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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Prediction of the Dynamic Yield Strength of Metals Using Two Structural-Temporal Parameters

The behavior of the yield strength of steel and a number of aluminum alloys is investigated in a wide range of strain rates, based on the incubation time criterion of yield and the empirical models of Johnson-Cook and Cowper-Symonds. In this paper, expressions for the parameters of the empirical models are derived through the characteristics of the incubation time criterion; a satisfactory agreement of these data and experimental results is obtained. The parameters of the empirical models can depend on some strain rate. The independence of the characteristics of the incubation time criterion of yield from the loading history and their connection with the structural and temporal features of the plastic deformation process give advantage of the approach based on the concept of incubation time with respect to empirical models and an effective and convenient equation for determining the yield strength in a wider range of strain rates.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2016

Study of hypervelocity projectile impact on thick metal plates

Hypervelocity impacts generate extreme pressure and shock waves in impacted targets that undergo severe localized deformation within a few microseconds. These impact experiments pose unique challenges in terms of obtaining accurate measurements. Similarly, simulating these experiments is not straightforward. This paper proposed an approach to experimentally measure the velocity of the back surface of an A36 steel plate impacted by a projectile. All experiments used a combination of a two-stage light-gas gun and the photonic Doppler velocimetry (PDV) technique. The experimental data were used to benchmark and verify computational studies. Two different finite-element methods were used to simulate the experiments: Lagrangian-based smooth particle hydrodynamics (SPH) and Eulerian-based hydrocode. Both codes used the Johnson-Cook material model and the Mie-Grüneisen equation of state. Experiments and simulations were compared based on the physical damage area and the back surface velocity. Finally, the results of this study showed that the proposed simulation approaches could be used to reduce the need for expensive experiments.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2013

A review of macroscopic ductile failure criteria.

The objective of this work was to describe several of the ductile failure criteria com- monly used to solve practical problems. The following failure models were considered: equivalent plastic strain, equivalent plastic strain in tension, maximum shear, Mohr- Coulomb, Wellman's tearing parameter, Johnson-Cook and BCJ MEM. The document presents the main characteristics of each failure model as well as sample failure predic- tions for simple proportional loading stress histories in three dimensions and in plane stress. Plasticity calculations prior to failure were conducted with a simple, linear hardening, J2 plasticity model. The resulting failure envelopes were plotted in prin- cipal stress space and plastic strain space, where the dependence on stress triaxiality and Lode angle are clearly visible. This information may help analysts select a ductile fracture model for a practical problem and help interpret analysis results.

Corona, Edmundo↗
DOE OSTI2014

Electron Beam Welding and Characterization of 21-6-9 Stainless Steel Annealed Plate and Welds

This report summarizes the electron beam (EB) welding and characterization work performed on annealed 21-6-9 stainless steel plate during the 2011-2012 time period. The work was directed at producing legacy autogeneous EB welds with the use of the Enhanced Modified Faraday Cup (EMFC) EB diagnostic to characterize the beam, and measuring the resulting tensile and hardness properties of the weld relative to annealed 21-6-9 stainless steel base metal. Different tensile bar configurations were produced, and the results were analyzed to determine how well the stress-strain behavior of small tensile samples compares to standard sized tensile samples for the same material. Additional comparisons were made between cross-weld tensile samples with and without weld steps to determine how the unwelded portion of a step joint affects the measured tensile behavior. Base metal tensile data was further used to calibrate a spherical indentation method to estimate uniaxial tensile behavior using a nanoindenter. The calibrated method was then used to generate the first engineering stress-strain curve for EB welded 21-6-9 stainless steel. Additional analysis was performed to determine Steinberg-Guinan and Johnson-Cook model parameters to represent both the annealed 21-6-9 SS base metal and the EB weld metal stress-strain behaviors under quasi static strain rate conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2015

An attempt to calibrate and validate a simple ductile failure model against axial-torsion experiments on Al 6061-T651

This report details a work in progress. We have attempted to calibrate and validate a Von Mises plasticity model with the Johnson-Cook failure criterion ( Johnson & Cook , 1985 ) against a set of experiments on various specimens of Al 6061-T651. As will be shown, the effort was not successful, despite considerable attention to detail. When the model was com- pared against axial-torsion experiments on tubes, it over predicted failure by 3 x in tension, and never predicted failure in torsion, even when the tube was twisted by 4 x further than the experiment. While this result is unfortunate, it is not surprising. Ductile failure is not well understood. In future work, we will explore whether more sophisticated material mod- els of plasticity and failure will improve the predictions. Selecting the appropriate advanced material model and interpreting the results of said model are not trivial exercises, so it is worthwhile to fully investigate the behavior of a simple plasticity model before moving on to an anisotropic yield surface or a similarly complicated model.

42 ENGINEERING↗
DOE OSTI2015

Validation Study of Unnotched Charpy and Taylor-Anvil Impact Experiments using Kayenta

Validation of a single computational model with multiple available strain-to-failure fracture theories is presented through experimental tests and numerical simulations of the standardized unnotched Charpy and Taylor-anvil impact tests, both run using the same material model (Kayenta). Unnotched Charpy tests are performed on rolled homogeneous armor steel. The fracture patterns using Kayenta’s various failure options that include aleatory uncertainty and scale effects are compared against the experiments. Other quantities of interest include the average value of the absorbed energy and bend angle of the specimen. Taylor-anvil impact tests are performed on Ti6Al4V titanium alloy. The impact speeds of the specimen are 321 m/s and 393 m/s. The goal of the numerical work is to reproduce the damage patterns observed in the laboratory. For the numerical study, the Johnson-Cook failure model is used as the ductile fracture criterion, and aleatory uncertainty is applied to rate-dependence parameters to explore its effect on the fracture patterns.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2014

Exploring the Interdependencies Between Parameters in a Material Model

A method is investigated to reduce the number of numerical parameters in a material model for a solid. The basis of the method is to detect interdependencies between parameters within a class of materials of interest. The method is demonstrated for a set of material property data for iron and steel using the Johnson-Cook plasticity model.

36 MATERIALS SCIENCE↗
DOE OSTI2016

The MIDAS touch for Accurately Predicting the Stress-Strain Behavior of Tantalum

Testing the behavior of metals in extreme environments is not always feasible, so material scientists use models to try and predict the behavior. To achieve accurate results it is necessary to use the appropriate model and material-specific parameters. This research evaluated the performance of six material models available in the MIDAS database [1] to determine at which temperatures and strain-rates they perform best, and to determine to which experimental data their parameters were optimized. Additionally, parameters were optimized for the Johnson-Cook model using experimental data from Lassila et al [2].

36 MATERIALS SCIENCE↗
DOE OSTI2018

Multilinear stress-strain and failure calibrations for Ti-6Al-4V.

This memo concerns calibration of an elastic-plastic J 2 material model for Ti-6Al-4V (grade 5) alloy based on tensile uniaxial stress-strain data obtained in the laboratory. In addition, tension tests on notched specimens provided data to calibrate two ductile failure models: Johnson-Cook and Wellman's tearing parameter. The tests were conducted by Kim Haulen- beek and Dave Johnson (1528) in the Structural Mechanics Laboratory (SML) during late March and early April, 2017. The SML EWP number was 4162. The stock material was a TIMETALR® 6-4 Titanium billet with 9 in. by 9 in. square section and length of 137 in. The product description indicates that it was a forging delivered in annealed condition (2 hours @ 1300oF, AC at the mill). The tensile mechanical properties reported in the material certi cation are given in Table 1, where σ o represents the 0.2% strain offset yield stress, σ u the ultimate stress, ε f the elongation at failure and R.A. the reduction in area.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Material Testing for Shear-Dominated Ductile Failure

An initial foray into the design of specimens that can be used to provide data about the quasistatic ductile failure of metals when subjected to shear-dominated (low triaxiality) states of stress was undertaken. Four specimen geometries made from two materials with different ductility (Al 7075, lower ductility and steel A286, higher ductility) were considered as candidates. Based on results from analysis and experimentation, it seems that two show promise for further consideration. Whereas preliminary results indicate that the Johnson-Cook model fit the failure data for Al 7075 well, it did not fit the data for steel A286. Further work is needed to consolidate the results and evaluate other failure models that may fit the steel data better, as well as to extend the results of this work to the dynamic loading regime.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Modular Growth and Nucleation Formulations in Modular Plasticity Models

Recent investigations like the second and third Sandia Fracture Challenges have characterized and demonstrated the performance of a variety of failure techniques and models. These surveys have considered a wide breadth of models encapsulating both general failure criteria as well as those focusing on pore nucleation and growth. Extensive reviews exist on both topics. The former category generally consists of classic models like the Johnson-Cook or Wilkins criteria. These models were recently added to modular plasticity models in the Library of Advanced Materials for Engineering (LAME) as criteria for use with element death capabilities. The latter category was not treated in that effort. There exists a large class of failure models based on predicting the evolution of pores and failure associated with such microstructures. While the exact mechanisms and corresponding impact on the macroscale behavior remain an active area of research, a large suite of formulations have been proposed combining different features of both pore nucleation and subsequent growth. The most famous of these are based on the popular Gurson model of pore growth derived via micromechanical analysis assuming a plastically incompressible matrix. Numerous other models exist for both growth and nucleation and the Cocks-Ashby growth and Horstemeyer-Gokhale nucleation models have been used successfully in recent Sandia Fracture Challenges. This specific combination is colloquially referred to as the "BCJ-failure model as it has been frequently used with the Bammann-Chisea-Johnson plasticity model.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Characterization of Tri-lab β-Tin (Sn)

This report documents details of the microstructure and mechanical properties of -tin (Sn), that is used in the Tri-lab (Los Alamos National Laboratory (LANL), Lawrence Livermore National Laboratory (LLNL), Sandia National Laboratories (SNL)) collaboration project on Multi-phase Tin Strength. We report microstructural features detailing the crystallographic texture and grain morphology of as-received -tin from electron back scatter diffraction (EBSD). Temperature and strain rate dependent mechanical behavior was investigated by multiple compression tests at temperatures of 200K to 400K and strain rates of 0.0001 /s to 100 /s. Tri-lab tin showed significant temperature and strain rate dependent strength with no significant plastic anisotropy. A sample to sample material variation was observed from duplicate compression tests and texture measurements. Compression data was used to calibrate model parameters for temperature and rate dependent strength models, Johnson-Cook (JC), Zerilli-Armstrong (ZA) and Preston-Tonks-Wallace (PTW) strength models.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effects of Model Uncertainties in Underground Chemical Explosions on Far-field Results

We used the CTH shock physics code to simulate the explosion of an 18-t chemical explosive at a depth of 250 m. We used the CTH in the two-dimensional axisymmetric (cylindrical) geometry (2DC) and most simulations included fully tamped explosions in wet tuff. Our study focused on parametric studies of three of the traditional strength models available in CTH, namely, geologic-yield, elastic perfectly-plastic von Mises, and Johnson-Cook strength (flow stress) models. We processed CTH results through a code that generates Reduced Displacement Potential (RDP) histories for each simulation. Since RDP is the solution of the linear wave equation in spherical coordinates, it is mainly valid at far-enough distance from the explosion the elastic radius. Among various parameters examined, we found the yield strength to have the greatest effect on the resulting RDP, where the peak RDP reduces almost linearly in log-log space as the yield strength increases. Moreover, an underground chemical explosion results in a cavity whose final diameter is inversely proportional to the material yield strength, i.e., as the material's yield strength increases the resulting final cavity radius decreases. Additionally, we found the choice of explosive material (COMP-C4 versus COMP-B) has minor effects on the peak RDP, where denser COMP-C4 shows higher peak RDP than the less dense COMP-B by a factor of ~1.1. In addition to wet tuff, we studied explosions in dry tuff, salt, and basalt, for a single strength model and yield strength value. We found wet tuff has the highest peak RDP value, followed by dry tuff, salt, and basalt. 2DC simulations of explosions in 11 m radius spherical, hemispherical, and cylindrical cavities showed the RDP signals have much lower magnitude than tamped explosions, where the cavity explosions mimicked nearly decoupled explosions.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2024

Calibration of Al7075 with Plate-Puncture Predictions

The following details calibration of a material model for Al7075-T6511. This aluminum alloy is commonly used across a host of engineering applications. Owing to its widespread prevalence, there is great benefit in improving simulation predictions for this alloy. In the present effort, a calibration is performed of its elastic-plastic response accounting for both rate and temperature dependence. The calibration is informed by a series of tests that include specimens of different geometries tested at different rates and temperatures. All specimens are derived from the same barstock, 3.5 inches in diameter. The fitted model itself uses an anisotropic, Hill yield surface coupled with a Johnson-Cook hardening model. Failure predictions are had by means of a modified Wilkins failure criterion. Following calibration of the material model, a validation exercise is performed against platepuncture experiments. These experiments include multiple probe shapes, probe diameters, and plate thicknesses. The puncture experiments are replicated in simulation with mesh studies performed to assess uncertainty. Key quantities of interest, notably the absorbed energy up to failure, are compared between simulation and experiment providing a means to assess the suitability of the calibration in puncture simulations.

36 MATERIALS SCIENCE↗
DOE OSTI2025

RaDIATE Collaboration Thermal shock studies

As next-generation accelerator target facilities (High Energy Physics, Spallation Sources, ... ) become increasingly more powerful and intense, high power target systems face key technical challenges, such as radiation damage and thermal shock. Those ultimately degrade the performance and lifetime of targets and have been identified as the leading cross-cutting challenges of high-power target facilities. In order to operate reliable beam-intercepting devices in the framework of energy and intensity increase for next generation accelerators, the RaDIATE Collaboration (Radiation Damage In Accelerator Target Environment), established in 2012 and managed by Fermilab, brings together existing expertise in nuclear material and accelerator targets from 20 international institutions, including CERN, to execute a coordinated strategy for high power targetry R&D. In this context, several thermal shock studies were performed at CERN's HiRadMat (High-Radiation to Materials) facility, that took a key step towards improving our knowledge on target damage tolerance. The first experiment HRMT-24, supported by EURCARD2 and completed in 2015, successfully validated the Johnson-Cook strength model developed at SwRI on beryllium S200FH (used for beam window material), providing a better confidence in simulating the thermal shock response of current and future S200FH beryllium components. HRMT-43, supported by ARIES and completed in 2018, tested various materials (Be, C, SiC, Si, Ti and ceramic nanofiber). It was a first and unique test which included pre-irradiated specimens from high energy proton beam irradiation to identify thermal shock response differences between non-irradiated and previously irradiated materials. Real-time measurement of dynamic thermomechanical response of graphite helped to benchmark numerical simulations.

43 PARTICLE ACCELERATORS↗
NASA NTRS2001

Impact Cratering Calculations

We examined the von Mises and Mohr-Coulomb strength models with and without damage effects and developed a model for dilatancy. The models and results are given in O'Keefe et al. We found that by incorporating damage into the models that we could in a single integrated impact calculation, starting with the bolide in the atmosphere produce final crater profiles having the major features found in the field measurements. These features included a central uplift, an inner ring, circular terracing and faulting. This was accomplished with undamaged surface strengths of approximately 0.1 GPa and at depth strengths of approximately 1.0 GPa. We modeled the damage in geologic materials using a phenomenological approach, which coupled the Johnson-Cook damage model with the CTH code geologic strength model. The objective here was not to determine the distribution of fragment sizes, but rather to determine the effect of brecciated and comminuted material on the crater evolution, fault production, ejecta distribution, and final crater morphology.

Ahrens, Thomas J.↗
NASA NTRS2015

Impact and Penetration of Thin Aluminum 2024 Flat Panels at Oblique Angles of Incidence

The U.S. Federal Aviation Administration (FAA) and the National Aeronautics and Space Administration (NASA) are actively involved in improving the predictive capabilities of transient finite element computational methods for application to safety issues involving unintended impacts on aircraft and aircraft engine structures. One aspect of this work involves the development of an improved deformation and failure model for metallic materials, known as the Tabulated Johnson-Cook model, or MAT224, which has been implemented in the LS-DYNA commercial transient finite element analysis code (LSTC Corp., Livermore, CA) (Ref. 1). In this model the yield stress is a function of strain, strain rate and temperature and the plastic failure strain is a function of the state of stress, temperature and strain rate. The failure criterion is based on the accumulation of plastic strain in an element. The model also incorporates a regularization scheme to account for the dependency of plastic failure strain on mesh size. For a given material the model requires a significant amount of testing to determine the yield stress and failure strain as a function of the three-dimensional state of stress, strain rate and temperature. In addition, experiments are required to validate the model. Currently the model has been developed for Aluminum 2024 and validated against a series of ballistic impact tests on flat plates of various thicknesses (Refs. 1 to 3). Full development of the model for Titanium 6Al-4V is being completed, and mechanical testing for Inconel 718 has begun. The validation testing for the models involves ballistic impact tests using cylindrical projectiles impacting flat plates at a normal incidence (Ref. 2). By varying the thickness of the plates, different stress states and resulting failure modes are induced, providing a range of conditions over which the model can be validated. The objective of the study reported here was to provide experimental data to evaluate the model under more extreme conditions, using a projectile with a more complex shape and sharp contacts, impacting flat panels at oblique angles of incidence.

Ruggeri, Charles R.↗
DOE OSTI2022

A Realistic Full-Scale 3D Modeling of Turning Using Coupled Smoothed Particle Hydrodynamics and Finite Element Method for Predicting Cutting Forces

Computational modelling is an effective technique for understanding the complex physics of machining. Large deformations, material separation, and high computational requirements are the key challenges faced while simulating machining. This work introduces a full-scale three-dimensional model of turning operations using a combined approach based on the Smoothed Particle Hydrodynamics (SPH) and Finite Element (FE) methods. By exploiting the advantages of each method, this approach leads to high-fidelity coupled SPH-FE machining models. Cutting forces and chip morphology are the primary results of interest. The machining models are validated with the results of turning experiments. Two-dimensional machining model underpredicts the cutting force and feed force by approximately 49% and 70%, respectively. Moreover, passive force cannot be predicted using the two-dimensional model. On the other hand, with the three-dimensional models developed in this manuscript, the difference between the total simulated force and experimentally measured force is ∼17%. The chip morphologies correlate with experiments in terms of the direction of the chip movement and the “long” continuous chips observed while turning Al 6061. This work expands the realm of machining simulations from two-dimensional orthogonal machining or sectional three-dimensional model to a full-scale realistic simulation. The encouraging simulation results show the potential to study more complex phenomena, such as machining stability and tool path modulation.

42 ENGINEERING↗