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NASA NTRS2018

A Nonlocal Progressive Damage Model for Composite Materials

Fiber reinforced composite materials are widely used in aerospace structures due to their high specific stiffness and strength. These materials exhibit complex deformation, damage and failure mechanisms under high strain rate loading conditions. Many different failure criteria have been proposed in literature to describe the damage initiation and evolution of fiber reinforced composite materials. Most of these damage models are based on a local framework. In a local framework, the material behavior is based on a point-wise constitutive relation which is independent of the effect of the surrounding points. These models include stiffness degradation when damage initiates in the material, which within a local framework leads to a highly mesh dependent result. This could be overcome using a nonlocal finite element approach. In the current work, a nonlocal formulation based on the work by Andrade et al [1] is adapted to describe composite material behavior. The LS-DYNA rate dependent progressive damage model, MAT162 is employed to detect the initiation and evolution of damage in orthotropic composite materials. This model is developed as a FORTRAN user material subroutine in the LS-DYNA environment. The results of MAT162 with and without the nonlocal formulation are compared at different mesh densities to validate the model. The numerical analysis exhibits the advantages of the nonlocal formulation.

Kodagali, Karan↗

DOE OSTI2023

Direct comparison between experiments and dislocation dynamics simulations of high rate deformation of single crystal copper

A long standing challenge in computational materials science is to establish a quantitative connection between the macroscopic properties of plastic deformation with the microscopic mechanisms of dislocations in crystalline materials. Although the discrete dislocation dynamics (DDD) simulation method has been developed for several decades with the goal of addressing this challenge, a one-to-one comparison between the DDD predictions on single crystal stress–strain curves and experimental measurements under identical conditions has not been possible to date. Such a comparison is an essential step towards establishing a dislocation-physics based theory of plasticity and a multiscale framework of the plastic behaviors of crystalline materials. Here we provide direct comparisons between the stress–strain curves of Cu single crystals under high strain rate loading in the [0 0 1] and [0 1 1] directions obtained from miniaturized desktop Kolsky bar experiments and those from DDD simulations under identical loading conditions. With an appropriate set of parameters, DDD simulations can produce stress–strain curves that are in reasonable agreement with the experimental results. However, the dislocation mobility values needed to achieve this agreement are an order of magnitude lower than expected based on previous measurements and atomistic simulations. We hypothesize that this discrepancy could be caused by drag forces from jogs and point defects produced during the plastic deformation. Cross-slip of screw dislocations is also found to be necessary to capture the experimental stress–strain behavior, especially for the [0 1 1] loading direction. Finally, this work provides an example of how direct comparisons between DDD simulations and experimental measurements can provide new insight into the fundamental mechanisms of plastic deformation.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Experimental Characterization of Hydrocarbons and Nitrogen Oxides Production in a Heavy-Duty Diesel–Natural Gas Reactivity-Controlled Compression Ignition Engine

Reactivity-Controlled Compression Ignition (RCCI) combustion is considered one of the most promising Low-Temperature Combustion (LTC) concepts aimed at reducing greenhouse gases for the transportation and power generation sectors. Due to the spontaneous combustion of a lean, nearly homogeneous mixture of air and low-reactivity fuel (LRF), ignited through the direct injection of a small quantity of high-reactivity fuel (HRF), RCCI (dual-fuel) shows higher efficiency and lower pollutants compared to conventional diesel combustion (CDC) if run at very advanced injection timing. Even though a HRF is used, the use of advanced injection timing leads to high ignition delays, compared to CDC, and generates high cycle-to-cycle variability, limited operating range, and high pressure rise rates at high loads. This work presents an experimental analysis performed on a heavy-duty single-cylinder compression ignited engine in dual-fuel diesel–natural gas mode. The objective of the present work is to investigate and highlight the correlations between combustion behavior and pollutant emissions, especially unburned hydrocarbons (HC) and oxides of nitrogen (NOx). Based on the analysis of crank-resolved pollutants measurements performed through fast FID and fast NOx systems under different engine operating conditions, two correlations were found demonstrating a good accordance between pollutant production and combustion behavior: Net Cyclic Hydrocarbon emission—cyclic IMEP variations (R 2 = 0.86), and Cyclic NOx—maximum value of the Rate of Heat Released (R 2 = 0.82).

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

A method for characterization of multiple dynamic constitutive parameters of FRCs

We propose a method to measure multiple dynamic material constitutive parameters of unidirectional fiber reinforced composites (FRCs) in a single experiment. Dynamic short-beam shear (DSBS) experiments were performed on a modified Kolsky compression bar, with integration of high-speed imaging and digital image correlation (DIC). The unidirectional FRCs investigated were S-2 glass fiber reinforced matrix of TGDDM-Jeffamine® D230 with monoamine functionalized partially reacted substructures (mPRS) and commercially available SC-15. Analytical solutions of normal and shear strains of a composite beam were derived based on Timoshenko beam theory, assuming material to be transversely isotropic and have different moduli in tension and compression in each principle material orientation. Tensile and compressive moduli were inversely computed through monitoring normal strain slope when specimen was constantly loaded at a speed of ~7.3 m/s within a small deflection. Non-linear shear stress-strain behavior of the composite was described via Ramberg–Osgood equation. Finite element (FE) analysis was conducted in ABAQUS, simultaneously defining via user subroutine UMAT the transverse isotropy of material, bi-modulus constitutive model, and non-linear shear stress-strain relation. The method proposed in this work was validated by comparing strain distributions computed by FE model and DIC measurements. Comparing with traditional dynamic tensile, compressive, and shear experiments on FRCs, this method significantly simplifies the specimen preparation and design of complicated gripping fixtures for multiple experiments. Here, systematic errors resulting from variations of specimen geometry and dimension, loading direction, and instrumentation are reduced, thereby providing compatible data for numerical studies on impact behavior of composites.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Spall strength of additively repaired 304L stainless steel

Additive manufacturing has the potential to repair damaged parts, but the performance of additive materials under high strain rate loading is still uncertain—especially with the added complexity of an interface with an existing wrought material. In this work, 304L stainless steel samples were intentionally damaged and then repaired with wire-fed laser additive manufacturing. The samples were subjected to shock loading to generate incipient spall. Velocimetry and post-mortem metallography results show that when the additive repair process parameters are optimized to reduce porosity and match the equation of state of the original material, the influence of the repair region on the shock propagation is negligible. In conclusion, the free-surface velocity profile and internal damage morphology of the repaired sample are shown to be practically identical to the pristine material.

36 MATERIALS SCIENCE↗

DOE OSTI2026

High waste loading glass formulation development for high-P HLW

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

High waste loading glass formulation development for High-Mn HLW

One of the primary objectives of the work described herein was to develop and identify HLW glass compositions and glass forming additive blends that achieve high waste loadings and processing rates for high manganese HLW streams while maintaining acceptable glass properties. Another objective was to determine the effect of the form of manganese (MnO, MnO2, MnCO3) on feed processing properties, glass production rates, and product quality while vitrifying a high manganese HLW stream. This was accomplished through a combination of crucible-scale tests, vertical gradient furnace tests, and confirmation tests on a DM100 melter system.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

Glass Formulation Development for Al, Fe, and Na Phosphate HLW

The primary objective of the work described herein was to develop and identify HLW glass compositions and glass forming additive blends that achieve high waste loadings and processing rates for high phosphorus HLW streams while maintaining acceptable glass properties. Another objective was to determine the effect of phosphate form (aluminum, iron, sodium) on feed processing properties, glass production rates, and product quality while vitrifying a high phosphorus HLW stream. This was accomplished through a combination of crucible-scale tests, vertical gradient furnace tests, and confirmation tests on a DM100 melter system.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

Direct vitrification of HLW: evaluation of candidate source tanks

The initial objective of the present work was to review Hanford HLW compositions to identify HLW streams that are good candidates for the HLW direct feed vitrification option. Another objective was to develop and identify HLW glass compositions and glass forming additive blends for vitrification of two HLW streams identified from the review that could be treated with little or no washing or other pretreatment and would be, therefore, good direct feed candidates. The HLW glass compositions and additive blends were developed to maintain high waste loadings, high processing rates, and acceptable product glass properties. This was accomplished through a combination of crucible-scale and DM100 melter system tests.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS1998

High Strain Rate Deformation Modeling of a Polymer Matrix Composite: Matrix Constitutive Equations - Part 1

Recently applications have exposed polymer matrix composite materials to very high strain rate loading conditions, requiring an ability to understand and predict the material behavior under these extreme conditions. In this first paper of a two part report, background information is presented, along with the constitutive equations which will be used to model the rate dependent nonlinear deformation response of the polymer matrix. Strain rate dependent inelastic constitutive models which were originally developed to model the viscoplastic deformation of metals have been adapted to model the nonlinear viscoelastic deformation of polymers. The modified equations were correlated by analyzing the tensile/ compressive response of both 977-2 toughened epoxy matrix and PEEK thermoplastic matrix over a variety of strain rates. For the cases examined, the modified constitutive equations appear to do an adequate job of modeling the polymer deformation response. A second follow-up paper will describe the implementation of the polymer deformation model into a composite micromechanical model, to allow for the modeling of the nonlinear, rate dependent deformation response of polymer matrix composites.

Goldberg, Robert K.↗

NASA NTRS1998

High Strain Rate Deformation Modeling of a Polymer Matrix Composite: Composite Micromechanical Model - Part 2

Recently applications have exposed polymer matrix composite materials to very high strain rate loading conditions, requiring an ability to understand and predict the material behavior under these extreme conditions. In this second paper of a two part report, a three-dimensional composite micromechanical model is described which allows for the analysis of the rate dependent, nonlinear deformation response of a polymer matrix composite. Strain rate dependent inelastic constitutive equations utilized to model the deformation response of a polymer are implemented within the micromechanics method. The deformation response of two representative laminated carbon fiber reinforced composite materials with varying fiber orientation has been predicted using the described technique. The predicted results compare favorably to both experimental values and the response predicted by the Generalized Method of Cells, a well-established micromechanics analysis method.

Goldberg, Robert K.↗

NASA NTRS1999

Strain Rate Dependent Deformation and Strength Modeling of a Polymer Matrix Composite Utilizing a Micromechanics Approach

Potential gas turbine applications will expose polymer matrix composites to very high strain rate loading conditions, requiring an ability to understand and predict the material behavior under extreme conditions. Specifically, analytical methods designed for these applications must have the capability of properly capturing the strain rate sensitivities and nonlinearities that are present in the material response. The Ramaswamy-Stouffer constitutive equations, originally developed to analyze the viscoplastic deformation of metals, have been modified to simulate the nonlinear deformation response of ductile, crystalline polymers. The constitutive model is characterized and correlated for two representative ductile polymers. Fiberite 977-2 and PEEK, and the computed results correlate well with experimental values. The polymer constitutive equations are implemented in a mechanics of materials based composite micromechanics model to predict the nonlinear, rate dependent deformation response of a composite ply. Uniform stress and uniform strain assumptions are applied to compute the effective stresses of a composite unit cell from the applied strains. The micromechanics equations are successfully verified for two polymer matrix composites. IM7/977-2 and AS4/PEEK. The ultimate strength of a composite ply is predicted with the Hashin failure criteria that were implemented in the composite micromechanics model. The failure stresses of the two composite material systems are accurately predicted for a variety of fiber orientations and strain rates. The composite deformation model is implemented in LS-DYNA, a commercially available transient dynamic explicit finite element code. The matrix constitutive equations are converted into an incremental form, and the model is implemented into LS-DYNA through the use of a user defined material subroutine. The deformation response of a bulk polymer and a polymer matrix composite are predicted by finite element analyses. The results compare reasonably well to experimental values, with some discrepancies. The discrepancies are at least partially caused by the method used to integrate the rate equations in the polymer constitutive model.

Goldberg, Robert K.↗

NASA NTRS2004

Implementation of Higher Order Laminate Theory Into Strain Rate Dependent Micromechanics Analysis of Polymer Matrix Composites

A procedure has been developed to investigate the nonlinear response of composite plates under large strain and high strain rate loading. A recently developed strain dependent micromechanics model is extended to account for the shear effects during impact. Four different assumptions of shear deformation effects are investigated to improve the development strain rate dependent micromechanics model. A method to determine through the thickness strain and transverse Poisson's ratio is developed. The revised micromechanics model is implemented into higher order laminate theory. Parametric studies are conducted to investigate transverse shear effects during impact.

Kim, Heung Soo↗

NASA NTRS2004

Implementation of Improved Transverse Shear Calculations and Higher Order Laminate Theory Into Strain Rate Dependent Analyses of Polymer Matrix Composites

A numerical procedure has been developed to investigate the nonlinear and strain rate dependent deformation response of polymer matrix composite laminated plates under high strain rate impact loadings. A recently developed strength of materials based micromechanics model, incorporating a set of nonlinear, strain rate dependent constitutive equations for the polymer matrix, is extended to account for the transverse shear effects during impact. Four different assumptions of transverse shear deformation are investigated in order to improve the developed strain rate dependent micromechanics model. The validities of these assumptions are investigated using numerical and theoretical approaches. A method to determine through the thickness strain and transverse Poisson's ratio of the composite is developed. The revised micromechanics model is then implemented into a higher order laminated plate theory which is modified to include the effects of inelastic strains. Parametric studies are conducted to investigate the mechanical response of composite plates under high strain rate loadings. Results show the transverse shear stresses cannot be neglected in the impact problem. A significant level of strain rate dependency and material nonlinearity is found in the deformation response of representative composite specimens.

Zhu, Lin-Fa↗

NASA NTRS1993

Tribological characteristics of perfluoropolyether liquid lubricants under sliding conditions in high vacuum

Tribological characteristics of three PFPE's (Fomblin Z, Demnum, and Krytox) were studied under high vacuum using a four-ball apparatus with 440C steel specimens. Fomblin Z and Demnum exhibited initial scuffing-like high friction whereas Krytox did not. Steady state friction with Fomblin Z was the lowest among the three oils. Frictional values for Demnum and Krytox were almost the same. The lowest wear rate in air was provided by Krytox regardless of load, and low wear rates in vacuum at high load were achieved with Krytox and Demnum. Results are explained by reactivity and pressure-viscosity characteristics of the oils.

Masuko, Masabumi↗

NASA NTRS2005

Mechanical Behavior of Gamma-Met PX under Uniaxial Loading at Elevated Temperatures and High Strain Rates

Gamma titanium aluminides have received considerable attention over the last decade. These alloys are known to have low density, good high temperature strength retention and good oxidation and corrosion resistance. However, poor ductility and low fracture toughness have been the key limiting factors in the full utilization of these alloys. More recently, a new generation of gamma titanium aluminide alloys, commonly referred to as Gamma-met PX, has been developed by GKSS, Germany. These alloys have been observed to have superior strength and better oxidation resistance at elevated temperatures when compared with conventional gamma titanium aluminides. The present paper discusses results of a study to understand the uniaxial mechanical behavior in both compression and tension of Gamma-Met PX at elevated temperatures and high strain rates. The compression and tensile tests are conducted using a modified split-Hopkinson bar apparatus at test temperatures ranging from room temperature to 900 C and strain rates of up to 3500/s. Under uniaxial compression, in the temperature range from room to 600 C, the flow stress is observed to be nearly independent of test temperature. However, at temperatures higher than 600 C thermal softening is observed at all strain rates with the rate of thermal softening increasing dramatically between 800 C and 900 C. The room temperature tensile tests show negligible strain-rate dependence on both yield stress and flow stress. With an increase in test temperature from room to 900 C the material shows a drop in both yield and flow stress at all levels of plastic strain. However, the measured flow stress is still higher when compared to nickel based super-alloys and other gamma titanium aluminides under similar test conditions. Also, no anomaly in yield stress is observed up to 900 C.

Shazly, Mostafa↗

NASA NTRS1988

Active control of tiltrotor blade in-plane loads during maneuvers

The origin of one/rev rotor aerodynamic loads which arise in tiltrotor aircraft during airplane-mode high speed pull-up and push-over maneuvers is examined using a coupled rotor/fuselage dynamic simulation. A modified eigenstructure assignment technique is used to design a controller which alleviates the in-plane loads during high pitch rate maneuvers. The controller utilizes rotor cyclic pitch inputs to restructure the aircraft short period and phugoid responses in order to achieve the coupling between pitch rate and rotor flapping responses which minimizes the rotor aerodynamic loading. Realistic time delays in the feedback path are considered during the controller design. Stability robustness in the presence of high frequency modeling errors is ensured through the use of singular value analysis.

Miller, David G.↗

DOE OSTI2026

Assessment of Vibration and Shock Loading Environments on Steels Used in Railroad Applications Considering Hydrogen Embrittlement

Studies that examine the combined effects of hydrogen and rail loading environments in the context of hydrogen embrittlement of steels have not been performed. Large-scale hydrogen storage requires either gaseous hydrogen stored in pressure vessels and tubing or liquid hydrogen in cryogenic, insulated tanks. Since the focus of this study is on steels, we examine the influence of hydrogen on stainless steel used for high pressure tubing and cryogenic tanks and Cr-Mo steel liners used in gaseous pressure vessels. Literature studies show that despite hydrogen degradation, these steels can be used effectively and safely if the stresses are managed. The shock and vibration environment on railcars present unique environments where stresses and loading rates can be high. A literature review was conducted to understand the accelerations experienced in rail by examining instrumented railcars of nuclear fuel casks. Hydrogen studies were examined that focused on steel pressure hardware with an emphasis on fatigue, fast loading rates, and low temperatures. A simplified fatigue assessment was performed to examine design cycles for three different hydrogen components: stainless steel tubing, stainless steel cryogenic tanks, and gaseous pressure vessels. The assessments were idealized and used bounding cases of accelerations in both normal rail conditions and coupling events. In normal shock and vibration environments when accelerations were less than 2 g, infinite design life was calculated. In extreme shock or coupling environments, finite design life was calculated which was shown to be dependent on unsupported lengths of pressure components. It was shown that adjusting the unsupported length can reduce the bending stress thereby increasing design life.

36 MATERIALS SCIENCE↗