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NASA NTRS1986

Unified constitutive materials model development and evaluation for high-temperature structural analysis applications

Unified constitutive material models were developed for structural analyses of aircraft gas turbine engine hot section components with particular application to an isotropic material used for combustor liners. Differential forms of models independently developed were considered in this study. These models combine the interactions of time-dependent (creep) and time-independent (plasticity) inelastic behavior of a material. Predicted stress-strain responses from these models were evaluated against cyclic isothermal and nonisothermal test results for uniaxial specimens of a nickel-base superalloy. The unified models were implemented in a nonlinear structural analysis code. Two unique NASA Lewis test facilities were used in the evaluation of the models for complex geometry specimens and evaluation of advanced temperature and high-temperature strain measurement instrumentation. Predicted nonlinear structural responses from one of the models for a flat plate and a segment of a conventional combustor liner are presented.

Thompson, R. L.↗

NASA NTRS2016

Analysis and Characterization of Damage Utilizing an Orthotropic Generalized Composite Material Model Suitable for Use in Impact Problems

The need for accurate material models to simulate the deformation, damage and failure of polymer matrix composites under impact conditions is becoming critical as these materials are gaining increased usage in the aerospace and automotive communities. In order to address a series of issues identified by the aerospace community as being desirable to include in a next generation composite impact model, an orthotropic, macroscopic constitutive model incorporating both plasticity and damage suitable for implementation within the commercial LS-DYNA computer code is being developed. The plasticity model is based on extending the Tsai-Wu composite failure model into a strain hardening-based orthotropic plasticity model with a non-associative flow rule. The evolution of the yield surface is determined based on tabulated stress-strain curves in the various normal and shear directions and is tracked using the effective plastic strain. To compute the evolution of damage, a strain equivalent semi-coupled formulation is used in which a load in one direction results in a stiffness reduction in multiple material coordinate directions. A detailed analysis is carried out to ensure that the strain equivalence assumption is appropriate for the derived plasticity and damage formulations that are employed in the current model. Procedures to develop the appropriate input curves for the damage model are presented and the process required to develop an appropriate characterization test matrix is discussed.

Impact↗

NASA NTRS2016

Analysis and Characterization of Damage Utilizing an Orthotropic Generalized Composite Material Model Suitable for Use in Impact Problems

Impact↗

DOE OSTI2016

Metrics for the Complexity of Material Models

Quantitative measures are proposed for characterizing the complexity of material models used in computational mechanics. The algorithms for evaluating these metrics operate on the mathematical equations in the model rather than a code implementation and are different from software complexity measures. The metrics do not rely on a physical understanding of the model, using instead only a formal statement of the equations. A new algorithm detects the dependencies, whether explicit or implicit, between all the variables. The resulting pattern of dependencies is expressed in a set of pathways, each of which represents a chain of dependence between the variables. These pathways provide the raw data used in the metrics, which correlate with the expected ease of understanding, coding, and applying the model. Usage of the ComplexityMetrics code is described, with examples.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1984

Modeling material failure with a vectorized routine

The computational aspects of modelling material failure in structural wood members are presented with particular reference to vector processing aspects. Wood members are considered to be highly orthotropic, inhomogeneous, and discontinuous due to the complex microstructure of wood material and the presence of natural growth characteristics such as knots, cracks and cross grain in wood members. The simulation of strength behavior of wood members is accomplished through the use of a special purpose finite element/fracture mechanics routine, program STARW (Strength Analysis Routine for Wood). Program STARW employs quadratic finite elements combined with singular crack tip elements in a finite element mesh. Vector processing techniques are employed in mesh generation, stiffness matrix formation, simultaneous equation solution, and material failure calculations. The paper addresses these techniques along with the time and effort requirements needed to convert existing finite element code to a vectorized version. Comparisons in execution time between vectorized and nonvectorized routines are provided.

Cramer, S. M.↗

DOE OSTI2026

Modeling Material Interfaces with the Six-Equation Model in FLEXO

FLEXO is a multiphysics code developed at Sandia National Laboratories for predictive simulation of pulsed power target physics with extended magnetohydrodynamics modeling. Given this application space, FLEXO must be able to perform high-fidelity simulations of pulsed-power systems that include multiple materials. This work presents the augmentation of FLEXO with a six-equation model for multimaterial flow. We design and analyze discretizations of the six-equation model, emphasizing desirable properties for robust multimaterial simulation. We also present solution limiting, bounds preservation, and pressure equilibration/relaxation techniques that enhance the robustness of the overall multimaterial scheme. We present a suite of test problems to document these new capabilities of the FLEXO code.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2023

Training material models using gradient descent algorithms

High temperature design requires accurate constitutive models to describe material inelastic deformation and failure behavior. Oftentimes, calibrating accurate models devolves into the problem of fitting the model parameters against experimental test data. Here, we present the pyopmat package, an open source framework for calibrating constitutive models against experiment data subjected to various loading conditions using machine learning techniques. The package calculates the exact gradient of the model response with respect to the parameters using a combination of automatic differentiation and the adjoint method. Given this exact gradient, we compare the performance of several gradient-based optimization techniques in fitting realistic constitutive models against data. Here, we demonstrate the efficiency and accuracy of our package through example problems using both synthetic data, generated using known parameter sets, under monotonic and cyclic loading conditions and also with an example applying the techniques developed here to actual high temperature creep-fatigue test data.

36 MATERIALS SCIENCE↗

NASA NTRS2017

Development of a Continuum Damage Mechanics Material Model of a Graphite-Kevlar(Registered Trademark) Hybrid Fabric for Simulating the Impact Response of Energy Absorbing Kevlar(Registered Trademark) Hybrid Fabric for Simulating the Impact Response of Energy Absorbing

This paper describes the development of input properties for a continuum damage mechanics based material model, Mat 58, within LS-DYNA(Registered Trademark) to simulate the response of a graphite-Kevlar(Registered Trademark) hybrid plain weave fabric. A limited set of material characterization tests were performed on the hybrid graphite-Kevlar(Registered Trademark) fabric. Simple finite element models were executed in LS-DYNA(Registered Trademark) to simulate the material characterization tests and to verify the Mat 58 material model. Once verified, the Mat 58 model was used in finite element models of two composite energy absorbers: a conical-shaped design, designated the "conusoid," fabricated of four layers of hybrid graphite-Kevlar(Registered Trademark) fabric; and, a sinusoidal-shaped foam sandwich design, designated the "sinusoid," fabricated of the same hybrid fabric face sheets with a foam core. Dynamic crush tests were performed on components of the two energy absorbers, which were designed to limit average vertical accelerations to 25- to 40-g, to minimize peak crush loads, and to generate relatively long crush stroke values under dynamic loading conditions. Finite element models of the two energy absorbers utilized the Mat 58 model that had been verified through material characterization testing. Excellent predictions of the dynamic crushing response were obtained.

Jackson, Karen E.↗

DOE OSTI2016

Development of Multiscale Materials Modeling Techniques and Coarse- Graining Strategies for Predicting Materials Degradation in Extreme Irradiation Environments

Exposure of metallic structural materials to irradiation environments results in significant microstructural evolution, property changes and performance degradation, which limits the extended operation of current generation light water reactors and restricts the design of advanced fission and fusion reactors [1-8]. This effect of irradiation on materials microstructure and properties is a classic example of an inherently multiscale phenomenon, as schematically illustrated in Figure 1a. Pertinent processes range from the atomic nucleus to structural component length scales, spanning more than 15 orders of magnitude. Time scales bridge more than 22 orders of magnitude, with the shortest being less than a femtosecond [1,8]. Further, the mix of radiation-induced features formed and the corresponding property degradation depend on a wide range of material and irradiation variables. This emphasizes the importance of closely integrating models with high-resolution experimental characterization of the evolving radiation- damaged microstructure, including measurements performed in-situ during irradiation. In this article, we review some recent successes through the use of closely coordinated modeling and experimental studies of the defect cluster evolution in irradiated body-centered cubic materials, followed by a discussion of outstanding challenges still to be addressed, which are necessary for the development of comprehensive models of radiation effects in structural materials.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2015

STREAMM-tools (Simulation Toolkit for Renewable Energy Advanced Materials Modeling) [SWR-15-29]

The Simulation Toolkit for Renewable Energy and Advanced Materials Modeling (STREAMM) is a python package that generates structures and input files for quantum chemical and molecular dynamics codes. STREAMM does not directly conduct simulations rather it is meant to drive quantum chemical and molecular dynamics codes to allow for high-throughput computational analysis of materials. The STREAMM package is written for python2.7 (https://www.python.org/download/releases/2.7/) and incorporates some of the core modules from the pymatgen (http://pymatgen.org/) code.

Sides, Scott↗

NASA NTRS2018

Quantification of Error Associated with Using Misaligned Meshes in Continuum Damage Mechanics Material Models for Matrix Crack Growth Predictions in Composites

The ability of a material model to capture in-plane matrix mode I and mode II crack growth is an essential component for modeling ply level damage evolution in composite structures. Previous studies using a continuum damage mechanics (CDM) approach have shown success in satisfying benchmark solutions for mode I and II crack growth. However, success was shown using a fiber-aligned meshing strategy, which encourages matrix cracks to propagate in a single band of elements, along the fiber direction. Generating a fiber-aligned mesh becomes a highly involved process for laminates including off-axis (non 0° or 90°) plies. The objective of this study is to quantify the effect of non-fiber aligned mesh discretization on predictions of in-plane matrix crack propagation. The approach taken incrementally varies the mesh orientation angle relative to the fiber orientation; more specifically, misaligned meshes are used to quantify the effect of element angle orientation relative to the initial crack orientation on the energy released during matrix crack propagation simulations using a CDM method. CDM solutions obtained with the misaligned meshes are evaluated against known benchmarks for mode I and II matrix crack growth. The CDM solutions reveal a near-polynomial trend of increased predicted failure stress with increased mesh misalignment angle; hence implying a potential relationship between element orientation angle and apparent fracture toughness.

Justusson, Brian↗

DOE OSTI2024

Summary of FY2024 Experimental Results to Support Development of New Inelastic Material Models and Validation of Section III, Division 5, Class A Design Rules

To address the data gap crucial for updating existing viscoplastic constitutive material models for the Class A materials in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors (ASME, 2023) for inelastic design analysis, Oak Ridge National Laboratory (ORNL) conducted experimental studies on Alloy 800H and Alloy 617 across a range of temperatures up to their maximum temperature limits in Section III, Division 5. The studies aim to characterize the materials' deformation behavior under both strain-controlled mechanical cyclic loading and thermal cycling conditions. This report summarizes ORNL's FY 2024 experimental findings on Alloy 800H and Alloy 617, focusing on pure fatigue tests, cyclic stress-strain curves, thermomechanical fatigue experiments, and verification of the high temperature cyclic damage summation design rules.

36 MATERIALS SCIENCE↗

NASA NTRS2018

A Case for High-Fidelity Material Response Modeling

Material response modeling of heatshields for planetary entry vehicles has remained largely unchanged since Aerotherm Corp. introduced the CMA program in 1967. Modern models, like FIAT, have tread the same path, introducing efficiencies and better material property data along the way, but otherwise following the same underlying model paradigm. The CMA approach has worked well for heatshield design up to this point. However, there are three motivations for the material response community to pursue higher fidelity beyond simplified, CMA-derived models. The first motivation is that missions are becoming increasingly demanding and complex and, as they do, confidence in simplified models naturally decreases. Second, reliability of materials is now as much or more of a driving concern for mission designers than thermal response. Third, NASA and other agencies are increasingly interested in flight instrumentation for engineering science. This latter motivation places far stricter requirements on model accuracy in order to meet requirements for flight environment reconstruction.

Barnhardt, Michael D.↗

DOE OSTI2017

FY17 end of year MARMOT materials model development update

This document summarizes the lower length scale progress made in FY17 in developing materials models for fuel performance modeling of oxide fuels and their implementation in the MARMOT code. The progress covers the development of a phase field recrystallization model for high-burnup structure formation in oxide fuels, a phase field model for studying stage-3 fission gas release in UO 2 , a phase-field model for irradiation-enhanced densification in UO 2 , a quantitative model for hydride morphology in Zirconium based cladding, and the calculation of hydrogen diffusivity under stress in various Zirconium based alloys as cladding candidates. Further development in the MARMOT code has been carried out as well to improve the multi-phase, multi-component phase field model, the representation of interfacial energy in the Kim-Kim-Suzuki model, and the description of interfacial stress. For most of the above, separated reports have been generated with detailed description. Here a brief summary is provided, with references pointing to the detailed reports to guide interested readers.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Accelerating Multiscale Materials Modeling with Machine Learning

The focus of this project is to accelerate and transform the workflow of multiscale materials modeling by developing an integrated toolchain seamlessly combining DFT, SNAP, LAMMPS, (shown in Figure 1-1) and a machine-learning (ML) model that will more efficiently extract information from a smaller set of first-principles calculations. Our ML model enables us to accelerate first-principles data generation by interpolating existing high fidelity data, and extend the simulation scale by extrapolating high fidelity data (10 2 atoms) to the mesoscale (10 4 atoms). It encodes the underlying physics of atomic interactions on the microscopic scale by adapting a variety of ML techniques such as deep neural networks (DNNs), and graph neural networks (GNNs). We developed a new surrogate model for density functional theory using deep neural networks. The developed ML surrogate is demonstrated in a workflow to generate accurate band energies, total energies, and density of the 298K and 933K Aluminum systems. Furthermore, the models can be used to predict the quantities of interest for systems with more number of atoms than the training data set. We have demonstrated that the ML model can be used to compute the quantities of interest for systems with 100,000 Al atoms. When compared with 2000 Al system the new surrogate model is as accurate as DFT, but three orders of magnitude faster. We also explored optimal experimental design techniques to choose the training data and novel Graph Neural Networks to train on smaller data sets. These are promising methods that need to be explored in the future.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Age-aware materials model for foam cushions - considering time-dependence of strain-rates and rate-independent measurements

Over the last few reports we have chronicled the progressive development of an age-aware materials model for foam cushions relevant to our systems. The latest version employs a N = 2 Ogden Hyperfoam model within a two-network Tobolsky scheme. As the material ages, the first network progressively loses in strength, while the second network progressively gains in strength. However, the two networks are in different strain states. Thus, in additive equilibrium (Tobolsky model) they manifest both permanent structural changes (measured as Compression Set) as well as changes in mechanical strength and modulus (measured as Load Retention).

36 MATERIALS SCIENCE↗

DOE OSTI2016

Proposal of a Novel Approach to Developing Material Models for Micro-scale Composites Based on Testing and Modeling of Macro-scale Composites

The Los Alamos National Laboratory's Weapon Systems Engineering division's Advanced Engineering Analysis group employs material constitutive models of composites for use in simulations of components and assemblies of interest. Experimental characterization, modeling and prediction of the macro-scale (i.e. continuum) behaviors of these composite materials is generally difficult because they exhibit nonlinear behaviors on the meso- (e.g. micro-) and macro-scales. Furthermore, it can be difficult to measure and model the mechanical responses of the individual constituents and constituent interactions in the composites of interest. Current efforts to model such composite materials rely on semi-empirical models in which meso-scale properties are inferred from continuum level testing and modeling. The proposed approach involves removing the difficulties of interrogating and characterizing micro-scale behaviors by scaling-up the problem to work with macro-scale composites, with the intention of developing testing and modeling capabilities that will be applicable to the mesoscale. This approach assumes that the physical mechanisms governing the responses of the composites on the meso-scale are reproducible on the macro-scale. Working on the macro-scale simplifies the quantification of composite constituents and constituent interactions so that efforts can be focused on developing material models and the testing techniques needed for calibration and validation. Other benefits to working with macro-scale composites include the ability to engineer and manufacture—potentially using additive manufacturing techniques—composites that will support the application of advanced measurement techniques such as digital volume correlation and three-dimensional computed tomography imaging, which would aid in observing and quantifying complex behaviors that are exhibited in the macro-scale composites of interest. Ultimately, the goal of this new approach is to develop a meso-scale composite modeling framework, applicable to many composite materials, and the corresponding macroscale testing and test data interrogation techniques to support model calibration.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Validation of Material Models For Automotive Carbon Fiber Composite Structures Via Physical And Crash Testing (VMM Composites Project)

As automotive fuel economy requirements increase, the push for reducing overall vehicle weight will likely include the consideration of materials that have not previously been part of mainstream vehicle design and manufacturing, including carbon fiber composites. Vehicle manufacturers currently rely on computer-aided engineering (CAE) methods as part of the design and development process, so going forward, the ability to accurately and predictably model carbon fiber composites will be necessary. If composites are to be used for structural components, this need applies to both, crash and quasi-static modeling. This final report covers the results of a five-year, $6.89M, 50% cost-shared research project between Department of Energy (DOE) and the US Advanced Materials Partnership (USAMP) under Cooperative Agreement DE-EE-0005661 known as “Validation of Material Models for Automotive Carbon Fiber Composite Structures Via Physical and Crash Testing (VMM).” The objective of the VMM Composites Project was to validate and assess the ability of physics-based material models to predict crash performance of automotive primary load-carrying carbon fiber composite structures. Simulation material models that were evaluated included micro-mechanics based meso-scale models developed by the University of Michigan (UM) and micro-plane models by Northwestern University (NWU) under previous collaborations with the DOE and Automotive Composites Consortium/USAMP, as well as five commercial crash codes: LS-DYNA, RADIOSS, VPS/PAM-CRASH, Abaqus, and GENOA-MCQ. CAE predictions obtained from seven organizations were compared with experimental results from quasi-static testing and dynamic crash testing of a thermoset carbon fiber composite front-bumper and crush-can (FBCC) system gathered under multiple loading conditions. This FBCC design was developed to demonstrate progressive crush, virtual simulation, tooling, fabrication, assembly, non-destructive evaluation and crash testing advances in order to assess the correlation of the predicted results to the physical tests. The FBCC was developed to meet a goal of 30-35% mass reduction while aiming for equivalent energy absorption as a steel component for which baseline experimental results were obtained from testing in the same crash modes. The project also evaluated crash performance of thermoplastic composite structures fabricated from commercial prepreg materials and low cost carbon fiber sourced from Oak Ridge National Laboratory. The VMM Project determined that no set of predictions from a CAE supplier were found to be universally accurate among all the six crash modes evaluated. In general, crash modes that were most dependent on the properties of the prepreg were more accurate than those that were dependent on the behavior of the joints. The project found that current CAE modeling methods or best practices for carbon fiber composites have not achieved standardization, and accuracy of CAE is highly reliant on the experience of its users. Coupon tests alone are not sufficient to develop an accurate material model, but it is necessary to bridge the gap between the coupon data and performance of the actual structure with a series of subcomponent level tests. Much of the unreliability of the predictions can be attributed to shortcomings in our ability to mathematically link the effects of manufacturing and material variability into the material models. This is a subject of ongoing research in the industry. The final report is organized by key technical tasks to describe how the validation project developed, modeled and compared crash data obtained on the composite FBCC to the multiple sets of CAE predictions. Highlights of the report include a discussion of the quantitative comparison between predictions and experimental data, as well as an in-depth discussion of remaining technological gaps that exist in the industry, which are intended to spur innovations and improvements in CAE technology.

36 MATERIALS SCIENCE↗