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At least 73 records · Page 4

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NASA NTRS2017

Three-Dimensional High Fidelity Progressive Failure Damage Modeling of NCF Composites

Performance prediction of off-axis laminates is of significant interest in designing composite structures for energy absorption. Phenomenological models available in most of the commercial programs, where the fiber and resin properties are smeared, are very efficient for large scale structural analysis, but lack the ability to model the complex nonlinear behavior of the resin and fail to capture the complex load transfer mechanisms between the fiber and the resin matrix. On the other hand, high fidelity mesoscale models, where the fiber tows and matrix regions are explicitly modeled, have the ability to account for the complex behavior in each of the constituents of the composite. However, creating a finite element model of a larger scale composite component could be very time consuming and computationally very expensive. In the present study, a three-dimensional mesoscale model of non-crimp composite laminates was developed for various laminate schemes. The resin material was modeled as an elastic-plastic material with nonlinear hardening. The fiber tows were modeled with an orthotropic material model with brittle failure. In parallel, new stress based failure criteria combined with several damage evolution laws for matrix stresses were proposed for a phenomenological model. The results from both the mesoscale and phenomenological models were compared with the experiments for a variety of off-axis laminates.

Aitharaju, Venkat↗

DOE OSTI2018

Micromechanical modeling of non-linear stress-strain behavior of polycrystalline microcracked materials under tension

The stress-strain behavior of microcracked polycrystalline materials (such as ceramics or rocks) under conditions of tensile, displacement-controlled, loading is discussed. Micromechanical explanation and modeling of the basic features, such as non-linearity and hysteresis in stress-strain curves, is developed, with stable microcrack propagation and “roughness” of intergranular cracks playing critical roles. Experiments involving complex loading histories were done on large- and medium grain size β-eucryptite ceramic. As a result, the model is shown to reproduce the basic features of the observed stress-strain curves.

36 MATERIALS SCIENCE↗

NASA NTRS1990

Application of path-independent integrals to elevated temperature crack growth

The applicability of the J-integral in elasto-plastic fracture mechanics is limited to isothermal, monotonic loading conditions from the theoretical viewpoint, while in many applications, for instance gas turbine engines, crack growth occurs in the presence of cyclic inelastic loading, thermomechanical loading and temperature gradients. A number of path-independent (P-I) integrals have been proposed which do not have the restrictions of the J-integral. A review indicates that four of these integrals, although they are not the classical conservation integrals, are path-independent under these complex loading conditions. This paper describes a combined analytical and experimental effort to evaluate the ability of these four P-I integrals to correlate the crack growth data of Alloy 718 at elevated temperatures. Results for uniform temperature, 538 C, cases indicate that all these integrals are capable of correlating the crack growth data over a wide range of cyclic plasticity.

Kim, K. S.↗

NASA NTRS1988

The relationship between observed fatigue damage and life estimation models

Observations of the surface of laboratory specimens subjected to axial and torsional fatigue loadings has resulted in the identification of three damage fatigue phenomena: crack nucleation, shear crack growth, and tensile crack growth. Material, microstructure, state of stress/strain, and loading amplitude all influence which of the three types of fatigue damage occurs during a dominant fatigue life fraction. Fatigue damage maps are employed to summarize the experimental observations. Appropriate bulk stress/strain damage parameters are suggested to model fatigue damage for the dominant fatigue life fraction. Extension of the damage map concept to more complex loadings is presented.

Kurath, Peter↗

NASA NTRS2006

Predicting Lifetime of a Thermomechanically Loaded Component

NASALIFE is a computer program for predicting the lifetime, as affected by low cycle fatigue (LCF) and creep rupture, of a structural component subject to temporally varying, multiaxial thermomechanical loads. The component could be, for example, part of an aircraft turbine engine. Empirical data from LCF tests, creep rupture tests, and static tensile tests are used as references for predicting the number of missions the component can withstand under a given thermomechanical loading condition. The user prepares an input file containing the creep-rupture and cyclic-fatigue information, temperature-dependent material properties, and mission loading and control flags. The creep rupture information can be entered in tabular form as stress versus life or by means of parameters of the Larson-Miller equation. The program uses the Walker mean-stress model to adjust predicted life for ranges of the ratio between the maximum and minimum stresses. Data representing complex load cycles are reduced by the rainflow counting method. Miner's rule is utilized to combine the damage at different load levels. Finally, the program determines the total damage due to creep and combines it with the fatigue damage due to the cyclic loading and predicts the approximate number of missions a component can endure before failing.

Murthy, Pappu L. N.↗

NASA NTRS1988

Life prediction modeling based on strainrange partitioning

Strainrange partitioning (SRP) is an integrated low-cycle-fatigue life predicting system. It was created specifically for calculating cyclic crack initiation life under severe high-temperature fatigue conditions. The key feature of the SRP system is its recognition of the interacting mechanisms of cyclic inelastic deformation that govern cyclic life at high temperatures. The SRP system bridges the gap between the mechanistic level of understanding that breeds new and better materials and the phenomenological level wherein workable engineering life prediction methods are in great demand. The system was recently expanded to address engineering fatigue problems in the low-strain, long-life, nominally elastic regime. This breakthrough, along with other advances in material behavior and testing technology, has permitted the system to also encompass low-strain thermomechanical loading conditions. Other important refinements of the originally proposed method include procedures for dealing with life-reducing effects of multiaxial loading, ratcheting, mean stresses, nonrepetitive (cumulative loading) loading, and environmental and long-time exposure. Procedure were also developed for partitioning creep and plastic strain and for estimating strainrange versus life relations from tensile and creep rupture properties. Each of the important engineering features of the SRP system are discussed and examples shown of how they help toward predicting high-temperature fatigue life under practical, although complex, loading conditions.

Halford, Gary R.↗

NASA NTRS1988

Cyclic fatigue damage characteristics observed for simple loadings extended to multiaxial life prediction

Fully reversed uniaxial strain controlled fatigue tests were performed on smooth cylindrical specimens made of 304 stainless steel. Fatigue life data and cracking observations for uniaxial tests were compared with life data and cracking behavior observed in fully reversed torsional tests. It was determined that the product of maximum principle strain amplitude and maximum principle stress provided the best correlation of fatigue lives for these two loading conditions. Implementation of this parameter is in agreement with observed physical damage and it accounts for the variation of stress-strain response, which is unique to specific loading conditions. Biaxial fatigue tests were conducted on tubular specimens employing both in-phase and out-of-phase tension torsion cyclic strain paths. Cracking observations indicated that the physical damage which occurred in the biaxial tests was similar to the damage observed in uniaxial and torsional tests. The Smith, Watson, and Topper parameter was then extended to predict the fatigue lives resulting from the more complex loading conditions.

Jones, David J.↗

NASA NTRS2002

Effects of Initial Geometric Imperfections On the Non-Linear Response of the Space Shuttle Superlightweight Liquid-Oxygen Tank

The results of an analytical study of the elastic buckling and nonlinear behavior of the liquid-oxygen tank for the new Space Shuttle superlightweight external fuel tank are presented. Selected results that illustrate three distinctly different types of non-linear response phenomena for thin-walled shells which are subjected to combined mechanical and thermal loads are presented. These response phenomena consist of a bifurcation-type buckling response, a short-wavelength non-linear bending response and a non-linear collapse or "snap-through" response associated with a limit point. The effects of initial geometric imperfections on the response characteristics are emphasized. The results illustrate that the buckling and non-linear response of a geometrically imperfect shell structure subjected to complex loading conditions may not be adequately characterized by an elastic linear bifurcation buckling analysis, and that the traditional industry practice of applying a buckling-load knock-down factor can result in an ultraconservative design. Results are also presented that show that a fluid-filled shell can be highly sensitive to initial geometric imperfections, and that the use a buckling-load knock-down factor is needed for this case.

Nemeth, Michael P.↗

NASA NTRSDate not supplied

Advanced Modeling of Control-Structure Interaction in Thrust Vector Control Systems

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. During the development of the SLS TVC system, a family of advanced dynamics models were developed to extend and compliment the simplified quasi-linear “simplex” model historically used for flight control design and stability analysis. The importance of these advanced models became increasingly evident after ambient and hot fire testing of the Core Stage, which revealed a number of findings associated with the dynamic response of the TVC integrated system. Test responses suggested that the TVC did not meet its performance specifications and its step and frequency responses exhibited unexpected departures from prior lab tests and modeled behavior. One driving factor for these results was a higher-than-expected degree of coupling between the TVC system, the engine dynamics, and the Core Stage structure. This paper is the third installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. In this paper, a new method of modeling rocket vehicle thrust vectoring servoelastic dynamics is presented. In this approach, the load dynamics are replaced by a detailed finite element model containing both the rigid body and elastic modes. A partitioning technique is used to compute the effective compliance from the modal data and obtain accurate simulation results using a reduced number of generalized coordinates. Coupled backup structure and nozzle attach compliance effects on multiple engines are captured in higher fidelity than with a spring approximation, eliciting novel effects due to the complex load paths involved in the Core Stage structure. Validation of the model is demonstrated using a variety of structural/modal, laboratory, and full-scale hot fire test data.

Launch Vehicles↗

NASA NTRSDate not supplied

Advanced Modeling of Control-Structure Interaction in Thrust Vector Control Systems

Launch Vehicles↗

NASA NTRS1995

Prediction and Measurement of the Vibration and Acoustic Radiation of Panels Subjected to Acoustic Loading

Interior noise and sonic fatigue are important issues in the development and design of advanced subsonic and supersonic aircraft. Conventional aircraft typically employ passive treatments, such as constrained layer damping and acoustic absorption materials, to reduce the structural response and resulting acoustic levels in the aircraft interior. These techniques require significant addition of mass and only attenuate relatively high frequency noise transmitted through the fuselage. Although structural acoustic coupling is in general very important in the study of aircraft fuselage interior noise, analysis of noise transmission through a panel supported in an infinite rigid baffle (separating two semi-infinite acoustic domains) can be useful in evaluating the effects of active/adaptive materials, complex loading, etc. Recent work has been aimed at developing adaptive and/or active methods of controlling the structural acoustic response of panels to reduce the transmitted noise1. A finite element formulation was recently developed to study the dynamic response of shape memory alloy (SMA) hybrid composite panels (conventional composite panel with embedded SMA fibers) subject to combined acoustic and thermal loads2. Further analysis has been performed to predict the far-field acoustic radiation using the finite element dynamic panel response prediction3. The purpose of the present work is to validate the panel vibration and acoustic radiation prediction methods with baseline experimental results obtained from an isotropic panel, without the effect of SMA.

Turner, Travis L.↗

DOE OSTI2025

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

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

Alloy 709↗

DOE OSTI2026

A Physics-Based Digital Twin for Wave Elevation and Seabed Moment Estimation of Offshore Monopiles: Preprint

In this work, we present a proof of concept of a physics-based digital twin for a monopile structure (with overhead inertia) subjected to wave loading. The digital twin is formulated using reduced-order models derived from first principles and combined with a Kalman filter for state estimation. The proposed framework estimates the monopile top motion, the wave elevation, and the section forces and moments along the pile using primarily acceleration measurements at the monopile top. Key innovations include the use of a hydrodynamic shape function to represent distributed wave loading in a compact and computationally efficient manner, and the introduction of a shaping filter to augment the state-space with wave kinematics. Synthetic measurement data are generated using OpenFAST and used as a reference to assess the performance of the digital twin. Results demonstrate that the wave elevation can be accurately reconstructed without direct sea-state measurements as long as the wave regime is inertia-dominated. Under the ideal tested conditions, the total hydrodynamic force and sea-bed bending moment are estimated with relative errors on the order of 1% and correlation coefficients exceeding 96%. Future work will evaluate the estimator's performance under operational uncertainties and more complex loading conditions.

17 WIND ENERGY↗

DOE OSTI2023

Modular machine learning-based elastoplasticity: Generalization in the context of limited data

The development of highly accurate constitutive models for materials that undergo path-dependent processes continues to be a complex challenge in computational solid mechanics. Challenges arise both in considering the appropriate model assumptions and from the viewpoint of data availability, verification, and validation. Recently, data-driven modeling approaches have been proposed that aim to establish stress-evolution laws that avoid user-chosen functional forms by relying on machine learning representations and algorithms. However, these approaches not only require a significant amount of data but also need data that probes the full stress space with a variety of complex loading paths. Furthermore, they rarely enforce all necessary thermodynamic principles as hard constraints. Hence, they are in particular not suitable for low-data or limited-data regimes, where the first arises from the cost of obtaining the data and the latter from the experimental limitations of obtaining labeled data, which is commonly the case in engineering applications. In this work, we discuss a hybrid framework that can work on a variable amount of data by relying on the modularity of the elastoplasticity formulation where each component of the model can be chosen to be either a classical phenomenological or a data-driven model depending on the amount of available information and the complexity of the response. The method is tested on synthetic uniaxial data coming from simulations as well as cyclic experimental data for structural materials. The discovered material models are found to not only interpolate well but also allow for accurate extrapolation in a thermodynamically consistent manner far outside the domain of the training data. This ability to extrapolate from limited data was the main reason for the early and continued success of phenomenological models and the main shortcoming in machine learning-enabled constitutive modeling approaches. Training aspects and details of the implementation of these models into Finite Element simulations are discussed and analyzed.

42 ENGINEERING↗

NASA NTRS1998

Thermomechanical Postbuckling of Shells

A number of issues involving the postbuckling of doubly-curved panels exposed to a non-uniform temperature field and subjected to a system of mechanical loads are considered in this paper. Effects played by transverse shear, initial geometric imperfections, membrane and thickness-wise temperature gradient, tangential edge constraints, linear/non-linear elastic foundation are incorporated and their implications on the non-linear response behavior of shells are discussed. Issues related with the delay of the occurrence of the snap-through buckling, alleviation of its intensity and even with its removal are addressed and remarks on conditions rendering a curved panel insensitive to initial geometric imperfections are included. Results on small vibration of shells about sub- and post-critical ranges are provided and structural modeling issues playing a non-negligible role towards a reliable prediction of the postbuckling behavior of shells under complex loading conditions are discussed. Results on non-linear response of flat reinforced panels subjected to thermomechanical loads are also presented. Finally, problems not covered by this article are briefly indicated.

Librescu, Liviu↗

DOE OSTI2017

Cyclic compression response of micropillars extracted from textured nanocrystalline NiTi thin-walled tubes

Compression-compression cyclic deformation of nanocrystalline NiTi tubes intended for medical stents and with an outer diameter of 1 mm and wall thickness of 70 μm was studied using micropillars produced by FIB with the loading axis orthogonal to the tube axis. These micropillars were cycled in a displacement-controlled mode using a nanoindenter equipped with a flat punch to strain levels of 4, 6 and 8% in each cycle and specimens were subjected to several hundred cycles. Furthermore, the cyclic response of two NiTi tubes, one with Af of 17 °C and the other with an Af of -5 °C is compared. The texture of the tube with the Af of -5 °C was measured at the microscopic level using transmission electron microscopy and at the macroscopic level by X-ray diffraction and good agreement was noted. Characteristics such as i) a reduction in the forward transformation stress, ii) increase in maximum stress for a given displacement amplitude, and iii) a reduction in the hysteresis loop area, all with increasing number of cycles, observed typically during cyclic deformation of conventional macroscopic specimens, were captured in the micropillar cyclic tests. Our observations lead to the conclusion that micropillar compression testing in a cyclic mode can enable characterizing the orientation-dependent response in such small dimension components that see complex loading in service, and additionally provide an opportunity for calibrating constitutive equations in micromechanical models.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Identifying Deformation and Strain Hardening Behaviors of Nanoscale Metallic Multilayers Through Nano-wear Testing

In complex loading conditions (e.g. sliding contact), mechanical properties, such as strain hardening and initial hardness, will dictate the long-term performance of materials systems. With this in mind, the strain hardening behaviors of Cu/Nb nanoscale metallic multilayer systems were examined by performing nanoindentation tests within nanoscratch wear boxes and undeformed, as-deposited regions. Both the architecture and substrate influence were examined by utilizing three different individual layer thicknesses (2, 20, and 100 nm) and two total film thicknesses (1 and 10 μm). After nano-wear deformation, multilayer systems with thinner layers showed less volume loss as measured by laser scanning microscopy. Additionally, the hardness of the deformed regions significantly rose with respect to the as-deposited measurements, which further increased with greater wear loads. Strain hardening exponents for multilayers with thinner layers (2 and 20 nm, n ≈ 0.018 and n ≈ 0.022 respectively) were less than was determined for 100 nm systems (n ≈ 0.041). These results suggest that singledislocation based deformation mechanisms observed for the thinner systems limit the extent of achievable strain hardening. This conclusion indicates that impacts of both architecture strengthening and strain hardening must be considered to accurately predict multilayer performance during sliding contact across varying length scales.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Accurate Effective Stress Measures: Predicting Creep Life for 3D Stresses Using 2D and 1D Creep Rupture Simulations and Data

Operating structural components experience complex loading conditions resulting in 3D stress states. Current design practice estimates multiaxial creep rupture life by mapping a general state of stress to a uniaxial creep rupture correlation using effective stress measures. The data supporting the development of effective stress measures are nearly always only uniaxial and biaxial, as 3D creep rupture tests are not widely available. This limitation means current effective stress measures must extrapolate from 2D to 3D stress states, potentially introducing extrapolation error. In this work, we use a physics-based, crystal plasticity finite element model to simulate uniaxial, biaxial, and triaxial creep rupture. Here, we use the virtual dataset to assess the accuracy of current and novel effective stress measures in extrapolating from 2D to 3D stresses and also explore how the predictive accuracy of the effective stress measures might change if experimental 3D rupture data was available. We confirm these conclusions, based on simulation data, against multiaxial creep rupture experimental data for several materials, drawn from the literature. The results of the virtual experiments show that calibrating effective stress measures using triaxial test data would significantly improve accuracy and that some effective stress measures are more accurate than others, particularly for highly triaxial stress states. Results obtained using experimental data confirm the numerical findings and suggest that a unified effective stress measure should include an explicit dependence on the first stress invariant, the maximum tensile principal stress, and the von Mises stress.

36 MATERIALS SCIENCE↗