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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 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Development of Predictive Model for Accurate Rupture Time from Multi-Axial Creep in Alloy 709 with Physics-Based Simulations

A physics-based model is developed to predict multiaxial creep behavior in Alloy 709 (A709), an advanced austenitic stainless steel intended for high-temperature applications such as Sodium Fast Reactors (SFRs). Compared to conventional stainless steels like 316H, A709 offers superior high-temperature performance; however, comprehensive data on its multiaxial creep response remain limited. To address this gap, a crystal plasticity finite element (CPFE) framework is used to simulate the deformation and failure mechanisms of A709 under multiaxial loading conditions. The model incorporates an extended Hu-Cocks dislocation creep formulation that accounts for precipitation effects, along with the Sham–Needleman model to capture grain boundary cavitation-driven failure. These advanced constitutive models enable a detailed understanding of the interplay between microstructural evolution and macroscopic creep response. Furthermore, the study evaluates the predictive accuracy of various effective stress measures in estimating creep rupture life, leveraging simulated multiaxial creep data. The findings provide critical insights into the applicability of different stress measures for engineering design and life prediction of A709 components operating under complex loading conditions. This work contributes to improving the reliability of high-temperature structural components by advancing predictive modeling capabilities for advanced austenitic steels.

Alloy 709↗
DOE OSTI2022

The effects of microstructure on deformation twinning in Mg WE43

The interplay between microstructure and deformation twinning in a WE43-T6 Mg alloy under uniaxial compression was investigated using a combination of scanning electron microscopy with digital image correlation (SEM-DIC) and crystal plasticity finite element (CPFE) simulation. To improve understanding of the statistical characteristics of deformation twin formation, microstructural effects were characterized in over 1000 grains through metrics including the nominal Schmid Factor, grain size, geometric compatibility factor (m'), residual Burgers vector, and the strain accommodated by neighboring grains. There was a strong correlation between the nominal Schmid Factor and both twin activation and variant selection, but this was not fully deterministic. Deformation twinning also exhibited a strong dependence on existing slip and twinning in the neighboring grain and on the m' value. Within the range of grain sizes present in this condition, grain size was determined to have minimal effect on deformation twinning. Finally, statistical analysis of CPFE simulations was used to further investigate microstructural effects on twinning, and qualitatively captured the effect of the nominal Schmid Factor.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A data-driven approach to modeling cancer cell mechanics during microcirculatory transport

In order to understand the effect of cellular level features on the transport of circulating cancer cells in the microcirculation, there has been an increasing reliance on high-resolution in silico models. Accurate simulation of cancer cells flowing with blood cells requires resolving cellular-scale interactions in 3D, which is a significant computational undertaking warranting a cancer cell model that is both computationally efficient yet sufficiently complex to capture relevant behavior. Given that the characteristics of metastatic spread are known to depend on cancer type, it is crucial to account for mechanistic behavior representative of a specific cancer’s cells. To address this gap, in the present work we develop and validate a means by which an efficient and popular membrane model-based approach can be used to simulate deformable cancer cells and reproduce experimental data from specific cell lines. Here, cells are modeled using the immersed boundary method (IBM) within a lattice Boltzmann method (LBM) fluid solver, and the finite element method (FEM) is used to model cell membrane resistance to deformation. Through detailed comparisons with experiments, we (i) validate this model to represent cancer cells undergoing large deformation, (ii) outline a systematic approach to parameterize different cell lines to optimally fit experimental data over a range of deformations, and (iii) provide new insight into nucleated vs. non-nucleated cell models and their ability to match experiments. While many works have used the membrane-model based method employed here to model generic cancer cells, no quantitative comparisons with experiments exist in the literature for specific cell lines undergoing large deformation. Here, we describe a phenomenological, data-driven approach that can not only yield good agreement for large deformations, but explicitly detail how it can be used to represent different cancer cell lines. This model is readily incorporated into cell-resolved hemodynamic transport simulations, and thus offers significant potential to complement experiments towards providing new insights into various aspects of cancer progression.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Comparison of three state-of-the-art crystal plasticity based deformation twinning models for magnesium alloys

In magnesium alloys, deformation twinning and its interactions with dislocation slip are responsible for a sigmoidal shape stress–strain behavior and an asymmetrical tension–compression yield strength in magnesium alloys. The sensitivity of twinning to the underlying microstructure renders the crystal plasticity method the most commonly adopted modeling approach for magnesium-twinning. This paper compares three state-of-the-art crystal plasticity-based twinning models from the literature, namely the elastic-viscoplastic self-consistent twinning-detwinning (EVPSC-TDT) model, crystal plasticity finite element model based on enhanced predominate twin reorientation approach (CPFE-ePTR), and the crystal plasticity finite element model based on “discrete twinning” approach (CPFE-DT). A polycrystalline microstructure is simulated with all three methods to compare the resulting stress–strain curves and lattice strains to those from the experimentally measured data. All three methods showed the capability of capturing the experimental results with different levels of accuracy. Additionally, the EVPSC-TDT method avoids solving the finite element matrices and showed the highest computational efficiency. The CPFE-ePTR model shows a higher accuracy in capturing the lattice strain. The CPFE-DT relies on high-resolution finite element mesh and is much slower than the other two methods, but it captured the local deformation concentration and stress reversal phenomena near the twin band, which was not possible with the other two methods. Based on the comparison, guidance for the selection of the appropriate model based on the specific modeling target is provided in this paper.

36 MATERIALS SCIENCE↗
NASA NTRS1991

A finite-element perturbation approach to fluid/rotor interaction in turbomachinery elements. I - Theory. II - Application

The vibrational characteristics of a rotor that is in contact with a fluid in an annular clearance gap are investigated. The disturbance under consideration involves the axis of rotation, and includes a virtual lateral eccentricity, together with a whirling motion around the housing centerline. The fluid reaction components arise from infinitesimally small deformations with varied magnitudes which are experienced by an assembly of finite elements in the rotor-to-housing gap. A perturbation model is presented in which the perturbation equations emerge from the flow-governing equations in their discrete finite-element form. It is concluded that restrictions on the rotor-to-housing gap geometry, or the manner in which the rotor virtual eccentricity occurs are practically nonexisting. This model is used to compute the rotordynamic coefficients of an annular seal. The rotordynamic behavior of a hydraulic seal with a clearance gap depth/length ratio of 0.01 is analyzed under a cylindrical type of rotor whirl and several running speeds.

Baskharone, E. A.↗
NASA NTRS1991

Deformation of the central Andes (15-27 deg S) derived from a flow model of subduction zones

A simple viscous flow model of a subduction zone is used to calculate the deformation within continental lithosphere above a subducting slab. This formulation accounts for two forces that dominate the deformation in the overriding lithosphere: tectonic forces and buoyancy forces. Numerical solutions, obtained by using a finite element technique, are compared with observations from the central Andes (15-27 deg S). The model predicts the observed deformation pattern of extension in the forearc, compression in the Western Monocline (corresponding to magmatic activity), extension in the Altiplano, compression in the Eastern Monocline and Subandes, and no deformation in the Brazilian Shield. By comparing the calculated solutions with the large-scale tectonic observations, the forces that govern the deformation in the central Andes are evaluated. The approximately constant subduction velocity in the past 26 million years suggests that the rate of crustal shortening in the Andes has decreased with time due to the thickening of the crust.

Wdowinski, Shimon↗
NASA NTRS1985

An evaluation of fracture analysis methods

The results of an experimental and predictive round robin on the applications of fracture analysis methods are presented. The objective of the round robin was to verify whether fracture analysis methods currently in use can or cannot predict failure loads on complex structural components containing cracks. Fracture results from tests on a number of compact specimens were used to make the predictions. The accuracy of the prediction methods was evaluated in terms of the variation in the ratio of predicted to experimental failure loads, and the predictions methods are ranked in order of minimum standard error. A range of applicability of the different methods was also considered in assessing their usefulness. For 7075-T651 aluminum alloy, the best methods were: the effective K sub R curve; the critical crack-tip opening displacement (CTOD) criterion using a finite element analysis; and the K sub R curve with the Dugdale model. For the 2024-T351 aluminum alloy, the best methods included: the two-parameter fracture criterion (TPFC); the CTOD parameter using finite element analysis; the K-curve with the Dugdale model; the deformation plasticity failure assessment diagram (DPFAD); and the effective K sub R curve with a limit load condition. For 304 stainless steel, the best methods were the limit load analysis; the CTOD criterion using finite-element analysis TPFC and DPFAD. Some sample experimental results are given in an appendix.

Newman, J. C., Jr.↗
DOE OSTI2020

Primal interface debonding formulation for finite strain isotropic plasticity

In this work, a framework is developed for modeling ductile damage of nonlinear materials whose plastic deformation is characterized using rate independent classical plasticity. This method relies on the assumption that the free energy can be decomposed into elastic, plastic and damage parts. A thermodynamically consistent method is derived which satisfies the second law of thermodynamics in the Clausius–Duhem inequality form. The dissipation associated with plasticity takes place in the domain only, while damage dissipation is localized to the interface. The method is developed using Variational Multiscale ideas to obtain definitions of the interface fluxes within a primal formulation analogous to the Discontinuous Galerkin method, which ensures weakly vanishing interface gap prior to reaching a damage initiation criterion. The local nonlinear problem to calculate both plastic deformation gradient and damage variable follows an incremental approach similar to classical plasticity return mapping algorithm. This elastoplastic damage formulation is developed for material undergoing finite strain, and it naturally accommodates a trapezoidal traction separation law (TSL) whose shape can be varied to model either ductile interface behavior or brittle interface behavior. The formulation's performance is assessed through modeling a patch test and a compact tension specimen.

42 ENGINEERING↗
NASA NTRS1993

Probabilistic nonlinear finite element analysis of composite structures

A probabilistic finite element analysis procedure for laminated composite shells is developed. A total Lagrangian finite element formulation, employing a degenerated three-dimensional laminated composite shell element with the full Green-Lagrange strains and first-order shear deformable kinematics, is used. The first-order second-moment technique for probabilistic finite element analysis of random fields is employed, and results are presented in the form of mean and variance of the structural response. Reliability calculations are made by using the first-order reliability method combined with sensitivity derivatives from the finite element analysis. Both ply-level and micromechanics-level random variables are incorporated, the latter by means of the Aboudi micromechanics model. Two sample problems are solved to verify the accuracy of the procedures developed and to quantify the variability of certain material type/structure combinations. In general, the procedure is quite effective in determining the response statistics and reliability for linear and geometric nonlinear behavior of laminated composite shells.

Engelstad, S. P.↗
DOE OSTI2020

Effect of nickel on the kinematic stability of retained austenite in carburized bearing steels – In-situ neutron diffraction and crystal plasticity modeling of uniaxial tension tests in AISI 8620, 4320 and 3310 steels

The presence of kinematically metastable retained austenite in the microstructure of bearing components can significantly affect the macro and micro-mechanical material response. In the present work, the influence of Ni on the stability of the retained austenite within three different grades of high carbon bearing steel using in-situ neutron diffraction is investigated. For the first time, the results show that presence of Ni increases the stability of the austenite in the elastic regime whereas the transformation rate remains unaffected. Crystal plasticity finite element (CPFE) modeling was used to study the deformation in these three steels and shows that the predominant factor causing the difference in mechanical behavior of these steels is the austenite stability. Finally, the elastic and plastic response of the matrix martensite was found to be identical among all specimens while the austenite demonstrates similar elastic behavior but remarkably different stabilities under monotonic loading.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Exact solutions of burst pressure for thick-walled cylinders in power-law strain hardening steels

Exact solutions of burst pressure for defect-free, thick-walled cylindrical pressure vessels with capped ends are developed using the flow theory of plasticity in terms of the Tresca, von Mises, and Zhu-Leis yield criteria. The material is assumed to obey a power-law strain hardening rule, and the finite strain theory is adopted to describe large plastic deformation. On this basis, internal pressure is obtained as a complex polynomial function of effective strains on the inside and outside surfaces of the pressure vessel with the use of the Bernoulli numbers. At burst failure, the effective strains and stresses on the inside and outside surfaces are first determined, and then three flow solutions of burst pressure are obtained as a power series function of the diameter ratio (D o /D i ), strain hardening exponent (n), and ultimate tensile strength (UTS). The power series solution is confirmed to agree well with the exact flow solution of burst pressure in a closed-form for each yield criterion, and the results show that the von Mises flow solution is an upper bound prediction, the Tresca flow solution is a lower bound prediction, and the Zhu-Leis flow solution is an intermediate prediction of burst pressure. In conclusion, two sets of full-scale burst test data are then utilized to evaluate and validate the proposed flow solutions of burst pressure for both thin-walled pipes and thick-walled cylindrical pressure vessels.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Crystal plasticity modeling and analysis for the transition from intergranular to transgranular failure in nickel-based alloy Inconel 740H at elevated temperature

The precipitation-strengthened Nickel alloy Inconel® 740H® (IN740H) exhibits increased ductility at higher applied strain rates during quasi-static tensile tests at an elevated temperature of 760°C. The examination of fracture surfaces in this context reveals a noteworthy transition of underlying fracture mechanisms from transgranular to intergranular fracture as the applied strain rate decreases from 1×10 -3 / s to 0.83×10 -4 / s . To thoroughly understand the mechanical response of IN740H under these conditions, this study develops a crystal plasticity finite element (CPFE) model. Further, this model incorporates various deformation mechanisms including dislocation slips, climb, and grain boundary sliding, which are relevant to the test conditions. The model is calibrated using data from both tensile tests at different strain rates and creep tests across a broad stress range at 760°C, enabling the accurate determination of model parameters for each mechanism. Simulation results well captured the experimental observations of different failure modes. At higher strain rates, the model shows a dominance of dislocation slip leading to heterogeneous plastic deformation and formation of transgranular shear bands causing the failure, while at lower strain rates, an increased activity of grain boundary sliding causes grain boundaries crack leading to intergranular failure.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Efficient mapping between void shapes and stress fields using Deep Convolutional Neural Networks with sparse data

Establishing fast and accurate structure-to-property relationships is an important component in the design and discovery of advanced materials. Physics-based simulation models like the finite element method (FEM) are often used to predict deformation, stress, and strain fields as a function of material microstructure in material and structural systems. Such models may be computationally expensive and time intensive if the underlying physics of the system is complex. This limits their application to solve inverse design problems and identify structures that maximize performance. In such scenarios, surrogate models are employed to make the forward mapping computationally efficient to evaluate. However, the high dimensionality of the input microstructure and the output field of interest often renders such surrogate models inefficient, especially when dealing with sparse data. Deep convolutional neural network (CNN) based surrogate models have shown great promise in handling such high-dimensional problems. In this paper, a single ellipsoidal void structure under a uniaxial tensile load represented by a linear elastic, high-dimensional and expensive-to-query, FEM model. We consider two deep CNN architectures, a modified convolutional autoencoder framework with a fully connected bottleneck and a UNet CNN, and compare their accuracy in predicting the von Mises stress field for any given input void shape in the FEM model. Additionally, a sensitivity analysis study is performed using the two approaches, where the variation in the prediction accuracy on unseen test data is studied through numerical experiments by varying the number of training samples from 20 to 100.

surrogate modeling; convolutional neural networks;↗
DOE OSTI2024

Integration of computer vision system to track the alignment SRF cavities into the test cryostat for PIP-II at Fermilab

PIP-II cryomodules use a computer vision system (H-BCAMs system) to monitor the alignment of SRF cavities and focusing lenses during assembly, testing, and operation. This contribution details the integration of the H-BCAMs into the Spoke Test Cryostat (STC) at Fermilab, which is utilized for cold testing SRF cavities prior to their integration into the string assembly. Thermal and structural finite element analyses were employed to estimate the cavities’ deformations, to be validated during cold testing in the STC using H-BCAMs. Notably, this marks the first instance of H-BCAMs integration into a cryostat and operation within a cryogenic environment.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

PAGOSA Theory Manual

PAGOSA is a computational fluid dynamics program developed at LANL for the study of high-speed compressible flow and high-rate material deformation. PAGOSA is a three-dimensional Eulerian finite-difference code, solving problems with a wide variety of EOS, material strength, and explosive modeling options. This document presents the finite difference equations that are used in the PAGOSA continuum mechanics computer code. This program is especially intended to be used for the numerical simulation of the interactions of gases, fluids, and solids.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Local Thermomechanical Processing for Improving Formability of High Strength Aluminum Sheets

Limited room temperature formability hinders the wide-spread use of high strength aluminum alloys in structural body-in-white parts. Stamping or extrusion at warm temperatures or from softer tempers are the current solutions. In this work, our approach is to start with age-hardened sheets from 7xxx and 6xxx family of alloys and improve their formability using local thermomechanical processing only in the regions demanding highest ductility in the forming processes. We achieved local formability improvements with friction stir processing and introduce another process named roller-bending as a concept and showed its feasibility through finite element simulations. Initial results from FSP indicated significant deformation in the processed zones with minimal sheet distortion. FSP also resulted in dynamically recrystallized, fine grained (d < 5 µm) microstructures in the processed regions with textures significantly different from the base material. This resulted in formability improvements of > 30% in 7085-T76 and > 50% in 6111-T6 alloys as measured by minimum bend radius (r/t) ratios established with V-bending tests performed at 90° and 180° bend angles. Based on the encouraging initial results, we envision applicability of these processes in both pre- and post-stamping stages through integration of the process tools as end-effectors to robotic arms.

Nasim, Wahaz↗
DOE OSTI2022

Instanton Effects in Euclidean vacuum, Real Time Production, and in the Light-front Wave Functions

Nontrivial topological structures of non-Abelian gauge fields were discovered in the 1970s. Instanton solutions, describing vacuum tunneling through topological barriers, have fermionic zero modes which are at the origin of ‘t Hooft effective Lagrangian. In the 1980s, instanton ensembles have been used to explain chiral symmetry breaking. In the 1990s, a large set of numerical simulations were performed deriving Euclidean correlation functions. The special role of scalar diquarks in nucleons and color superconductivity in dense quark matter has been elucidated. In these lectures, we discuss further developments of physics related to gauge topology. We show that the instanton–anti-instanton “streamline” configurations describe “sphaleron transitions” in high-energy collisions, which result in production of hadronic clusters with nontrivial topological/chiral charges. (They are not yet observed, but discussions of dedicated experiments at the LHC and RHIC are ongoing.) Another new direction is instanton effects in hadronic spectroscopy, both in the rest frame and on the light front. We will discuss their role in central and spin-dependent potentials, form factors and antiquark nuclear “sea”. Finally, we summarize the advances in the semiclassical theory of deconfinement, and chiral phase transitions at finite temperature, in QCD, and in some of its “deformed” versions.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
NASA NTRS1983

Development of a simplified procedure for rocket engine thrust chamber life prediction with creep

An analytical method for predicting engine thrust chamber life is developed. The method accounts for high pressure differentials and time-dependent creep effects both of which are significant in limiting the useful life of the shuttle main engine thrust chamber. The hot-gas-wall ligaments connecting adjacent cooling channels ribs and separating the coolant flow from the combustion gas are subjected to a high pressure induced primary stress superimposed on an alternating cyclic thermal strain field. The pressure load combined with strain-controlled cycling produces creep ratcheting and consequent bulging and thinning of these ligaments. This mechanism of creep-enhanced ratcheting is analyzed for determining the hot-gas-wall deformation and accumulated strain. Results are confirmed by inelastic finite element analysis. Fatigue and creep rupture damage as well as plastic tensile instability are evaluated as potential failure modes. It is demonstrated for the NARloy Z cases analyzed that when pressure differentials across the ligament are high, creep rupture damage is often the primary failure mode for the cycle times considered.

Badlani, M. L.↗