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At least 631 records · Page 35
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

A Novel Approach for Bounding the Stress Experienced by the Core of Utility-Scale Printed Circuit Heat Exchangers Under Thermohydraulic Loads

Printed circuit heat exchangers (PCHEs) have rapidly gained popularity since being introduced nearly three decades ago, and they are currently widely deployed in the petrochemical and aviation industry. Their compactness, thermohydraulic efficiency, inherent suitability for high temperature/pressure fluids containment, and demonstrated durability are some of the reasons the nuclear industry is seeking to adopt this technology as well. However, the relatively strict nuclear-related regulatory design code, especially when classified as critical to the safety of the reactors, is posing challenges to adopting the technology. From stress analysis point of view, one undesirable feature of PCHEs is their geometrical complexity, which is implied by their multilength-scale features. As a result, a full-scale model of a utility-scale exchanger cannot simply be solved on a computer because meshing such components results in a vast number of degrees-of-freedom. Here, this work seeks to address the challenge of stress analyses to PCHEs by presenting a method to simplify the geometry of PCHE designs. The models proposed by this work can be practically analyzed on a standard computer and provide a path for implementing ASME design rules. The analyses presented herein are divided into five separate investigations. Each is carried out to incrementally simplify the analyzed model by addressing features such as the shapes of the flow passages, the complex distribution of stress in large components, the three-dimensionality of the stress and strain, the thermal stresses caused by thermohydraulic operation observed experimentally and more.

42 ENGINEERING↗
NASA NTRS1979

Normal and radial impact of composites with embedded penny-shaped cracks

A method is developed for the dynamic stress analysis of a layered composite containing an embedded penny-shaped crack and subjected to normal and radial impact. The material properties of the layers are chosen such that the crack lies in a layer of matrix material while the surrounding material possesses the average elastic properties of a two-phase medium consisting of a large number of fibers embedded in the matrix. Quantitatively, the time-dependent stresses near the crack border can be described by the dynamic stress intensity factors. Their magnitude depends on time, on the material properties of the composite and on the relative size of the crack compared to the composite local geometry. Results obtained show that, for the same material properties and geometry of the composite, the dynamic stress intensity factors for an embedded (penny-shaped) crack reach their peak values within a shorter period of time and with a lower magnitude than the corresponding dynamic stress intensity factors for a through-crack.

Sih, G. C.↗
NASA NTRSDate not supplied

Material Properties and Modeling of Room Temperature Vulcanizing Silicone

Room Temperature Vulcanizing silicone (RTV) is a high-temperature adhesive that has successfully been used as a gap-filler between Thermal Protection System (TPS) tiles for heatshields on numerous missions. It is also used to bond instrumentation plugs such as temperature and pressure sensors into the heatshields. While RTV has been traditionally assumed to be a non-porous and non-ablating material, numerous experiments have shown that RTV pyrolyzes and becomes highly porous as it is heated. Heating RTV has also shown swelling, or intumescence, which can pose unique problems that lead to roughness induced boundary-layer transition, surface oxide formation and contamination of heat shield sensors. Therefore, it is crucial to understand and model the intumescence phenomenon of RTV. As data for RTV material properties is limited, the first step in modeling RTV is to collect material properties such as pyrolysis mass-loss, microstructure change, virgin and char porosity, etc. which was performed in our initial study. Additionally, thermomechanical properties such as Young’s modulus and Poisson ratio are required for modeling the intumescence of RTV, which were taken from literature and the coefficient of thermal expansion was collected using in-situ heating and Micro Computed Tomography (µ-CT) in previous studies. Finally, numerous other properties such as pyrolysis gas properties, virgin and char thermal conductivity and specific heat were compiled from previous experiments and literature into a material database that can be used for simulations. In Porous Material Analysis Toolbox based on OpenFOAM (PATO) [4], structural mechanics coupled with material response was used for simulating the intumescence of RTV as it is heated. However, since the permeability of the material is very low, the pyrolysis gas creates an internal pressure build-up as the material is being heated, significantly contributing to the deformation of the material. To correctly characterize this phenomenon, additional physics models were implemented into PATO's stress analysis solver, and results were compared with RTV dilatometry test data as a preliminary verification case. Future work will include experiments of RTV at the Plasmatron X facility and the in-situ heating cell with µ-CT, and improvement of simulation tools to more accurately model RTV intumescence.

PATO↗
NASA NTRS1989

Three-dimensional analysis of surface crack-Hertzian stress field interaction

The results are presented of a stress intensity factor analysis of semicircular surface cracks in the inner raceway of an engine bearing. The loading consists of a moving spherical Hertzian contact load and an axial stress due to rotation and shrink fit. A 3-D linear elastic Boundary Element Method code was developed to perform the stress analysis. The element library includes linear and quadratic isoparametric surface elements. Singular quarter point elements were employed to capture the square root displacement variation and the inverse square root stress singularity along the crack front. The program also possesses the capability to separate the whole domain into two subregions. This procedure enables one to solve nonsymmetric fracture mechanics problems without having to separate the crack surfaces a priori. A wide range of configuration parameters was investigated. The ratio of crack depth to bearing thickness was varied from one-sixtieth to one-fifth for several different locations of the Hertzian load. The stress intensity factors for several crack inclinations were also investigated. The results demonstrate the efficiency and accuracy of the Boundary Element Method. Moreover, the results can provide the basis for crack growth calculations and fatigue life prediction.

Ballarini, R.↗
NASA NTRS1989

Computing Stress, Stability, And Vibration Of Shells

BOSOR4 computer program developed as comprehensive program for analysis of stress, stability, and vibration of complex, branched shells of revolution made of elastic materials. Used to analyze prismatic shells and panels. Performs large-deflection axisymmetric stress analysis, small-deflection nonsymmetric stress analysis, modal vibration analysis with axisymmetric nonlinear prestress included, and buckling analysis with axisymmetric or nonsymmetric prestress. One main advantage, provisions for such realistic engineering details as eccentric load paths, internal supports, arbitrary branching conditions, and "library" of wall constructions. Based on finite-difference energy method and offers very rapid convergence with increasing numbers of mesh points. Written in FORTRAN 77.

Bushnell, David↗
DOE OSTI2020

A Hybrid AI/ML and Computational Mechanics Based Approach for Time-Series State and Fatigue Life Estimation of Nuclear Reactor Components

Environmental fatigue modeling is a complex problem due to multiple failure modes and their intermixing. The failure modes are function of various underlying causes in addition to the corrosive effect of reactor coolant environment. Some of the major causes are time-dependence of material associated with cyclic loading, load sequence effect associated with random/variable amplitude loading, effect of strain amplitude and rates, effect of varying temperature (along both temporal and spatial directions) and the effect of mean strain and stress. The nonlinear intermixing of failure modes associated with above mentioned causing parameters makes the environmental fatigue modeling is a challenging task. Because of this challenge, fatigue is traditionally being modeled based on experimental data. However, test based empirical approach often requires hundreds of fatigue tests to model the above-mentioned intermixing failure causes even for a single material system. The problem is further exaggerated for reactor component made from multi-material systems such as made from both carbon and stainless-steel base metals and their similar and dissimilar metal welds. With the difficulty of conducting hundreds of fatigue tests to capture the above-mentioned intermixing failure causes, fatigue modeling approaches often depends on empirical models based on limited available test data such as available through ASME code and NUREG 6909. However, these limited test-data-based models may not be enough to accurately predict the life of reactor components. Accurate prediction of life of reactor component would become a necessity, particularly when the license of the reactors to be extended for long-term-operation (LTO) that is for well beyond its original design life of 40 years. The requirement of extending the license of reactor under LTO requires hundreds of fatigue tests to be conducted to understand the mechanism associated with the above-mentioned interdependent failure causes. However, conducting large number of fatigue tests is not a feasibility due to the cost involved. To address this issues Argonne National Laboratory (ANL) with the sponsorship of DOE Light Water Reactor Sustainability (LWRS) program trying to develop a hybrid predictive modeling approach. This is based on limited experiment-data, Artificial-intelligence (AI) – Machine-Learning (ML) - Deep-Learning (DL) based techniques and Multiphysics-computational-mechanics based modeling tools. The hybrid approach not-only can improve the accuracy of the existing stress analysis and fatigue modeling approach but also can reduce the over-dependency on test-based approach. Towards this goal following are some of the major contributions based on ANL’s FY-20 environmental fatigue modeling activities: 1) A cyclic plasticity material model database for 82/182 dissimilar metal weld, which can be readily shared with US nuclear industry and regulatory agency on request. 2) A well validated analytical modeling methodology to perform cycle-by-cycle stress prediction under both constant amplitude fatigue loading and variable amplitude fatigue loading (with load-sequence effect). 3) An AI/ML/DL based methodology to predict unmeasurable cyclic strain based on other available sensor signals. This type of approach can be used for estimating strain in real reactor components from other sensor readings. 4) An AI/ML based approach to improve the US capability on environmental fatigue testing. This is by improving ANL’s existing environmental fatigue testing capacity to conduct ASME required strain-controlled tests (by controlling strain amplitudes and its rate), while not measuring the strain (due to the difficulty of placing an extensometer in a narrow autoclave in a PWR-water-test system). 5) A simulation and experiment based probabilistic modeling methodology for time-series fatigue state and life estimation of reactor metal such as dissimilar metal weld.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1998

Analysis and Design of Variable Stiffness Composite Cylinders

An investigation of the possible performance improvements of thin circular cylindrical shells through the use of the variable stiffness concept is presented. The variable stiffness concept implies that the stiffness parameters change spatially throughout the structure. This situation is achieved mainly through the use of curvilinear fibers within a fiber-reinforced composite laminate, though the possibility of thickness variations and discrete stiffening elements is also allowed. These three mechanisms are incorporated into the constitutive laws for thin shells through the use of Classical Lamination Theory. The existence of stiffness variation within the structure warrants a formulation of the static equilibrium equations from the most basic principles. The governing equations include sufficient detail to correctly model several types of nonlinearity, including the formation of a nonlinear shell boundary layer as well as the Brazier effect due to nonlinear bending of long cylinders. Stress analysis and initial buckling estimates are formulated for a general variable stiffness cylinder. Results and comparisons for several simplifications of these highly complex governing equations are presented so that the ensuing numerical solutions are considered reliable and efficient enough for in-depth optimization studies. Four distinct cases of loading and stiffness variation are chosen to investigate possible areas of improvement that the variable stiffness concept may offer over traditional constant stiffness and/or stiffened structures. The initial investigation deals with the simplest solution for cylindrical shells in which all quantities are constant around the circumference of the cylinder. This axisymmetric case includes a stiffness variation exclusively in the axial direction, and the only pertinent loading scenarios include constant loads of axial compression, pressure, and torsion. The results for these cases indicate that little improvement over traditional laminates exists through the use of curvilinear fibers, mainly due to the presence of a weak link area within the stiffness variation that limits the ultimate load that the structure can withstand. Rigorous optimization studies reveal that even though slight increases in the critical loads can be produced for designs with an arbitrary variation of the fiber orientation angle, the improvements are not significant when compared to traditional design techniques that utilize ring stiffeners and frames. The second problem that is studied involves arbitrary loading of a cylinder with a stiffness variation that changes only in the circumferential direction. The end effects of the cylinder are ignored, so that the problem takes the form of an analysis of a cross-section for a short cylinder segment. Various load cases including axial compression, pressure, torsion, bending, and transverse shear forces are investigated. It is found that the most significant improvements in load-carrying capability exist for cases which involve loads that also vary around the circumference of the shell, namely bending and shear forces. The stiffness variation of the optimal designs contribute to the increased performance in two ways: lowering the stresses in the critical areas through redistribution of the stresses; and providing a relatively stiff region that alters the buckling behavior of the structure. These results lead to an in-depth optimization study involving weight optimization of a fuselage structure subjected to typical design constraints. Comparisons of the curvilinear fiber format to traditional stiffened structures constructed of isotropic and composite materials are included. It is found that standard variable stiffness designs are quite comparable in terms of weight and load-carrying capability yet offer the added advantage of tailorability of distinct regions of the structure that experience drastically different loading conditions. The last two problems presented in this work involve the nonlinear phenomenon of long tubes under bending. Though this scenario is not as applicable to fuselage structures as the previous problems, the mechanisms that produce the nonlinear effect are ideally suited to be controlled by the variable stiffness concept. This is due to the fact that the dominating influence for long cylinders under bending is the ovalization of the cross-section, which is governed mainly by the stiffness parameters of the cylindrical shell. Possible improvement of the critical buckling moments for these structures is investigated using either a circumferential or axial stiffness variation. For the circumferential case involving infinite length cylinders, it is found that slight improvements can be observed by designing structures that resist the cross-sectional deformation yet do not detract from the buckling resistance at the critical location. The results also indicate that buckling behavior is extremely dependent on cylinder length. This effect is most easily seen in the solution of finite length cylinders under bending that contain an axial stiffness variation. For these structures, the only mechanism that exhibits improved response are those that effectively shorten the length of the cylinder, thus reducing the cross-sectional deformation due to the forced restraint at the ends. It was found that the use of curvilinear fibers was not able to achieve this effect in sufficient degree to resist the deformation, but that ring stiffeners produced the desired response admirably. Thus, it is shown that the variable stiffness concept is most effective at improving the bending response of long cylinders through the use of a circumferential stiffness variation.

Tatting, Brian F.↗
NASA NTRS1979

Approximation methods for combined thermal/structural design

Two approximation concepts for combined thermal/structural design are evaluated. The first concept is an approximate thermal analysis based on the first derivatives of structural temperatures with respect to design variables. Two commonly used first-order Taylor series expansions are examined. The direct and reciprocal expansions are special members of a general family of approximations, and for some conditions other members of that family of approximations are more accurate. Several examples are used to compare the accuracy of the different expansions. The second approximation concept is the use of critical time points for combined thermal and stress analyses of structures with transient loading conditions. Significant time savings are realized by identifying critical time points and performing the stress analysis for those points only. The design of an insulated panel which is exposed to transient heating conditions is discussed.

Haftka, R. T.↗
NASA NTRS1973

NASTRAN cyclic symmetry capability

A development for NASTRAN which facilitates the analysis of structures made up of identical segments symmetrically arranged with respect to an axis is described. The key operation in the method is the transformation of the degrees of freedom for the structure into uncoupled symmetrical components, thereby greatly reducing the number of equations which are solved simultaneously. A further reduction occurs if each segment has a plane of reflective symmetry. The only required assumption is that the problem be linear. The capability, as developed, will be available in level 16 of NASTRAN for static stress analysis, steady state heat transfer analysis, and vibration analysis. The paper includes a discussion of the theory, a brief description of the data supplied by the user, and the results obtained for two example problems. The first problem concerns the acoustic modes of a long prismatic cavity imbedded in the propellant grain of a solid rocket motor. The second problem involves the deformations of a large space antenna. The latter example is the first application of the NASTRAN Cyclic Symmetry capability to a really large problem.

Macneal, R. H.↗
NASA NTRS1981

Analytical and experimental evaluation of biaxial contact stress

Contact stress analysis was conducted for ceramic-metal and ceramic-ceramic interfaces using a finite element model. Ceramics investigated included NC-132 hot-pressed silicon nitride, NC-350 reaction-bonded silicon nitride, Hexaloy SA SiC, and RBN104 reaction-bonded silicon nitride. The results are shown to be well correlated with closed-form solution both for normal and normal-tangential loading. The latter load condition is found to be especially critical for ceramic materials due to the presence of a high tensile stress at the trailing edge of the ceramic surface contact zone. It is shown that during sliding contact or biaxial loading, the magnitude of this tensile stress increases with the coefficient of friction.

Richerson, D. W.↗
NASA NTRS1982

Improved finite element methodology for integrated thermal structural analysis

An integrated thermal-structural finite element approach for efficient coupling of thermal and structural analyses is presented. New thermal finite elements which yield exact nodal and element temperature for one dimensional linear steady state heat transfer problems are developed. A nodeless variable formulation is used to establish improved thermal finite elements for one dimensional nonlinear transient and two dimensional linear transient heat transfer problems. The thermal finite elements provide detailed temperature distributions without using additional element nodes and permit a common discretization with lower order congruent structural finite elements. The accuracy of the integrated approach is evaluated by comparisons with analytical solutions and conventional finite element thermal-structural analyses for a number of academic and more realistic problems. Results indicate that the approach provides a significant improvement in the accuracy and efficiency of thermal stress analysis for structures with complex temperature distributions.

Dechaumphai, P.↗
NASA NTRS1982

Extension of the hole-drilling method to birefringent composites

A complete stress analysis and reliable failure criteria are essential for important structural applications of composites in order to fully utilize their unique properties. The inhomogeneity, anisotropy and inelasticity of many composites make the use of experimental methods indispensable. Among the experimental techniques, transmission photoelasticity has been extended to birefringent composites in recent years. The extension is not straight-forward, in view of the complex nature of the photoelastic response of such model materials. This paper very briefly reviews the important developments in the subject and then describes the theoretical basis for a new method of determining the individual values of principal stresses in composite models. The method consists in drilling very small holes at points where the state of stress has to be determined. Experiments are then described which verify the theoretical predictions. The limitations of the method are pointed out and it is concluded that valuable information concerning the state of stress in a composite model can be obtained through the suggested method.

Prabhakaran, R.↗
NASA NTRS1991

An analysis of the wear behavior of SiC whisker reinforced alumina from 25 to 1200 C

A model is described for predicting the wear behavior of whisker reinforced ceramics. The model was successfully applied to a silicon carbide whisker reinforced alumina ceramic composite subjected to sliding contact. The model compares the friction forces on the whiskers due to sliding, which act to pull or push them out of the matrix, to the clamping or compressive forces on the whiskers due to the matrix, which act to hold the whiskers in the composite. At low temperatures, the whiskers are held strongly in the matrix and are fractured into pieces during the wear process along with the matrix. At elevated temperatures differential thermal expansion between the whiskers and matrix can cause loosening of the whiskers and lead to pullout during the wear process and to higher wear. The model, which represents the combination of elastic stress analysis and a friction heating analysis, predicts a transition temperature at which the strength of the whiskers equals the clamping force holding them in the matrix. Above the transition the whiskers are pulled out of the matrix during sliding, and below the transition the whiskers are simply fractured. The existence of the transition gives rise to a dual wear mode or mechanism behavior for this material which was observed in laboratory experiments. The results from this model correlate well with experimentally observed behavior indicating that the model may be useful in obtaining a better understanding of material behavior and in making material improvements.

Dellacorte, Christopher↗
NASA NTRS1993

An analysis of the wear behavior of SiC whisker-reinforced alumina from 25 to 1200 C

A model is described for predicting the wear behavior of whisker reinforced ceramics. The model was successfully applied to a silicon carbide whisker reinforced alumina ceramic composite subjected to sliding contact. The model compares the friction forces on the whiskers due to sliding, which act to pull or push them out of the matrix, to the clamping or compressive forces on the whiskers due to the matrix, which act to hold the whiskers in the composite. At low temperatures, the whiskers are held strongly in the matrix and are fractured into pieces during the wear process along with the matrix. At elevated temperatures differential thermal expansion between the whiskers and matrix can cause loosening of the whiskers and lead to pullout during the wear process and to higher wear. The model, which represents the combination of elastic stress analysis and a friction heating analysis, predicts a transition temperature at which the strength of the whiskers equals the clamping force holding them in the matrix. Above the transition the whiskers are pulled out of the matrix during sliding, and below the transition the whiskers are simply fractured. The existence of the transition gives rise to a dual wear mode or mechanism behavior for this material which was observed in laboratory experiments. The results from this model correlate well with experimentally observed behavior indicating that the model may be useful in obtaining a better understanding of material behavior and in making material improvements.

Dellacorte, Christopher↗
NASA NTRS1985

Constitutive modeling for isotropic materials

The objective is to develop a unified constitutive model for finite element structural analysis of turbine engine hot-section components. This effort constitutes a different approach for non-linear finite-element computer codes which have heretofore been based on classical inelastic methods. The unified constitutive theory to be developed will avoid the simplifying assumptions of classical theory and should more accurately represent the behavior of superalloy materials under cyclic loading conditions and high temperature environments. During the first two years of the program, extensive experimental correlations were made with two representative unified models. The experiments were both uniaxial and biaxial at temperatures up to 1093 C (2000 F). In addition, the unified models were adopted to the MARC finite element code and used for stress analysis of notched bar and turbine blade geometries.

Lindholm, Ulric S.↗
NASA NTRS1982

Improved finite element methodology for integrated thermal structural analysis

An integrated thermal-structural finite element approach for efficient coupling of thermal and structural analysis is presented. New thermal finite elements which yield exact nodal and element temperatures for one dimensional linear steady state heat transfer problems are developed. A nodeless variable formulation is used to establish improved thermal finite elements for one dimensional nonlinear transient and two dimensional linear transient heat transfer problems. The thermal finite elements provide detailed temperature distributions without using additional element nodes and permit a common discretization with lower order congruent structural finite elements. The accuracy of the integrated approach is evaluated by comparisons with analytical solutions and conventional finite element thermal structural analyses for a number of academic and more realistic problems. Results indicate that the approach provides a significant improvement in the accuracy and efficiency of thermal stress analysis for structures with complex temperature distributions.

Dechaumphai, P.↗
NASA NTRS1988

A high heat flux experiment for verification of thermostructural analysis

A major concern in advancing the state of the art technologies for hypersonic vehicles is the development of an aeropropulsion system capable of handling the high heat fluxes during flight. The leading edges of such systems must not only tolerate the maximum heating rates, but must also minimize distortions to the flow field due to excessive blunting and/or thermal warping of the compression surface to achieve the high inlet performance required. A combined analytical and experimental effort to study the aerothermodynamic loads on actively cooled structures for hypersonic applications was established. A hydrogen/oxygen rocket engine was modified to establish a high enthalpy high heat flux environment. The facility provides heat flux levels from about 200 up to 10000 Btu/sq ft/sec. Cross flow and parallel flow regeneratively cooled model can be tested and analyzed by using cooling fluids of water and hydrogen. Results are presented of the experiment and the characteristics of the Hot Gas Test Facility. The predicted temperature results of the cross flow model are compared with the experimental data on the first monolithic specimens and are found to be in good agreement. Thermal stress analysis results are also presented.

Gladden, Herbert J.↗
NASA NTRS1988

A high heat flux experiment for verification of thermostructural analysis

A major concern in advancing the state of the art technologies for hypersonic vehicles is the development of an aeropropulsion system capable of handling the high heat fluxes during flight. The leading edges of such systems must not only tolerate the maximum heating rates, but must also minimize distortions to the flow field due to excessive blunting and/or thermal warping of the conmpression surface to achieve the high inlet performance required. A combined analytical and experimental effort to study the aerothermodynamic loads on actively cooled structures for hypersonic applications was established. A hydrogen/oxygen rocket engine was modified to establish a high enthalpy high heat flux environment. The facility provides heat flux levels from about 200 up to 10000 Btu/sq ft/sec. Cross flow and parallel flow regeneratively cooled model can be tested and analyzed by using cooling fluids of water and hydrogen. Results are presented of the experiment and the characteristics of the Hot Gas Test Facility. The predicted temperature results of the cross flow model are compared with the experimental data on the first monolithic specimens and are found to be in good agreement. Thermal stress analysis results are also presented.

Gladden, H. J.↗