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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 793 records · Page 44
All sourcesNASA NTRSDOE OSTI
NASA NTRS1994

Investigation of finite element: ABC methods for electromagnetic field simulation

The mechanics of wave propagation in the presence of obstacles is of great interest in many branches of engineering and applied mathematics like electromagnetics, fluid dynamics, geophysics, seismology, etc. Such problems can be broadly classified into two categories: the bounded domain or the closed problem and the unbounded domain or the open problem. Analytical techniques have been derived for the simpler problems; however, the need to model complicated geometrical features, complex material coatings and fillings, and to adapt the model to changing design parameters have inevitably tilted the balance in favor of numerical techniques. The modeling of closed problems presents difficulties primarily in proper meshing of the interior region. However, problems in unbounded domains pose a unique challenge to computation, since the exterior region is inappropriate for direct implementation of numerical techniques. A large number of solutions have been proposed but only a few have stood the test of time and experiment. The goal of this thesis is to develop an efficient and reliable partial differential equation technique to model large three dimensional scattering problems in electromagnetics.

Chatterjee, A.↗
DOE OSTI2025

Lattice Structured Lightweight Structural Materials

The development of lightweight structural materials is crucial for enhancing the performance and deployment feasibility of fission batteries. This study aims to produce lightweight structural materials whose strength-to-weight ratios exceed those of current widely used structural materials. To achieve this, advanced modeling and simulation tools were employed to design lattice structures with different lattice parameters and different lattice types. A process was successfully developed for transforming lattice-structured models into Multiphysics Object Oriented Simulation Environment (MOOSE) inputs. Finite element modeling (FEM) was used to simulate the uniaxial tensile testing of the lattice-structured parts to investigate the stress distribution at a given displacement. The modeling results showed that the lattice-structured sample displayed a lower Young’s modulus in comparison to the solid material; the increase in solid shell thickness and blend radius enhances the mechanical performance; and the effect of unit cell size on macro scale stress is minimal. Tensile testing was conducted on the solid and lattice-structured materials fabricated by laser powder bed fusion (LPBF) additive manufacturing. The experimental results agreed well with the model prediction. The approach of using modeling as a guiding tool for preliminary material design can significantly save time and cost for new material development.

lightweight material↗
NASA NTRS1994

Development of a nondestructive vibration technique for bond assessment of Space Shuttle tiles

This final report describes the achievements of the above titled project. The project is funded by NASA-KSC (Grant No. NAG 10-0117) for the period of 1 Jan. to 31 Dec. 1993. The purpose of this project was to develop a nondestructive, noncontact technique based on 'vibration signature' of tile systems to quantify the bond conditions of the thermal protection system) tiles of Space Shuttle orbiters. The technique uses a laser rapid scan system, modal measurements, and finite element modeling. Finite element models were developed for tiles bonded to both clamped and deformable integrated skin-stringer orbiter mid-fuselage. Results showed that the size and location of a disbonded tile can be determined from frequency and mode shape information. Moreover, a frequency response survey was used to quickly identify the disbonded tiles. The finite element results were compared with experimentally determined frequency responses of a 17-tile test panel, where a rapidscan laser system was employed. An excellent degree of correlation between the mathematical simulation and experimental results was realized. An inverse solution for single-tile assemblies was also derived and is being implemented into a computer program that can interact with the modal testing software. The output of the program displays the size and location of disbond. This program has been tested with simulated input (i.e., finite element data), and excellent agreement between predicted and simulated disbonds was shown. Finally, laser vibration imaging and acoustic emission techniques were shown to be well suited for detecting and monitoring the progressive damage in Graphite/Epoxy composite materials.

Moslehy, Faissal A.↗
DOE OSTI2024

A Comprehensive Review on Finite Element Analysis of Laser Shock Peening

Laser shock peening (LSP) is a formidable cold working surface treatment that provides high-energy precision to enhance the mechanical properties of materials. This paper delves into the intricacies of the LSP process, offering insights into its methodology and the simulation thereof through the finite element method. This review critically examines various points, such as laser energy, overlapping of shots, effect of LSP on residual stress, effect of LSP on grain refinement, and algorithms for simulation extrapolated from finite element analyses conducted by researchers, shedding light on the nuanced considerations integral to this technique. As the significance of LSP continues to grow, the collective findings underscore its potential as a transformative technology for fortifying materials against mechanical stress and improving their overall performance and longevity. The discourse encapsulates the evolving landscape of the LSP, emphasizing the pivotal role played by finite element analysis in advancing our understanding and application of this innovative surface treatment.

36 MATERIALS SCIENCE↗
NASA NTRS2015

Simulation of Delamination-Migration and Core Crushing in a CFRP Sandwich Structure

Following the onset of damage caused by an impact load on a composite laminate structure, delaminations often form propagating outwards from the point of impact and in some cases can migrate via matrix cracks between plies as they grow. The goal of the present study is to develop an accurate finite element modeling technique for simulation of the delamination-migration phenomena in laminate impact damage processes. An experiment was devised where, under a quasi-static indentation load, an embedded delamination in the facesheet of a laminate sandwich specimen migrates via a transverse matrix crack and then continues to grow on a new ply interface. The quasistatic nature of the indentation results in structural behavior equivalent to that seen in low-velocity impact and also allows for highly detailed real time damage characterization. Several finite element damage simulation methods were investigated. Comparing the experimental results with those of the different models reveals certain modeling features that are important to include in a numerical simulation of delamination-migration and some that may be neglected.

McElroy, M.↗
DOE OSTI2023

Effects of Encapsulant Properties on the Thermo-Mechanical Reliability of Double-Side Cooled Power Modules for Traction Inverters

Double-side cooled power modules are being developed for next-generation traction inverters due to their better heat extraction, lower profile, and lower parasitic inductances. However, due to their rigid structure, they cause reliability concerns arising from high thermo-mechanical stresses at the interconnection joints in the module. In this work, a materials-based approach using rigid encapsulants is presented for reducing thermo-mechanical fatigue. Finite-element thermo- mechanical simulations were performed to examine the effects of the elastic modulus and coefficient of thermal expansion of epoxy- based encapsulants on the bond deformation inside a double-side cooled power module. It was found that a rigid encapsulant with a high modulus of 6.0 GPa or above and a coefficient of thermal expansion around 20 ppm/oC would improve the thermo- mechanical reliability of double-side cooled power modules by decreasing the permanent bond deformation inside the modules by 50-60%.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Layer Time Control for Large Scale Additive Manufacturing Using High Performance Computing

This work proposes to optimize an additive manufacturing AM process to reduce energy and printing cost. The polymer AM process is inherently dependent on the time-temperature history of each layer to maintain geometric tolerances and mechanical integrity. Our preliminary study shows that regression-based layer time control model using thermal images could result in up to 30% build time reduction for simple geometries. This proposed work would use high-performance computing (HPC) to couple the data-driven model with thermal simulation for better predicting layer temperature profiles, improving throughput of large-scale additive manufacturing, and reducing its energy cost. We have developed a method to optimize a layer deposition time (a.k.a. layer time) for large-scale AM via physics-based simulations. A long layer time leads to an over-cooled surface on which a new layer is deposited, and therefore, it may result in a weak bonding or debonding between layers, cracking, or warping. A short layer time leads to a high temperature of the structure due to insufficient cooling, and therefore, the structure may not be stiff enough and may collapse during manufacturing. Therefore, it is important to estimate the optimal layer time in additive manufacturing for a high-quality product. The temperature of a top layer right before deposition is recommended to be slightly higher than the glass temperature of the material. A temperature cooling was approximated to an exponential function of time, and the optimized layer time was obtained based on a target temperature while maintaining a minimal printing time. The material used is carbon fiber-reinforced polycarbonate (CF/PC), and the large-scale deposition system used is LSAM TM from Thermwood Corporation. Three different layer time cases were used for experiments, and a series of thermal images were obtained via an infra-red (IR) camera during the entire AM processes. AM process simulations were performed using a finite element method and the temperature profiles from the simulation were in good agreements with those from experiments. The layer time optimization was performed based on the temperature profiles from the simulations. A layer temperature with the optimal layer time was confirmed as the target temperature through simulation. In addition to the development of a layer time optimization method, we have developed a numerical framework for AM simulation with element activations in sync with toolpath, based on an open source finite element framework, DEAL.II. A major portion of this work was presented at SAMPE 2022 Conference and Exhibition on May 2022, and published in Proceedings of SAMPE 2022.

42 ENGINEERING↗
NASA NTRS2023

Modeling and Simulation Credibility Assessments of Whole-Body Finite Element Computational Models for Use in NASA Extravehicular Activity Applications

Computational finite element (FE) models are used in suited astronaut injury risk assessments; however, these models’ verification, validation, and credibility (VV&C) procedures for simulating injuries in altered gravity environments are limited. Our study conducts VV&C assessments of THUMS and Elemance whole-body FE models for predicting suited astronaut injury biomechanics using eight credibility factors, as per NASA-STD-7009A. Credibility factor ordinal scores are assigned by reviewing existing documentation describing VV&C practices, and credibility sufficiency thresholds are assigned based on input from subject matter experts. Our results show the FE models are credible for suited astronaut injury investigation in specific ranges of kinematic and kinetic conditions correlating to highway and contact sports events. Nevertheless, these models are deficient when applied outside these ranges. Several credibility elevation strategies are prescribed to improve models’ credibility for the NASA-centric application domain.

Finite Element↗
NASA NTRS2023

Modeling and simulation credibility assessments of whole-body finite element computational models for use in NASA extravehicular activity applications

Computational finite element (FE) models are used in suited astronaut injury risk assessments; however, these models’ verification, validation, and credibility (VV&C) procedures for simulating injuries in altered gravity environments are limited. Our study conducts VV&C assessments of THUMS and Elemance whole-body FE models for predicting suited astronaut injury biomechanics using eight credibility factors, as per NASA-STD-7009A. Credibility factor ordinal scores are assigned by reviewing existing documentation describing VV&C practices, and credibility sufficiency thresholds are assigned based on input from subject matter experts. Our results show the FE models are credible for suited astronaut injury investigation in specific ranges of kinematic and kinetic conditions correlating to highway and contact sports events. Nevertheless, these models are deficient when applied outside these ranges. Several credibility elevation strategies are prescribed to improve models’ credibility for the NASA-centric application domain.

Finite Element↗
DOE OSTI2019

Experiments and Simulation of a Borehole in Salt to Understand Heat, Brine, and Vapor Migration - 19192

Disposition of heat-generating nuclear waste (HGNW) remains a continuing technical and sociopolitical challenge. Numerous concepts for HGNW management have been proposed and examined internationally, including an extensive focus on geologic disposal. One proposed geologic material is salt because of its low permeability and viscoplastic deformation that causes self-repair of damage done to the salt by waste emplacement activities. Evaluating the safety and technical challenges of storing HGNW in a salt repository is an ongoing process involving experiments and supporting numerical simulation. Currently an experiment is underway at the Waste Isolation Pilot Plant (WIPP) to explore how the presence of a heat generating source affects phenomena such as brine migration, vapor transport, and mechanical changes to the bedded salt. A sub-horizontal heated borehole test is in progress in the underground at the WIPP that includes a centrally located 10.2 cm diameter borehole with an adjustable heater surrounded with smaller diameter boreholes instrumented with thermocouples. The central borehole contains an inflatable packer, heating block, brine sampler, and constantly flowing nitrogen gas circulation system. Air-injection tests performed in the central borehole provide pressure measurements that are used to constrain permeability of the system. The steady-state temperatures, as well as the rise and fall of temperature when the heater is cycled on and off, have been measured for up to 60 days. In the borehole, dry nitrogen gas circulation evaporates water and outflows to a desiccant container where water mass is measured daily during the experiment to quantify vapor removal. Although this test is a 'shake-down' for a planned second round of fresh borehole testing, we have gathered a rich dataset. These data allow us to build simulations using the Finite Element Heat and Mass transfer code (FEHM) to evaluate the experimental results, determine field-scale parameters, and identify code improvements to reproduce important physical processes that may not be accounted for at present. A 3-D numerical mesh, built using LaGrit software (lagrit.lanl.gov; Miller et al., 2007), includes increasing resolution around the central borehole. Modeling of the experiment allows for determining the local thermal conductivity and permeability of any damaged bedded salt around the borehole, where damage from drilling may change the permeability, porosity and saturation conditions, by parameter testing and inverse methods. Additionally, assumptions about brine and vapor flow and transport are being tested by comparing measured and simulated results. The combination of experimental data and model results provide additional data to help support the safety case for safe and effective HGNW disposition in bedded salt formations. Initial results from this experiment show that water flow into the borehole is within previous experimental results. Further, we have found that the design of the heater block is restricting energy to flow into the rock salt. Thus, this test has proven useful in design of the next generation experiment where infrared heating may be used to bypass issues caused by air gaps located around the current stainless steel block heater. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Microstructure-process relationships in monolithic U-10Mo fuel foil single-pass rolling: A parametric simulation study

In this work, a previously validated coupling of Kinetic Monte Carlo (KMC) Potts Model and finite element method (FEM) simulations was implemented to investigate the effects of microstructural features in as-cast and homogenized monolithic U-10Mo foils on the emergent microstructure after rolling and reheating. Parameters that could potentially affect recrystallization behavior of the rolled U-10Mo foils were considered: grain size distribution, uranium carbide (UC) size distribution, UC volume fraction, spatial distribution of UC, and rolling reduction magnitude. Grain structure and the magnitude of rolling reduction have the strongest influence on recrystallization kinetics and the fabricated grain size distribution. The UC distribution had only a weak effect on the recrystallization kinetics and final microstructures. While particle-stimulated nucleation (PSN) occurred in simulation more frequently as grain size increased, its incidence did not appear to considerably affect the recrystallization kinetics or grain size distribution.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Simulation of the PBX 9501 Self-Ignited Heavily Confined Cookoff Test

The PBX 9501 self-ignited thermally damaged explosive (SITX) test was carried out by Holmes et al. A 6-inch diameter sphere made of the PBX 9501 was heated inside a steel confinement vessel until it underwent a thermal explosion. This test provided measured temperature data that was used to define a boundary condition to carry out post-experiment finite element (FE) thermal simulations and comparisons of the FE thermal response with the experimental time to thermal ignition and internal temperature measurements at the center of the PBX 9501 sphere. Finite element models of this experiment were constructed using the heat transfer code Aria. A cookoff model for PBX 9501 was used to simulate the thermal decomposition of PBX 9501 and to predict the time to thermal ignition. An inverse heat conduction scheme was designed and applied to estimate a 1D temperature boundary condition.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2021

Sockeye: A One-Dimensional, Two-Phase, Compressible Flow Heat Pipe Application

Sockeye is a heat pipe analysis application based on the Multiphysics Object-Oriented Simulation Environment (MOOSE) finite element framework. The primary purpose of Sockeye is to provide a transient heat pipe simulation tool to be used in the analysis of nuclear microreactor designs. Sockeye provides the capability to perform one-dimensional, two-phase, compressible flow simulation of a heat pipe working fluid and two-dimensional, axisymmetric heat conduction for the heat pipe cladding and its surroundings. Sockeye is demonstrated against analytical solutions and experimental data from the SAFE-30 heat pipe module test.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Additive Manufacturing with Cellulose-Based Composites: Materials, Modeling, and Applications

Recent advances in large-scale additive manufacturing (AM) with polymer-based composites have enabled efficient production of high-performance materials. Cellulose nanomaterials (CNMs) have emerged as bio-based feedstocks due to their exceptional strength and sustainability. However, challenges such as hornification and poor dispersion in polymer matrices still limit large-scale CNM–polymer composite manufacturing, requiring novel strategies. Here, this review outlines an approach starting with atomic-level simulations to link molecular composition to key parameters like bulk density, viscosity, and modulus. These simulations provide data for finite element analysis (FEA), which informs large-scale experiments and reduces the need for extensive trials. The strategy explores how atomic interactions impact the morphology, adhesion, and mechanical properties of CNM-based composites in AM processes. The review also discusses current developments in AM, along with predictions of mechanical and thermal properties for structural applications, packaging, flexible electronics, and hydrogel scaffolds. By integrating experimental findings with molecular dynamics (MD) simulations and finite element modeling (FEM), valuable insights for material design, process optimization, and performance enhancement in CNM-based AM are provided to address ongoing challenges.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Application of the general thermal field model to simulate the behaviour of nanoscale Cu field emitters

Strong field electron emission from a nanoscale tip can cause a temperature rise at the tip apex due to Joule heating. This becomes particularly important when the current value grows rapidly, as in the pre-breakdown (the electrostatic discharge) condition, which may occur near metal surfaces operating under high electric fields. The high temperatures introduce uncertainties in calculations of the current values when using the Fowler–Nordheim equation, since the thermionic component in such conditions cannot be neglected. In this paper, we analyze the field electron emission currents as the function of the applied electric field, given by both the conventional Fowler–Nordheim field emission and the recently developed generalized thermal field emission formalisms. We also compare the results in two limits: discrete (atomistic simulations) and continuum (finite element calculations). The discrepancies of both implementations and their effect on final results are discussed. In both approaches, the electric field, electron emission currents, and Joule heating processes are simulated concurrently and self-consistently. We show that the conventional Fowler–Nordheim equation results in significant underestimation of electron emission currents. We also show that Fowler–Nordheim plots used to estimate the field enhancement factor may lead to significant overestimation of this parameter especially in the range of relatively low electric fields.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2019

Theoretical realization of three-dimensional nanolattice structure fabrication based on high-order waveguide-mode interference and sample rotation

A theoretical method of using high-order waveguide-mode interference combined with sample rotation is proposed to fabricate different kinds of three-dimensional nanolattice structures. The lithography sample is assisted by an asymmetric metal-cladding dielectric waveguide structure. High-order waveguide modes can be excited in the photoresist layer by both transverse magnetic and transverse electric polarized light. By utilizing multiple exposures of high-order waveguide-mode interference combined with sample-rotation, various three-dimensional nanolattice structures can be obtained. The resulting optical field distributions are simulated using the finite element method in this study, and sample rotation is expressed by coordinate matrix transformation. As examples, the three-dimensional optical field distributions resulting from fifth-order waveguide-mode interference were simulated with 90° and 60° sample rotations and multiple exposures. The results show that a quasi-cuboid structure with a simple tetragonal arrangement and a quasi-hexagonal structure with a hexagonal close-packed lattice can be obtained. Moreover, the numerical simulation results revealed that the shapes, sizes, arrangements, and periods of the structures can be controlled by the rotation method, photoresist thickness, waveguide modes used for exposure, and so on.

77 NANOSCIENCE AND NANOTECHNOLOGY↗