload from space to a planetary surface currently requires the development of an application specific landing system to protect the payload from forces imparted during impact with the planet surface. Often, active energy attenuating systems such as retro-rockets, deployable parachutes, and airbags are utilized within these landing systems to reduce landing impact energy. Unfortunately, these active systems come at a cost; active energy attenuating systems are susceptible to system faults which may limit or completely negate their energy attenuating capability. Additionally, components needing to be stowed such as fuel, parachutes, and airbags increase design complexity, cost, and weight. To overcome these limitations, this study examines the potential of passive energy attenuation through energy absorbing structural design and composite materials to mitigate landing loads for small payload planetary delivery. Researchers at the National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC) have conducted extensive research into developing energy absorbing structures and components for the attenuation of impact energy under various loading conditions including aircraft crash and spacecraft impact. The current study leverages this research to design a lightweight planetary delivery system which utilizes unique outer mold line (OML) geometry and passive energy absorbing structural design to limit landing loads across potential planetary surface environments. The OML geometry is designed to control impact orientation and provide self-righting capabilities for slopped impact surfaces. The internal structure is composed of composite material structures arranged to provide energy absorption which is robust to impact angle and impact velocity. The developed planetary delivery design concept will be evaluated using finite element (FE) model analysis. Simulations of landing impacts with representative soil surface environments will be used to characterize the energy absorbing capabilities of the landing system. Sensitivity of predicted impact force to landing environment, impact angle, and impact velocity will be assessed to identify capabilities and limitations of the initial structural design. Results will be used to determine the feasibility of a lightweight composite structure to passively absorb landing energy for robust planetary payload delivery.

Crashworthiness↗

NASA NTRS2023

Integrating Forest Structural Diversity Measurement Into Ecological Research

The measurement of forest structure has evolved steadily due to advances in technology, methodology, and theory. Such advances have greatly increased our capacity to describe key forest structural elements and resulted in a range of measurement approaches from traditional analog tools such as measurement tapes to highly derived and computationally intensive methods such as advanced remote sensing tools (e.g., lidar, radar). This assortment of measurement approaches results in structural metrics unique to each method, with the caveat that metrics may be biased or constrained by the measurement approach taken. While forest structural diversity (FSD) metrics foster novel research opportunities, understanding how they are measured or derived, limitations of the measurement approach taken, as well as their biological interpretation is crucial for proper application. We review the measurement of forest structure and structural diversity—an umbrella term that includes quantification of the distribution of functional and biotic components of forests. We consider how and where these approaches can be used, the role of technology in measuring structure, how measurement impacts extend beyond research, and current limitations and potential opportunities for future research.

Jeff W. Atkins↗

NASA NTRS2024

Effective structural impact detection and localization using convolutional neural network and Bayesian information fusion with limited sensors

Due to their unpredictable nature, many impact events (e.g., overheight vehicles striking on bridges) go unnoticed or get reported many hours later. However, they can induce structural failures or hidden damage that accelerates the structure’s long-term degradation. Therefore, prompt impact detection and localization strategies are essential for early warning of impact events and rapid maintenance of structures. Most existing impact detection strategies are developed for aircraft composite panels utilizing high-rate synchronized measurement from densely deployed sensors. Limited efforts have been made for infrastructure or human habitats which generally require large-scale but low-rate measurement. In particular, due to harsh environments (e.g., deep space habitats under meteoroids), structural impact localization must be robust to limited sensors (e.g., sensor damage during impacts) and multi-source errors (e.g., measurement errors). In this study, an effective impact detection and localization strategy is proposed using a limited number of vibration measurements, especially in harsh environments (e.g. in deep space). Convolutional neural networks are trained for each sensor node and are fused using Bayesian theory to improve the accuracy of impact localization. Special considerations are paid to evaluate the effect of both measurement error and modeling error in the analysis. The proposed strategy is illustrated using 1D structure, and further validated in 3D geodesic dome structure numerically. The results demonstrate that it can detect and localize impact events accurately and robustly on structures.

Yuguang Fu↗

DOE OSTI2021

Self-sensing of printed polymer structures

A structural health monitoring method is provided that utilizes self-sensing printed polymer structures. The method is based on resistivity properties of conductive materials, which can be integrated to a 3D printed polymer structure during additive manufacturing. An article to be monitored has at least one 3D printed polymer structure including a circuit comprising at least one conductive pathway extending through a non-conductive material. The resistance across the circuit is measured during or after loading of the article to determine a resistance value. The measured resistance value is compared to a known resistance value, and based on the comparison, a defect can be detected in the 3D printed polymer structure. Structural health monitoring systems and articles with integrated structural health monitoring are also provided.

Kunc, Vlastimil↗

DOE OSTI2022

Disentangling the EMC effect: from free to bound nucleon structure

Deep inelastic scattering experiments using electron beams on fixed targets allow for the study of the structure of nucleons. While the structure of the free proton has been well measured, the free neutron structure and the modification of nucleon structure in the nuclear environment, the EMC effect, remain open questions. Studies suggest that the EMC effect may arise due to strongly-interacting nucleon-nucleon systems, referred to as short-range correlations. The BAND experiment at the Thomas Jefferson National Accelerator Facility seeks to probe the bound proton structure when in a strongly-interacting state, using spectator-tagged deep inelastic scattering. This thesis presents the results of the BAND experiment, demonstrating the proton is modified when strongly-interacting with the spectator neutron in deuterium. This thesis also explores efforts to describe inclusive and tagged deep inelastic scattering data within a uniform theoretical framework to explore nucleon structure modification effects and extract the free neutron structure.

Segarra, Efrain↗

DOE OSTI2022

System, method, and computer program for creating an internal conforming structure

A system for creating an internal formation of a tubular structure having an inner surface via additive manufacturing. The system broadly includes a computer modeling system and an additive manufacturing system. The computer modeling system may include a processor for generating a lattice cellular component via computer-aided design software according to inputs received from a user. The processor may also generate an internal formation lattice structure based on the lattice cellular component and modify the lattice structure to follow and/or conform to the curvature of the inner surface of the outer wall of the tubular structure. The additive manufacturing system may be configured to produce the lattice structure and the tubular structure via additive manufacturing material deposited layer by layer according to the lattice structure.

42 ENGINEERING↗

DOE OSTI2023

Intercalation And High-Pressure Effects On Structural Phase Transitions In Layered As x P 1-x Alloys

This project was aimed at understanding the role of composition, intercalation, and high pressure on the structural evolution of black phosphorous (BP) and layered arsenic phosphorous alloys, As y P 1-y . Under normal conditions, BP is the most stable phase of phosphorous, known as the α-phase, characterized by an orthorhombic honeycomb puckered crystal structure with the Cmca space group. On the other hand, the most stable phase of arsenic is its β-phase, known as gray arsenic (g-As), which has a rhombohedral buckled layered crystal structure with the R3m space group. In a wide range of compositions (y < 0.83), the arsenic phosphorous alloys form the α-phase, known as black arsenic phosphorous (b-As y P 1-y ) with a similar structure to BP. The project was aimed at the synthesis of BP and b-As y P 1-y with different compositions and at studying the structural evolution of these materials during intercalation with alkali metal (especially Li), and under high-pressure conditions. The main goals were to gain a better understanding of these processes and structural changes taking place under these conditions. In particular, the project was aimed at addressing whether such conditions could induce a structural transition between the α- and β-phases. For this, a series of systematic in-situ studies were conducted, including electrochemical lithium intercalation in an in-situ electrochemical cell, and high-pressure experiments in a diamond anvil cell (DAC). Overall, both types of experiments have shown that above a certain composition-dependent threshold level of intercalation or high pressure, the system undergoes phase segregation rather than phase transition. Specifically, the segregation of the excess arsenic was observed, and a single-phase system of b-As y P 1-y transformed into a two-phase system consisting of b-As y P 1-y and g-As, through the following process: 1∗(b-As y P 1-y ) → 1∗(b As y-δ P 1-y ) + δ∗(g-As). Also, the study showed that intercalation and high-pressure are two competing rather than synergistic processes causing at least a partial cancelation of these two factors

36 MATERIALS SCIENCE↗

DOE OSTI2023

Wind Loading on Parabolic Trough Collectors: Wind and Structural Loads Measurements at an Operational Powerplant

Concentrated Solar Power (CSP) is a promising method for using solar power for electricity generation with thermal energy storage for industrial applications. Solar collectors constitute almost 1/3 of the total cost of the power plant. One of the primary drivers of unrealiability of these collectors is wind-driven loading of mirrors, support structures, and drives. To date, the design of the solar collector structures has relied on data from wind tunnels that do not adequately capture the dynamic effects observed at scale. NREL initiated a field measurement campaign at the operational Nevada Solar One (NSO) parabolic trough powerplant. At this plant, parabolic trough solar collectors track the sun from east to west in the course of a day and face varying wind loads depending on the wind properties and the angle of the troughs. The aim of the project is a detailed characterization of prevailing wind and turbulence conditions and resulting operational loads on parabolic troughs, providing insights into structural dynamic response, and generating a comprehensive wind-loading dataset for validating simulations of wind loading on collector structures. The measurements at NSO consist of sonic anemometers on masts at different heights to characterize the incoming flow and conditions at four trough rows at the edge of the trough field. In addition, a Doppler Lidar scans the horizontal plane above the troughs. The wind measurements at NSO have been continuously collecting data since October 2021 and are combined with structural load measurements that started in November 2022. The load measurements were installed on the same four outermost trough rows and include support structure bending moments, drive torque moments, dynamic accelerations of the spaceframe, mirror displacement, and tilt angles. Measurements are planned to continue until May 2023, providing a first-of-a-kind, high-resolution multi-month dataset of combined wind and load measurements. In this presentation, we show first results of the measurement campaign. Based on the measurements, we identified three main factors altering the flow over the parabolic troughs: Wind speed, wind direction, and the angle of the parabolic troughs. Most interactions between incoming wind and the trough field are observed when the wind blows perpendicular to the trough rows. In this case, the first rows experience the highest wind speed and block the downwind rows, creating conditions with decreased wind speed and enhanced turbulence within the trough field. Also, turbulent length scales are smaller after the first row. This leads to the highest static loads (bending and torque moments) at the first row but potentially increased dynamic loads within the field. We illustrate our findings with case studies focused on different wind conditions and will present fatigue analysis to highlight the impact of wind-driven loads on collector structures.

CSP collectors↗

DOE OSTI2023

Automated analysis of lattice structures using computed tomography

Systems, methods, and computer-readable media for evaluating a set of computed tomography data associated with a lattice structure. The lattice structure may be additively manufactured. The computed tomography data may be segmented using a filter for identifying blob-like structures to identify nodes present within the lattice structure. A three-dimensional path traversal is applied to volumetric data to identify a plurality of struts within the lattice structure that are compared to corresponding struts within a set if three-dimensional mesh data of the lattice structure to identify defective struts. Further, two-dimensional slices may be extracted from each of the computed tomography data and the mesh data and compared to identify one or more inconsistencies indicative of defects within the lattice structure.

Schiefelbein, Bryan E.↗

DOE OSTI2024

Development of Lightweight Structural Materials with Improved Properties for Fission Batteries

The notion of a “fission battery” conveys a vision focused on realizing very simple “plug-and-play” nuclear systems that can be integrated into a variety of applications requiring affordable, reliable energy in the form of electricity and/or heat and function without operations and maintenance staff. Fission batteries require lightweight structural materials to increase their mobility, and the lightweight materials must demonstrate structural resilience under various conditions. The objective of this work is to develop lightweight structural material featuring a good combination of mechanical properties using advanced modeling and simulation together with an advanced additive manufacturing technique such as laser powder bed fusion. The preliminary results show that different lattice structures and types can be successfully meshed using nTopology software, and the lattice structure data can be successfully transformed to Multiphysics Object-Oriented Simulation Environment (MOOSE) input. Finite Element Analysis (FEA) displays that, at macro/engineering scale simulation, the weight saving design has an obvious effect on tensile behavior such as effective elastic modulus and yield stress. The novel approaches of this work are (1) development of optimized lattice structures for improved mechanical properties using advanced simulation and modeling techniques; and (2) model predictions of the mechanical properties (e.g., strength and stress distribution) of macroscopic materials in order to preliminarily select a lattice structure for additive manufacturing.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Automated analysis of lattice structures using computed tomography

Schiefelbein, Bryan E.↗

DOE OSTI2023

Exploration, Prediction, and Experimental Verification of Structure and Optoelectronic Properties in I 2 -Eu-IV-X 4 (I = Li, Cu, Ag; IV = Si, Ge, Sn; X = S, Se) Chalcogenide Semiconductors

Recently, there has been extensive research into photovoltaic, thermoelectric, and nonlinear optical applications of chalcogenide semiconductors within the large set of defect-resistant I 2 -II-IV-X4 (I = Li, Cu, Ag; II = Ba, Sr, Eu, Pb; IV = Si, Ge, Sn; X = S, Se) compounds. Five Eu-including compounds have previously been reported within this family, but a comparative study of possible structures and electronic properties of all 18 Eu-based combinations is still absent. Herein, we use hybrid density functional theory to study rare-earth-including I 2 -II-IV-X 4 semiconductors with Eu on the II site, in order to further understand this family and test the geometric tolerance factor approach (reported in our previous work) as a tool for predicting potential stable structures. We investigate how the exchange mixing parameter of the HSE06 density functional, α, affects the energetic positions of electronic levels, especially of the localized f-electron orbitals near the band edges of the extended semiconductor structures, using literature photoemission and band gap data of EuS for comparison. Lowest-energy quaternary structure candidates, energy band structures, and densities of states are computationally predicted for all 18 materials. Based on its predicted photovoltaics-relevant band gap, the previously unknown compound Cu 2 EuSnSe 4 was selected and synthesized. Furthermore, the experimental structure, lattice parameters, and band gap of Cu 2 EuSnSe 4 are consistent with the computational predictions, confirming a 1.55 eV band gap.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Temperature-Dependent Structural Transition in Cu-Intercalated Trigonal CuYbSe 2

Rare-earth delafossites, ARCh 2 ; A = alkali metal, R = rare-earth, Ch = chalcogen which consist of intercalated rare-earth metal dichalcogenides, host frustrated triangular lattices that are fertile ground for exotic phenomena. In most cases, the triangular rare-earth sublattice arises from R-3m (No. 166) structures with three layers of rare-earth metal dichalcogenide octahedra or P6 3 /mmc (No. 194) structures with two such layers, analogous to those found in transition metal dichalcogenides. Substituting the alkali metal with Cu + yields a distinct trigonal crystal symmetry P-3m1 (No. 164) in these structures. This symmetry change alters the coordination environment from ASe 6 octahedra in R-3m AYbSe 2 to CuSe 4 tetrahedra in CuYbSe 2 , resulting in shortened rare-earth to rare-earth separations and significantly reduced interlayer distances. Using X-ray single-crystal diffraction, powder neutron diffraction, resistance, and specific heat measurements, a structural transition slightly below room temperature (258 K) is observed. The low-temperature structure is a lower-symmetry I2/m structure, accompanied by partial Cu-site vacancy ordering. The combination of Cu disorder and the triangular lattice geometry in CuYbSe 2 provides a promising platform for investigating frustrated magnetism and unconventional transport phenomena.

Chemical structure↗