Results for “Defect modelling” — Page 18

NASA NTRS2020

A 3D Model to Predict Explicit Morphologies and Volume Fraction of Lack-of-Fusion Pores Generated in Selective Laser Melting Processes

The performance of an additively manufactured (AM) component is dependent on the distribution of process-induced defects in addition to the complex microstructure of the material, surface roughness of the component and the process-induced residual stresses. For instance, it has been well demonstrated that lack-of-fusion (LoF) pores produced in the selective laser melting (SLM) AM process can significantly limit the fatigue performance of the material. Although two-dimensional (2D) models exist to predict the 2D profiles of LoF pores, the 2D pore profiles cannot be directly inserted into a three-dimensional (3D) microstructure domain that is output from several prevailing process simulation packages. A few commercial packages that simulate the SLM process can predict LoF pores in a 3D domain, but the morphologies of LoF pores are voxelated and hence do not capture sharp corners of the pores, thereby obviating their use in fatigue crack initiation studies. In order to address the aforementioned gaps, a high-fidelity model that predicts not only the volume fraction, but also the explicit 3D morphologies and spatial distributions of LoF pores has been developed using a computer aided design-based environment. The model has been partially validated for Ti-6Al-4V alloy by comparing the predictions of the volume fraction of LoF pores predicted by the model with experimental data obtained from the literature. Absolute error in predicted volume fraction of LoF pores varied between 5.16% and 1.87% for energy density values between 13 J/mm3 and 45 J/mm3 where a significant amount (over 3% volume fraction) of LoF porosity was measured. The absolute error was within 1.87% for energy density values greater than 45 J/mm3.

Saikumar R. Yeratapally↗

NASA NTRS1976

Crack-growth analysis

Flexible, adaptable, integrative routine, computer program incorporates Collipriest-Ehret and Paris-Forman equations. Calculates growth from initial defect size and terminates calculation when crack is sufficiently large for critical condition. Wheeler, Willenborg, and Grumman Closure models are available.

Bianca, C.↗

NASA NTRS1991

A computer program to perform flow and thermal analysis during pressurization of the Space Shuttle Solid Rocket Motor field joint

A computational technique for prediction of the flow and thermal environment in the SRM field joint cavities is described. The SRM field joint hardware was tested with a defect in the insulation, and due to this defect, the O-ring gland cavities are pressurized during the early part of the ignition. A computer model is developed to predict the thermal environment and flow through the simulated flaw, during the pressurization of the field joint. The transient mass, momentum, and energy conservation equations in the flow passage together with the thermodynamic equation of state are solved by a fully implicit iterative numerical procedure.

Clayton, J. Louie↗

NASA NTRS1999

Thermophysical Property Measurements of Molten Semiconductors in 1-g and Reduced-g Condition

Understanding and controlling the formation kinetics of varieties of crystal imperfections such as point defects, non uniform distribution of doping atoms, and impurity atoms in growing crystals are very important. Theoretical (numerical) modeling of the crystal growth process is an essential step to achieving these objectives. In order to obtain reliable modeling results, input parameters, i.e. various thermophysical parameters, must be accurate. The importance of accurate thermophysical properties of semiconductors in crystal growth cannot be overly emphasized. The total hemispherical emissivity, for instance, has a dramatic impact on the thermal environment. It determines the radiative emission from the surface of the melt which determines to a large extent the profile of the solidified crystal. In order to understand the convection and the turbulence in a melt, viscosity becomes an important parameter. The liquid surface tension determines the shape of the liquid-atmosphere interface near the solid-liquid-atmosphere triple point. Currently used values for these parameters are rather inaccurate, and this program intends to provide more reliable measurements of these thermophysical properties. Thus, the objective of this program is in the accurate measurements of various thermophysical properties which can be reliably used in the modeling of various crystal growth processes. In this program, thermophysical properties of molten semiconductors, such as Si, Ge, Si-Ge, and InSb will be measured as a function of temperature using the High Temperature Electrostatic Levitator at JPL. Each material will be doped by different kinds of impurities at various doping levels. Thermophysical properties which will be measured include: density, thermal expansion coefficient, surface tension, viscosity, specific heat, hemispherical total emissivity, and perhaps electrical and thermal conductivities. Many molten semiconductors are chemically reactive with crucibles. As a result, these dispersed impurities in the melts tend to substantially modify the properties of pure semiconductors. Sample levitation done in a vacuum clearly helps maintain the sample purity. However, in the 1-g environment, all gravity caused effects such as convection, sedimentation and buoyancy are still present in the sample. In addition, large forces needed to levitate a sample in the presence of the gravity can cause additional flows in the melt. The use of the High Temperature Electrostatic Levitator (HTESL) for the present research is a recent development and little is known about the flows induced by the electrostatic forces. In this ground base program, we will define the limits of HTESL technology as various thermophysical properties of molten semiconductors are measured.

Rhim, Won-Kyu↗

NASA NTRSDate not supplied

Flash Thermal Diffusivity Measurements and Inspection of Additively Manufactured Ti-6Al-4V Specimens with Varying Process Parameters

Flash thermal diffusivity measurements were obtained on additively manufactured Ti-6Al-4V disk shaped specimens with various process parameters. For additively manufactured metal parts, processing parameters such as laser power and scanning speed are critical to ensure the desired microstructure. For this study, the laser powder bed fusion process parameters were changed at various angular sections on a 21 mm diameter and 3.0 mm thick disk. The measurement of thermal diffusivity was performed by fitting a 1-dimensional thermal model to the data pixel by pixel to produce an inspection image. The image revealed the detection of defects such as lack of fusion porosity and areas of aggregated porosity. The thermal diffusivity imagery was compared to immersion scan ultrasonic and X-ray computed tomography (CT) measurements for validation. Based on these results, additional samples were investigated using a single side thermal inspection technique to detect lack of fusion porosity and near surface voids.

thermal nondestructive evaluation↗

NASA NTRS2023

Flash Thermal Diffusivity Measurements and Inspection of Additively Manufactured Ti-6Al-4V Specimens with Varying Process Parameters

Flash thermal diffusivity measurements were obtained on additively manufactured Ti-6Al-4V disk shaped specimens with various process parameters. For additively manufactured metal parts, processing parameters such as laser power and scanning speed are critical to ensure the desired microstructure. For this study, the laser powder bed fusion process parameters were changed at various angular sections on a 21 mm diameter and 3.0 mm thick disk. The measurement of thermal diffusivity was performed by fitting a 1-dimensional thermal model to the data pixel by pixel to produce an inspection image. The image revealed the detection of defects such as lack of fusion porosity and areas of aggregated porosity. The thermal diffusivity imagery was compared to immersion scan ultrasonic and X-ray computed tomography (CT) measurements for validation. Based on these results, additional samples were investigated using a single side thermal inspection technique to detect lack of fusion porosity and near surface voids.

thermal nondestructive evaluation↗

NASA NTRS1993

Analysis of resistance data on a good ceramic sample of YBa2Cu3O(7-x)

Resistance data between 91.4 and 200 K on a ceramic sample of YBa2Cu3O(7-x) are analyzed using a two-band model for normal-state conductance plus the Lawrence-Doniach theory for effects of superconducting fluctuations. The data is fitted to a rms accuracy of 0.16 percent of the resistance in the middle of the temperature range. The steepest slope of the resistance of the sample occurs at 91.13 K, and the analysis shows that the critical region extends to less than 0.3 K above Tc. Values of parameters found indicate that defect or impurity scattering within grains is unusually small in this sample. Some difficulties in understanding Hall data using either simple two-band models or more sophisticated one-band models are discussed briefly.

Eagles, David M.↗

NASA NTRS2007

Analysis of Composite Panel-Stiffener Debonding Using a Shell/3D Modeling Technique

Interlaminar fracture mechanics has proven useful for characterizing the onset of delaminations in composites and has been used successfully primarily to investigate onset in fracture toughness specimens and laboratory size coupon type specimens. Future acceptance of the methodology by industry and certification authorities, however, requires the successful demonstration of the methodology on the structural level. For this purpose, a panel was selected that is reinforced with stiffeners. Shear loading causes the panel to buckle, and the resulting out-of-plane deformations initiate skin/stiffener separation at the location of an embedded defect. A small section of the stiffener foot, web and noodle as well as the panel skin in the vicinity of the delamination front were modeled with a local 3D solid model. Across the width of the stiffener foot, the mixedmode strain energy release rates were calculated using the virtual crack closure technique. A failure index was calculated by correlating the results with a mixed-mode failure criterion of the graphite/epoxy material. Computed failure indices were compared to corresponding results where the entire web was modeled with shell elements and only a small section of the stiffener foot and panel were modeled locally with solid elements. Including the stiffener web in the local 3D solid model increased the computed failure index. Further including the noodle and transition radius in the local 3D solid model changed the local distribution across the width. The magnitude of the failure index decreased with increasing transition radius and noodle area. For the transition radii modeled, the material properties used for the noodle area had a negligible effect on the results. The results of this study are intended to be used as a guide for conducting finite element and fracture mechanics analyses of delamination and debonding in complex structures such as integrally stiffened panels.

Krueger, Ronald↗

NASA NTRSDate not supplied

Progressive Damage Failure Analysis of Post-Buckled Composite Single-Stringer Panel with Teflon Inserts

The high strength-to-weight and stiffness-to-weight ratio materials, such as laminated composites, are advantageous for modern aircraft. Laminated composites with initial flaws are susceptible to delamination under buckling loads. PDA tools help enhance the industry’s understanding of the mechanisms for damage initiation and growth in composite structures while assisting in the design, analysis, and sustainment methods of these composite structures. The global-local modeling approach for the single-stringer post-buckled panel was evaluated through this effort, using Teflon inserts to simulate the defect of damage during manufacturing. This understanding is essential for designing the post-buckled structure, reducing weight while predicting damage initiation location, and addressing a potential design review for future aircraft repairs. In this work, the initial damage was captured with Teflon inserts as the starting configuration; and any reference to the damage initiation refers to any damage beyond the “initial unbonded region.” The effort aims to develop, evaluate, and enhance methods to predict damage initiation and progression and the failure of post-buckled hat-stiffened panels using multiple Abaqus FEA Virtual Crack Closure Technique (VCCT) definitions. Validation of the PDA using the VCCT material model was performed on a large single-stringer panel subjected to compressive loading. The compressive loading of the panel caused the skin to buckle before any damage began to occur locally. In addition, comparisons are made for critical aspects of the damage morphology, such as a growth pattern that included delamination from the skin-stiffener interface to the skin and ply interfaces. When compared against the experimental data produced through the NASA Advanced Composites Project (ACP), the present model captured damage migration from one surface to another, and model validations were within 4% of the experimental data.

PDA↗

NASA NTRS2007

A Decision Tool that Combines Discrete Event Software Process Models with System Dynamics Pieces for Software Development Cost Estimation and Analysis

The development process for a large software development project is very complex and dependent on many variables that are dynamic and interrelated. Factors such as size, productivity and defect injection rates will have substantial impact on the project in terms of cost and schedule. These factors can be affected by the intricacies of the process itself as well as human behavior because the process is very labor intensive. The complex nature of the development process can be investigated with software development process models that utilize discrete event simulation to analyze the effects of process changes. The organizational environment and its effects on the workforce can be analyzed with system dynamics that utilizes continuous simulation. Each has unique strengths and the benefits of both types can be exploited by combining a system dynamics model and a discrete event process model. This paper will demonstrate how the two types of models can be combined to investigate the impacts of human resource interactions on productivity and ultimately on cost and schedule.

Mizell, Carolyn Barrett↗

NASA NTRS1990

Evolution of light domain walls interacting with dark matter, part 1

The evolution of domain walls generated in the early Universe is discussed considering an interaction between the walls and a major gaseous component of the dark matter. The walls are supposed able to reflect the particles elastically and with a reflection coefficient of unity. A toy Lagrangian that could give rise to such a phenomenon is discussed. In the simple model studied, highly non-relativistic and slowly varying speeds are obtained for the domain walls (approximately 10 (exp -2)(1+z)(exp -1)) and negligible distortions of the microwave background. In addition, these topological defects may provide a mechanism of forming the large scale structure of the Universe, by creating fluctuations in the dark matter (delta rho/rho approximately O(1)) on a scale comparable with the distance the walls move from the formation (in the model d less than 20 h(exp -1) Mpc). The characteristic scale of the wall separation can be easily chosen to be of the order of 100 Mpc instead of being restricted to the horizon scale, as usually obtained.

Massarotti, Alessandro↗

NASA NTRS1984

Fan noise reduction achieved by removing tip flow irregularities behind the rotor - forward arc test configurations

The noise source caused by the interaction of the rotor tip flow irregularities (vortices and velocity defects) with the downstream stator vanes was studied. Fan flow was removed behind a 0.508 meter (20 in.) diameter model turbofan through an outer wall slot between the rotor and stator. Noise measurements were made with far-field microphones positioned in an arc about the fan inlet and with a pressure transducer in the duct behind the stator. Little tone noise reduction was observed in the forward arc during flow removal; possibly because the rotor-stator interaction noise did not propagate upstream through the rotor. Noise reductions were maded in the duct behind the stator and the largest decrease occurred with the first increment of flow removal. This result indicates that the rotor tip flow irregularity-stator interaction is as important a noise producing mechanism as the normally considered rotor wake-stator interaction.

Dittmar, J. H.↗

NASA NTRS1987

Numerical Simulation Of Silicon-Ribbon Growth

Mathematical model includes nonlinear effects. In development simulates growth of silicon ribbon from melt. Takes account of entire temperature and stress history of ribbon. Numerical simulations performed with new model helps in search for temperature distribution, pulling speed, and other conditions favoring growth of wide, flat, relatively defect-free silicon ribbons for solar photovoltaic cells at economically attractive, high production rates. Also applicable to materials other than silicon.

Woda, Ben K.↗

NASA NTRS2003

Flaw Tolerance In Lap Shear Brazed Joints

This paper presents results of the second part of an on-going effort to gain better understanding of defect tolerance in braze joints. In the first part of this three-part series, we mechanically tested and modeled the strength of the lap joints as a function of the overlap distance. A failure criterion was established based on the zone damage theory, which predicts the dependence of the lap joint shear strength on the overlap distance, based on the critical size of a finite damage zone or an overloaded region in the joint. In this second part of the study, we experimentally verified the applicability of the damage zone criterion on prediction of the shear strength of the lap joint and introduced controlled flaws into the lap joints. The purpose of the study was to evaluate the lap joint strength as a function of flaw size and its location through mechanical testing and nonlinear finite element analysis (FEA) employing damage zone criterion for definition of failure. The results obtained from the second part of the investigation confirmed that the failure of the ductile lap shear brazed joints occurs when the damage zone reaches approximately 10% of the overlap width. The same failure criterion was applicable to the lap joints containing flaws.

Wang, Len↗

NASA NTRS2005

The Application of Infrared Thermographic Inspection Techniques to the Space Shuttle Thermal Protection System

The Nondestructive Evaluation Sciences Branch at NASA s Langley Research Center has been actively involved in the development of thermographic inspection techniques for more than 15 years. Since the Space Shuttle Columbia accident, NASA has focused on the improvement of advanced NDE techniques for the Reinforced Carbon-Carbon (RCC) panels that comprise the orbiter s wing leading edge. Various nondestructive inspection techniques have been used in the examination of the RCC, but thermography has emerged as an effective inspection alternative to more traditional methods. Thermography is a non-contact inspection method as compared to ultrasonic techniques which typically require the use of a coupling medium between the transducer and material. Like radiographic techniques, thermography can be used to inspect large areas, but has the advantage of minimal safety concerns and the ability for single-sided measurements. Principal Component Analysis (PCA) has been shown effective for reducing thermographic NDE data. A typical implementation of PCA is when the eigenvectors are generated from the data set being analyzed. Although it is a powerful tool for enhancing the visibility of defects in thermal data, PCA can be computationally intense and time consuming when applied to the large data sets typical in thermography. Additionally, PCA can experience problems when very large defects are present (defects that dominate the field-of-view), since the calculation of the eigenvectors is now governed by the presence of the defect, not the "good" material. To increase the processing speed and to minimize the negative effects of large defects, an alternative method of PCA is being pursued where a fixed set of eigenvectors, generated from an analytic model of the thermal response of the material under examination, is used to process the thermal data from the RCC materials. Details of a one-dimensional analytic model and a two-dimensional finite-element model will be presented. An overview of the PCA process as well as a quantitative signal-to-noise comparison of the results of performing both embodiments of PCA on thermographic data from various RCC specimens will be shown. Finally, a number of different applications of this technology to various RCC components will be presented.

Cramer, K. E.↗

NASA NTRS2015

Principal Component Analysis of Thermographic Data

Principal Component Analysis (PCA) has been shown effective for reducing thermographic NDE data. While a reliable technique for enhancing the visibility of defects in thermal data, PCA can be computationally intense and time consuming when applied to the large data sets typical in thermography. Additionally, PCA can experience problems when very large defects are present (defects that dominate the field-of-view), since the calculation of the eigenvectors is now governed by the presence of the defect, not the "good" material. To increase the processing speed and to minimize the negative effects of large defects, an alternative method of PCA is being pursued where a fixed set of eigenvectors, generated from an analytic model of the thermal response of the material under examination, is used to process the thermal data from composite materials. This method has been applied for characterization of flaws.

Winfree, William P.↗

NASA NTRSDate not supplied

Simulation of Etch Pit Formation in DSMC Through Active Sites in Carbon Fiber Micro-Structures

Erosion of carbon due to oxidation does not occur uniformly but through localized etch pit formation because of active surface sites. In this work we demonstrate a newly developed capability to capture pitting of carbon fiber microstructures such as FiberForm, which is commonly used as the base material for NASA’s spacecraft ablative thermal protection systems (TPS). The simulations are performed at the meso-scale in order to capture the pit formation and growth using direct simulation Monte Carlo (DSMC), specifically using the Stochastic PArallel Rarefied-gas Time-accurate Analyzer (SPARTA) code. Legacy and latest models both assume uniform reactivity of carbon surface sites with oxygen even at the meso-scale level. However, in reality the carbon surface has locally different reaction rates due to the presence of defects at the atomic scale. The defective nature of these sites enhances their reactivity with atmospheric gases compared to the non-defective sites (2-3 orders of magnitude) and are termed as “active sites”. Thus, these sites tend to be the first to react and eventually get removed through the formation of gases such as CO, CO2, and CN. Their removal results in all the neighboring atoms becoming defective, thus leading to chain reaction of localized carbon removal and formation of etch pits. Capturing the formation of pits during the ablation simulation of carbon micro-structures is critical to predicting their structural failure. Recently a detailed surface chemistry framework was developed in SPARTA, capable of incorporating various detailed surface reaction mechanisms. We have implemented the capability of a single surface having multiple site sets with different reactivities within this framework. We have used this feature to model the presence of active sites on carbon surfaces, whose reactivity is orders of magnitude higher than that of the passive sites due to the presence of defects. The active site fraction is a property of surface elements within SPARTA and is directly proportional to the local reactivity of each surface element. By introducing an initial distribution of the active site fraction across the carbon surface and propagating it in a manner that mimics the evolution of real reacting carbon surfaces, we can capture the formation and growth of etch pits as a result of surface consumption reactions such as oxidation.

DSMC↗

NASA NTRSDate not supplied

DSMC Simulation of Etch Pit Formation Through Active Sites in Carbon Fiber Micro-Structures

Erosion of carbon due to oxidation does not occur uniformly but through localized etch pit formation because of active surface sites. In this work we demonstrate a newly developed capability to capture pitting of carbon fiber microstructures such as FiberForm, which is commonly used as the base material for NASA’s spacecraft ablative thermal protection systems (TPS). The simulations are performed at the meso-scale in order to capture the pit formation and growth using direct simulation Monte Carlo (DSMC), specifically using the Stochastic PArallel Rarefied-gas Time-accurate Analyzer (SPARTA) code. Legacy and latest models both assume uniform reactivity of carbon surface sites with oxygen even at the meso-scale level. However, in reality the carbon surface has locally different reaction rates due to the presence of defects at the atomic scale. The defective nature of these sites enhances their reactivity with atmospheric gases compared to the non-defective sites (2-3 orders of magnitude) and are termed as “active sites”. Thus, these sites tend to be the first to react and eventually get removed through the formation of gases such as CO, CO2, and CN. Their removal results in all the neighboring atoms becoming defective, thus leading to chain reaction of localized carbon removal and formation of etch pits. Capturing the formation of pits during the ablation simulation of carbon micro-structures is critical to predicting their structural failure. Recently a detailed surface chemistry framework was developed in SPARTA, capable of incorporating various detailed surface reaction mechanisms. We have implemented the capability of a single surface having multiple site sets with different reactivities within this framework. We have used this feature to model the presence of active sites on carbon surfaces, whose reactivity is orders of magnitude higher than that of the passive sites due to the presence of defects. The active site fraction is a property of surface elements within SPARTA and is directly proportional to the local reactivity of each surface element. By introducing an initial distribution of the active site fraction across the carbon surface and propagating it in a manner that mimics the evolution of real reacting carbon surfaces, we can capture the formation and growth of etch pits as a result of surface consumption reactions such as oxidation.

DSMC↗