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DOE OSTI2023

Effects of rejuvenation modes on the microstructures and mechanical properties of metallic glasses

This study systematically investigates the effects of three rejuvenation modes, namely biaxial loading, thermal pressure loading, and cryogenic thermal cycling, on the microstructures and mechanical properties of Cu 64 Zr 36 metallic glasses (MGs) using molecular dynamics (MD) simulations. The simulation results demonstrate that biaxial tension application during loading results in a rejuvenated glassy state with high strength. Specifically, we find that the yield stress, Young's modulus, and shear modulus of the rejuvenated glass obtained by biaxial tensile loading decreased by 2.8%, 2.1%, and 2.7%, respectively, compared to an as-cast MG reference. We also find that MGs achieve the greatest degree of rejuvenation, at the expense of strength, with the use of thermal pressure loading. Interestingly, the application of cryogenic thermal cycling results in a rejuvenated state with a lower strength drop compared to thermal pressure loading. Furthermore, analysis of the potential energy and medium-range-order (MRO) size indicates that the microstructures of MGs achieves a high-energy ordered glass state after thermal pressure loading, but a high-energy disordered glass state after biaxial tensile loading and cryogenic thermal cycling. Furthermore, these findings provide meaningful insights into the effect of rejuvenation modes on the microstructures and mechanical properties of MGs, as well as useful guidelines for designing MGs with high strength and superior plasticity for prospective applications in industry.

36 MATERIALS SCIENCE↗

NASA NTRS1972

A fracture mechanics analysis of adhesive failure in a single lap shear joint.

Discussion of adhesive fracture of single lap shear joints in terms of a maximum stress criterion and an energy balance. The Goland and Reissner (1944) analysis is used to determine the stress distribution in the adhesive assembly, and the results obtained are introduced into an energy balance to determine the initiation of adhesive fracture. In the stress analysis the loads at the edges of the joint are first determined. This is a problem in which the deformation of the joint sheets must be taken into account and is solved by using the finite-deflection theory of cylindrically bent plates. Then the stress in the joint due to applied loads is determined. This problem is formulated as one in plane strain consisting of two rectangular sheets of equal thickness and unit width. With the aid of this stress analysis and the stresses obtained from the conditions of equilibrium the contributions to the energy change with crack length are calculated. The analysis performed is then compared with a maximum stress criterion for a lap joint.

Devries, K. L.↗

NASA NTRS1988

Analysis and test of a space truss foldable hinge

The Mini-Mast is a 20-meter long deployable, three-longeron, truss-beam being used to develop analytical and experimental methods for predicting the physical behavior of large space structures. With 57 corner-body hinges and 54 mid-body hinges, the Mini-Mast is highly joint-dominated, necessitating inclusion of the compliance of the joints in analytical models. This study demonstrates an approach for calculating the stiffness properties of a complicated hinge called the mid-body hinge. The process includes detailed modeling with solid-body modeling software and the use of finite element analysis. Load-deflection tests were conducted to determine the axial stiffness of the mid-body hinge. This is compared to the axial stiffness value determined from a finite element analysis.

Nimmo, N. A.↗

DOE OSTI2020

Analysis of Space-Conditioning Loads in Commercial Buildings

Space conditioning end-uses, which include heating, cooling, and ventilation, represent a significant fraction of commercial building energy use, with a wide variety of heating and cooling technology options available in the market. In the interest of improving the overall efficiency of heating, ventilation and air-conditioning (HVAC) technologies, governments, utilities and private sector entities have implemented a variety of market transformation policies that aim to influence consumer purchase decisions. To evaluate the costs and benefits of such programs, analysts typically postulate a hypothetical default equipment choice, and compare it to one that provides comparable service with lower energy and/or power use. The corresponding reduced operating cost provides a benefit that offsets the potential higher cost of improved efficiency. Typically, life-cycle cost or cash-flow analyses are used to quantify the net economic benefit. These analyses require the capability to assess how a given equipment design would perform across a broad range of characteristics, both of the building and of the local weather. While these assessments can be performed using customized building simulations, it is generally not practical to develop and validate detailed building simulation code to cover all the potential variations of equipment design and installation. An alternative, and somewhat simpler, approach is to solely use detailed building simulations to generate time series of heating and cooling loads in commercial buildings. These loads can then be used as input to more detailed, stand-alone engineering models that simulate HVAC system performance under different equipment designs. This approach was used to evaluate a range of high-efficiency commercial packaged air conditioner design options for the Department of Energy’s Appliance and Equipment Standards Program (DOE-EERE 2015). While there may be some loss of precision relative to full simulation, the accuracy of this approach is sufficient for practical applications of cost-benefit analysis. This report describes the development of a database of commercial building heating and cooling loads, generated using the EnergyPlus software package, a whole building energy use model supported by the Department of Energy (DOE-EERE 2020a). EnergyPlus takes as input a set of configuration files that describe the building itself (size, zoning, envelope characteristics, etc.) and the various systems within it (HVAC, lighting, water heating, etc.). This analysis uses a publicly available collection of commercial reference buildings (CRB), comprised of sixteen building types and three vintages (DOE-EERE 2020b; Deru et al 2011). Each building is simulated in eighteen different locations, covering a wide range of climatic conditions. The prototype building description files assign the type of HVAC equipment used, and capacities across climate zones.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Data Privacy for the Grid: Toward a Data Privacy Standard for Inverter-Based and Distributed Energy Resources

The traditional approach to planning the distribution grid has focused on reliability in the context of gradual and reasonably predictable load growth. Forecasts of load growth, combined with asset management practices, were used by system planners to identify upgrades to the system to maintain or improve reliability. The decisions, typically based within load flow analysis tools, included considerations about contingency scenarios and corporate forecasts (i.e., top-down predictions at a summary level of what would happen in a particular area that could impact load growth and behavior). As a result, today, this traditional approach no longer fits all purposes.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS1975

Crack growth under spectrum loading: A crack closure model

A concept based on the crack-closure phenomenon was developed to replace random load spectra with constant amplitude loading in both analysis and tests. The maximum load and the crack opening load in the constant amplitude loading are chosen to be equal to those for the spectrum, so that both crack growth mode and the crack length at failure are equivalent to those under random load spectra. The number of cycles of constant- amplitude loading is chosen so that the amount of crack growth is equal to that due to a given sequence or block of the random spectrum loading. The concept was tested experimentally after predicting the equivalent number of constant-amplitude cycles for six different random load sequences. The agreement between predictions and test results was good.

Elber, W.↗

NASA NTRS1991

HITCAN for actively cooled hot-composite thermostructural analysis

A computer code, high temperature composite analyzer (HITCAN), was developed to analyze/design hot metal matrix composite structures. HITCAN is a general purpose code for predicting the global structural and local stress-strain response of multilayered (arbitrarily oriented) metal matrix structures both at the constituent (fiber, matrix, and interphase) and the structural level, including the fabrication process effects. The thermomechanical properties of the constituents are considered to be nonlinearly dependent on several parameters, including temperature, stress, and stress rate. The computational procedure employs an incremental iterative nonlinear approach utilizing a multifactor-interaction material behavior model, i.e., the material properties are expressed in terms of a product of several factors that affect the properties. HITCAN structural analysis capabilities (static, load stepping - a multistep static analysis with material properties updated at each step, modal, and buckling) for cooled hot structures are demonstrated through a specific example problem.

Chamis, C. C.↗

NASA NTRS1992

HITCAN for actively cooled hot-composite thermostructural analysis

Chamis, C. C.↗

NASA NTRS2002

Mechanics of Granular Materials-3 (MGM-3)

Scientists are going to space to understand how earthquakes and other forces disturb grains of soil and sand. They will examine how the particle arrangement and structure of soils, grains and powders are changed by external forces and gain knowledge about the strength, stiffness and volume changes properties of granular materials at low pressures. The Mechanics of Granular Materials (MGM) experiment uses the microgravity of orbit to test sand columns under conditions that cannot be obtained in experiments on Earth. Research can only go so far on Earth because gravity-induced stresses complicate the analysis and change loads too quickly for detailed analysis. This new knowledge will be applied to improving foundations for buildings, managing undeveloped land, and handling powdered and granular materials in chemical, agricultural, and other industries. NASA wants to understand the way soil behaves under different gravity levels so that crews can safely build habitats on Mars and the Moon. Future MGM experiments will benefit from extended tests aboard the International Space Station, including experiments under simulated lunar and Martian gravity in the science centrifuge.

Stein Sture↗

NASA NTRS1991

Residual thermal and moisture influences on the strain energy release rate analysis of local delaminations from matrix cracks

An analysis utilizing laminated plate theory is developed to calculate the strain energy release rate associated with local delaminations originating at off-axis, single ply, matrix cracks in laminates subjected to uniaxial loads. The analysis includes the contribution of residual thermal and moisture stresses to the strain energy released. Examples are calculated for the strain energy release rate associated with local delaminations originating at 90 degrees and angle-ply (non-90 degrees) matrix ply cracks in glass epoxy and graphite epoxy laminates. The solution developed may be used to assess the relative contribution of mechanical, residual thermal, and moisture stresses on the strain energy release rate for local delamination for a variety of layups and materials.

Obrien, T. K.↗

NASA NTRS1993

Analysis Of Fractures In Sublaminates

Computational procedure developed to predict mechanical behavior and interactions of individual plies or sublaminates of fiber/matrix laminate structures. Embodied in computer code, procedure useful for computation of stresses in regions affected by delaminations, transverse cracks, discontinuities caused by manufacturing errors, configurations, and loading conditions. Analysis applied to all layers in laminate or to only few layers surrounding defects.

Valisetty, R. R.↗

NASA NTRS1992

Residual thermal and moisture influences on the analysis of local delaminations

An analysis using laminated plate theory is developed to calculate the strain energy release rate associated with local delaminations originating at off-axis, angle-ply, matrix cracks in laminates subjected to uniaxial loads. The analysis includes the contribution of residual thermal and moisture stresses to the strain energy released. Examples are calculated for the strain energy release rate associated with local delaminations originating at 90 deg and angle-ply(non 90 deg) matrix-ply cracks in glass-epoxy and graphite-epoxy laminates. The solution developed may be used to assess the relative contribution of mechanical, residual thermal, and moisture stresses on the strain energy release rate for local delamination for a variety of lay-ups and materials.

O'Brien, T. K.↗

NASA NTRS2004

Predicting the Influence of Nano-Scale Material Structure on the In-Plane Buckling of Orthotropic Plates

A multi-scale analysis of the structural stability of a carbon nanotube-polymer composite material is developed. The influence of intrinsic molecular structure, such as nanotube length, volume fraction, orientation and chemical functionalization, is investigated by assessing the relative change in critical, in-plane buckling loads. The analysis method relies on elastic properties predicted using the hierarchical, constitutive equations developed from the equivalent-continuum modeling technique applied to the buckling analysis of an orthotropic plate. The results indicate that for the specific composite materials considered in this study, a composite with randomly orientated carbon nanotubes consistently provides the highest values of critical buckling load and that for low volume fraction composites, the non-functionalized nanotube material provides an increase in critical buckling stability with respect to the functionalized system.

Gates, Thomas S.↗

NASA NTRS1975

Spectrum analysis of acoustic emissions from boron-aluminum composites

Acoustic emissions were monitored from unidirectional tension specimens of boron-aluminum composites. It is shown that a sudden increase in count rate presages final failure. This sudden increase, however, occurs at a variable point relative to final failure load. Spectrum analysis in the range from 1 to 100 kHz was performed on the emissions with the result that no immediately obvious recognition pattern exists to distinguish between types of failure mechanisms. It is suggested that either acoustic emissions cannot be used to distinguish different failure modes in boron-aluminum composites in the frequency range studied or the specimens used had only one failure mode operating with sufficient energy release to be detected. The spectrum analysis did show, however, that the acoustic emissions had frequency components much higher than the frequencies for the fundamental modes of natural vibration of the specimen.

Henneke, E. G., II↗

NASA NTRS2000

Slow Crack Growth Analysis of Advanced Structural Ceramics Under Combined Loading Conditions: Damage Assessment in Life Prediction Testing

Slow crack growth analysis was performed with three different loading histories including constant stress-rate/constant stress-rate testing (Case I loading), constant stress/constant stress-rate testing (Case II loading), and cyclic stress/constant stress-rate testing (Case III loading). Strength degradation due to slow crack growth arid/or damage accumulation was determined numerically as a Function of percentage of interruption time between the two loading sequences for a given loading history. The numerical solutions were examined with the experimental data determined at elevated temperatures using four different advanced ceramic materials, two silicon nitrides, one silicon carbide and one alumina for the Case I loading history, and alumina for the Case II loading history. The numerical solutions were in reasonable agreement with the experimental data, indicating that notwithstanding some degree of creep deformation presented for some test materials slow crack growth was a governing mechanism associated with failure for all the test material&

Choi, Sung R.↗

NASA NTRS2000

Slow Crack Growth Analysis of Advanced Structural Ceramics Under Combined Loading Conditions: Damage Assessment in Life Prediction Testing

Slow crack growth analysis was performed with three different loading histories including constant stress-rate/constant stress-rate testing (Case 1 loading), constant stress/constant stress-rate testing (Case 2 loading), and cyclic stress/constant stress-rate testing (Case 2 loading). Strength degradation due to slow crack growth and/or damage accumulation was determined numerically as a function of percentage of interruption time between the two loading sequences for a given loading history. The numerical solutions were examined with the experimental data determined at elevated temperatures using four different advanced ceramic materials, two silicon nitrides, one silicon carbide and one alumina for the Case 1 loading history, and alumina for the Case 3 loading history. The numerical solutions were in reasonable agreement with the experimental data, indicating that notwithstanding some degree of creep deformation presented for some test materials slow crack growth was a governing mechanism associated with failure for all the test materials.

Choi, Sung R.↗

NASA NTRS2001

Slow Crack Growth Analysis of Advanced Structural Ceramics Under Combined Loading Conditions: Damage Assessment in Life Prediction Testing

Slow crack growth analysis was performed with three different loading histories including constant stress- rate/constant stress-rate testing (Case I loading), constant stress/constant stress-rate testing (Case II loading), and cyclic stress/constant stress-rate testing (Case III loading). Strength degradation due to slow crack growth and/or damage accumulation was determined numerically as a function of percentage of interruption time between the two loading sequences for a given loading history. The numerical solutions were examined with the experimental data determined at elevated temperatures using four different advanced ceramic materials, two silicon nitrides, one silicon carbide and one alumina for the Case I loading history, and alumina for the Case II loading history. The numerical solutions were in reasonable agreement with the experimental data, indicating that notwithstanding some degree of creep deformation presented for some test materials slow crack growth was a governing mechanism associated with failure for all the rest materials.

Choi, S. R.↗

NASA NTRS2020

Lessons Learned from Recent Space Flight Assessments

This paper highlights four space flight assessments, each with an important lesson. The first assessment points to the challenge of material substitution for weight saving. Space Shuttle’s external tank stringers were changed from Al 2024 to Al 2090 without comprehensive analysis. Lack of understanding the low Short-Transverse (S-T) strength associated with Al 2090 led to widespread cracking. The second assessment addresses the failure to understand that time-dependent relationships and loading interactions of multiple disciplines can lead to non-conservative results. An aerodynamic test article of the Orion Multi-Purpose Crew Vehicle (MPCV) Launch Abort System (LAS) was analyzed for worst-case single discipline loads, showing positive structural margins. When disciplines were combined with time dependent loading, the analysis resulted in negative margins. The third assessment highlights the pitfalls of putting blind trust in historical architecture. The MPCV re-entry heat shield adopted the Apollo design approach despite fundamental differences between the two designs (e.g., the underlying substructure design, material differences, scale, and geometry). Manufacturing resulted in cracking along seams of the cured MPCV heat shield and produced lower mechanical properties of the Avcoat witness panels. Subsequently, the design was changed to a block architecture, which introduced unperceived technical, cost, and schedule risk. The fourth assessment shows how the lack of a comprehensive investigation of design modifications and inappropriate Finite Element Analyses (FEA) can lead to trouble. A mass reduction campaign eliminated highly critical internal struts on the ISS Node-1 pressurized module based on inadequate and uncorrelated FEA. High strains were noted and ignored as a modeling aberration. A system level high fidelity FEA discovered large plastic strains in the gussets of all four radial ports. These findings initiated a full-scale test campaign, new test correlated assembly-level FEA, and significant design modifications.

James P Smith↗