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NASA NTRS2006

Development of Design Analysis Methods for C/SiC Composite Structures

The stress-strain behavior at room temperature and at 1100 C (2000 F) was measured for two carbon-fiber-reinforced silicon carbide (C/SiC) composite materials: a two-dimensional plain-weave quasi-isotropic laminate and a three-dimensional angle-interlock woven composite. Micromechanics-based material models were developed for predicting the response properties of these two materials. The micromechanics based material models were calibrated by correlating the predicted material property values with the measured values. Four-point beam bending sub-element specimens were fabricated with these two fiber architectures and four-point bending tests were performed at room temperature and at 1100 C. Displacements and strains were measured at various locations along the beam and recorded as a function of load magnitude. The calibrated material models were used in concert with a nonlinear finite element solution to simulate the structural response of these two materials in the four-point beam bending tests. The structural response predicted by the nonlinear analysis method compares favorably with the measured response for both materials and for both test temperatures. Results show that the material models scale up fairly well from coupon to subcomponent level.

Sullivan, Roy M.↗

NASA NTRS2006

Multiscale Analysis of Delamination of Carbon Fiber-Epoxy Laminates with Carbon Nanotubes

A multi-scale analysis is presented to parametrically describe the Mode I delamination of a carbon fiber/epoxy laminate. In the midplane of the laminate, carbon nanotubes are included for the purposes of selectively enhancing the fracture toughness of the laminate. To analyze carbon fiber epoxy carbon nanotube laminate, the multi-scale methodology presented here links a series of parameterizations taken at various length scales ranging from the atomistic through the micromechanical to the structural level. At the atomistic scale molecular dynamics simulations are performed in conjunction with an equivalent continuum approach to develop constitutive properties for representative volume elements of the molecular structure of components of the laminate. The molecular-level constitutive results are then used in the Mori-Tanaka micromechanics to develop bulk properties for the epoxy-carbon nanotube matrix system. In order to demonstrate a possible application of this multi-scale methodology, a double cantilever beam specimen is modeled. An existing analysis is employed which uses discrete springs to model the fiber bridging affect during delamination propagation. In the absence of empirical data or a damage mechanics model describing the effect of CNTs on fracture toughness, several tractions laws are postulated, linking CNT volume fraction to fiber bridging in a DCB specimen. Results from this demonstration are presented in terms of DCB specimen load-displacement responses.

Riddick, Jaret C.↗

NASA NTRS2008

Reliability and Confidence Interval Analysis of a CMC Turbine Stator Vane

High temperature ceramic matrix composites (CMC) are being explored as viable candidate materials for hot section gas turbine components. These advanced composites can potentially lead to reduced weight, enable higher operating temperatures requiring less cooling and thus leading to increased engine efficiencies. However, these materials are brittle and show degradation with time at high operating temperatures due to creep as well as cyclic mechanical and thermal loads. In addition, these materials are heterogeneous in their make-up and various factors affect their properties in a specific design environment. Most of these advanced composites involve two- and three-dimensional fiber architectures and require a complex multi-step high temperature processing. Since there are uncertainties associated with each of these in addition to the variability in the constituent material properties, the observed behavior of composite materials exhibits scatter. Traditional material failure analyses employing a deterministic approach, where failure is assumed to occur when some allowable stress level or equivalent stress is exceeded, are not adequate for brittle material component design. Such phenomenological failure theories are reasonably successful when applied to ductile materials such as metals. Analysis of failure in structural components is governed by the observed scatter in strength, stiffness and loading conditions. In such situations, statistical design approaches must be used. Accounting for these phenomena requires a change in philosophy on the design engineer s part that leads to a reduced focus on the use of safety factors in favor of reliability analyses. The reliability approach demands that the design engineer must tolerate a finite risk of unacceptable performance. This risk of unacceptable performance is identified as a component's probability of failure (or alternatively, component reliability). The primary concern of the engineer is minimizing this risk in an economical manner. The methods to accurately determine the service life of an engine component with associated variability have become increasingly difficult. This results, in part, from the complex missions which are now routinely considered during the design process. These missions include large variations of multi-axial stresses and temperatures experienced by critical engine parts. There is a need for a convenient design tool that can accommodate various loading conditions induced by engine operating environments, and material data with their associated uncertainties to estimate the minimum predicted life of a structural component. A probabilistic composite micromechanics technique in combination with woven composite micromechanics, structural analysis and Fast Probability Integration (FPI) techniques has been used to evaluate the maximum stress and its probabilistic distribution in a CMC turbine stator vane. Furthermore, input variables causing scatter are identified and ranked based upon their sensitivity magnitude. Since the measured data for the ceramic matrix composite properties is very limited, obtaining a probabilistic distribution with their corresponding parameters is difficult. In case of limited data, confidence bounds are essential to quantify the uncertainty associated with the distribution. Usually 90 and 95% confidence intervals are computed for material properties. Failure properties are then computed with the confidence bounds. Best estimates and the confidence bounds on the best estimate of the cumulative probability function for R-S (strength - stress) are plotted. The methodologies and the results from these analyses will be discussed in the presentation.

Murthy, Pappu L. N.↗

NASA NTRS2008

Predicting Properties of Unidirectional-Nanofiber Composites

A theory for predicting mechanical, thermal, electrical, and other properties of unidirectional-nanofiber/matrix composite materials is based on the prior theory of micromechanics of composite materials. In the development of the present theory, the prior theory of micromechanics was extended, through progressive substructuring, to the level of detail of a nanoscale slice of a nanofiber. All the governing equations were then formulated at this level. The substructuring and the equations have been programmed in the ICAN/JAVA computer code, which was reported in "ICAN/JAVA: Integrated Composite Analyzer Recoded in Java" (LEW-17247), NASA Tech Briefs, Vol. 26, No. 12 (December 2002), page 36. In a demonstration, the theory as embodied in the computer code was applied to a graphite-nanofiber/epoxy laminate and used to predict 25 properties. Most of the properties were found to be distributed along the through-the-thickness direction. Matrix-dependent properties were found to have bimodal through-the-thickness distributions with discontinuous changes from mode to mode.

Chamis, Christos C.↗

NASA NTRS2010

Use of Modal Acoustic Emission to Monitor Damage Progression in Carbon Fiber/Epoxy and Implications for Composite Structures

Broad-band modal acoustic emission (AE) data was used to characterize micromechanical damage progression in uniaxial IM7 and T1000 carbon fiber-epoxy tows and an IM7 composite overwrapped pressure vessel (COPV) subjected to an intermittent load hold tensile stress profile known to activate the Felicity ratio (FR). Damage progression was followed by inspecting the Fast Fourier Transforms (FFTs) associated with acoustic emission events. FFT analysis revealed the occurrence of cooperative micromechanical damage events in a frequency range between 100 kHz and 1 MHz. Evidence was found for the existence of a universal damage parameter, referred to here as the critical Felicity ratio, or Felicity ratio at rupture (FR*), which had a value close to 0.96 for the tows and the COPV tested. The implications of using FR* to predict failure in carbon/epoxy composite materials and related composite components such as COPVs are discussed. Trends in the FFT data are also discussed; namely, the difference between the low and high energy events, the difference between early and late-life events, comparison of IM7 and T1000 damage progression, and lastly, the similarity of events occurring at the onset of significant acoustic emission used to calculate the FR.

Waller, J. M.↗

NASA NTRS2006

STRANAL-PMC Version 2.0

Version 2.0 of the Strain Rate Dependent Analysis of Polymer Matrix Composites (STRANAL-PMC) software has been released. A prior version was reported in Analyzing Loads and Strains in Polymer- Matrix Composites (LEW-17227), NASA Tech Briefs, Vol. 26, No. 11 (November 2002), page 36. To recapitulate: Modified versions of constitutive equations of viscoplasticity of metals are used to represent deformation of a polymeric matrix. The equations are applied in a micromechanical approach, proceeding upward from slices of unit cells, through the ply level, to the laminate level. The constitutive equations are integrated in time by a Runge- Kutta technique. To predict the ultimate strength of each composite ply, failure criteria are implemented within the micromechanics. The inputs to STRANAL-PMC are the laminate geometry, properties of the fiber and matrix materials, and applied stress or strain versus time. The outputs are time-dependent stresses and strains at the slice, ply, and laminate levels. The improvements in version 2.0 include more rigorous representation of hydrostatic- stress effects in the matrix, refinement and extension of ply failure models, and capabilities to analyze transverse shear stresses. Version 2.0 can be implemented as a material-model code within transient dynamic finite-element codes.

Goldberg, Robert↗

NASA NTRS2012

Utilization of the Generalized Method of Cells to Analyze the Deformation Response of Laminated Ceramic Matrix Composites

In order to practically utilize ceramic matrix composites in aircraft engine components, robust analysis tools are required that can simulate the material response in a computationally efficient manner. The MAC/GMC software developed at NASA Glenn Research Center, based on the Generalized Method of Cells micromechanics method, has the potential to meet this need. Utilizing MAC/GMC, the effective stiffness properties, proportional limit stress and ultimate strength can be predicted based on the properties and response of the individual constituents. In this paper, the effective stiffness and strength properties for a representative laminated ceramic matrix composite with a large diameter fiber are predicted for a variety of fiber orientation angles and laminate orientations. As part of the analytical study, methods to determine the in-situ stiffness and strength properties of the constituents required to appropriately simulate the effective composite response are developed. The stiffness properties of the representative composite have been adequately predicted for all of the fiber orientations and laminate configurations examined in this study. The proportional limit stresses and strains and ultimate stresses and strains were predicted with varying levels of accuracy, depending on the laminate orientation. However, for the cases where the predictions did not have the desired level of accuracy, the specific issues related to the micromechanics theory were identified which could lead to difficulties that were encountered that could be addressed in future work.

Goldberg, Robert K.↗

NASA NTRS2012

NDT and SHM of Carbon Fiber Composites using Linear Drive MWM-Arrays

Carbon fiber composites are used in a wide range of structural applications due to their excellent specific strength and stiffness. However, the anisotropic mechanical and electrical properties associated with the fibers within each composite layer present challenges, and opportunities, for Nondestructive Testing (NDT) methods used to characterize and assess the structure condition. This includes composite condition after manufacture (such as fiber orientation and density, porosity, delamination, and bond strength) and during usage (such as damage from impact, fiber breakage, thermal exposure or applied stress). Ultrasonic and thermographic methods can address some of these challenges, but eddy current methods provide an alternative method for composite structures that contain a conducting material, such as carbon fibers or a metallic liner. This presentation reviews recent advances in the development of eddy current sensors and arrays for carbon fiber composite NDT and Structural Health Monitoring (SHM) applications. The focus is on eddy current sensor constructs with linear drive windings, such as MWM -Arrays, that induce currents primarily within the linear fibers of the composite. By combining this type of sensor construct with micromechanical models that relate composite constituent properties to measurable sensor responses, insight is obtained into the volumetric distribution of electrical properties within the composite and the associated manufacturing, damage, or strain conditions. With knowledge of the fiber layup, this MWM-Array technology is able to detect damage and strain/stress as a function of depth and fiber orientation. This work has been funded by NASA, NA V AIR and the Army for applications ranging from composite overwrapped pressure vessels (COPVs) to aircraft structures and rotorcraft blades. This presentation will specifically present background on the MWM-Array technology, results from the micromechanical modeling effort, and results from ongoing efforts for high resolution imaging and volumetric strain sensing.

Washabaugh, Andrew↗

NASA NTRS2014

Assessment of Shape Memory Alloys - From Atoms To Actuators - Via In Situ Neutron Diffraction

As shape memory alloys (SMAs) become an established actuator technology, it is important to identify the fundamental mechanisms responsible for their performance by understanding microstructure performance relationships from processing to final form. Yet, microstructural examination of SMAs at stress and temperature is often a challenge since structural changes occur with stress and temperature and microstructures cannot be preserved through quenching or after stress removal, as would be the case for conventional materials. One solution to this dilemma is in situ neutron diffraction, which has been applied to the investigation of SMAs and has offered a unique approach to reveal the fundamental micromechanics and microstructural aspects of bulk SMAs in a non-destructive setting. Through this technique, it is possible to directly correlate the micromechanical responses (e.g., internal residual stresses, lattice strains), microstructural evolutions (e.g., texture, defects) and phase transformation properties (e.g., phase fractions, kinetics) to the macroscopic actuator behavior. In this work, in situ neutron diffraction was systematically employed to evaluate the deformation and transformation behavior of SMAs under typical actuator conditions. Austenite and martensite phases, yield behavior, variant selection and transformation temperatures were characterized for a polycrystalline NiTi (49.9 at. Ni). As the alloy transforms under thermomechanical loading, the measured textures and lattice plane-level variations were directly related to the cyclic actuation-strain characteristics and the dimensional instability (strain ratcheting) commonly observed in this alloy. The effect of training on the shape memory characteristics of the alloy and the development of two-way shape memory effect (TWSME) were also assessed. The final conversion from a material to a useful actuator, typically termed shape setting, was also investigated in situ during constrained heatingcooling and subsequent shape recovery experiments. Neutron diffraction techniques are also being applied to the investigation of novel high temperature SMAs with the objective of designing alloys with better stability, higher transition temperatures and ultimately superior durability.

Shape Memory Alloys↗

NASA NTRS2016

Multiscale Static Analysis of Notched and Unnotched Laminates Using the Generalized Method of Cells

The generalized method of cells (GMC) is demonstrated to be a viable micromechanics tool for predicting the deformation and failure response of laminated composites, with and without notches, subjected to tensile and compressive static loading. Given the axial [0], transverse [90], and shear [+45/-45] response of a carbon/epoxy (IM7/977-3) system, the unnotched and notched behavior of three multidirectional layups (Layup 1: [0,45,90,-45](sub 2S), Layup 2: [0,60,0](sub 3S), and Layup 3: [30,60,90,-30, -60](sub 2S)) are predicted under both tensile and compressive static loading. Matrix nonlinearity is modeled in two ways. The first assumes all nonlinearity is due to anisotropic progressive damage of the matrix only, which is modeled, using the multiaxial mixed-mode continuum damage model (MMCDM) within GMC. The second utilizes matrix plasticity coupled with brittle final failure based on the maximum principle strain criteria to account for matrix nonlinearity and failure within the Finite Element Analysis--Micromechanics Analysis Code (FEAMAC) software multiscale framework. Both MMCDM and plasticity models incorporate brittle strain- and stress-based failure criteria for the fiber. Upon satisfaction of these criteria, the fiber properties are immediately reduced to a nominal value. The constitutive response for each constituent (fiber and matrix) is characterized using a combination of vendor data and the axial, transverse, and shear responses of unnotched laminates. Then, the capability of the multiscale methodology is assessed by performing blind predictions of the mentioned notched and unnotched composite laminates response under tensile and compressive loading. Tabulated data along with the detailed results (i.e., stress-strain curves as well as damage evolution states at various ratios of strain to failure) for all laminates are presented.

GMC↗

NASA NTRS2016

Plasticity Tool for Predicting Shear Nonlinearity of Unidirectional Laminates Under Multiaxial Loading

This study implements a plasticity tool to predict the nonlinear shear behavior of unidirectional composite laminates under multiaxial loadings, with an intent to further develop the tool for use in composite progressive damage analysis. The steps for developing the plasticity tool include establishing a general quadratic yield function, deriving the incremental elasto-plastic stress-strain relations using the yield function with associated flow rule, and integrating the elasto-plastic stress-strain relations with a modified Euler method and a substepping scheme. Micromechanics analyses are performed to obtain normal and shear stress-strain curves that are used in determining the plasticity parameters of the yield function. By analyzing a micromechanics model, a virtual testing approach is used to replace costly experimental tests for obtaining stress-strain responses of composites under various loadings. The predicted elastic moduli and Poisson's ratios are in good agreement with experimental data. The substepping scheme for integrating the elasto-plastic stress-strain relations is suitable for working with displacement-based finite element codes. An illustration problem is solved to show that the plasticity tool can predict the nonlinear shear behavior for a unidirectional laminate subjected to multiaxial loadings.

Wang, John T.↗

NASA NTRS2016

Stochastic-Strength-Based Damage Simulation Tool for Ceramic Matrix and Polymer Matrix Composite Structures

Stochastic-based, discrete-event progressive damage simulations of ceramic-matrix composite and polymer matrix composite material structures have been enabled through the development of a unique multiscale modeling tool. This effort involves coupling three independently developed software programs: (1) the Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC), (2) the Ceramics Analysis and Reliability Evaluation of Structures Life Prediction Program (CARES/ Life), and (3) the Abaqus finite element analysis (FEA) program. MAC/GMC contributes multiscale modeling capabilities and micromechanics relations to determine stresses and deformations at the microscale of the composite material repeating unit cell (RUC). CARES/Life contributes statistical multiaxial failure criteria that can be applied to the individual brittle-material constituents of the RUC. Abaqus is used at the global scale to model the overall composite structure. An Abaqus user-defined material (UMAT) interface, referred to here as "FEAMAC/CARES," was developed that enables MAC/GMC and CARES/Life to operate seamlessly with the Abaqus FEA code. For each FEAMAC/CARES simulation trial, the stochastic nature of brittle material strength results in random, discrete damage events, which incrementally progress and lead to ultimate structural failure. This report describes the FEAMAC/CARES methodology and discusses examples that illustrate the performance of the tool. A comprehensive example problem, simulating the progressive damage of laminated ceramic matrix composites under various off-axis loading conditions and including a double notched tensile specimen geometry, is described in a separate report.

composite structures↗

NASA NTRS2017

A Compilation of MATLAB Scripts and Functions for MACGMC Analyses

The primary aim of the current effort is to provide scripts that automate many of the repetitive pre- and post-processing tasks associated with composite materials analyses using the Micromechanics Analysis Code with the Generalized Method of Cells. This document consists of a compilation of hundreds of scripts that were developed in MATLAB (The Mathworks, Inc., Natick, MA) programming language and consolidated into 16 MATLAB functions. (MACGMC). MACGMC is a composite material and laminate analysis software code developed at NASA Glenn Research Center. The software package has been built around the generalized method of cells (GMC) family of micromechanics theories. The computer code is developed with a user-friendly framework, along with a library of local inelastic, damage, and failure models. Further, application of simulated thermo-mechanical loading, generation of output results, and selection of architectures to represent the composite material have been automated to increase the user friendliness, as well as to make it more robust in terms of input preparation and code execution. Finally, classical lamination theory has been implemented within the software, wherein GMC is used to model the composite material response of each ply. Thus, the full range of GMC composite material capabilities is available for analysis of arbitrary laminate configurations as well. The pre-processing tasks include generation of a multitude of different repeating unit cells (RUCs) for CMCs and PMCs, visualization of RUCs from MACGMC input and output files and generation of the RUC section of a MACGMC input file. The post-processing tasks include visualization of the predicted composite response, such as local stress and strain contours, damage initiation and progression, stress-strain behavior, and fatigue response. In addition to the above, several miscellaneous scripts have been developed that can be used to perform repeated Monte-Carlo simulations to enable probabilistic simulations with minimal manual intervention. This document is formatted to provide MATLAB source files and descriptions of how to utilize them. It is assumed that the user has a basic understanding of how MATLAB scripts work and some MATLAB programming experience.

Materials Engineering↗

NASA NTRS2018

Simulation of Stochastic Mud-Crack Damage Formation in an Environmental Barrier Coating

The integrated Finite Element Analysis–Micromechanics Analysis Code/Ceramics Analysis and Reliability Evaluation of Structures (FEAMAC/CARES) program was used to simulate the formation of mudflat-cracks from thermomechanical loading on a multi-layered Environmental Barrier Coating (EBC) system deposited on a ceramic substrate. FEAMAC/CARES combines MAC/GMC multiscale composite micromechanics code with CARES/Life probabilistic multiaxial failure criteria code and Abaqusfinite element analysis. In this work, step function elastic modulus reduction of randomly damaged finite elements was used to represent discrete cracking events. The use of many small-sized low-aspect-ratio finite elements enabled the depiction of crack boundaries and formation of mudflat patterned damage. Demonstrated examples include finite element models of button–sized disk–shaped 3-D specimen, and a 2-D model of through-the-thickness cross-section. All models were subjected to a progressive cool down from 1300oC to room temperature. Mudflat crack damage in the coating system resulted from the buildup of residual tensile stresses between the individual material constituents from thermal expansion mismatch. A 2-parameter Weibull distribution characterized the coating layer stochastic strength response and the effect of the Weibull modulus on the formation of damage was studied here.

residual tensile stress↗

NASA NTRS2020

Stochastic Simulation of Mudcrack Damage Formation in an Environmental Barrier Coating

The FEAMAC/CARES program, which integrates finite element analysis (FEA) with the MAC/GMC (Micromechanics Analysis Code with Generalized Method of Cells) and the CARES/Life (Ceramics Analysis and Reliability Evaluation of Structures / Life Prediction) programs, was used to simulate the formation of mudcracks during the cooling of a multilayered environmental barrier coating (EBC) deposited on a silicon carbide substrate. FEAMAC/CARES combines the MAC/GMC multiscale micromechanics analysis capability (primarily developed for composite materials) with the CARES/Life probabilistic multiaxial failure criteria (developed for brittle ceramic materials) and Abaqus (Dassault Systèmes) FEA. In this report, elastic modulus reduction of randomly damaged finite elements was used to represent discrete cracking events. The use of many small-sized low-aspect-ratio elements enabled the formation of crack boundaries, leading to development of mudcrack-patterned damage. Finite element models of a disk-shaped three-dimensional specimen and a twodimensional model of a through-the-thickness cross section subjected to progressive cooling from 1,300 °C to an ambient temperature of 23 °C were made. Mudcrack damage in the coating resulted from the buildup of residual tensile stresses between the individual material constituents because of thermal expansion mismatches between coating layers and the substrate. A two-parameter Weibull distribution characterized the coating layer stochastic strength response and allowed the effect of the Weibull modulus on the formation of damage and crack segmentation lengths to be studied. The spontaneous initiation of cracking and crack coalescence resulted in progressively smaller mudcrack cells as cooling progressed, consistent with a fractal-behaved fracture pattern. Other failure modes such as delamination, and possibly spallation, could also be reproduced. The physical basis assumed and the heuristic approach employed, which involves a simple stochastic cellular automaton methodology to approximate the crack growth process, are described. The results ultimately show that a selforganizing mudcrack formation can derive from a Weibull distribution that is used to describe the stochastic strength response of the bulk brittle ceramic material layers of an EBC.

Nemeth, Noel N.↗

NASA NTRSDate not supplied

A Convolutional Neural Network for Multiscale Modeling of Composite Materials

An artificial convolutional neural network was created to efficiently mimic a micromechanics model, the High Fidelity Generalized Method of Cells, for use in multi-scale structural finite element analysis. The network was found to quickly and accurately replicate the stiffness predicted by the micromechanics model using a 2D image of an idealized representative volume element of a fiber/matrix microstructure. The long-term goal of this work is to efficiently apply multi-scale methods for predicting the damage progression of a composite structure.

Composites↗

NASA NTRSDate not supplied

The Nasa Multiscale Analysis Tool: an Enabling Platform for Achieving Vision 2040

Vision 2040 is a community-driven consensus document, written in 2018, aimed at defining the potential 25-year future state required for performing integrated multiscale modeling of materials and systems for future aerospace and aeronautical applications. Nine Vision Key Elements (KEs) were defined along with associated technical gaps. This paper will address current NASA GRC research efforts utilizing the NASA Multiscale Analysis Tool (NASMAT). This paper will specifically focus on NASMAT’s ability to address gaps in three of the nine Vision 2040 KEs: 1) Models and Methods, 2) Multiscale Measurements and Characterization Tools and Methods, and 6) Data, Informatics, and Visualization. NASMAT is a versatile platform for performing computationally efficient multiscale analyses of heterogeneous materials. NASMAT offers the user flexibility to define an arbitrary number of length scales (levels) where a variety of micromechanics theories can be implemented at each level. Micromechanics theories can be selected to balance accuracy and computational efficiency and range from analytical (Mori-Tanaka) to several semi-analytical (method of cells) formulations. NASMAT can also be coupled with external software and used to perform multiscale analyses of more complex structures. The paper will include a recent application of NASMAT to model a complex, three-dimensional woven composite, with a particular emphasis placed on multiscale measurements utilized to enhance the quality of the multiscale analysis. Since typical NASMAT analyses can be completed in on the order of seconds to minutes, a second example will demonstrate NASMAT’s ability to generate large quantities of data useful for sensitivity analysis, uncertainty quantification, or machine learning applications. Current progress on developing multiscale data visualization tools will also be addressed along with the challenges associated with and proposed solutions for sifting through large amounts of data. These examples will demonstrate that NASMAT is an enabling platform for achieving the goals in Vision 2040.

Vision 2040↗

NASA NTRSDate not supplied

Multiscale Modeling of Reconstructed Tricalcium Silicate using NASA Multiscale Analysis Tool

To study microstructure characteristics of cementitious materials hydrated in space; previously, cement binder formations were processed under microgravity conditions and was further compared against ground-based experiments. For accurate estimation of process-structure-property linkage, particularly on samples hydrated in the microgravity environment, it is desired to have a high-fidelity volumetric representation of the microstructure. However, owing to small sample size and high porosity of the space-returned samples, conventional experimental characterization techniques are not viable. Hence, a deep learning-based reconstruction algorithm was employed to obtain high fidelity 3D volumes from sparse high resolution 2D Scanning Electron Microscopy (SEM) images, as inputs to micromechanics-based modeling. This machine learning-based reconstruction methodology validated against low-order statistical descriptors, captured the microstructural topology of both sample types (ground, 1g and microgravity, μg). Due to the lack of gravity, hydration products of the samples processed in space differed from those processed-on ground. Such AI-generated virtual samples were analyzed in a multiscale recursive micromechanics approach using the NASA Multiscale Analysis Tool (NASMAT). Here, we present a methodology to rapidly integrate and evaluate these AI-generated volumes in NASMAT. The synthesized microstructural volumes are directly employed as Representative Volume Elements (RVEs) to preserve the fidelity (1 pixel = 0.54 m). Invariably, analysis of such largescale problems (5123 voxels) requires huge amount of computational resources. By taking advantage of the NASMAT architecture, we also focused on systematic multiscale integration of these AI-reconstructed virtual volumes to reduce the computational demands. In this work, this methodology is demonstrated on the ground-based, 1g samples. The estimated stiffness value of 15.90 GPa is comparable to experimentally obtained modulus of hydrated tricalcium silicate sample. The workflow presented here paves the way for utilizing the NASMAT tool to perform multiscale analyses of other multi-phase material systems using either 3D virtual datasets synthesized using AI or obtained via micro-CT.

Machine Learning↗