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Results for “BENDING MOMENT”

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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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Reduction of baseplate distortion during directed energy deposition using compliant features

Distortion in additive manufacturing (AM) remains a barrier to its adoption in precision industries. Baseplate warpage is one such issue which compromises the feasibility of post-process precision machining. The restriction to thermal contraction of the deposited part, imposed by the baseplate, generates bending moments, that in turn causes warpage. A novel distortion mitigation strategy using baseplates with integrated compliant features, which enables thermal contraction of the build is presented. Six unique design concepts are evaluated, including a solid reference, using two deposition geometries. A laser, hot-wire, directed energy deposition (DED) process is used to deposit a symmetric cylindrical part (C-part) and a T-shaped asymmetric part (T-part). Flatness deviation of baseplates is measured using structured light 3D scanning. Measurements reveal a reduction in net flatness deviation of 58.8% for the C-part and 40.9% for the T-part, compared to the solid reference. While most designs yielded reductions exceeding 30% and 20% for the C- and T-parts, respectively, one configuration resulted in increased deviation. Finite element (FE) simulations are performed to elucidate the underlying mechanisms affecting distortion of compliant baseplates during DED. Despite variations between predictions and measurements, agreement in the general trend is observed. It also revealed that initial flatness errors in baseplates significantly affect its deviation during deposition. Predictions indicate that compliant features significantly affect the thermal distribution as well as the evolution of flatness deviation in the baseplate during deposition. Notably, one design exhibited a reduction in distortion during cooling, following its initial increase during deposition. FE predictions show a maximum reduction of 60.9% and 38.8% in net flatness deviation for the C- and T-parts, respectively. The performance of compliant baseplates is found to be governed by both its the thermal and mechanical characteristics, which are crucial factors to be considered during design.

Mathews, Ritin [ORNL] (ORCID:0000000301440828)↗
DOE OSTI2026

Performance assessment of 3D printed multi-material energy absorber for automotive bumper: pedestrian lower extremity protection

Designing an energy absorber for automotive bumpers involves balancing low-speed and high-speed impacts to ensure safety, reduce repair costs, and meet regulatory standards. Here, this study explores a novel design using multi-material 3D printing and structural optimization to fabricate a lightweight and cost-efficient energy absorber. The design effectively dissipates energy in low-speed collisions and minimizes force transmission in high-speed pedestrain impacts, helping to meet both safety and performance requirements. The energy absorber design combines 20% carbon fiber-reinforced acrylonitrile butadiene styrene (CF-ABS) and thermoplastic polyurethane (TPU) for optimal stiffness and flexibility. It uses 3D-printed lattice structures optimized through finite element simulations to help meet both low-speed and high-speed impact requirements. Full-scale energy absorbers were 3D-printed using optimized CF-ABS/TPU blends and tested under high-speed impact using the Flexible Pedestrian Legform Impactor (Flex-PLI). For fair comparison, a baseline bumper with a traditional triangular lattice structure, also 3D-printed from the same CF-ABS/TPU materials, was similarly tested. Interestingly, both the optimized and baseline 3D-printed energy absorbers showed nearly identical performance, successfully meeting injury limits. Their performances were also benchmarked against an injection-molded energy absorber. While both 3D-printed and injection-molded designs met injury limits, the 3D-printed absorber exhibited a higher tibia bending moment, indicating an opportunity for further optimization. A Techno-Economic Analysis compared the costs of producing energy absorbers using traditional manufacturing and 3D printing. The analysis highlighted that 3D printing offers cost benefits for low to medium production volumes, with the total cost per energy absorber at ∼ $\$$74, compared to traditional methods that become economical beyond 2000 units.

Additive manufacturing↗
DOE OSTI2025

Laser-induced slip casting as an additive manufacturing approach for silicon carbide

Here, this work presents processing silicon carbide (SiC) with the laser-induced slip casting (LIS) additive manufacturing (AM). SiC was stabilized in water with polyethyleneimine (PEI) dispersant, and SiC slurries were made with rheology for LIS printing. High-density ceramic parts were printed, followed by single-step binder burnout and sintering. The printed parts achieved 93–95 % of theoretical density. X-ray computed tomography (XCT) revealed a small distribution of flaws exceeding 100 microns. The mechanical properties were measured in both parallel and perpendicular to the printing layers, and the orientation with layers perpendicular to the bending moment resulted in higher strength compared to the parallel direction. Porosity resulting from processing and large inclusions of boron carbide (B4C) were the root cause of failure in the measured samples. Despite these defects through this effort, this new approach demonstrates promise for green forming of SiC with densities greater than 95 % theoretical and tensile strengths above 250 MPa.

Additive Manufacturing↗
DOE OSTI2026

Closed-Loop Wind Turbine Controllers for Active Wake Mixing Strategies

Wind turbine active wake mixing (AWM) is an exciting new field of research where dynamic actuation, usually on the blade pitch angles, is used to increase wind farm-wide power production. From a controls perspective, the current state-of-the-art AWM strategies are very simple: a dynamic, usually periodic, reference signal is prescribed to actuators in an open-loop (OL) fashion. The actuation is then presumed to have a certain desired effect on the system, i.e., the wind turbine and the flow it affects. However, this system is highly nonlinear and experiences disturbances in the form of wind variations that are not known a priori. As a result, the OL approach might not yield optimal results. In this article, a novel approach is presented, which closes the loop on AWM controllers. A feedback loop is implemented, which uses measurements of the individual blade bending moments that are widely available on modern wind turbines to determine the individual blade pitch angles. A proof of concept of this implementation is presented in this article, and a thorough comparison with the OL method is executed using high-fidelity flow simulations. These simulations show that the novel closed-loop controller does not substantially increase wake mixing but achieves similar performance as the OL controller while reducing fatigue loads on the controlled turbine.

17 WIND ENERGY↗
DOE OSTI2025

Ring Pull Strain Analysis Version 1.1

This report details an analysis package, Ring Pull Strain Analysis (RPSA), that can be used to present and quantify digital image correlation (DIC) data as it relates to a gaugeless ring pull test. Gaugeless ring pull is a testing technique for mechanical testing of small annular samples, usually cut from a thin-walled tube. DIC data is often necessary for this kind of test because bending moments present on the ring cause a non-uniform strain distribution and localized measurements are necessary. In addition, the annular geometry of a ring lends itself to a polar representation, which is not present with typical DIC analysis methods. RPSA was made to calculate and plot the polar representation of strain from standard pre-processed DIC data of a gaugeless ring pull test. Further analysis can be done on ring pull including a quasi-uniaxial tensile analysis and coating analysis, which are also performed by RPSA. In addition, due to the universality of DIC plotting and ring pull test analysis, RPSA can accommodate a wide variety of tests, though it is tailored for ring pull testing. This report details how RPSA works, including the theory, assumptions, and logic behind the calculations and the structure of the program.

36 MATERIALS SCIENCE↗
DOE OSTI2024

OC6 project Phase IV: validation of numerical models for novel floating offshore wind support structures

Abstract. This paper provides a summary of the work done within Phase IV of the Offshore Code Comparison Collaboration, Continued with Correlation and unCertainty (OC6) project, under International Energy Agency Wind Technology Collaboration Programme Task 30. This phase focused on validating the loading on and motion of a novel floating offshore wind system. Numerical models of a 3.6 MW horizontal-axis wind turbine atop the TetraSpar floating support structure were compared using measurement data from a 1:43-Froude-scale test performed in the University of Maine's Alfond Wind–Wave (W2) Ocean Engineering Laboratory. Participants in the project ran a series of simulations, including system equilibrium, surge offsets, free-decay tests, wind-only conditions, wave-only conditions, and a combination of wind and wave conditions. Validation of the models was performed by comparing the aerodynamic loading, floating support structure motion, tower base loading, mooring line tensions, and keel line tensions. The results show a relatively good estimation of the aerodynamic loading and a reasonable estimation of the platform motion and tower base fore–aft bending moment. However, there is a significant dispersion in the dynamic loading for the upwind mooring line. Very good agreement was observed between most of the numerical models and the experiment for the keel line tensions.

17 WIND ENERGY↗
NASA NTRS1962

BUCKLING AND POST-BUCKLING OF ELASTIC SHELLS

Some theoretical investigations of buckling of elastic shells are surveyed in this report. Only geometrically perfect shells are considered; initial dents and out-of-roundness are not taken into account. Several questions raised by the studies are: (a) Under what conditions is the infinitesimal theory of buckling of shells adequate? (b) How does the energy theory of buckling of shells correlate with the method based on equilibrium equations for bending moments, tensions, and shears in a buckled configuration? (c) How important are nonlinear terms in the tangential displacements u, v in the strain-displacement relations for buckling and post-buckling studies? (d) How important are the boundary conditions for u, v in affecting stability? (e) If a condition of snap-through is approached, how much external work is required to push the shell "over the hump" into the buckled configuration? (f) How reliable are mathematical approximations used previously in the infinitesimal theory of buckling of shells? Tentative and incomplete answers to some of these questions are suggested.

ELASTIC BUCKLING↗
NASA NTRS1970

Testing filamentary composites

NOL ring split-dee tensile test has the advantages that the specimen is readily fabricated by winding and the test is performed in a conventional testing machine without special fixtures. Strain gages cannot be mounted, however, and substantial bending moments are introduced.

Dow, N. F.↗
NASA NTRS1971

Attitude control systems for load relief of Saturn-class launch vehicles

The effectiveness of attitude control laws that are designed to reduce bending moment loads and improve the controllability of large Saturn class boosters is discussed. These laws are referred to as load relief control systems. The two factors are assessed by simulations of varying degrees of complexity, from 2-D rigid body to 6-D with flexible body. A load relief control system, nicknamed AGE, is selected as the most effective of the various proposed schemes. This system is compared with other load relief laws and with simple attitude control. Most nominal vehicles use attitude control laws since their goal is to stay on the flight path without regard to the induced loads.

Sharp, J.↗