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DOE OSTI2021

Microstructural Model for Creep-Fatigue Interaction in Grade 91 Steel

This report describes the completion of a crystal plasticity finite element simulation framework for creep-fatigue deformation and damage in Grade 91 steel. In addition to a description of the framework and a set of verification calculations, the report details an initial set of simulations applying the framework to examine low cycle fatigue and creep-fatigue interaction in Grade 91 at 600° C. Grade 91 is a likely material for future advanced microreactors and creep-fatigue will be a limiting structural damage mechanism, particularly for mobile reactors or load following systems. The framework described here could provide a better understanding of creep-fatigue damage mechanisms and directly examine creep, fatigue, and creep-fatigue interaction for Grade 91 at realistic component service conditions. This in turn could lead to improved design methods and component life estimation approaches, leading to more efficient and economical component designs.

36 MATERIALS SCIENCE↗

DOE OSTI2023

A mechanistic model for creep and thermal aging in Alloy 709

This report describes a physics-based model for creep and thermal aging in Alloy 709. Alloy 709 is an advanced austenitic alloy, targeted for use in future Sodium Fast Reactors (SFRs) and other advanced reactors. The material has superior high temperature properties compared to currently qualified 316 and 304 stainless steels. However, the available creep and thermal aging test database for Alloy 709 is significantly more limited compared to the historical materials. The physics-based model developed here is one way to accelerate the qualification of the material by providing more accurate long-term predictions for creep properties and thermal aging, compared to current empirical time-extrapolate techniques. The crystal plasticity finite element model is used to predict the deformation and failure of alloy 709. The same setup for the CPFE model is used in both the baseline model calibration process and the simulation campaigns for parameter inference. Specific constitutive choices are made for Alloy 709 to capture the primary deformation mechanisms. The dislocation creep formulation developed by Hu and Cocks is extended to account for coupled precipitation formation and the grain boundary cavitation model developed by Sham, Needleman, et al. is used to model grain boundary cavitation-induced failure. A novel update algorithm is proposed to render the semi-discrete constitutive update for the Sham-Needleman model unconditionally stable. A progressive calibration approach is adopted based on the observations that several types of material responses can be effectively decoupled. A surrogate model is trained based on full-fledged CPFE simulations to accelerate the forward model evaluations, and stochastic variational inference (SVI) is used to calibrate the unknown microstructural model parameters. The calibrated mechanistic model is used to predict the long-term creep life of Alloy 709, and the predictions are compared against classical empirical approaches.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Effect of Computational Schemes on Coupled Flow and Geo-Mechanical Modeling of CO 2 Leakage through a Compromised Well

Carbon capture, utilization, and storage (CCUS) describes a set of technically viable processes to separate carbon dioxide (CO 2 ) from industrial byproduct streams and inject it into deep geologic formations for long-term storage. Legacy wells located within the spatial domain of new injection and production activities represent potential pathways for fluids (i.e., CO 2 and aqueous phase) to leak through compromised components (e.g., through fractures or micro-annulus pathways). The finite element (FE) method is a well-established numerical approach to simulate the coupling between multi-phase fluid flow and solid phase deformation interactions that occur in a compromised well system. We assumed the spatial domain consists of a three-phases system: a solid, liquid, and gas phase. For flow in the two fluids phases, we considered two sets of primary variables: the first considering capillary pressure and gas pressure (PP) scheme, and the second considering liquid pressure and gas saturation (PS) scheme. Fluid phases were coupled with the solid phase using the full coupling (i.e., monolithic coupling) and iterative coupling (i.e., sequential coupling) approaches. The challenge of achieving numerical stability in the coupled formulation in heterogeneous media was addressed using the mass lumping and the upwinding techniques. Numerical results were compared with three benchmark problems to assess the performance of coupled FE solutions: 1D Terzaghi’s consolidation, Liakopoulos experiments, and the Kueper and Frind experiments. We found good agreement between our results and the three benchmark problems. For the Kueper and Frind test, the PP scheme successfully captured the observed experimental response of the non-aqueous phase infiltration, in contrast to the PS scheme. These exercises demonstrate the importance of fluid phase primary variable selection for heterogeneous porous media. We then applied the developed model to the hypothetical case of leakage along a compromised well representing a heterogeneous media. Considering the mass lumping and the upwinding techniques, both the monotonic and the sequential coupling provided identical results, but mass lumping was needed to avoid numerical instabilities in the sequential coupling. Additionally, in the monolithic coupling, the magnitude of primary variables in the coupled solution without mass lumping and the upwinding is higher, which is essential for the risk-based analyses.

deformation flow↗

DOE OSTI2025

Instability of Nagaoka State and Quantum Phase Transition via Kinetic Frustration Control

We investigate the Nagaoka-Thouless (NT) ferromagnetic instability in the strongly interacting t-t' Hubbard model by continuously breaking particle-hole symmetry on a tunable square-triangular lattice geometry. We use an analytic approach to show that the fully spin-polarized state becomes unstable to a metastable spin-polaron when the kinetic frustration t'/t exceeds a critical, dimension-dependent value. Large-scale density matrix renormalization group (DMRG) simulations reveal a quantum phase transition from the NT ferromagnet to a spiral spin-density wave, which evolves continuously into the Haerter-Shastry antiferromagnet in the large-frustration limit. Remarkably, this transition remains robust at low but finite hole density, making it accessible in cold-atom and moiré Hubbard platforms under strong interactions. A variational analysis further captures the instability mechanism at finite density via frustration-induced magnon band deformation.

FOS: Physical sciences↗

NASA NTRS1975

The motion of interconnected flexible bodies

The equations of motion for an arbitrarily interconnected collection of substructures are derived. The substructures are elastic bodies which may be idealized as finite element assemblies and are subject to small deformations relative to a nominal state. Interconnections between the elastic substructures permit large relative translations and rotations between substructures, governed by Pfaffian constraints describing the connections. Screw connections (permitting rotation about and translation along a single axis) eliminate constraint forces and incorporate modal coupling. The problem of flexible spacecraft simulation is discussed. Hurty's component mode approach is extended by permitting interconnected elastic substructures large motions relative to each other and relative to inertial space. The hybrid coordinate methods are generalized by permitting all substructures to be flexible (rather than only the terminal members of a topological tree of substructures). The basic relationships of continuum mechanics are developed.

Hopkins, A. S.↗

NASA NTRS1979

Recent finite element studies in plasticity and fracture mechanics

The paper reviews recent work on fundamentals of elastic-plastic finite-element analysis and its applications to the mechanics of crack opening and growth in ductile solids. The presentation begins with a precise formulation of incremental equilibrium equations and their finite-element forms in a manner valid for deformations of arbitrary magnitude. Special features of computational procedures are outlined for accuracy in view of the near-incompressibility of elastic-plastic response. Applications to crack mechanics include the analysis of large plastic deformations at a progressively opening crack tip, the determination of J integral values and of limitations to J characterizations of the intensity of the crack tip field, and the determination of crack tip fields in stable crack growth.

Rice, J. R.↗

NASA NTRS1984

Coseismic and postseismic vertical movements associated with the 1940 M7.1 Imperial Valley, California, earthquake

Leveling surveys conducted along two routes that cross the Imperial fault in southern California indicate spatially coherent elevation changes attributable to coseismic and postseismic effects of the 1940, M7.1 Imperial Valley earthquake. The 1931-1941 elevation changes are consistent with theoretical models of vertical deformation of an elastic half space for a finite length strike-slip fault, using fault parameters that are consistent with the observed surface offsets following the 1940 earthquake. The elevation changes suggest an earthquake scenario consisting of a large coeismic slip in the southern half of the fault which transferred stress to the northern part as well as to the Brawley fault to the northeast.

Reilinger, R.↗

NASA NTRS1988

Thermo-viscoelastic response of graphite/epoxy composites

The thermo-viscoelastic behavior of composite material is studied analytically using a special finite-element formulation. Numerical results on stress and deformation histories are obtained for both unnotched and notched graphite/epoxy composites subjected to mechanical and thermal spectrum loads. The results indicate that time-dependent effects are important in composites with matrix-dominated layup orientations. Such effects also strongly depend on the specific environment condition and load spectrum applied.

Lin, Kuen↗

NASA NTRS1990

The Interpretation of Crustal Dynamics Data in Terms of Plate Interactions and Active Tectonics of the Anatolian Plate and Surrounding Regions in the Middle East

During the past 6 months, efforts were concentrated on the following areas: (1) Continued development of realistic, finite element modeling of plate interactions and associated deformation in the Eastern Mediterranean; (2) Neotectonic field investigations of seismic faulting along the active fault systems in Turkey with emphasis on identifying seismic gaps along the North Anatolian fault; and (3) Establishment of a GPS regional monitoring network in the zone of ongoing continental collision in eastern Turkey (supported in part by NSF).

Toksoz, M. Nafi↗

NASA NTRS1991

Finite element implementation of state variable-based viscoplasticity models

The implementation of state variable-based viscoplasticity models is made in a general purpose finite element code for structural applications of metals deformed at elevated temperatures. Two constitutive models, Walker's and Robinson's models, are studied in conjunction with two implicit integration methods: the trapezoidal rule with Newton-Raphson iterations and an asymptotic integration algorithm. A comparison is made between the two integration methods, and the latter method appears to be computationally more appealing in terms of numerical accuracy and CPU time. However, in order to make the asymptotic algorithm robust, it is necessary to include a self adaptive scheme with subincremental step control and error checking of the Jacobian matrix at the integration points. Three examples are given to illustrate the numerical aspects of the integration methods tested.

Iskovitz, I.↗

NASA NTRS1992

Collapse of composite tubes under end moments

Cylindrical tubes of moderate wall thickness such as those proposed for the original space station truss, may fail due to the gradual collapse of the tube cross section as it distorts under load. Sometimes referred to as the Brazier instability, it is a nonlinear phenomenon. This paper presents an extension of an approximate closed form solution of the collapse of isotropic tubes subject to end moments developed by Reissner in 1959 to include specially orthotropic material. The closed form solution was verified by an extensive nonlinear finite element analysis of the collapse of long tubes under applied end moments for radius to thickness ratios and composite layups in the range proposed for recent space station truss framework designs. The finite element analysis validated the assumption of inextensional deformation of the cylindrical cross section and the approximation of the material as specially orthotropic.

Stockwell, Alan E.↗

NASA NTRS1991

Effect of thermal convection on the shape of a solid-liquid interface

The effect of thermal convection on the shape of solid-liquid interface was investigated in experiments conducted in a transparent Bridgman-type directional solidification furnace. The relationship was numerically modeled using a standard 2D finite-difference approach, with the solid-liquid deformable interface approximated by a blocking-off technique. The directional solidification furnace was used with pure succinonitrile (which is also transparent) contained in a long square ampoule made of borosilicate glass. With the furnace in the vertical configuration, a flat interface was observed, in agreement with the model. On the other hand, a highly distorted interface was obtained in the horizontal configuration; the numerical results showed a strong recirculating cell in front of the interface due to natural thermal convection. The results indicate that thermal convection is responsible for the interface distortion.

Mennetrier, C.↗

NASA NTRS1993

Finite element implementation of state variable-based viscoplasticity models

Chang, T. Y. P.↗

NASA NTRS1993

State of stress, faulting, and eruption characteristics of large volcanoes on Mars

The formation of a large volcano loads the underlying lithospheric plate and can lead to lithospheric flexure and faulting. In turn, lithospheric stresses affect the stress field beneath and within the volcanic edifice and can influence magma transport. Modeling the interaction of these processes is crucial to an understanding of the history of eruption characteristics and tectonic deformation of large volcanoes. We develop models of time-dependent stress and deformation of the Tharsis volcanoes on Mars. A finite element code is used that simulates viscoelastic flow in the mantle and elastic plate flexural behavior. We calculate stresses and displacements due to a volcano-shaped load emplaced on an elastic plate. Models variously incorporate growth of the volcanic load with time and a detachment between volcano and lithosphere. The models illustrate the manner in which time-dependent stresses induced by lithospheric plate flexure beneath the volcanic load may affect eruption histories, and the derived stress fields can be related to tectonic features on and surrounding martian volcanoes.

Mcgovern, Patrick J.↗

NASA NTRS1993

TransFit: Finite element analysis data fitting software

The Advanced X-Ray Astrophysics Facility (AXAF) mission support team has made extensive use of geometric ray tracing to analyze the performance of AXAF developmental and flight optics. One important aspect of this performance modeling is the incorporation of finite element analysis (FEA) data into the surface deformations of the optical elements. TransFit is software designed for the fitting of FEA data of Wolter I optical surface distortions with a continuous surface description which can then be used by SAO's analytic ray tracing software, currently OSAC (Optical Surface Analysis Code). The improved capabilities of Transfit over previous methods include bicubic spline fitting of FEA data to accommodate higher spatial frequency distortions, fitted data visualization for assessing the quality of fit, the ability to accommodate input data from three FEA codes plus other standard formats, and options for alignment of the model coordinate system with the ray trace coordinate system. TransFit uses the AnswerGarden graphical user interface (GUI) to edit input parameters and then access routines written in PV-WAVE, C, and FORTRAN to allow the user to interactively create, evaluate, and modify the fit. The topics covered include an introduction to TransFit: requirements, designs philosophy, and implementation; design specifics: modules, parameters, fitting algorithms, and data displays; a procedural example; verification of performance; future work; and appendices on online help and ray trace results of the verification section.

Freeman, Mark↗

NASA NTRS1997

Thermostructural Behavior of a Hypersonic Aircraft Sandwich Panel Subjected to Heating on One Side

Thermostructural analysis was performed on a heated titanium honeycomb-core sandwich panel. The sandwich panel was supported at its four edges with spar-like substructures that acted as heat sinks, which are generally not considered in the classical analysis. One side of the panel was heated to high temperature to simulate aerodynamic heating during hypersonic flight. Two types of surface heating were considered: (1) flat-temperature profile, which ignores the effect of edge heat sinks, and (2) dome-shaped-temperature profile, which approximates the actual surface temperature distribution associated with the existence of edge heat sinks. The finite-element method was used to calculate the deformation field and thermal stress distributions in the face sheets and core of the sandwich panel. The detailed thermal stress distributions in the sandwich panel are presented, and critical stress regions are identified. The study shows how the magnitudes of those critical stresses and their locations change with different heating and edge conditions. This technical report presents comprehensive, three-dimensional graphical displays of thermal stress distributions in every part of a titanium honeycomb-core sandwich panel subjected to hypersonic heating on one side. The plots offer quick visualization of the structural response of the panel and are very useful for hot structures designers to identify the critical stress regions.

Ko, William L.↗

NASA NTRS1961

Cross-Sectional Deformations of Monocoque Beams and Their Effects on the Natural Vibration Frequencies

The variational principle, differential equations, and boundary conditions governing the cross-sectional distortions due to inertia loading of a two-dimensional model of a thin monocoque wing are shown. A theoretical analysis of this simplified model is made in order to determine the nature of the coupling between the cross-sectional modes and the spanwise deformation modes. General solutions are obtained in finite-difference form for arbitrary cross sections and an exact solution is presented for a parabolic-arc cross section of constant cover thickness. The application of these results in evaluating the coupled frequencies of the actual structure is discussed. Frequencies evaluated for a parabolic-arc monocoque beam show good agreement with experimental values.

Thomson, Robert G.↗

NASA NTRS2000

Optical Performance Modeling of FUSE Telescope Mirror

We describe the Metrology Data Processor (METDAT), the Optical Surface Analysis Code (OSAC), and their application to the image evaluation of the Far Ultraviolet Spectroscopic Explorer (FUSE) mirrors. The FUSE instrument - designed and developed by the Johns Hopkins University and launched in June 1999 is an astrophysics satellite which provides high resolution spectra (lambda/Delta(lambda) = 20,000 - 25,000) in the wavelength region from 90.5 to 118.7 nm The FUSE instrument is comprised of four co-aligned, normal incidence, off-axis parabolic mirrors, four Rowland circle spectrograph channels with holographic gratings, and delay line microchannel plate detectors. The OSAC code provides a comprehensive analysis of optical system performance, including the effects of optical surface misalignments, low spatial frequency deformations described by discrete polynomial terms, mid- and high-spatial frequency deformations (surface roughness), and diffraction due to the finite size of the aperture. Both normal incidence (traditionally infrared, visible, and near ultraviolet mirror systems) and grazing incidence (x-ray mirror systems) systems can be analyzed. The code also properly accounts for reflectance losses on the mirror surfaces. Low frequency surface errors are described in OSAC by using Zernike polynomials for normal incidence mirrors and Legendre-Fourier polynomials for grazing incidence mirrors. The scatter analysis of the mirror is based on scalar scatter theory. The program accepts simple autocovariance (ACV) function models or power spectral density (PSD) models derived from mirror surface metrology data as input to the scatter calculation. The end product of the program is a user-defined pixel array containing the system Point Spread Function (PSF). The METDAT routine is used in conjunction with the OSAC program. This code reads in laboratory metrology data in a normalized format. The code then fits the data using Zernike polynomials for normal incidence systems or Legendre-Fourier polynomials for grazing incidence systems. It removes low order terms from the metrology data, calculates statistical ACV or PSD functions, and fits these data to OSAC models for the scatter analysis. In this paper we briefly describe the laboratory image testing of FUSE spare mirror performed in the near and vacuum ultraviolet at John Hopkins University and OSAC modeling of the test setup performed at NASA/GSFC. The test setup is a double-pass configuration consisting of a Hg discharge source, the FUSE off-axis parabolic mirror under test, an autocollimating flat mirror, and a tomographic imaging detector. Two additional, small fold flats are used in the optical train to accommodate the light source and the detector. The modeling is based on Zernike fitting and PSD analysis of surface metrology data measured by both the mirror vendor (Tinsley) and JHU. The results of our models agree well with the laboratory imaging data, thus validating our theoretical model. Finally, we predict the imaging performance of FUSE mirrors in their flight configuration at far-ultraviolet wavelengths.

Saha, Timo T.↗