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At least 199 records · Page 11

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DOE OSTI2021

Effects of as-received defects on ceramic matrix composites properties using high-fidelity microstructures with periodic boundary conditions

The presence of microstructural defects in as-received specimens of ceramic matrix composites (CMCs) significantly influences their constitutive response and damage, highlighting the importance of characterization and quantification of these defects for accurate assessment of damage and failure in the service environment. In a recent effort, the authors developed an algorithm to generate stochastic representative volume elements (SRVEs) of Carbon fiber Silicon-Carbide-Nitride matrix (C/SiNC) CMCs based on extensive multiscale material and defect characterization data. This paper implements this algorithm within a commercial finite element solver with periodic boundary conditions (PBCs) for high-fidelity micromechanics analysis and investigation of macroscopic material behavior of C/SiNC composites. Different loading directions are used to predict the global mechanical properties, and the results are in excellent agreement with theoretical (rule of mixture) predictions. Subsequently, the effects of as-received defects on the global and local responses are investigated. The results show that intratow porosity has pronounced degradation effects on the global elastic properties and results in complex stress localization patterns, which can be attributed to potential damage initiation sites.

Khafagy, Khaled H.↗

NASA NTRS1979

Thermographic measurement of fatigue damage

The paper presents a thermographic technique developed to measure the extent of fatigue damage in composite materials during fatigue loading. It is noted that heat generated by cyclic loading of fatigue damaged material raises the surface temperature. These temperatures were measured with an infrared camera and were used as boundary conditions in a finite element heat transfer program, which has been developed especially to calculate the extent of the heat generation zone, and thereby to define the fatigue damage zone. It is reported that the finite element program was verified by comparing calculated heat generation with the actual heat generation for a simple heat transfer problem that had a closed form solution. Damage zones are calculated for several boron/epoxy fatigue specimens from thermograms of specimens. The calculated damage zones were compared with damage detected by C-scan, X-ray, and scanning electron microscope (SEM) examinations. It is concluded that the analysis was effective in locating the boundaries of the fatigue damage zones.

Whitcomb, J. D.↗

NASA NTRS2016

Solving Fluid Structure Interaction Problems with an Immersed Boundary Method

An immersed boundary method for the compressible Navier-Stokes equations can be used for moving boundary problems as well as fully coupled fluid-structure interaction is presented. The underlying Cartesian immersed boundary method of the Launch Ascent and Vehicle Aerodynamics (LAVA) framework, based on the locally stabilized immersed boundary method previously presented by the authors, is extended to account for unsteady boundary motion and coupled to linear and geometrically nonlinear structural finite element solvers. The approach is validated for moving boundary problems with prescribed body motion and fully coupled fluid structure interaction problems. Keywords: Immersed Boundary Method, Higher-Order Finite Difference Method, Fluid Structure Interaction.

Structure Interactions↗

DOE OSTI2025

Analysis of the weighted shifted boundary method for the Poisson and Stokes problems

The Shifted Boundary Method (SBM) belongs to the class of unfitted (or immersed, or embedded) finite element methods, and relies on reformulating the original boundary value problem over a surrogate (approximate) computational domain. Accuracy is maintained by properly shifting the location and values of the boundary conditions. This avoids integration over cut cells and the associated implementation issues. Recently, the Weighted SBM (WSBM) was proposed for the Navier-Stokes equations with free surfaces and the Stokes flow with moving boundaries. The attribute “weighted” in the name WSBM stems from the fact that its variational form is weighted with the elemental volume fraction of active fluid. The motivation for the development of the WSBM was the preservation of the volume of active fluid to a higher degree of accuracy, which in turn resulted in improved stability and robustness characteristics in moving-boundary, time-dependent simulations. In this article, we present the numerical analysis of the WSBM formulations for the Poisson and Stokes problems. We give mathematical conditions under which the bilinear forms defining the discrete variational formulations are uniformly coercive (Poisson problem) or inf-sup stable (Stokes problem). By these results, stability and optimal convergence is proven in the natural norm; L2-error estimates can also be derived.

Approximate domain boundaries↗

NASA NTRS1980

Grid generation using coarse, smooth finite elements

Grid quality solutions of a wide variety of equations can be generated to fit reasonable functional boundary conditions in two dimensions using very coarse rectangular finite elements. Some wavy operators (with no natural variational expression) were tried in order to demonstrate the method's versatility.

Dickson, L. J.↗

DOE OSTI2022

Structural Characterization of a Toppling Rock Slab From Array-Based Ambient Vibration Measurements and Numerical Modal Analysis

Accurate assessments of the internal structure and boundary conditions of unstable rock slopes are imperative for evaluating landslide hazard scenarios. However, instability characterization at depth remains challenging and is often limited by costly or invasive subsurface investigations. Here, we develop a new approach coupling array-based ambient vibration modal analysis and numerical modeling to improve structural characterization of rock slope instabilities at depth. We used ambient noise cross-correlation on 4 hr of seismic data recorded by an array of 30 nodal geophones at a 500-m-long toppling rock slab in Utah, USA to identify modal frequencies between 0.8 and 3.5 Hz and derive modal displacements. We show that transverse and longitudinal bending modes span the length of the instability, indicating an interconnected slab. Further, statistical comparison of field results with outputs from >1,000 finite element models with varying boundary conditions showed that the instability depth varies between 40–70 and 10–20 m in the middle and lateral regions, respectively. Our approach yields new information on the structural conditions of rock cliff and column instabilities at depth, which is not easily obtained by other means but is imperative for change detection monitoring and improved hazard assessments.

58 GEOSCIENCES↗

DOE OSTI2020

Extended Finite Element Based Approach in Additive Manufacturing Modeling for Optimizing Highly Complex Manifold in Protonic Ceramic Electrochemical Cells

The objective of this project is to develop a novel numerical approach based on the extended finite element method (XFEM) for modeling moving boundaries of material deposited in additive manufacturing (AM) process with improved accuracy and reduced computational cost. One of the major challenges in simulating AM processes is that the boundaries of the computational domain need to change as material is deposited. Previous approaches have achieved this by activating new finite elements, but this requires a high level of mesh refinement to capture small movement of the boundary. XFEM allows the solution boundary to move independently of the mesh, permitting smooth representation of the evolution of the boundary as material is deposited. As a result, this new method will significantly improve the simulation accuracy while reducing the computational cost compared with existing approaches. Furthermore, this project will bring significant improvements for the design and AM process optimization in an iterative fashion among numerical simuation, parameter optimization, and experimental validation. Specifically, this project will support the protonic ceramic electrochemical cells (PCEC) stack development at INL by providing insights into the density, residual stress, thermal and mechanical properties of the PCEC manifold and interconnect, which is critical in enhancing the system lifetime and reducing the overall cost. Upon the success of proposed development and validation of the proposed approach, simulation will be applied to determine an optimal set of AM process parameters for the PCEC manifold production. This project will consolidate Idaho National Laboratory (INL)’s simulation capabilities provided by the MOOSE framework and the Valhalla AM simulation application, with encouraging expansion to emerging PCEC applications and AM technologies at INL and beyond.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1992

Large-amplitude finite element flutter analysis of composite panels in hypersonic flow

Consideration is given to a finite-element approach for determining the nonlinear flutter characteristics of 3D thin laminated composite panels using the full third-order-piston transverse-loading aerodynamic theory. The unsteady hypersonic aerodynamic theory and the von Karman large-deflection-plate theory are used to formulate the aeroelasticity problem. Nonlinear flutter analyses are performed to assess the influence of the higher-order aerodynamic theory on the structure's limit-cycle amplitude and the dynamic pressure of the flow velocity. A solution procedure is presented to solve the nonlinear panel flutter and large-amplitude free-vibration finite-element equations. Nonlinear flutter analyses are performed for different boundary support-conditions and for various system parameters. Linear finite-element flutter for isotropic and composite panels and large-amplitude isotropic panel flutter results are compared with existing classical solutions. The large-amplitude panel flutter results using the full third-order piston aerodynamic theory are presented to assess the influence of the nonlinear aerodynamic theory.

Gray, Carl E., Jr.↗

DOE OSTI2023

Mesh refinement for anisotropic diffusion in magnetized plasmas

Highly accurate simulation of plasma transport is needed to drive the successful design and operation of magnetically confined fusion reactors. Unfortunately, the extreme anisotropy present in magnetized plasmas results in thin boundary layers that are expensive to resolve. Here, this work investigates how various mesh refinement strategies might reduce that expense to allow for more efficient simulation by comparing standard variable refinement approaches that use a field quantity to an adaptive approach that uses an error estimator. It is first verified that higher order discretization only realizes the proper rate of convergence once the mesh resolves the thin boundary layer, therefore motivating the focusing of refinement on the boundary layer. For three two-dimensional test cases that contain characteristic features of tokamak magnetic fields, an exponential refinement strategy based on the magnetic flux function, which is the standard refinement approach in the field, is compared to an adaptive strategy utilizing the established Zienwiekicz and Zhu error estimator. The adaptive mesh refinement strategy consistently achieves the same accuracy using orders of magnitude less degrees of freedom than either exponential or uniform refinement. This result makes the adaptive refinement strategy more efficient than the exponential refinement strategy while also being more generalizable to problems with complex magnetic geometries. Scaling laws are derived that quantify the improvement in cost of the adaptive refinement strategy over other refinement approaches in 2D and 3D.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2026

Onset of High-Harmonic Fast Wave Propagation in Annulus Geometry

Previous experiments on NSTX have reported high-harmonic fast wave (HHFW) power losses in the scrape-off layer (SOL), with dependencies on the wave parallel wavenumber, plasma density, and magnetic field. This study presents an analysis of HHFW propagation in the SOL plasma, focusing on parasitic coupling to the waveguide mode bounded by the steep gradient pedestal and the outer wall boundary. The analytic and finite element wave models are discussed using a 2D annulus geometry, which serves as a simplified representation of the NSTX-U plasma. The model shows that a minimum radial gap width is required to support wave propagation, analogous to the higher-order modes in coaxial geometries. The impact of several factors, including gap width, wave parallel phasing, and magnetic field strength, on parasitic wave coupling is examined, highlighting the role of the geometric dimension in relation to the wave perpendicular wavelength. The findings suggest that controlling the edge/SOL density profile (gap control) is crucial for mitigating parasitic coupling when the density in front of the antenna exceeds the density cutoff.

Baek, Seung-Gyou [Massachusetts Inst. of Technolog↗

DOE OSTI2022

Thermal Optimization of a Silicon Carbide, Half-Bridge Power Module

This project describes the modeling process to design the packaging and heat exchanger for a half-bridge wide-bandgap (WBG) power semiconductor module. The module uses two silicon carbide, metal-oxide-semiconductor field-effect transistor (MOSFET) devices per switch position that are soldered to an aluminum nitride, direct-bond copper (DBC) substrate. A baseplate cooling configuration (e.g., no thermal grease) is used along with a water-ethylene glycol, jet-impingement-style heat exchanger. The heat exchanger was designed to be fabricated using prototyping equipment from the National Renewable Energy Laboratory, complies with automotive standards (for minimal channel sizes, flow rates, and coolant), and considers reliability aspects (i.e., erosion/corrosion). Device-scale computational fluid dynamics (CFD) is used first to design the slot jet impingement cooling configuration and compute the effective heat transfer coefficient (HTC) of the concept. The computed HTCs are then used as boundary conditions for a finite element study to optimize the package geometry (e.g., device layout and baseplate thickness) to minimize thermal resistance and minimize temperature variation between the module's four devices. Finally, a fluid manifold is designed to generate the slot jets and cool the devices. Module-scale CFD predicts a relatively low junction-to-fluid thermal resistance of 16.7 mm2 K/W, a 1.4 degrees C temperature variation between devices, and a total pressure drop of 5,860 Pa (0.85 psi) for the design. The thermal resistance of the module design is about 67% lower than the 2015 BMW i3 power electronics/modules thermal resistance.

DIRECT ENERGY CONVERSION↗

DOE OSTI2024

Rupture Jumping and Seismic Complexity in Models of Earthquake Cycles for Fault Stepovers with Off-Fault Plasticity

ABSTRACT Fault stepovers are prime examples of geometric complexity in natural fault zones that may affect seismic hazard by determining whether an earthquake rupture continues propagating or abruptly stops. However, the long-term pattern of seismicity near-fault stepovers and underlying mechanisms of rupture jumping in the context of earthquake cycles are rarely studied. Leveraging a hybrid numerical scheme combining the finite element and the spectral boundary integral methods, FEBE, we carry out fully dynamic simulations of sequences of earthquakes and aseismic slip for both compressive and tensile stepovers with off-fault plasticity. We consider a rate-and-state friction law for the fault friction and pressure-sensitive Drucker–Prager plasticity for the off-fault bulk response. We observe that the accumulation of plastic deformation, an indication of off-fault damage, is significantly different in the two cases, with more plastic deformation projected in the overlapping region for the tensile stepover. The seismic pattern for a tensile stepover is more complex than for a compressive stepover, and incorporating plasticity also increases complexity, relative to the elastic case. A tensile stepover with off-fault plasticity shows rupture segmentation, temporal clustering, and frequent rupture jumping from one fault to another. These results shed light on possible mechanisms of rupture jumping in fault stepovers as well as the long-term evolution of the fault zone.

Geochemistry & Geophysics↗

NASA NTRS1977

Compliance calibration of specimens used in the R-curve practice

The compliance calibrations for the compact (CS) and crack-line-wedge-loaded (CLWL) specimens have been determined by experimental measurements and by boundary-collocation analysis. The CS and CLWL specimen configurations were modeled more accurately than those used in previous analytical investigations. Polynomial expressions for the compliance at various stations along the crack line for CS and CLWL specimens are presented. The compliance calibrations for the center-crack tension (CCT) specimen have been determined theoretically by boundary-collocation and finite-element analysis. The calculated compliance values for the CCT specimen are compared with values obtained from the Irwin-Westergaard expression and from a modification to the Irwin-Westergaard expression proposed by Eftis and Liebowitz. The Eftis-Liebowitz expression was found to be in good agreement (plus or minus 2 percent) with both analyses for crack aspect ratios up to 0.8 and for gage half-span to specimen width ratios up to 0.5.

Mccabe, D. E.↗

NASA NTRS1986

Prediction of sound fields in cavities using boundary element methods

Two boundary element formulations of acoustical behavior exist; the Direct Boundary Element Methods (DBEM) based on the Helmholtz Integral Equations and the Indirect Boundary Element Methods (IBEM) based on Huygen's Principle. In this investigation, both methods are implemented utilizing a simple linear superparametric element. In addition the IBEM is studied using a quadratic isoparametric element. The accuracy and relative efficiency of the various techniques are examined. In order to properly model aircraft interior cavities the additional capability to model wall treatments and internal point sources is added to the methods. The procedures are verified for several well-understood cavity problems. The relative merits of each boundary element method and the finite element method are examined.

Bernhard, R. J.↗

NASA NTRS1987

Accuracy of the domain method for the material derivative approach to shape design sensitivities

Numerical accuracy for the boundary and domain methods of the material derivative approach to shape design sensitivities is investigated through the use of mesh refinement. The results show that the domain method is generally more accurate than the boundary method, using the finite element technique. It is also shown that the domain method is equivalent, under certain assumptions, to the implicit differentiation approach not only theoretically but also numerically.

Yang, R. J.↗

NASA NTRS1990

Computing Deformations Of Rubbery Materials

Better use made of experimental data in finite-element computations. New formulation of constitutive equations of rubbery, nonlinearly elastic material enables finite-element analysis of boundary-value stress-and-strain problems involving arbitrary shapes and loads. In development of formulation, principal stretches used as arguments of strain-energy-density function.

Peng, Steven T. J.↗

NASA NTRS1991

Elasto-plastic coupled temperature-displacement finite element analysis of two-dimensional rolling-sliding contact with a translating heat source

The present paper describes a transient translating elastoplastic thermomechanical finite element model to study two-dimensional frictional rolling contact. Frictional two-dimensional contact is simulated by repeatedly translating a nonuniform thermomechanical distribution across the surface of an elastoplastic half space. The half space is represented by a two-dimensional finite element mesh with appropriate boundaries. Calculations are for an elastic-perfectly plastic material and the selected thermophysical properties are assumed to be temperature independent. The paper presents temperature variations, stress and plastic strain distributions and deformations. Residual tensile stresses are observed. The magnitude and depth of these stresses depends on (1) the temperature gradients and (2) the magnitudes of the normal and tangential tractions.

Rubin, C. A.↗

NASA NTRS1993

Small hydrogen/oxygen rocket flowfield behavior from heat flux measurements

The mixing and heat transfer phenomena in small rocket flow fields with fuel film cooling is not well understood. An instrumented, water-cooled chamber with a gaseous hydrogen/gaseous oxygen injector was used to gather steady-state inner and outer wall temperature profiles. The chamber was tested at 414 kPa (60 psia) chamber pressure, from mixture ratios of 3.41 to 8.36. Sixty percent of the fuel was used for film cooling. These temperature profiles were used as boundary conditions in a finite element analysis program, MSC/NASTRAN, to calculate the local radial and axial heat fluxes in the chamber wall. The normal heat fluxes were then calculated and used as a diagnostic of the rocket's flow field behavior. The normal heat fluxes determined were on the order of 1.0 to 3.0 MW/meters squared (0.6 to 1.8 Btu/sec-inches squared). In the cases where mixture ratio was 5 or above, there was a sharp local heat flux maximum in the barrel section of the chamber. This local maximum seems to indicate a reduction or breakdown of the fuel film cooling layer, possibly due to increased mixing in the shear layer between the film and core flows. However, the flow was thought to be completely laminar, as the throat Reynolds numbers were below 50,000 for all the cases. The increased mixing in the shear layer in the higher mixture ratio cases appeared not to be due to the transition of the flow from laminar to turbulent, but rather due to increased reactions between the hydrogen film and oxidizer-rich core flows.

Reed, Brian D.↗