SEARCH · Engineering Papers

Results for “performance envelope”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,549 records · Page 86

All sources NASA NTRS DOE OSTI

DOE OSTI2024

Comparative Analysis of Heat Exchangers for High Temperature High Pressure Helium Component Testing

Helium gas loops have been designed and built to gain a better understanding of the gas thermohydraulic phenomena that take place in a helium system. Some of these loops are used for validation and testing of components for high temperature gas-cooled reactors (HTGRs). However, most of them operate at lower pressure and temperature than an HTGR. While these loops can provide valuable information about gas-cooled reactor components, the operating envelope of the experiment is constrained by the maximum operating conditions of the helium loop. In response to the lack of an experimental facility that can provide the infrastructure needed to validate and test components at nominal pressures and temperatures of HTGRS, the HElium Component Testing Out-of-pile Research (HECTOR) facility was designed at Idaho National Laboratory with the assistance of University of Idaho and Walsh Engineering. With the capability to test at temperatures up to 800°C and pressures of 8MPa, HECTOR serves as a critical tool for the advancement of HTGR technology. The facility's primary role is to provide a controlled, high-fidelity environment for the assessment of component resilience and efficiency under nominal HTGR conditions. In the quest to enhance the efficiency and performance of HECTOR, a comparative analysis of three distinct types of heat exchangers—shell and tube, offset strip fin, and printed-circuit—was conducted, focusing primarily on two critical metrics: the required surface area and pressure drop characteristics. The shell and tube heat exchanger, renowned for its robust design and widespread industrial application, was evaluated against the offset strip fin and the cuttingedge printed-circuit heat exchangers, both of which are lauded for their compactness and thermal effectiveness. This comparative study aims to provide detailed insights into the thermal management capabilities of each heat exchanger type under the conditions inherent to HECTOR, thereby facilitating an informed selection for systems demanding high operational integrity and efficiency.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Smartphone application for visualizing building air leakage

Annually, unwanted air leakage through building envelopes accounts for 4 quads of energy consumption in the United States, which translates to about 10% of total building energy consumption. Locating and sealing leakage sites is crucial fordecreasing building energy consumption. Smartphones are ubiquitous and contain sophisticated cameras and highperformance processors that could be employed to visualize air leakage using the background-oriented schlieren imaging technique, making leak detection cheaper and easier. This technique requires a textured and high-contrast background such as a brick or concrete masonry unit wall, a building air leak that has a temperature difference compared with the ambient air, and an imaging system. This work focuses on using smartphones as the imaging system to visualize air leakages. The paper discusses application development and the results of testing to determine leakage visualization performance as a function of leak temperature. The results show that leaks with a temperature difference greater than 16°C compared with the ambient air temperature were visualized using existing smartphones.

Boudreaux, Philip [ORNL] (ORCID:0000000229564665)↗

DOE OSTI2016

PROTOSTELLAR OUTFLOWS AND RADIATIVE FEEDBACK FROM MASSIVE STARS. II. FEEDBACK, STAR-FORMATION EFFICIENCY, AND OUTFLOW BROADENING

We perform two-dimensional axially symmetric radiation hydrodynamic simulations to assess the impact of outflows and radiative force feedback from massive protostars by varying when the protostellar outflow starts, and to determine the ratio of ejection to accretion rates and the strength of the wide-angle disk wind component. The star-formation efficiency, i.e., the ratio of final stellar mass to initial core mass, is dominated by radiative forces and the ratio of outflow to accretion rates. Increasing this ratio has three effects. First, the protostar grows slower with a lower luminosity at any given time, lowering radiative feedback. Second, bipolar cavities cleared by the outflow become larger, further diminishing radiative feedback on disk and core scales. Third, the higher momentum outflow sweeps up more material from the collapsing envelope, decreasing the protostar's potential mass reservoir via entrainment. The star-formation efficiency varies with the ratio of ejection to accretion rates from 50% in the case of very weak outflows to as low as 20% for very strong outflows. At latitudes between the low-density bipolar cavity and the high-density accretion disk, wide-angle disk winds remove some of the gas, which otherwise would be part of the accretion flow onto the disk; varying the strength of these wide-angle disk winds, however, alters the final star-formation efficiency by only ±6%. For all cases, the opening angle of the bipolar outflow cavity remains below 20° during early protostellar accretion phases, increasing rapidly up to 65° at the onset of radiation pressure feedback.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2024

Low-cost Retrofit Kit for Integral Reciprocating Compressors (IRCs) to Reduce Emissions and Enhance Efficiency

Methane emissions from natural gas engines within the oil and gas industry pose a significant environmental challenge, contributing approximately 34.1 MMTCO2 eq to the total of 239 MMTCO2 eq of methane emissions in 2021, according to the EPA report. In response to this pressing issue, a collaborative effort involving the University of Oklahoma and key industry partners—WAGO Automation, Mid Continental Rental, Elipsa, and Perscient—has resulted in the development of a retrofit kit designed to reduce emissions from integral reciprocating compressors (IRCs), which are integrated compressors and engines. The retrofit kit developed comprises an Air Management System (AMS), Integrated Sensors, and a Cloud-Connected Control Unit with Graphical User Interface (GUI)/Human-Machine Interface (HMI). This solution enhances operational efficiency, reduces emissions, and expands the operational envelope of IRCs in the natural gas industry. The project successfully completed all tasks, including the installation of a full-size IRC at a designated site in Oklahoma, the development of an optimized AMS, integration of sensors, and implementation of a data acquisition system. Significant achievements include a notable reduction in CH 4 emissions, up to 84% at specific loads, and the successful deployment of the retrofit kit in diverse field conditions. The system's capabilities were enhanced through the creation of a feedback control algorithm for the AMS using a correlation matrix illustrating relationships between engine parameters, and the design of a predictive and preventive maintenance platform. The project concluded with the deployment of the entire retrofit kit to another location, confirming its effectiveness in reducing emissions and enhancing IRC performance. The comprehensive solution offers valuable benefits for IRCs, making them invaluable assets in the natural gas industry.

03 NATURAL GAS↗

DOE OSTI2022

Capsule network-based semantic segmentation model for thermal anomaly identification on building envelopes

Thermography technology is widely used to inspect thermal anomalies in building façade systems. Computer vision-based techniques provide opportunities to autonomously detect such heat anomalies to significantly improve the efficiency of decision-making for building envelope retrofitting and maintenance. Here, in this work, we propose a novel Capsule Network-based deep learning model – CapsLab – that detects and identifies thermal anomalies by semantic segmentation. CapsLab is built based on our proposed prediction-tuning capsule (PT-Capsule) layer. Different from a traditional capsule layer, which consists of part-whole transformation and capsule-routing process, the proposed layer is composed of a prediction and tuning process, which helps decreasing the number of model parameters significantly. While the applicability of traditional Capsule Networks (CapsNets) has been limited to simpler tasks and smaller datasets due to their scalability issue, we can leverage the lightweight of the proposed PT-Capsule layer, and apply it to the semantic segmentation task. In this work, we also employ our previously presented performance metric, referred to as the Anomaly Identification Metric (AIM) (Kakillioglua et al. 2021), to evaluate the segmentation outputs. Traditional performance metrics do not accurately reflect the true performance of the segmentation models in thermal anomaly identification due to the high subjectivity in the annotation process and higher overlap ratio sensitivity of the standard metrics. AIM, on the other hand, is robust to these drawbacks. Experimental results show, both qualitatively and quantitatively, that our proposed segmentation method can effectively segment the thermal anomalies. Specifically, our model provides 9.38% and 13.53% improvements over the baseline model – DeepLabV3+ – based on traditional mIoU score and the AIM score, respectively, while requiring less model parameters and less computation at the same time. In addition, the scores that the AIM metric generates better align with the scores provided by building performance experts.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2014

Advanced Small Modular Reactor (SMR) Probabilistic Risk Assessment (PRA) Demonstration

A key area of the Advanced Small Modular Reactor (SMR) Probabilistic Risk Assessment (PRA) strategy is the development of methodologies and tools that will be used to predict the safety, security, safeguards, performance, and deployment viability of SMRs. The goal of the SMR PRA activity will be to develop quantitative methods and tools and the associated analysis framework for assessing a variety of risks. Development and implementation of SMR-focused safety assessment methods may require new analytic methods or adaptation of traditional methods to the advanced design and operational features of SMRs. We will need to move beyond the current limitations such as static, logic-based models in order to provide more integrated, scenario-based models based upon predictive modeling which are tied to causal factors. The development of SMR-specific safety models for margin determination will provide a safety case that describes potential accidents, design options (including postulated controls), and supports licensing activities by providing a technical basis for the safety envelope. This report documents the progress that was made to implement the PRA framework, specifically by way of demonstration of an advanced 3D approach to representing, quantifying and understanding flooding risks to a nuclear power plant.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS2011

Planetary Gearbox Fault Detection Using Vibration Separation Techniques

Studies were performed to demonstrate the capability to detect planetary gear and bearing faults in helicopter main-rotor transmissions. The work supported the Operations Support and Sustainment (OSST) program with the U.S. Army Aviation Applied Technology Directorate (AATD) and Bell Helicopter Textron. Vibration data from the OH-58C planetary system were collected on a healthy transmission as well as with various seeded-fault components. Planetary fault detection algorithms were used with the collected data to evaluate fault detection effectiveness. Planet gear tooth cracks and spalls were detectable using the vibration separation techniques. Sun gear tooth cracks were not discernibly detectable from the vibration separation process. Sun gear tooth spall defects were detectable. Ring gear tooth cracks were only clearly detectable by accelerometers located near the crack location or directly across from the crack. Enveloping provided an effective method for planet bearing inner- and outer-race spalling fault detection.

Lewicki, David G.↗

NASA NTRS2019

Global Validation of Columnar Water Vapor Derived from EOS MODIS-MAIAC Algorithm Against the Ground-Based AERONET Observations

The water vapor is a relevant greenhouse gas in the Earth's climate system, and satellite products become one of the most effective way to characterize and monitor the columnar water vapor (CWV) content at global scale. Recently, a new product (MCD19) was released as part of MODIS (Moderate Resolution Imaging Spectroradiometer) Collection 6 (C6). This operational product from the Multi-Angle Implementation for Atmospheric Correction (MAIAC) algorithm includes a high 1-kilometer resolution CWV retrievals. This study presents the first global validation of MAIAC C6 CWV obtained from MODIS MCD19A2 product. This evaluation was performed using Aerosol Robotic Network (AERONET) observations at 265 sites (2000-2017). Overall, the results show a good agreement between MAIAC/AERONET CWV retrievals, with correlation coefficient higher than 0.95 and RMS (Root Mean Square) error lower than 0.250 centimeters. The binned error analysis revealed an underestimation (approximately 10 percent) of Aqua CWV retrievals with negative bias for CWV higher than 3.0 centimeters. In contrast, Terra CWV retrievals show a slope of regression close to unity and a low mean bias of 0.075 centimeters. While the accuracy is relatively similar between 1.0 and 5.0 centimeters for both sensor products, Terra dataset is more reliable for applications in humid tropical areas (less than 5.0 centimeters). The expected error was defined as plus or minus 15 percent, with less than 68 percent of retrievals falling within this envelope. However, the accuracy is regionally dependent, and lower error should be expected in some regions, such as South America and Oceania. Since MODIS instruments have exceeded their design lifetime, time series analysis was also presented for both sensor products. The temporal analysis revealed a systematic offset of global average between Terra and Aqua CWV records. We also found an upward trend (approximately 0.2 centimeters per decade) in Terra CWV retrievals, while Aqua CWV retrievals remain stable over time. The sensor degradation influences the ability to detect climate signals, and this study indicates the need for revisiting calibration of the MODIS bands 17-19, mainly for Terra instrument, to assure the quality of the MODIS water vapor product. Finally, this study presents a comprehensive validation analysis of MAIAC CWV over land, raising the understanding of its overall quality.

MAIAC↗

DOE OSTI2014

Using Whole-House Field Tests to Empirically Derive Moisture Buffering Model Inputs

Building energy simulations can be used to predict a building's interior conditions, along with the energy use associated with keeping these conditions comfortable. These models simulate the loads on the building (e.g., internal gains, envelope heat transfer), determine the operation of the space conditioning equipment, and then calculate the building's temperature and humidity throughout the year. The indoor temperature and humidity are affected not only by the loads and the space conditioning equipment, but also by the capacitance of the building materials, which buffer changes in temperature and humidity. This research developed an empirical method to extract whole-house model inputs for use with a more accurate moisture capacitance model (the effective moisture penetration depth model). The experimental approach was to subject the materials in the house to a square-wave relative humidity profile, measure all of the moisture transfer terms (e.g., infiltration, air conditioner condensate) and calculate the only unmeasured term: the moisture absorption into the materials. After validating the method with laboratory measurements, we performed the tests in a field house. A least-squares fit of an analytical solution to the measured moisture absorption curves was used to determine the three independent model parameters representing the moisture buffering potential of this house and its furnishings. Follow on tests with realistic latent and sensible loads showed good agreement with the derived parameters, especially compared to the commonly-used effective capacitance approach. These results show that the EMPD model, once the inputs are known, is an accurate moisture buffering model.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2014

Using Whole-House Field Tests to Empirically Derive Moisture Buffering Model Inputs

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2018

Thermal characterization of full-scale PCM products and numerical simulations, including hysteresis, to evaluate energy impacts in an envelope application

This article presents combined measurements of fatty acid-based organic PCM products and numerical simulations to evaluate the energy benefits of adding a PCM layer to an exterior wall. The thermal storage characteristics of the PCM were measured using a heat flow meter apparatus (HFMA). The PCM characterization is based on a recent ASTM International standard test method, ASTM C1784. The PCM samples were subjected to step changes in temperature and allowed to stabilize at each temperature. By measuring the heat absorbed or released by the PCM, the temperature-dependent enthalpy functions for melting and freezing were determined.Here, the simulations were done using a previously-validated two-dimensional (2D) wall model containing a PCM layer and incorporating the HFMA-measured enthalpy functions. The wall model was modified to include the hysteresis phenomenon observed in PCMs, which is reflected in different melting and freezing temperatures of the PCM. Simulations were done with a single enthalpy curve based on the PCM melting tests, both melting and freezing enthalpy curves, and with different degrees of hysteresis between the melting and freezing curves. Significant differences were observed between the thermal performances of the modeled wall with the PCM layer under the different scenarios.

2D wall model with PCM↗

DOE OSTI2020

Experiments and simulations of isochorically heated warm dense carbon foam at the Texas Petawatt Laser

An experimental and simulation study of warm dense carbon foams at ambient density (n e ~10 21 cm –3 ) is presented. This study of isochorically heated foams is motivated by their potential application in carbon-atmosphere white-dwarf envelopes, where there are modeling uncertainties due to the equation of state. The foams are heated on an approximately picosecond time scale with a laser-accelerated proton beam. The cooling and expansion of the heated foams can be modeled with appropriately initialized radiation-hydrodynamics codes; xRAGE code is used in this work. The primary experimental diagnostic is the streaked optical pyrometer, which images a narrow band of radiation from the rear surface of the heated material. Presented are xRAGE modeling results for both solid aluminum targets and carbonized resorcinol-formaldehyde foam targets, showing that the foam appears to cool slowly on the pyrometer because of partial transparency. So that simulations of cooling foam are processed properly, it is necessary to account for finite optical depth in the photosphere calculation, and the methods for performing that calculation are presented in depth.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Orthogonal chemical genomics approaches reveal genomic targets for increasing anaerobic chemical tolerance in Zymomonas mobilis

Genetically engineered microbes have the potential to increase efficiency in the bioeconomy by overcoming growth-limiting production stress. Screens of gene perturbation libraries against production stressors can identify high-value engineering targets, but follow-up experiments needed to guard against false positives are slow and resource-intensive. In principle, the use of orthogonal gene perturbation approaches could increase recovery of true positives over false positives because the strengths of one technique compensate for the weaknesses of the other, but, in practice, two parallel screens are rarely performed at the genome scale. Here, we screen genome-scale CRISPRi (CRISPR interference) knockdown and transposon insertion libraries of the bioenergy-relevant Alphaproteobacterium, Zymomonas mobilis, against growth inhibitors commonly found in deconstructed plant material. Integrating data from the two gene perturbation techniques, we established an approach for defining engineering targets with high specificity. This allowed us to identify all known genes in the cytochrome bc1 and cytochrome c synthesis pathway as potential targets for engineering resistance to phenolic acids under anaerobic conditions, a subset of which we validated using precise gene deletions. Strikingly, this finding is specific to the cytochrome bc1 and cytochrome c pathway and does not extend to other branches of the electron transport chain. We further show that exposure of Z. mobilis to ferulic acid causes substantial remodeling of the cell envelope proteome, as well as the downregulation of TonB-dependent transporters. Our work provides a generalizable strategy for identifying high-value engineering targets from gene perturbation screens that is broadly applicable.

CRISPRi↗

NASA NTRS2016

Extending the Operational Envelope of a Turbofan Engine Simulation into the Sub-Idle Region

In many non-linear gas turbine simulations, operation in the sub-idle region can lead to model instability. This paper lays out a method for extending the operational envelope of a map based gas turbine simulation to include the sub-idle region. This method develops a multi-simulation solution where the baseline component maps are extrapolated below the idle level and an alternate model is developed to serve as a safety net when the baseline model becomes unstable or unreliable. Sub-idle model development takes place in two distinct operational areas, windmilling/shutdown and purge/cranking/startup. These models are based on derived steady state operating points with transient values extrapolated between initial (known) and final (assumed) states. Model transitioning logic is developed to predict baseline model sub-idle instability, and transition smoothly and stably to the backup sub-idle model. Results from the simulation show a realistic approximation of sub-idle behavior as compared to generic sub-idle engine performance that allows the engine to operate continuously and stably from shutdown to full power.

gas path dynamics↗

NASA NTRS2016

Extending the Operational Envelope of a Turbofan Engine Simulation into the Sub-Idle Region

In many non-linear gas turbine simulations, operation in the sub-idle region can lead to model instability. This paper lays out a method for extending the operational envelope of a map based gas turbine simulation to include the sub-idle region. This method develops a multi-simulation solution where the baseline component maps are extrapolated below the idle level and an alternate model is developed to serve as a safety net when the baseline model becomes unstable or unreliable. Sub-idle model development takes place in two distinct operational areas, windmilling/shutdown and purge/cranking/ startup. These models are based on derived steady state operating points with transient values extrapolated between initial (known) and final (assumed) states. Model transitioning logic is developed to predict baseline model sub-idle instability, and transition smoothly and stably to the backup sub-idle model. Results from the simulation show a realistic approximation of sub-idle behavior as compared to generic sub-idle engine performance that allows the engine to operate continuously and stably from shutdown to full power.

aerothermodynamics↗

DOE OSTI2021

Development of Additively Manufactured Complex Tools for Autoclave Cure Composites

IACMI Project 4.9, Tooling for Composites with Washout Features Produced by Additive Manufacturing, assembled a team including the industry lead, Ability Composites, NREL and Colorado State University (CSU). Ability Composites had originally expressed interest in alternate methods of producing tooling for composite parts. In follow-up discussions, it became clear that one of the bigger tooling challenges revolved around small production volume composite parts that were tooled on washout material due to the complex geometry. To build an understanding of the potential, both from a technology and a cost perspective, for replacing conventional washout tooling with 3D printed thermoplastic tooling, a number of commercially available dissolvable FDM printing materials were evaluated, leading to tooling representative of commercial articles of interest to Ability Composites. Ultimately, Ability Composites was able to directly compare autoclave processed prepreg composite parts produced on conventional washout tooling to composite parts molded on 3D printed dissolvable tooling produced at CSU. Small, laboratory test specimens were developed to investigate the structural performance of the candidate materials under autoclave processing conditions, which were nominally 121 °C (250 °F) and 345 kPa (50 psi). In addition, several internal structural configurations (infills) were evaluated under autoclave conditions using model materials. The results of these tests indicated that two materials, Stratasys ST 130 and Infinite Materials Solutions Aquasys 180 (AQ 180), were the best candidates, given the specified autoclave processing conditions. ST-130 was slightly more robust than AQ-180; however, the AQ-180 was carried forward as it was dissolvable in water, not requiring the basic solution needed to dissolve ST-130. Based on the preliminary material and 3D printed structures evaluations, larger tools with a truncated square pyramid geometry were created to produce prepreg composite test articles for 3D printed dissolvable tool evaluation under standard autoclave fabrication conditions. Two tools were manufactured using ST-130 and one tool using traditional ceramic washout tooling media. The tools were evaluated for geometric fidelity and surface roughness changes before and after carbon fiber/epoxy prepreg composites were manufactured on the tooling. The autoclave processing did not impact the geometry significantly and was completed at 121 °C and 345 kPa, indicating satisfactory tool performance. The results from surface roughness testing of both the resulting composite and the associated tooling indicated that an adequate surface resulted without the need for a surface sealing step, as was required for the conventional washout tooling. Based on results of the truncated pyramid tests as a basis, ST-130, AQ-120 and AQ-180 materials were carried forward to the tool geometry of interest to Ability Composites. These hollow rectangular bent ducts, which were complex in nature and not extractable after cure, were used to understand the impacts of tool material and thickness. One ST-130 tool was produced as a partially solid part, with an enclosed 40% dense infill region to reduce weight and material use. This was the same approach evaluated in the truncated pyramid portion of the study. This tool was to be envelope vacuum bagged and directly compared to a monolithic tool of conventional washout material. The traditional monolithic ceramic tool was manufactured by Ability composites using CNC-based subtractive methods. An additional five dissolvable polymer tools, manufactured from ST-130, AQ-120, and AQ-180, using a hollow design were 3D printed and used to produce carbon fiber/epoxy composite evaluation articles. These hollow dissolvable tools were expected to be less influenced by the autoclave conditions as the wall was solid and vacuum bagging was inside and outside the tool. This alternative geometry was also evaluated as an option in techno-economic modeling. Print times were reduced from in excess of 3 days to under 30 hours, while surface quality and and tool integrity were substantially improved in the transition from the partially solid tool to the hollow tooling concept. Ability Composites produced autoclave-cured prepreg ducts on each of these tools. The autoclave conditions utilized were more severe than those of the initial trials, reaching temperatures of 160 °C and a pressure of 414 kPa. Under these conditions, the partially solid 3D printed tool with skin and 40% dense infill crushed significantly; however, the thicker ST-130 hollow tool showed good promise, deforming only slightly. The thinner hollow tool walls were unsuccessful as were the other materials. Overall, the hollow tool manufacturing process saved significant amounts of time and material in manufacturing as compared to the solid ducts and produced composite surface quality improvements compared to the traditional washout tooling. The TEM was developed to allow direct comparisons between conventional washout tool manufacturing processes and those developed at CSU. It also allowed for two separate 3D printed tool geometries to be analyzed and compared. In this case, the square bent duct tool geometry was determined to be representative of common washout tools. This geometry was compared with a scaled-up version of it to assess differences in the two manufacturing processes based on tool size. The model was developed to make use of user input in the form of geometry details, process steps, manufacturing parameters, bulk material costs, capital equipment costs, and general costs to calculate overall labor, material, capital equipment, and energy costs per manufactured tool for the conventional and additive manufacturing processes for the two representative geometries. It was also able to estimate step-by-step process times for the manufacturing process and geometries. Based on significant input from Ability Composites and CSU from their knowledge gained from hands-on manufacturing of the 3D printed bent duct tool geometry, costs and process times were calculated for the two manufacturing processes. Results showed that the additive manufacturing techniques developed at CSU can substantially reduce the costs of tool manufacturing by reducing labor times and material usage. This is because additive manufacturing is a relatively hands-off process and allows for the tool design to be optimized to reduce material usage. The disadvantage, however, is that process times for additive manufacturing are significantly longer. The three-dimensional (3D) printing process is slow if tight tolerances are required, but the analysis did show that print times could be reduced with the hollow tool geometry. Also, further advances in additive manufacturing could expedite the process. Costs and process times for the tool washout process were calculated separately. They showed that costs are relatively insignificant when compared to the overall tool manufacturing processes, but with increases in tool size, costs for the conventional manufacturing approach are larger than for additive manufacturing. Again, the washout process for conventional tools is very hands-on, whereas for additively manufactured tools the print medium is dissolved in an automated detergent bath at the sacrifice of process time. The analysis showed that optimizing the additively manufactured tools may also reduce washout times. Overall, Project 4.9 demonstrated that commercially available dissolvable 3D printing materials exist that can be used to produce dissolvable tooling capable of surviving prepreg composites fabrication under autoclave conditions of 121 °C (250 °F) and 345 kPa (50 psi). An alternative hollow dissolvable tool design was developed which was structurally superior to the initial concept and was cost and time effective versus conventional washout tooling. The 3D printed sacrificial tool required no added surface sealing steps prior to composite part layup and cure, offering a significant advantage over the porous conventional washout tooling.

36 MATERIALS SCIENCE↗

NASA NTRS1994

F/A-18 forebody vortex control. Volume 2: Rotary-balance tests

A rotary-balance wind tunnel test was conducted on a six percent model of the F/A-18 at the NASA Ames 7 X 10-Foot Low Speed Wind Tunnel. The data reduction was specially written for the test in National Instruments' LabVIEW. The data acquisition, reduction and analysis was performed with a Macintosh computer. The primary objective of the test was to evaluate the effectiveness of several forebody vortex control configurations in a rotary flow field. The devices that were found to be the most effective during the static tests (Volume 1) were investigated and included both mechanical and pneumatic configurations. The mechanical systems evaluated were small, single and dual, rotating nose tip strakes and a vertical nose strake. The jet blowing configuration used nozzles canted inboard 60 degrees. A two segment tangential slot was also evaluated. The different techniques were evaluated at angles of attack of 30 degrees, 45 degrees, 51 degrees, and 60 degrees. Sideslip and Reynolds number were varied for some of the configurations. All of the techniques proved to be effective in the rotating flow field. The vertical nose strake had the largest 'envelope' of effectiveness. Forebody vortex control provides large, robust yawing moments at medium to high angles of attack, even during combat maneuvers such as loaded roll.

Kramer, Brian R.↗

NASA NTRS2002

Flight Evaluation of the Army/NASA Variable Stability Fly-by-Wire Rotorcraft Aircrew Systems Concept Airborne Laboratory (RASCAL) JUH-60A

NASA Ames Research Center and the U.S. Army Aeroflight dynamics Directorate (AFDD) have performed initial flight evaluations of the Research Flight Control System (RFCS) integrated into the Army/NASA Rotorcraft Aircrew Systems Concepts Airborne Laboratory (RASCAL) JUH-GOA. The highly modified JUH-GOA Black Hawk helicopter is a full authority, high bandwidth, variable stability, in-flight simulator designed to support development of advanced flight control, sensor, and integrated display and control technologies in a fail safe environment. Preparation for flight test required an extensive hazard analysis and ground testing to ensure proper system operation. A hardware in the loop development facility was utilized to evaluate control law stability following software changes, assess servo hardover upset conditions during manual and monitor disengagements and provide pilot familiarization of test techniques and software changes prior to flight. First engagement of the RFCS was conducted on 31 Aug 2001. RFCS transfer system operation, envelope expansion and a limited rate monitor evaluation have been completed with low bandwidth and model following control laws. The presentation will discuss the following - System overview including aircraft modifications and integrated development facilities used with the RASCAL facility. - Preliminary hazard identification and mitigation prior to flight test. - Ground testing used to qualify the RFCS transfer system and verify fault monitor operation. - Flight test results of low-bandwidth and model following control law evaluations including maneuver agility, control limitations, fault monitor reliability, and recovery from manual and monitor disengagement. - Lessons learned including test techniques using a passive three-axis sidearm controller, the value of the development facility in reducing risk and crew coordination issues related to the operation of a full authority, variable stability platform. - Future research and modifications planned for the RASCAL aircraft.

Dave Arterburn↗