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Results for “Casting Modeling Simulation”

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.

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NASA NTRS1989

Comparison of NAE porous wall and NASA adaptive wall test results using the NAE CAST-10 airfoil model

Wind tunnels can now simulate flows over airfoils at high Reynolds numbers and high subsonic speeds. Methods to correct for (or reduce) test section wall interference at these test conditions must be validated. The National Aeronautics Establishment (NAE) of Canada and NASA have a cooperative agreement to study this area. The NAE designed, built, and tested a CAST-10 airfoil model in its conventional Two-Dimensional High Reynolds Number Facility. The results were corrected using classical correction techniques. NASA then tested the same model in its 0.3-meter Transonic Cryogenic Tunnel with the adaptive wall test section. The adaptive wall test section reduced the wall interference to what was expected to be an acceptable level. The corrected NAE results are compared with the uncorrected NASA results. The NAE results are also compared with NASA results after residual corrections for top and bottom wall interference. Finally, a comparison of both sets of results corrected for interference from all four walls is presented.

Mineck, Raymond E.↗

NASA NTRS2016

Modeling SMAP Spacecraft Attitude Control Estimation Error Using Signal Generation Model

Two ground simulation software are used to model the SMAP spacecraft dynamics. The CAST software uses a higher fidelity model than the ADAMS software. The ADAMS software models the spacecraft plant, controller and actuator models, and assumes a perfect sensor and estimator model. In this simulation study, the spacecraft dynamics results from the ADAMS software are used as CAST software is unavailable. The main source of spacecraft dynamics error in the higher fidelity CAST software is due to the estimation error. A signal generation model is developed to capture the effect of this estimation error in the overall spacecraft dynamics. Then, this signal generation model is included in the ADAMS software spacecraft dynamics estimate such that the results are similar to CAST. This signal generation model has similar characteristics mean, variance and power spectral density as the true CAST estimation error. In this way, ADAMS software can still be used while capturing the higher fidelity spacecraft dynamics modeling from CAST software.

Soil Moisture Active Passive↗

NASA NTRS2010

Aerodynamic Simulation of Runback Ice Accretion

This report presents the results of recent investigations into the aerodynamics of simulated runback ice accretion on airfoils. Aerodynamic tests were performed on a full-scale model using a high-fidelity, ice-casting simulation at near-flight Reynolds (Re) number. The ice-casting simulation was attached to the leading edge of a 72-in. (1828.8-mm ) chord NACA 23012 airfoil model. Aerodynamic performance tests were conducted at the ONERA F1 pressurized wind tunnel over a Reynolds number range of 4.7?10(exp 6) to 16.0?10(exp 6) and a Mach (M) number ran ge of 0.10 to 0.28. For Re = 16.0?10(exp 6) and M = 0.20, the simulated runback ice accretion on the airfoil decreased the maximum lift coe fficient from 1.82 to 1.51 and decreased the stalling angle of attack from 18.1deg to 15.0deg. The pitching-moment slope was also increased and the drag coefficient was increased by more than a factor of two. In general, the performance effects were insensitive to Reynolds numb er and Mach number changes over the range tested. Follow-on, subscale aerodynamic tests were conducted on a quarter-scale NACA 23012 model (18-in. (457.2-mm) chord) at Re = 1.8?10(exp 6) and M = 0.18, using low-fidelity, geometrically scaled simulations of the full-scale castin g. It was found that simple, two-dimensional simulations of the upper- and lower-surface runback ridges provided the best representation of the full-scale, high Reynolds number iced-airfoil aerodynamics, whereas higher-fidelity simulations resulted in larger performance degrada tions. The experimental results were used to define a new subclassification of spanwise ridge ice that distinguishes between short and tall ridges. This subclassification is based upon the flow field and resulting aerodynamic characteristics, regardless of the physical size of the ridge and the ice-accretion mechanism.

Broeren, Andy P.↗

NASA NTRS1988

A case study of large-scale structure in a 'hot' model universe

Large-scale structure is studied in an Omega(0) = 1 model universe filled with 'hot' dark matter. A particle mesh computer code is used to calculate the development of gravitational instabilities in 64-cubed mass clouds on a 64-cubed three-dimensional grid over an expansion factor of about 1000. The present epoch is identified by matching the slope of the model particle-particle two-point correlation function with that obtained from observations of galaxies, and the model then corresponds to a cubical sample of the universe of about 105/h Mpc on a side. Properties of the simulated universe are investigated by casting the model quantities into observer's coordinates and comparing the results with observations of the spatial and velocity distributions of luminous matter. It is concluded based on simple arguments that current limits on the time of galaxy formation do not rule out 'hot' dark matter.

Centrella, Joan M.↗

NASA NTRS1992

Development of a CFD code for casting simulation

The task of developing a computational fluid dynamics (CFD) code to accurately model the mold filling phase of a casting operation was accomplished in a systematic manner. First the state-of-the-art was determined through a literature search, a code search, and participation with casting industry personnel involved in consortium startups. From this material and inputs from industry personnel, an evaluation of the currently available codes was made. It was determined that a few of the codes already contained sophisticated CFD algorithms and further validation of one of these codes could preclude the development of a new CFD code for this purpose. With industry concurrence, ProCAST was chosen for further evaluation. Two benchmark cases were used to evaluate the code's performance using a Silicon Graphics Personal Iris system. The results of these limited evaluations (because of machine and time constraints) are presented along with discussions of possible improvements and recommendations for further evaluation.

Murph, Jesse E.↗

NASA NTRS1997

Heat Transfer Measurements on Surfaces with Natural Ice Castings and Modeled Roughness

An experimental method is described to measure and compare the convective heat transfer coefficient of natural and simulated ice accretion roughness and to provide a rational means for determining accretion-related enhanced heat transfer coefficients. The natural ice accretion roughness was a sample casting made from accretions at the NASA Lewis Icing Research Tunnel (IRT). One of these castings was modeled using a Spectral Estimation Technique (SET) to produce three roughness elements patterns that simulate the actual accretion. All four samples were tested in a flat-plate boundary layer at angle of attack in a "dry" wind tunnel test. The convective heat transfer coefficient was measured using infrared thermography. It is shown that, dispite some problems in the current data set, the method does show considerable promise in determining roughness-induced heat transfer coefficients, and that, in addition to the roughness height and spacing in the flow direction, the concentration and spacing of elements in the spanwise direction are important parameters.

Breuer, Kenneth S.↗

NASA NTRS1976

Analysis of the survivability of the shuttle (ALT) fault-tolerant avionics system

An extension of the Complementary-Analytic-Simulative Technique (CAST) is presented which is applicable to the Shuttle Data Processing Subsystem (DPS). A two step process was used. The first step provides models, both analytic and simulative, for analysis of the Approach-Landing Test (ALT) configuration. The ALT modeling and analysis are presented. Since CAST had already been shown to be multicomputer systems, the emphasis was placed on extending the CAST concept so it is applicable to computer systems including the multiplicity of input and output devices found in a real-time control system application. The DPS mission-critical survivability for a six-hour mission was determined to be 0.999863 for the Shuttle ALT baseline configuration. Thus it can be said that for ALT, the survivability is adequate. However, the fact that orbiting missions of up to 30 days are planned illustrates the necessity of extending the ALT work to be applicable to OFT and actual mission scenarios. The above analysis led to the evaluation of three selected options which identified two areas of possible improvement. These improvements would result from use of a recovery technique which combines roll ahead with memory copy, and increased TACAN fault detectability.

Source record↗

NASA NTRS1984

Development of a VOR/DME model for an advanced concepts simulator

The report presents a definition of a VOR/DME, airborne and ground systems simulation model. This description was drafted in response to a need in the creation of an advanced concepts simulation in which flight station design for the 1980 era can be postulated and examined. The simulation model described herein provides a reasonable representation of VOR/DME station in the continental United States including area coverage by type and noise errors. The detail in which the model has been cast provides the interested researcher with a moderate fidelity level simulator tool for conducting research and evaluation of navigator algorithms. Assumptions made within the development are listed and place certain responsibilities (data bases, communication with other simulation modules, uniform round earth, etc.) upon the researcher.

Steinmetz, G. G.↗

NASA NTRSDate not supplied

3D Phase-Field Simulations of Pattern Formation During Freeze Casting

We present the results of a combined experimental and phase-field modeling study of pattern formation during freeze casting. Those studies use unidirectional freezing of simple binary liquid mixtures of water and sugars (sucrose and trehalose) in a temperature gradient, which suffice to produce hierarchical templated structures similar to those observed in more complex multi-component freeze-cast systems including lamellae, undulated ridges, and more exotic “jellyfish-like” substructures. Multiscale 3D phase-field simulations reproduce remarkably well those structures quantitatively and identify key properties of the ice-water interface that control their formation. They further reveal that lamellae form as a result of a novel symmetry-breaking secondary instability of partially faceted cellular structures and pinpoint additional secondary instability mechanisms giving rise to smaller-scale substructures.

Kaihua Ji↗

NASA NTRSDate not supplied

3D Phase-Field Simulations of Pattern Formation During Freeze Casting

Kaihua Ji↗

NASA NTRS1993

Thermosolutal convection and macrosegregation in dendritic alloys

A mathematical model of solidification, that simulates the formation of channel segregates or freckles, is presented. The model simulates the entire solidification process, starting with the initial melt to the solidified cast, and the resulting segregation is predicted. Emphasis is given to the initial transient, when the dendritic zone begins to develop and the conditions for the possible nucleation of channels are established. The mechanisms that lead to the creation and eventual growth or termination of channels are explained in detail and illustrated by several numerical examples. A finite element model is used for the simulations. It uses a single system of equations to deal with the all-liquid region, the dendritic region, and the all-solid region. The dendritic region is treated as an anisotropic porous medium. The algorithm uses the bilinear isoparametric element, with a penalty function approximation and a Petrov-Galerkin formulation. The major task was to develop the solidification model. In addition, other tasks that were performed in conjunction with the modeling of dendritic solidification are briefly described.

Poirier, David R.↗

NASA NTRS1982

Changes in blood volume and response to vaso-active drugs in horizontally casted primates

Experiments were performed on horizontally casted primates (male rhesus monkeys) in order to note changes in blood volume caused by horizontal restraint, to compare orthostatic tolerance before and after casting using the responses to upright tilting, to begin to uncover the cardiovascular and neural mechanisms involved in deconditioning, and to compare the data with that obtained from bed-rested human subjects and from humans exposed to weightlessness. Bolus injections of norepinephrine of 2.0 microgram/kg, phenylephrine of 4.0 microgram/kg, and nitroprusside of 2.0 microgram/kg were administered; and aortic pressure and heart rate were recorded during the injections. The results indicate that the horizontally casted primate is a valid animal model for studying the effects of simulated zero-G on the human cardiovascular system.

Dickey, D. T.↗

NASA NTRS2002

Nonlinear Internal Waves in the South China Sea During ASIAEX

Internal wave distribution maps have been compiled from more than one hundred ERS-1/2, RADARSAT and Space Shuttle SAR images in the South China Sea (SCS) from 1993 to 2000. Based on these distribution maps, most of internal waves in the northeast part of SCS were propagating westward. The wave crest can be as long as 200 km with amplitude of 100 m, due to strong current from the Kuroshio branching out into the SCS. In recent Asian Seas International Acoustics Experiment (ASIAEX), moorings have been deployed in April 2000 and May 2001. Simultaneous RADARSAT ScanSAR images have been collected during the field test to integrate with the model and the in-situ measurements in the SCS. During ASIAEX in May 2001, many large internal waves were observed at the test area and were the major features for acoustic volume interaction. The environmental parameters have been calculated based on extensive CTD castings and mooring data. Nonlinear internal wave models have been applied to simulate the wave evolution on the continental shelf and the results compare reasonably with mooring measurements. The evolution and dissipation of huge internal waves on the shelf break, mode-two waves, elevation waves, and wave-wave interaction are very important issues for acoustic propagation. The implication of internal wave effects on acoustic propagation will also be discussed.

ACOUSTIC PROPAGATION↗

NASA NTRS1993

Development of a CFD code for casting simulation

Because of high rejection rates for large structural castings (e.g., the Space Shuttle Main Engine Alternate Turbopump Design Program), a reliable casting simulation computer code is very desirable. This code would reduce both the development time and life cycle costs by allowing accurate modeling of the entire casting process. While this code could be used for other types of castings, the most significant reductions of time and cost would probably be realized in complex investment castings, where any reduction in the number of development castings would be of significant benefit. The casting process is conveniently divided into three distinct phases: (1) mold filling, where the melt is poured or forced into the mold cavity; (2) solidification, where the melt undergoes a phase change to the solid state; and (3) cool down, where the solidified part continues to cool to ambient conditions. While these phases may appear to be separate and distinct, temporal overlaps do exist between phases (e.g., local solidification occurring during mold filling), and some phenomenological events are affected by others (e.g., residual stresses depend on solidification and cooling rates). Therefore, a reliable code must accurately model all three phases and the interactions between each. While many codes have been developed (to various stages of complexity) to model the solidification and cool down phases, only a few codes have been developed to model mold filling.

Murph, Jesse E.↗

NASA NTRS2017

Macrosegregation Resulting from Directional Solidification Through an Abrupt Change in Cross-Sections

Simulations of the directional solidification of two hypoeutectic alloys (Al-7Si alloy and Al-19Cu) and resulting macrosegregation patterns are presented. The casting geometries include abrupt changes in cross-section from a larger width of 9.5 mm to a narrower 3.2 mm width then through an expansion back to a width of 9.5 mm. The alloys were chosen as model alloys because they have similar solidification shrinkages, but the effect of Cu on changing the density of the liquid alloy is about an order of magnitude greater than that of Si. The simulations compare well with experimental castings that were directionally solidified in a graphite mold in a Bridgman furnace. In addition to the simulations of the directional solidification in graphite molds, some simulations were effected for solidification in an alumina mold. This study showed that the mold must be included in numerical simulations of directional solidification because of its effect on the temperature field and solidification. For the model alloys used for the study, the simulations clearly show the interaction of the convection field with the solidifying alloys to produce a macrosegregation pattern known as "steepling" in sections with a uniform width. Details of the complex convection- and segregation-patterns at both the contraction and expansion of the cross-sectional area are revealed by the computer simulations. The convection and solidification through the expansions suggest a possible mechanism for the formation of stray grains. The computer simulations and the experimental castings have been part of on-going ground-based research with the goal of providing necessary background for eventual experiments aboard the ISS. For casting practitioners, the results of the simulations demonstrate that computer simulations should be applied to reveal interactions between alloy solidification properties, solidification conditions, and mold geometries on macrosegregation. The simulations also presents the possibility of engineering the mold-material to avoid, or mitigate, the effects of thermosolutal convection and macrosegregation by selecting a mold material with suitable thermal properties, especially its thermal conductivity.

Lauer, M.↗

NASA NTRS1995

Transitional flow in thin tubes for space station freedom radiator

A two dimensional finite volume method is used to predict the film coefficients in the transitional flow region (laminar or turbulent) for the radiator panel tubes. The code used to perform this analysis is CAST (Computer Aided Simulation of Turbulent Flows). The information gathered from this code is then used to augment a Sinda85 model that predicts overall performance of the radiator. A final comparison is drawn between the results generated with a Sinda85 model using the Sinda85 provided transition region heat transfer correlations and the Sinda85 model using the CAST generated data.

Loney, Patrick↗

NASA NTRS2010

Application of a Near Infrared Imaging System for Thermographic Imaging of the Space Shuttle during Hypersonic Re-Entry

High resolution calibrated near infrared (NIR) imagery was obtained of the Space Shuttle s reentry during STS-119, STS-125, and STS-128 missions. The infrared imagery was collected using a US Navy NP-3D Orion aircraft using a long-range infrared optical package referred to as Cast Glance. The slant ranges between the Space Shuttle and Cast Glance were approximately 26-41 nautical miles at point of closest approach. The Hypersonic Thermodynamic Infrared Measurements (HYTHIRM) project was a NASA Langley led endeavor sponsored by the NASA Engineering Safety Center, the Space Shuttle Program Office and the NASA Aeronautics Research Mission Directorate to demonstrate a quantitative thermal imaging capability. HYTHIRM required several mission tools to acquire the imagery. These tools include pre-mission acquisition simulations of the Shuttle trajectory in relationship to the Cast Glance aircraft flight path, radiance modeling to predict the infrared response of the Shuttle, and post mission analysis tools to process the infrared imagery to quantitative temperature maps. The spatially resolved global thermal measurements made during the Shuttle s hypersonic reentry provides valuable flight data for reducing the uncertainty associated with present day ground-to-flight extrapolation techniques and current state-of-the-art empirical boundary-layer transition or turbulent heating prediction methods. Laminar and turbulent flight data is considered critical for the development of turbulence models supporting NASA s next-generation spacecraft. This paper will provide the motivation and details behind the use of an upgraded NIR imaging system used onboard a Navy Cast Glance aircraft and describe the characterizations and procedures performed to obtain quantitative temperature maps. A brief description and assessment will be provided of the previously used analog NIR camera along with image examples from Shuttle missions STS-121, STS-115, and solar tower test. These thermal observations confirmed the challenge of a long-range acquisition during re-entry. These challenges are due to unknown atmospheric conditions, image saturation, vibration etc. This provides the motivation for the use of a digital NIR sensor. The characterizations performed on the digital NIR sensor included radiometric, spatial, and spectral measurements using blackbody radiation sources and known targets. An assessment of the collected data for three Space Shuttle atmospheric re-entries, STS-119, STS-125, and STS-128, are provided along with a description of various events of interest captured using the digital NIR imaging system such as RCS firings and boundary layer transitions. Lastly the process used to convert the raw image counts to quantitative temperatures is presented along with comparisons to the Space Shuttle's onboard thermocouples.

Zalameda, Joseph N.↗

NASA NTRS2024

Distributed Sand-Grain Roughness Effects on Blunt Body Hypersonic Transition and Heating

An experimental investigation of distributed sand-grain surface roughness effects on boundary-layer transition and convective heating has been performed. Two representative entry vehicle geometries, a spherical-cap aeroshell and a sphere-cone aeroshell, were considered. Multiple cast ceramic wind tunnel models of each geometry were fabricated with various roughness heights to simulate an ablated thermal protection system. Wind tunnel testing was performed at Mach 6 over a range of Reynolds numbers sufficient to produce laminar, transitional, and turbulent flow. Aeroheating and boundary-layer transition onset data were obtained using global phosphor thermography. The experimental heating data are presented herein, as are comparisons to laminar and turbulent smooth-wall heat transfer distributions from computational flow field simulations.

Brian R. Hollis↗