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At least 73 records · Page 4

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NASA NTRS1998

An Integrated Tool for the Coupled Thermal and Mechanical Analysis of Pyrolyzing Heatshield Materials

Materials that pyrolyze at elevated temperature have been commonly used as thermal protection materials in hypersonic flight, and advanced pyrolyzing materials for this purpose continue to be developed. Because of the large temperature gradients that can arise in thermal protection materials, significant thermal stresses can develop. Advanced applications of pyrolytic materials are calling for more complex heatshield configurations, making accurate thermal stress analysis more important, and more challenging. For non-pyrolyzing materials, many finite element codes are available and capable of performing coupled thermal-mechanical analyses. These codes do not, however, have a built-in capability to perform analyses that include pyrolysis effects. When a pyrolyzing material is heated, one or more components of the original virgin material pyrolyze and create a gas. This gas flows away from the pyrolysis zone to the surface, resulting in a reduction in surface heating. A porous residue, referred to as char, remains in place of the virgin material. While the processes involved can be complex, it has been found that a simple physical model in which virgin material reacts to form char and pyrolysis gas, will yield satisfactory analytical results. Specifically, the effects that must be modeled include: (1) Variation of thermal properties (density, specific heat, thermal conductivity) as the material composition changes; (2) Energy released or absorbed by the pyrolysis reactions; (3) Energy convected by the flow of pyrolysis gas from the interior to the surface; (4) The reduction in surface heating due to surface blowing; and (5) Chemical and mass diffusion effects at the surface between the pyrolysis gas and edge gas Computational tools for the one-dimensional thermal analysis these materials exist and have proven to be reliable design tools. The objective of the present work is to extend the analysis capabilities of pyrolyzing materials to axisymmetric configurations, and to couple thermal and mechanical analyses so that thermal stresses may be efficiently and accurately calculated.

Pronchick, Stephen W.↗

DOE OSTI2021

Wear Mechanism Analysis of a New Rotary Shear Biomass Comminution System

A new biomass comminution system, Crumbler rotary shear, was developed to process fuel-grade biomass. The rotary shear is more efficient than the traditional hammer mill in comminuting high-moisture biomass and producing more uniform particles with minimal fines. However, the milling unit experiences significant wear in processing dirty woodchips. This study investigated the wear mechanisms of the rotary shear system based on analysis of the minerals carried by woodchips and characterization of actual worn components. Abrasive wear was found to be the dominant effect, and localized adhesive wear (material transfer), microfracture (chipping), and plastic deformation were additional effects. Connections have been made between the wear progression of key cutting components and the particle size change of biomass extrinsic minerals. On the basis of the wear mechanism understanding, mitigations based on advanced tool materials and optimized tool geometric designs are being developed for improving the tool life and cutting efficiency.

09 BIOMASS FUELS↗

NASA NTRS1974

Fracture mechanics analysis of a high-pressure hydrogen facility compressor

The investigation and analysis of a high-pressure hydrogen facility compressor is chronicled, and a life prediction based on fracture mechanics is presented. Crack growth rates in SA 105 Gr II steel are developed for the condition of sustained loading, using a hypothesis of hydrogen embrittlement associated with plastic zone reverse yielding. The resultant formula is compared with test data obtained from laboratory specimens.

Vroman, G. A.↗

DOE OSTI2015

Full quantum mechanical analysis of atomic three-grating Mach–Zehnder interferometry

Atomic three-grating Mach–Zehnder interferometry constitutes an important tool to probe fundamental aspects of the quantum theory. There is, however, a remarkable gap in the literature between the oversimplified models and robust numerical simulations considered to describe the corresponding experiments. Consequently, the former usually lead to paradoxical scenarios, such as the wave–particle dual behavior of atoms, while the latter make difficult the data analysis in simple terms. Here these issues are tackled by means of a simple grating working model consisting of evenly-spaced Gaussian slits. As is shown, this model suffices to explore and explain such experiments both analytically and numerically, giving a good account of the full atomic journey inside the interferometer, and hence contributing to make less mystic the physics involved. More specifically, it provides a clear and unambiguous picture of the wavefront splitting that takes place inside the interferometer, illustrating how the momentum along each emerging diffraction order is well defined even though the wave function itself still displays a rather complex shape. To this end, the local transverse momentum is also introduced in this context as a reliable analytical tool. The splitting, apart from being a key issue to understand atomic Mach–Zehnder interferometry, also demonstrates at a fundamental level how wave and particle aspects are always present in the experiment, without incurring in any contradiction or interpretive paradox. On the other hand, at a practical level, the generality and versatility of the model and methodology presented, makes them suitable to attack analogous problems in a simple manner after a convenient tuning. - Highlights: • A simple model is proposed to analyze experiments based on atomic Mach–Zehnder interferometry. • The model can be easily handled both analytically and computationally. • A theoretical analysis based on the combination of the position and momentum representations is considered. • Wave and particle aspects are shown to coexist within the same experiment, thus removing the old wave-corpuscle dichotomy. • A good agreement between numerical simulations and experimental data is found without appealing to best-fit procedures.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRS1999

Some Aspects on the Mechanical Analysis of Micro-Shutters

An array of individually addressable micro-shutters is being designed for spectroscopic applications. Details of the design are presented in a companion paper. The mechanical design of a single shutter element has been completed. This design consists of a shutter blade suspended on a torsion beam manufactured out of single crystal silicon membranes. During operation the shutter blade will be rotated by 90 degrees out of the array plane. Thus, the stability and durability of the beams are crucial for the reliability of the devices. Structures were fabricated using focused ion beam milling in a FEI 620 dual beam machine, and subsequent testing was completed using the same platform. This allowed for short turn around times. We performed torsion and bending experiments to determine key characteristics of the membrane material. Results of measurements on prototype shutters were compared with the predictions of the numerical models. The data from these focused studies were used in conjunction with experiments and numerical models of shutter prototypes to optimize the design. In this work, we present the results of the material studies, and assess the mechanical performance of the resulting design.

Fettig, Rainer K.↗

DOE OSTI2014

Dynamic mechanical analysis of phase transformations and anelastic relaxation in stabilized Zirconias

Elastic properties of polycrystalline stabilized zirconias, namely Yttria Stabilized Zirconia (YSZ) and Scandia, Ceria Stabilized Zirconia (SCSZ), were studied by Dynamic Mechanical Analyzer (DMA) in air. Changes of storage modulus E', loss modulus E" and mechanical damping (tanδ) with temperature were simultaneously monitored at various frequencies. In 8 mol% (8YSZ) and 10 mol% (10YSZ) Yttria Stabilized Zirconia, a drop in storage modulus of ~37% was observed in the 30°C to 400°C temperature range, together with two frequency dependent damping peaks. While the first tanδ peak can be attributed to the anelastic relaxation of (Y'ZrVO••)• elastic (and dielectric) dipoles, the second one is probably the result of local ordering of oxygen vacancies and/or relaxation of (2Y'ZrVO••)x dipoles. For cubic SCSZ, four damping peaks were observed in the similar temperature regime accompanied by significant nonlinear drop of the storage modulus. The first tanδ is attributed to anealstic relaxation of (Sc'ZrVO••)•. Furthermore, it was also found that stress induced phase transformation from cubic to rhombohedral structure is the reason for the frequency dependent third peak in the tanδ spectra while the fourth frequency independent peak was found to be the result of the phase transformation from rhombohedral to cubic structure.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Electrode Mesoscale as a Collection of Particles: Coupled Electrochemical and Mechanical Analysis of NMC Cathodes

Battery electrodes are composed of polydisperse particles and a porous, composite binder domain. These materials are arranged into a complex mesostructure whose morphology impacts both electrochemical performance and mechanical response. We present image-based, particle-resolved, mesoscale finite element model simulations of coupled electrochemical-mechanical performance on a representative NMC electrode domain. Beyond predicting macroscale quantities such as half-cell voltage and evolving electrical conductivity, studying behaviors on a per-particle and per-surface basis enables performance and material design insights previously unachievable. Voltage losses are primarily attributable to a complex interplay between interfacial charge transfer kinetics, lithium diffusion, and, locally, electrical conductivity. Mesoscale heterogeneities arise from particle polydispersity and lead to material underutilization at high current densities. Particle-particle contacts, however, reduce heterogeneities by enabling lithium diffusion between connected particle groups. While the porous composite binder domain (CBD) may have slower ionic transport and less available area for electrochemical reactions, its high electrical conductivity makes it the preferred reaction site late in electrode discharge. Mesoscale results are favorably compared to both experimental data and macrohomogeneous models. This work enables improvements in materials design by providing a tool for optimization of particle sizes, CBD morphology, and manufacturing conditions.

42 ENGINEERING↗

NASA NTRS1986

Tether pointing platform and space elevator mechanisms analysis of the key concepts for SATP and scaled SATP

The key concepts for a scaled and full model Science and Applications Tethered Platform (SATP) are analysized. This includes a tether pointing platform and a space elevator. The mechanism concepts and technological solutions are given. The idea of the tether pointing platform mechanism is to control and stabilize the attitude of a platform by means of a movable tether. The idea of the space elevator mechanism for a scaled SATP is to drag the tether gripping it between two rotating wheels.

Turci, E.↗

DOE OSTI2026

Structural and Mechanical Analysis of Individual Mineralized Collagen Fibrils Using In Situ Transmission Electron Microscopy

Bone serves as an example of nature’s architectured material with its characteristic blend of strength and toughness, all at a lightweight design. Given the hierarchical nature of these materials, it is essential to understand the governing mechanisms and organization of their constituents across length scales for bioinspired structural design. Despite recent advances in transmission electron microscopy (TEM) that have allowed us to witness the hierarchical arrangement of bone at micro-down to the nanoscale, we are still missing the details about the structural organization and mechanical properties of the main building blocks of bone─mineralized collagen fibrils (MCFs). Here, we present a method to extract individual MCFs from nature’s model material, mineralized turkey leg tendon, using a dropcasting procedure. By isolating the MCFs onto TEM supporting grids, we visualized the arrangement of organic and mineral phases within individual MCFs at the nanoscale. Using a four-dimensional scanning transmission electron microscopy (4D-STEM) approach, the orientation of individual mineral crystals within the MCFs was examined. Furthermore, we conducted in situ tensile experiments, revealing exceptional tensile strains of at least 8%, demonstrating the intricate relationship between structural organization and the mechanical behavior of MCFs. These insights into the ultrastructure of mineralized tissue building blocks, as well as the proposed sample-extraction method compatible with in situ mechanical testing, provide a strong basis for research into nature-inspired material design.

4D-STEM↗

NASA NTRS1991

Micro-mechanical analysis of damage growth and fracture in discontinuous fiber reinforced metal matrix composites

An experimental verification is presented for a new two parameter fracture model based on the equivalent remote biaxial stresses (ERBS). A detailed comparison is made between the new theory and the constant K(sub IC) approach of linear elastic fracture mechanics (LEFM). Fracture is predicted through a failure curve representing the change in a variable fracture toughness K(sub IC) with the ERBS ratio B(sub E). The nonsingular term (T) in the series expansion of the near crack-tip transverse stress is included in the model. Experimental results for polymethyl methacrylate (PPMA) show that the theory can account for the effects of geometry on fracture toughness as well as indicate the initiation of crack branching. It is shown that the new criterion predicts failure for PMMA with a 95 percent confidence zone which is nearly three times smaller than that of the LEFM K(sub IC) approach.

Goree, James G.↗

DOE OSTI2016

Fuel rod thermo-mechanic analysis of Kuosheng NPP in MSIVC transient with RELAP5 MOD3.3/Fraptran/Python code in SNAP interface

Kuosheng NPP (Nuclear Power Plant) is located on the northern coast of Taiwan. Its nuclear steam supply system (NSSS) is a type of boiling water reactor (BWR/6) designed and built by General Electric on a twin unit concept. Each unit includes two loops of recirculation piping and four main steam lines, with the thermal rated power of 2894 MWt. Unit 1 started SPU (Stretch Power Uprate) from Cycle 24 and Unit 2 started SPU from Cycle 23. The operating power is 104.7% of the OLTP (Original Licensed Thermal Power), which is 3030 MWt now. In order to estimate the safety of Kuosheng NPP, the methodology of Kuosheng NPP SPU safety analysis model was developed. This methodology is shown in Fig. 1. There are three main steps considered in this methodology. The first step is the development of the Kuosheng NPP SPU RELAP5 model. The next step is the main steam line isolation valve closure (MSIVC) analysis of Kuosheng NPP SPU RELAP5 model in order to confirm the maximum pressure of vessel below the acceptance limit of 9.58 MPa. The final step is the fuel rods integrity analysis of FRAPTRAN under the above conditions. From FRAPTRAN analysis results, we find that the peak value of cladding hoop strain is smaller than 0.01, the acceptance limit; furthermore, the fuel enthalpy values are smaller than 150 cal/g. These two results indicate that the fuel rods are still in safe condition after turbine trip accident. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2014

Mechanical Analysis of W78/88-1 Life Extension Program Warhead Design Options

Life Extension Program (LEP) is a program to repair/replace components of nuclear weapons to ensure the ability to meet military requirements. The W78/88-1 LEP encompasses the modernization of two major nuclear weapon reentry systems into an interoperable warhead. Several design concepts exist to provide different options for robust safety and security themes, maximum non-nuclear commonality, and cost. Simulation is one capability used to evaluate the mechanical performance of the designs in various operational environments, plan for system and component qualification efforts, and provide insight into the survivability of the warhead in environments that are not currently testable. The simulation efforts use several Sandia-developed tools through the Advanced Simulation and Computing program, including Cubit for mesh generation, the DART Model Manager, SIERRA codes running on the HPC TLCC2 platforms, DAKOTA, and ParaView. Several programmatic objectives were met using the simulation capability including: (1) providing early environmental specification estimates that may be used by component designers to understand the severity of the loads their components will need to survive, (2) providing guidance for load levels and configurations for subassembly tests intended to represent operational environments, and (3) recommending design options including modified geometry and material properties. These objectives were accomplished through regular interactions with component, system, and test engineers while using the laboratory's computational infrastructure to effectively perform ensembles of simulations. Because NNSA has decided to defer the LEP program, simulation results are being documented and models are being archived for future reference. However, some advanced and exploratory efforts will continue to mature key technologies, using the results from these and ongoing simulations for design insights, test planning, and model validation.

42 ENGINEERING↗

DOE OSTI2018

FEA Model and Mechanical Analysis of the Nb 3 Sn 15-T Dipole Demonstrator

Nb$_{3}$Sn magnets with a nominal operation field of ~15 T are being considered for the large hadron collider (LHC) energy upgrade high-energy large hadron collider (HE-LHC) and a post-LHC future circular collider. To demonstrate the feasibility of 15-T accelerator quality dipole magnets, the U.S. magnet development program is developing a single-aperture 15-T Nb$_{3}$Sn dipole demonstrator based on a 4-layer graded cos-theta coil with 60 mm aperture and cold iron yoke. The main design challenges for 15-T accelerator magnets include large Lorentz forces at this field level. To counteract them, an innovative mechanical structure based on a vertically split iron yoke, locked by large aluminum IC-clamps and supported by a thick stainless steel skin, has been developed at Fermilab. To study the performance of the structure, a parametric multiphysics finite element analysis (FEA) model has been set up. This paper describes the numerical model as well as the results of a sensitivity analysis of the effect of geometrical tolerances and assembly parameters.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2021

Mechanical analysis of heterogeneous materials with higher-order parameters

Abstract Even though heterogeneous porous materials are widely used in a variety of engineering and scientific fields, such as aerospace, energy-storage technology, and bio-engineering, the relationship between effective material properties of porous materials and their underlying morphology is still not fully understood. To contribute to this knowledge gap, this paper adopts a higher-order asymptotic homogenization method to numerically investigate the effect of complex micropore morphology on the effective mechanical properties of a porous system. Specifically, we use the second-order scheme that is an extension of the first-order computational homogenization framework, where a generalized continuum enables us to introduce length scale into the material constitutive law and capture both pore size and pore distribution. Through several numerical case studies with different combinations of porosity, pore shapes, and distributions, we systematically studied the relationship between the underlying morphology and effective mechanical properties. The results highlight the necessity of higher-order homogenization in understanding the mechanical properties and reveal that higher-order parameters are required to capture the role of realistic pore morphologies on effective mechanical properties. Furthermore, for specific pore shapes, higher-order parameters exhibit dominant influence over the first-order continuum.

42 ENGINEERING↗

NASA NTRS2006

Fracture Mechanics Analysis of LH2 Feed Line Flow Liners

Inspections of the Space Shuttle Main Engine revealed fatigue cracks growing from slots in the flow liner of the liquid hydrogen (LH2) feed lines. During flight, the flow liners experience complex loading induced by flow of LH2 and the resonance characteristics of the structure. The flow liners are made of Inconel 718 and had previously not been considered a fracture critical component. However, fatigue failure of a flow liner could have catastrophic effect on the Shuttle engines. A fracture mechanics study was performed to determine if a damage tolerance approach to life management was possible and to determine the sensitivity to the load spectra, material properties, and crack size. The load spectra were derived separately from ground tests and material properties were obtained from coupon tests. The stress-intensity factors for the fatigue cracks were determined from a shell-dynamics approach that simulated the dominant resonant frequencies. Life predictions were obtained using the NASGRO life prediction code. The results indicated that adequate life could not be demonstrated for initial crack lengths of the size that could be detected by traditional NDE techniques.

James, Mark A.↗

DOE OSTI2020

Tensile testing and fracture mechanism analysis of polyvinyl alcohol nanofibrous webs

Abstract A tensile properties testing study was conducted to understand the influence of thickness, cross‐head speed (speed of testing), gauge length (GL; specimen test length), and sample shape on important tensile properties of polyvinyl alcohol (PVA) nanofiber webs. The effects of each testing parameter on load at break, extension at break, Young's modulus, and tensile stress–strain curve of PVA nanofiber webs are analyzed. The Welch two sample t ‐tests show the significant difference among tested data. Using interaction plots, two‐way analysis of variance, and margin mean plots, the interaction effects among testing parameters have been analyzed. Of all the factors, cross‐head speed, the interaction among GL, and sample thickness (GL: Thickness) and the interaction among GL, testing speed and sample thickness (GL: Speed: Thickness) have significant influence on the tensile properties of PVA nanofiber webs. Moreover, the hypothesized model of mechanism of tensile strain–stress curve of PVA nanofiber webs has been proposed. Based on the model, the tensile strain–stress curve can be split into three stages: linear elastic, partial break up, and complete breakage. This study will provide a better understanding of tensile testing parameters' effects and their interaction effects on the tensile properties of nanowebs.

Lou, Lihua↗

NASA NTRS2008

Elastic-Plastic Fracture Mechanics Analysis of Critical Flaw Size in ARES I-X Flange-to-Skin Welds

NASA's Ares 1 Upper Stage Simulator (USS) is being fabricated from welded A516 steel. In order to insure the structural integrity of these welds it is of interest to calculate the critical initial flaw size (CIFS) to establish rational inspection requirements. The CIFS is in turn dependent on the critical final flaw size (CFS), as well as fatigue flaw growth resulting from transportation, handling and service-induced loading. These calculations were made using linear elastic fracture mechanics (LEFM), which are thought to be conservative because they are based on a lower bound, so called elastic, fracture toughness determined from tests that displayed significant plasticity. Nevertheless, there was still concern that the yield magnitude stresses generated in the flange-to-skin weld by the combination of axial stresses due to axial forces, fit-up stresses, and weld residual stresses, could give rise to significant flaw-tip plasticity, which might render the LEFM results to be non-conservative. The objective of the present study was to employ Elastic Plastic Fracture Mechanics (EPFM) to determine CFS values, and then compare these values to CFS values evaluated using LEFM. CFS values were calculated for twelve cases involving surface and embedded flaws, EPFM analyses with and without plastic shakedown of the stresses, LEFM analyses, and various welding residual stress distributions. For the cases examined, the computed CFS values based on elastic analyses were the smallest in all instances where the failures were predicted to be controlled by the fracture toughness. However, in certain cases, the CFS values predicted by the elastic-plastic analyses were smaller than those predicted by the elastic analyses; in these cases the failure criteria were determined by a breakdown in stress intensity factor validity limits for deep flaws (a greater than 0.90t), rather than by the fracture toughness. Plastic relaxation of stresses accompanying shakedown always increases the calculated CFS values compared to the CFS values determined without shakedown. Thus, it is conservative to ignore shakedown effects.

Chell, G. Graham↗

DOE OSTI2016

Thermo-Mechanical Analysis of SBLOCA with Loss of One Safety Injection System Using SCDAP/RELAP5

Design Extension Condition (DEC) for nuclear power plants has been being deliberated to bring it within a safety regulation boundary, following the 2011 Fukushima Daiichi accident. Moreover, a new regulation on the LOCA accident analysis designated as 10CFR50.45(c) has been proposed based on a concern of the non-conservatism of current criterion neglecting fuel burn-up effect on the cladding embrittlement. Therefore, a more comprehensive and realistic simulation of fuel rod behavior is required to cope with the stringent environment under LOCA accidents. A SCDAP/RELAP5 system analysis code has been used mainly on the prediction of severe accident phenomena. It has a set of mechanistic models for the fuel deformation, which plays an important role particularly in the early phase progression of the fuel melting. However, limited work has been done focusing on the models only to the fuel failure estimation through the DBA or candidates of DEC. Therefore, some analyses were performed here with a burnup dependent core model to understand the capability of SCDAP/RELAP5 to predict the thermo-mechanical behavior of the fuel cladding such as ballooning, burst and external/internal oxidation. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗