Results for “Finite Element Simulation” — Page 7

DOE OSTI2022

On Residual Stresses and Reference Temperatures in Thermomechanical Simulations of Photovoltaic Modules Using the Finite Element Method

Thermomechanical simulation of photovoltaic (PV) modules using the finite element method (FEM) is a useful tool to evaluate module design features in terms of structural integrity, reliability, and durability. One of the main challenges in the numerical modeling of a PV module is the incorporation of residual stresses induced by the manufacturing process. Modeling assumptions and abstractions are necessary to limit the model complexity and reduce the computational time. However, oversimplifications and incorrect assumptions can lead to erroneous numerical results. Unfortunately, much simulation work still neglects process-induced stresses. This can lead to incorrect predictions of the stress-strain history and erroneous conclusions during the design process. In this work, we review current modeling practices for incorporating process-induced stresses, and contrast numerical models that consider residual stresses with those that neglect them. We find that the simulation objective and available material properties dictate which process steps need to be modeled, and explore in depth the modeling of residual stresses induced by the lamination process. We demonstrate that a simplified cooldown procedure at the beginning of the simulation can increase the model accuracy and discuss appropriate choices for starting and reference temperatures in the finite element model.

14 SOLAR ENERGY↗

NASA NTRS1989

Interfacing modules for integrating discipline specific structural mechanics codes

An outline of the organization and capabilities of the Engine Structures Computational Simulator (Simulator) at NASA Lewis Research Center is given. One of the goals of the research at Lewis is to integrate various discipline specific structural mechanics codes into a software system which can be brought to bear effectively on a wide range of engineering problems. This system must possess the qualities of being effective and efficient while still remaining user friendly. The simulator was initially designed for the finite element simulation of gas jet engine components. Currently, the simulator has been restricted to only the analysis of high pressure turbine blades and the accompanying rotor assembly, although the current installation can be expanded for other applications. The simulator presently assists the user throughout its procedures by performing information management tasks, executing external support tasks, organizing analysis modules and executing these modules in the user defined order while maintaining processing continuity.

Endres, Ned M.↗

DOE OSTI2024

Fabrication and Performance Evaluation of Double-Sided Copper Nanowire Arrays as Thermal and Electrical Interfacial Layers

Reducing contact interface thermal and electrical resistances is in great demand across various industries, particularly in the semiconductor industry. This study introduces an approach using double-sided copper nanowire (Cu NW) arrays on copper sheets as both thermal and electrical interfacial layers, designed to effectively accommodate the topographical inconsistencies between contact surfaces. Further, experimental outcomes reveal a significant reduction in thermal contact resistance (TCR), with a value of 2.5 mm 2 K W –1 , thereby exceeding the efficiency of reported nanostructural thermal interface materials (TIMs). Additionally, when utilized as an electrical interfacial layer, these double-sided Cu NWs arrays dramatically reduced electrical contact resistance (ECR), outperforming traditional conductive grease in applications necessitating separable bonding, though showing comparable performance to costly silver-based conductive epoxies required for permanent, inseparable bonds. The promising results of the double-sided Cu NWs arrays in reducing both TCR and ECR, confirmed by finite element simulation, highlight their substantial potential in advancing TIMs and electrical interconnection applications across various sectors.

42 ENGINEERING↗

NASA NTRS2009

Orion Landing Simulation Eight Soil Model Comparison

LS-DYNA finite element simulations of a rigid Orion Crew Module (CM) were used to investigate the CM impact behavior on eight different soil models. Ten different landing conditions, characterized by the combination of CM vertical and horizontal velocity, hang angle, and roll angle were simulated on the eight different soils. The CM center of gravity accelerations, pitch angle, kinetic energy, and soil contact forces were the outputs of interest. The simulation results are presented, with comparisons of the CM behavior on the different soils. The soils analyzed in this study can be roughly categorized as soft, medium, or hard, according to the CM accelerations that occur when landing on them. The soft group is comprised of the Carson Sink Wet soil and the Kennedy Space Center (KSC) Low Density Dry Sand. The medium group includes Carson Sink Dry, the KSC High Density In-Situ Moisture Sand and High Density Flooded Sand, and Cuddeback B. The hard soils are Cuddeback A and the Gantry Unwashed Sand. The softer soils were found to produce lower peak accelerations, have more stable pitch behavior, and to be less sensitive to the landing conditions. This investigation found that the Cuddeback A soil produced the highest peak accelerations and worst stability conditions, and that the best landing performance was achieved on the KSC Low Density Dry Sand.

Mark, Stephen D.↗

DOE OSTI2022

Performance of a MQXF Nb 3 Sn Quadrupole Magnet Under Different Stress Level

In a dipole or in a quadrupole accelerator magnet, the displacement of the coil turns induced by the electromagnetic forces can cause quenches limiting the magnet performance. For this reason, an azimuthal preload is applied to avoid azimuthal movements of the coil up to the required operational current. However, several tests showed that accelerator magnets can operate with a partial preload, i.e. that coil unloading during the ramp does not prevent reaching higher currents. This issue is particularly relevant for Nb 3 Sn magnets, where the loads applied to the Nb3Sn filaments can reach the degradation limits of critical current. In order to investigate the impact of coil preload on the quench performance, the MQXFS6 short model quadrupole for the High Luminosity Upgrade was tested under an azimuthal preload at 80% of the short sample current, reaching 93% of short sample current at 1.9 K. The preload was then released to 60%, still showing ability to operate in the range of 80-85% of short sample current as required by HL-LHC project. With this lower preload, the ability of going above 90% of short sample was lost, and a significant training appeared above 85%. When the preload was restored to the original 80% value, the magnet reached with few quenches 95% of short sample (13.4 T peak field). Magnetic measurements confirm the larger movement of the coil in the case with lower preload, and agree with finite element simulations.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2020

Thermodynamic theory of crystal plasticity: Formulation and application to polycrystal fcc copper

We present a thermodynamic description of crystal plasticity. Our formulation is based on the Langer-Bouchbinder-Lookman thermodynamic dislocation theory (TDT), which asserts the fundamental importance of an effective temperature that describes the state of configurational disorder and therefore the dislocation density of the crystalline material. We extend the TDT description from isotropic plasticity to crystal plasticity with many slip systems. Finite-element simulations show favourable comparison with experiments on polycrystal fcc copper under uniaxial compression, tension, and simple shear. Here, the thermodynamic theory of crystal plasticity thus provides a thermodynamically consistent and physically rigorous description of dislocation motion in crystals. We also discuss new insights about the interaction of dislocations belonging to different slip systems.

36 MATERIALS SCIENCE↗

DOE OSTI2024

A high-frequency, low-power resonant radio-frequency neutron spin flipper for high-resolution spectroscopy

Here, we present a resonant-mode, transverse-field, radio-frequency (rf) neutron spin flipper design that uses high-temperature superconducting films to ensure sharp transitions between uniform magnetic field regions. Resonant mode allows for low-power, high-frequency operation but requires strict homogeneity of the magnetic fields inside the device. This design was found to efficiently flip neutrons at 96.6 ± 0.6% at an effective frequency of 4 MHz in bootstrap configuration with a beam size of 2.4 × 2.5 cm 2 and a wavelength of 0.4 nm. The high frequency and efficiency enable this device to perform high-resolution neutron spectroscopy with comparable performance with currently implemented rf flipper designs. The limitation of the maximum frequency was found due to the field homogeneity of the device. We numerically analyze the maximum possible efficiency of this design using a Bloch solver simulation with magnetic fields generated from finite-element simulations. We also discuss future improvements of the efficiency and frequency to the design based on the experimental and simulation results.

47 OTHER INSTRUMENTATION↗

DOE OSTI2023

Machine learning–assisted prediction of heat fluxes through thermally anisotropic building envelopes

Thermally anisotropic building envelope (TABE) is a novel active building envelope that can save energy use to maintain thermal comfort in buildings by redirecting heat and coolness from building envelopes to thermal loops. Finite element models (FEMs) can be used to compute the heat fluxes through TABEs, but the high computational cost of finite element simulations has prevented parametric studies and design optimizations. This paper proposes a domain knowledge–informed, finite element–based machine learning framework to reduce the computation cost for the energy management of buildings installed with TABE that uses a ground thermal loop. First, the training heat flux data set was generated by FEM simulations with different thermal loop schedules. Then, both shallow learning models (i.e., multivariate linear regression and eXtreme Gradient Boost, or XGBoost) and a deep learning model (i.e., deep neural network, or DNN) were trained to predict the heat fluxes. Domain knowledge was used for data preprocessing and feature selection. Finally, the suitability of the selected machine learning model was tested under different thermal loop schedules. Herein, the case study results showed that: (1) XGBoost can be as accurate as DNN (coefficient of determination equal to 0.81) with much less training time; (2) the annual energy cost savings for different thermal loop schedules obtained by the XGBoost-predicted and FEM-calculated heat fluxes are consistent, having a difference of only 4%; and (3) XGBoost can reduce the computation time for the annual energy analysis of the case study building with a given thermal loop schedule from around 12 h by using FEM to less than 1 min.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRSDate not supplied

In-Situ Ice Adhesion Testing using the Deformed Skin Adhesion Test

There exists a plethora of ice adhesion testing methods such as centrifuge-based methods, push/pull methods, and lap joint shear tests. However, these methods often cannot be done in-situ during an icing spray and require researcher handling/preparation prior to testing. Additionally, many of these methods test ice accretions that are not representative of the ice shapes that grow on airframes which can have unintended consequences such as edge or corner stress concentrations. In order to mitigate the issues present with other ice adhesion tests a novel, hands-free, in-situ test method imbedded into the leading edge of the airfoil has been developed and tested in the NASA Glenn Research Center Icing Research Tunnel. The mechanics of the new test method are discussed with finite element simulations being used to highlight the fundamental mechanics of this test method. The testing procedures used during the experimental test campaign are discussed along with the icing cloud test matrix. Analysis of the force-displacement results highlights the repeatability of the test method with regards to both sample behavior across several days of testing and different ice shapes. The results from first run of the day showed a significant discrepancy from subsequent runs and differential image analysis was used to determine differences in the interfacial bonding states between runs.

Ice Adhesion↗

NASA NTRSDate not supplied

In-Situ Ice Adhesion Testing using the Deformed Skin Adhesion Test

There exists a plethora of ice adhesion testing methods such as centrifuge-based methods, push/pull methods, and lap joint shear tests. However, these methods often cannot be done in-situ during an icing spray and require researcher handling/preparation prior to testing. Additionally, many of these methods test ice accretions that are not representative of the ice shapes that grow on airframes which can have unintended consequences such as edge or corner stress concentrations. In order to mitigate the issues present with other ice adhesion tests a novel, hands-free, in-situ test method imbedded into the leading edge of the airfoil has been developed and tested in the NASA Glenn Research Center Icing Research Tunnel. The mechanics of the new test method are discussed with finite element simulations being used to highlight the fundamental mechanics of this test method. The testing procedures used during the experimental test campaign are discussed along with the icing cloud test matrix. Analysis of the force-displacement results highlights the repeatability of the test method with regards to both sample behavior across several days of testing and different ice shapes. The results from first run of the day showed a significant discrepancy from subsequent runs and differential image analysis was used to determine differences in the interfacial bonding states between runs.

Ice Adhesion↗

DOE OSTI2021

Toughening of interface networks through the introduction of weak links

The resistance of polycrystalline materials to intergranular fracture depends on the toughness of the interfaces between neighboring grains. Using finite element simulations on model, two-dimensional microstructures, we demonstrate that the steady-state crack growth resistance of a polycrystal that contains exclusively high toughness interfaces is suboptimal: its crack growth resistance may be increased by introducing a minority fraction of weak interfaces at random locations within the interface network. Furthermore, the weaker are these interfaces, the greater is their toughening effect. These weak interfaces toughen the material through crack deflection and branching, nucleation of secondary cracks, and inelastic dissipation within intact interfaces. Furthermore, our findings suggest that fracture resistance-oriented material development should not aim to eliminate all weak interfaces, but rather judiciously incorporate a low fraction of them.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Nanoscopic Imaging of Self-Propelled Ultrasmall Catalytic Nanomotors

Ultrasmall nanomotors (<100 nm) are highly desirable nanomachines for their size-specific advantages over their larger counterparts in applications spanning nanomedicine, directed assembly, active sensing, and environmental remediation. While there are extensive studies on motors larger than 100 nm, the design and understanding of ultrasmall nanomotors have been scant due to the lack of high-resolution imaging of their propelled motions with orientation and shape details resolved. Here, we report the imaging of the propelled motions of catalytically powered ultrasmall nanomotors─hundreds of them─at the nanometer resolution using liquid-phase transmission electron microscopy. These nanomotors are Pt nanoparticles of asymmetric shapes (“tadpoles” and “boomerangs”), which are colloidally synthesized and observed to be fueled by the catalyzed decomposition of NaBH4 in solution. Statistical analysis of the orientation and position trajectories of fueled and unfueled motors, coupled with finite element simulation, reveals that the shape asymmetry alone is sufficient to induce local chemical concentration gradient and self-diffusiophoresis to act against random Brownian motion. Our work elucidates the colloidal design and fundamental forces involved in the motions of ultrasmall nanomotors, which hold promise as active nanomachines to perform tasks in confined environments such as drug delivery and chemical sensing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRSDate not supplied

Parallelized Quadrupole Simulations of Thermographic Responses of Composites

Thermography has been shown to be a viable technique for inspection of composites. Model inversion of the thermography data requires a fast method for performing the forward problem. Viable numerical methods for the thermal response forward problem are finite element, finite difference and the quadrupole method. Normally both the finite element and finite difference methods solve for the thermal response in the time domain which limits one’s ability to increase the speed of the simulation by parallelization. In contrast, the quadrupole method solves for the Laplace transform of the thermal response. One of the features of the Laplace transform methodology is the solution at any discrete time is independent of the solution at all other times. Therefore, it is easy to separate into a set of independent calculations with each of the times of interest being performed in parallel. Additionally, the numeric inversion of the Laplace transform typically involves numerically solving for the Laplace transform at multiple Laplace frequencies. Each of those solutions are also independent of solutions at other frequencies and can be calculated in parallel. By parallelization of this method, it is possible to perform the simulations of three-dimensional configurations in seconds. When the input stimulus for thermal response is a delta function heat flux (a reasonable approximation for flash heating), the thermal response is smooth. For this case, it is possible to accurately estimate the thermal response at any time within a given time interval from a set of simulations separated by exponentially increasing time steps. From these simulations, it is possible to accurately interpolate to find the response at intermediate times by a spline interpolation of the logarithm of time versus logarithm of temperature. The thermal response with exponential time stepping is shown to produce values for the thermal response which are within 1% of values within the time interval. The simulations are compared to finite element simulations of the same inspection configurations. The simulations are also compared to the thermographic measurements on composites where shape and depth of the delaminations are obtained from other inspection methods.

Thermography↗

NASA NTRSDate not supplied

Parallelized Quadrupole Simulations of Thermographic Responses of Composites

Thermography has been shown to be a viable technique for inspection of composites. Model inversion of the thermography data requires a fast method for performing the forward problem. Viable numerical methods for the thermal response forward problem are finite element, finite difference and the quadrupole method. Normally both the finite element and finite difference methods solve for the thermal response in the time domain which limits one’s ability to increase the speed of the simulation by parallelization. In contrast, the quadrupole method solves for the Laplace transform of the thermal response. One of the features of the Laplace transform methodology is the solution at any discrete time is independent of the solution at all other times. Therefore, it is easy to separate into a set of independent calculations with each of the times of interest being performed in parallel. Additionally, the numeric inversion of the Laplace transform typically involves numerically solving for the Laplace transform at multiple Laplace frequencies. Each of those solutions are also independent of solutions at other frequencies and can be calculated in parallel. By parallelization of this method, it is possible to perform the simulations of three-dimensional configurations in seconds. When the input stimulus for thermal response is a delta function heat flux (a reasonable approximation for flash heating), the thermal response is smooth. For this case, it is possible to accurately estimate the thermal response at any time within a given time interval from a set of simulations separated by exponentially increasing time steps. From these simulations, it is possible to accurately interpolate to find the response at intermediate times by a spline interpolation of the logarithm of time versus logarithm of temperature. The thermal response with exponential time stepping is shown to produce values for the thermal response which are within 1% of values within the time interval. The simulations are compared to finite element simulations of the same inspection configurations. The simulations are also compared to the thermographic measurements on composites where shape and depth of the delaminations are obtained from other inspection methods.

Thermography↗

NASA NTRS2013

Parametric Thermal Soak Model for Earth Entry Vehicles

The analysis and design of an Earth Entry Vehicle (EEV) is multidisciplinary in nature, requiring the application many disciplines. An integrated tool called Multi Mission System Analysis for Planetary Entry Descent and Landing or M-SAPE is being developed as part of Entry Vehicle Technology project under In-Space Technology program. Integration of a multidisciplinary problem is a challenging task. Automation of the execution process and data transfer among disciplines can be accomplished to provide significant benefits. Thermal soak analysis and temperature predictions of various interior components of entry vehicle, including the impact foam and payload container are part of the solution that M-SAPE will offer to spacecraft designers. The present paper focuses on the thermal soak analysis of an entry vehicle design based on the Mars Sample Return entry vehicle geometry and discusses a technical approach to develop parametric models for thermal soak analysis that will be integrated into M-SAPE. One of the main objectives is to be able to identify the important parameters and to develop correlation coefficients so that, for a given trajectory, can estimate the peak payload temperature based on relevant trajectory parameters and vehicle geometry. The models are being developed for two primary thermal protection (TPS) materials: 1) carbon phenolic that was used for Galileo and Pioneer Venus probes and, 2) Phenolic Impregnated Carbon Ablator (PICA), TPS material for Mars Science Lab mission. Several representative trajectories were selected from a very large trade space to include in the thermal analysis in order to develop an effective parametric thermal soak model. The selected trajectories covered a wide range of heatload and heatflux combinations. Non-linear, fully transient, thermal finite element simulations were performed for the selected trajectories to generate the temperature histories at the interior of the vehicle. Figure 1 shows the finite element model that was used for the simulations. The results indicate that it takes several hours for the thermal energy to soak into the interior of the vehicle and achieve maximum payload temperatures. In addition, a strong correlation between the heatload and peak payload container temperature is observed that will help establishing the parametric thermal soak model.

Agrawal, Parul↗

NASA NTRS2008

Multiscale Modeling of Intergranular Fracture in Aluminum: Constitutive Relation For Interface Debonding

Intergranular fracture is a dominant mode of failure in ultrafine grained materials. In the present study, the atomistic mechanisms of grain-boundary debonding during intergranular fracture in aluminum are modeled using a coupled molecular dynamics finite element simulation. Using a statistical mechanics approach, a cohesive-zone law in the form of a traction-displacement constitutive relationship, characterizing the load transfer across the plane of a growing edge crack, is extracted from atomistic simulations and then recast in a form suitable for inclusion within a continuum finite element model. The cohesive-zone law derived by the presented technique is free of finite size effects and is statistically representative for describing the interfacial debonding of a grain boundary (GB) interface examined at atomic length scales. By incorporating the cohesive-zone law in cohesive-zone finite elements, the debonding of a GB interface can be simulated in a coupled continuum-atomistic model, in which a crack starts in the continuum environment, smoothly penetrates the continuum-atomistic interface, and continues its propagation in the atomistic environment. This study is a step towards relating atomistically derived decohesion laws to macroscopic predictions of fracture and constructing multiscale models for nanocrystalline and ultrafine grained materials.

Yamakov, V.↗

DOE OSTI2025

Automated design of an additive manufactured compact broadband antenna for plasma reflectometry

Broadband antennas operating in the gigahertz frequency range are regularly used for plasma reflectometry diagnostics. Due to a lack of space and unique diagnostic constraints, these antennas are often custom in design and frequency range. Recent advances in additive manufacturing of high temperature copper alloys allow for expanded freedom in design of these diagnostic antennas. In this work, a heuristic simulated annealing algorithm is used alongside 3-D finite element simulation to automate the design of a double ridged rectangular horn antenna for a reflectometry diagnostic on the DIII-D tokamak. Optimization of antenna performance given the design constraints results in a compact broadband (6-20+ GHz) antenna design. Measured transmission from the additively manufactured antenna matches simulation within reasonable error, and experimental plasma electron density profiles from the DIII-D high-field side scrape-off layer are shown.

Additive manufacturing↗

DOE OSTI2020

Phase Shift Control of a Three-Phase Inverter for Balanced Secondary Currents in Misaligned Three-Phase Inductive Power Transfer Systems

This paper presents a strategy for generating fundamental reference voltage commands for a double-sided LCC tuned three-phase wireless power transfer (WPT) system to achieve balanced output currents when the receiver and transmitter are not perfectly aligned. Formulas for translating the normalized fundamental current commands into phase-shift commands for two of the phase legs in a two-level three-phase inverter are derived. The methodology is validated through circuit simulations performed using coupler models derived from finite-element simulations. Simulation results for a 1.5 k W system design are included, which indicate near perfect correction of imbalance in the secondary currents for a typical misalignment case.

Pries, Jason↗