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NASA NTRS1992

Compression failure mechanisms of uni-ply composite plates with a circular cutout

The effect of circular-hole size on the failure mode of uniply graphite-epoxy composite plates is investigated experimentally and analytically for uniaxial compressive loading. The test specimens are sandwiched between polyetherimide plastic for nondestructive evaluations of the uniply failure mechanisms associated with a range of hole sizes. Finite-element modeling based on classical lamination theory is conducted for the corresponding materials and geometries to reproduce the experimental results analytically. The type of compressive failure is found to be a function of hole size, with fiber buckling/kinking at the hole being the dominant failure mechanism for hole diam/plate width ratios exceeding 0.062. The results of the finite-element analysis supported the experimental data for these failure mechanisms and for those corresponding to smaller hole sizes.

Khamseh, A. R.↗

NASA NTRS1978

NASTRAN analysis of Tokamak vacuum vessel using interactive graphics

Isoparametric quadrilateral and triangular elements were used to represent the vacuum vessel shell structure. For toroidally symmetric loadings, MPCs were employed across model boundaries and rigid format 24 was invoked. Nonsymmetric loadings required the use of the cyclic symmetry analysis available with rigid format 49. NASTRAN served as an important analysis tool in the Tokamak design effort by providing a reliable means for assessing structural integrity. Interactive graphics were employed in the finite element model generation and in the post-processing of results. It was felt that model generation and checkout with interactive graphics reduced the modelling effort and debugging man-hours significantly.

Miller, A.↗

NASA NTRS2001

Dynamic Characterization of an Inflatable Concentrator for Solar Thermal Propulsion

An inflatable structural system that is a technology demonstrator for solar thermal propulsion and other applications is characterized for structural dynamic behavior both experimentally and computationally. The inflatable structure is a pressurized assembly developed for use in orbit to support a Fresnel lens or inflatable lenticular element for focusing sunlight into a solar thermal rocket engine. When the engine temperature reaches a pre-set level, the propellant is injected into the engine, absorbs heat from an exchanger, and is expanded through the nozzle to produce thrust. The inflatable structure is a passively adaptive system in that a regulator and relief valve are utilized to maintain pressure within design limits during the full range of orbital conditions. Modeling and test activities are complicated by the fact that the polyimide film material used for construction of the inflatable is nonlinear, with modulus varying as a function of frequency, temperature, and level of excitation. Modal vibration testing and finite element modeling are described in detail in this paper. The test database is used for validation and modification of the model. This work is highly significant because of the current interest in inflatable structures for space application, and because of the difficulty in accurately modeling such systems.

Leigh, Larry↗

NASA NTRS2012

Application of Benchmark Examples to Assess the Single and Mixed-Mode Static Delamination Propagation Capabilities in ANSYS

The application of benchmark examples for the assessment of quasi-static delamination propagation capabilities is demonstrated for ANSYS. The examples are independent of the analysis software used and allow the assessment of the automated delamination propagation in commercial finite element codes based on the virtual crack closure technique (VCCT). The examples selected are based on two-dimensional finite element models of Double Cantilever Beam (DCB), End-Notched Flexure (ENF), Mixed-Mode Bending (MMB) and Single Leg Bending (SLB) specimens. First, the quasi-static benchmark examples were recreated for each specimen using the current implementation of VCCT in ANSYS . Second, the delamination was allowed to propagate under quasi-static loading from its initial location using the automated procedure implemented in the finite element software. Third, the load-displacement relationship from a propagation analysis and the benchmark results were compared, and good agreement could be achieved by selecting the appropriate input parameters. The benchmarking procedure proved valuable by highlighting the issues associated with choosing the input parameters of the particular implementation. Overall the results are encouraging, but further assessment for three-dimensional solid models is required.

Krueger, Ronald↗

NASA NTRS1985

Study for the optimization of a transport aircraft wing for maximum fuel efficiency. Volume 1: Methodology, criteria, aeroelastic model definition and results

Work performed in the design of a transport aircraft wing for maximum fuel efficiency is documented with emphasis on design criteria, design methodology, and three design configurations. The design database includes complete finite element model description, sizing data, geometry data, loads data, and inertial data. A design process which satisfies the economics and practical aspects of a real design is illustrated. The cooperative study relationship between the contractor and NASA during the course of the contract is also discussed.

Radovcich, N. A.↗

NASA NTRS1998

Numerical Modeling of Solidification in Space With MEPHISTO-4

A pre-flight analysis of the directional solidification of BiSn with MEPHISTO-4 is presented. Simplified Bridgman growth under microgravity conditions is simulated using a two dimensional finite element model. This numerical model is a single domain, pseudo-steady state model, and includes the effects of both thermal and solutal convection. The results show that for all orientations of the applied steady state gravity vector, of magnitude 1 micro-g, the directional solidification process remains diffusion controlled. The maximum convective velocity was found to be 4.424 x 10(exp -5) cm/s for the horizontal Bridgman growth configuration. This value is an order of magnitude lower than the growth velocity. The maximum and minimum values or solute concentration in the liquid at the crystal-melt interface were 13.867 at.% and 13.722 at.%, respectively. This gives a radial segregation value of xi = 1.046% at the interface. A secondary objective of this work was to compare the results obtained to those that consider thermal convection only (no solutal convection). It was found that the convective flow patterns in simulations which included solutal convection were significantly different from those which ignored solutal convection. The level of radial segregation predicted by the current simulations is an order of magnitude lower than that found in simulations which ignore solutal convection. The final aim was to investigate the effect of g-jitter on the crystal growth process. A simulation was performed to calculate the system response to a 1 second, 100 micro-g gravity impulse acting normal to the direction of growth. This pulse is consistent with that induced by Orbiter thruster firings. The results obtained indicate that such a gravity pulse causes an increase in the level of radial solute segregation at the interface from the steady state values. The maximum value of solute concentration in the liquid was found to be 13.888 at.%, the minimum value calculated was 13.706 at.%, yielding a radial segregation value of xi = 1.31% at the interface. These values occurred 126 seconds after the pulse terminated. Thus it is anticipated that the process will remain diffusion controlled even when subjected to such g-jitter.

Simpson, James E.↗

DOE OSTI2016

Seismic and LOCA safety testing and analysis program for Westinghouse PWR fuel under end of life conditions

The NRC issued Information Notice - IN 2012-09 in June 2012 which challenges approved assumptions based on the beginning of life (BOL) conditions in seismic and LOCA analysis. Westinghouse manufactures a variety of PWR fuel designs, including 14*14, 15*15, 16*16 and 17*17 array, also different fuel lengths from 12 feet to 14 feet. The fuels are supplied to the cores designed by Westinghouse and Combustion Engineering, and other cores around world. To address IN 2012-09 efficiently and economically, Westinghouse and PWR Owner Groups launched a testing and analysis program funded by PWROG. The program planed testing and analysis matrices based on types of fuel designs. The testing plan includes grid crush tests, fuel assembly mechanical tests and flowing water damping tests. Applying modelling technique, the program will reduce the number of test and cost. The ultimate goal of the program is to generate fuel assembly EOL models for all fuel designs manufactured by Westinghouse and to be ready for any plant specific seismic and LOCA analysis to address NRC IN for EOL effect. The phase I of PWROG for EOL conditions has been completed and several conclusions are obtained. First, the gapped grids reduce grid dynamic stiffness, local impact stiffness and crush strength. Also, due to gapped grids, both the fuel assembly natural frequency and stiffness are reduced. Secondly, applying higher fuel assembly damping due to the flowing water effect can significantly reduce fuel assembly impact forces. However, during a seismic event the reactor coolant pumps may trip resulting in a coast-down. As such, reduced flow rates that occur during the pump coast-down must be considered. Thirdly, the analytical model representation of a reactor core adequately characterizes the core response under seismic and LOCA excitations. Static and dynamic structural test results of a fuel assembly compared with analytical predictions indicate that the fuel assembly lateral and axial structural behavior can be fully determined with finite element models. Fourthly, analyses for EOL fuel assemblies under seismic and LOCA loads demonstrate EOL effect and flowing water damping effect. With flowing water damping benefit, significant margin can be recovered for fuel assemblies with EOL conditions and under seismic loads.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2018

PhaseChange Material Freezing in an Energy Storage Module for a Micro Environmental ControlSystem

This study analyzes phase change material (PCM) freezing process in a novel latent heat storage device (LHSD). Heat is removed from the PCM with an embedded evaporator. A mathematical model of freezing in a finite-thickness PCM slab is presented. An experimentally validated reduced-order model (ROM) based on the mathematical model was developed to analyze the heat transfer between the freezing PCM and an evaporating refrigerant flowing inside a flat, microchannel tube coil embedded in the PCM. A detailed finite element model (FEM) of the same device was also developed and employed to verify the validity of the ROM over a wider range of conditions. The freezing times and total “cooling” stored in the PCM computed by the ROM agree very well with those computed by the detailed FEM. The ROM executes in ~1 min for a full heat exchanger, compared with more than 10 h for the FEM, making the former much more practical for use in parametric analysis and optimization of design alternatives.

Engineering↗

NASA NTRS2019

A Multi-Physics Study on High-Specific Power Li-O2 Batteries for Electric Aircraft

Commercialization of lithium-air batteries faces many challenges, such as electrolyte decomposition, short cycle life, low energy and power density, etc. However, commercialization of Li-O2 batteries for aeronautics is much more challenging due to additional safety constraints on cyclability and performance (high specific power and specific energy). For this presentation, we will discuss inter-related aspects of physics-based modeling of a pack: cell and battery model calibration. In addition, we will evaluate and present optimal battery designs for high discharge current density, high discharge time, and low battery mass using simulation-based optimization.The Finite Element Model (FEM) used to simulate a Li-O2 cell is based on the work of Bevara [1]. The different aspects of the model are based on: porous electrode theory and concentrated electrolyte theory; quantum tunneling model for the resistance of conformal layer of discharge product (Li2O2) [1]; Butler-Volmer kinetics for electrochemical reaction; Fick's diffusion for oxygen transport; and an oxygen dissolution model is applied at the air/electrolyte interface [2]. The electrolyte properties such as ion conductivity, ion diffusion, oxygen diffusion, and mass density of the electrolyte were taken from Molecular Dynamics (MD) simulations [3]; while the other model parameters, which includes mass of cell components, were calibrated to match experiments at high discharge current densities. The cell mass includes the anode, cathode, separator, electrolyte, and other components (such as current collector). This calibrated model is used to perform parametric studies on cathode thickness, porosity, tortuosity, carbon particle size, electrolyte transport and material properties, partial pressure of oxygen, discharge time, and discharge current density to study optimal designs for high specific power and energy. References:1. Bevara, V. & Andrei, P. (2014), J. Electrochem. Soc. 161 (14), A2068-A2079.2.Mehta, M. & Andrei, P. (2015), J. Power Sources. 286, 299-308.3.Liyana-Arachchi, T.; Haskins, J.; Burke, C.; Diederichsen, K.; McCloskey, B.; & Lawson, J. (2018), J. Phys. Chem. B. 122 (36), 8548 - 8559.4.Choi, W.; Kikumoto, H.; Choudhary, R. & Ooka, R. (2018), Applied Energy, 209, 306-321.

Mehta, Mohit↗

DOE OSTI2021

A Combined Experimental and Modeling Approach to Investigate the Performance of Joint Between AZ31 Magnesium and Uncoated DP590 Steel Using Friction Stir-Assisted Scribe Technique

In this study, friction stir assisted scribe technique is used to achieve a viable joint between AZ31 magnesium alloy and uncoated DP590 steel. Here, the mechanical properties and performance of the joint are investigated using finite element modeling and electron microscopy. The joint strength can be ascribed to two factors, the mechanical interlocking and the metallurgical bonding of two materials at their interface. The contribution of both factors is intended, and the metallurgical bonding is studied to understand the basic joining phenomenon.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Investigation on Effect of Magnetic Field Dependency Coefficient of Critical Current Density on the AC Magnetizing Loss in HTS Tapes Exposed to External Field

High-temperature superconducting (HTS) technology is the most promising, advanced, and beneficial technological developments of the last two decades in terms of fabricating more efficient, compact, and reliable electrical power apparatus. The second-generation HTS wires are now quite competitive with traditional conductors from the cost point of view. In addition, they are of high interest in electrical machine manufacturing due to their unique merits such as high current density, high magnetic field, and low loss. The most significant issue for any superconducting devices which work with alternating current or magnetic field is the AC loss of the HTS tapes. Since HTS tapes are always exposed to an external magnetic field in electrical machine applications, it is vital to consider the effect of this external field on their AC magnetizing (ACMG) loss. It is well-known that external magnetic field decreases the current carrying capability of the wire. In real life, critical current density of HTS tapes is dependent to magnetic field but this dependency sometime was not considered in modeling stage in order to make it faster and simple. In this paper, the electromagnetic properties of HTS tapes for use in superconducting electric machines have been investigated with a particular focus on the ACMG loss of YBCO tapes. For this purpose, a two-dimensional finite element model has been implemented based on the H formulation in order to study the effect of dependency of critical current density to magnetic field on the variation of ACMG loss. The modeling results will be helpful for electrical machine designers to have a better understanding about this effect and have a more accurate estimate of ACMG loss in design stage.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2016

Design and performance of optimal detectors for guided wave structural health monitoring

Ultrasonic guided wave measurements in a long term structural health monitoring system are affected by measurement noise, environmental conditions, transducer aging and malfunction. This results in measurement variability which affects detection performance, especially in complex structures where baseline data comparison is required. This paper derives the optimal detector structure, within the framework of detection theory, where a guided wave signal at the sensor is represented by a single feature value that can be used for comparison with a threshold. Three different types of detectors are derived depending on the underlying structure’s complexity: (i) Simple structures where defect reflections can be identified without the need for baseline data; (ii) Simple structures that require baseline data due to overlap of defect scatter with scatter from structural features; (iii) Complex structure with dense structural features that require baseline data. The detectors are derived by modeling the effects of variabilities and uncertainties as random processes. Analytical solutions for the performance of detectors in terms of the probability of detection and false alarm are derived. A finite element model is used to generate guided wave signals and the performance results of a Monte-Carlo simulation are compared with the theoretical performance. initial results demonstrate that the problems of signal complexity and environmental variability can in fact be exploited to improve detection performance.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2025

Simulation of Creep Deformation and Failure in Graded AM Microstructures

This report describes modeling tools and techniques developed to simulate the long-term material performance of 316H stainless steel manufactured using Laser Powder Bed Fusion (LPBF). A physics-based Crystal Plasticity Finite Element model is used to simulate creep in microstructures and to study the roles of grain morphology, porosity, and texture. We describe our modeling methodology, including an orientation-mapping technique to capture the spatially varying crystallographic orientation that results from the build conditions. Our study of microstructural features shows that AM microstructures produced by LPBF tend to creep faster in the build direction, while texture and grain boundaries strengthen the transverse directions. However, when grain-boundary porosity and the consequent cavity growth are included in the model, the transverse directions begin to creep faster. In examining texture, the results indicate that spatially varying orientation arising from the build conditions increases anisotropy in the material, making it critical to account for orientation gradients in the material to accurately model its mechanical behavior. We also describe a material-model calibration campaign in which we calibrated the constitutive model specifically for LPBF 316H stainless steel at 725℃ for both solution-annealed and as-built conditions. Finally, these tools and techniques are used to model creep in microstructures representing different regions of an LPBF material with graded microstructure, owing to intentional variation in processing conditions. The creep simulation results show good agreement with experimental data across all three microstructures, with future work planned to study rupture in the material.

36 MATERIALS SCIENCE↗

NASA NTRS1981

SPAR analysis of LDEF vibration characteristics

This paper presents a structural dynamic modeling of the Long Duration Exposure Facility (LDEF), which is a Space Shuttle payload of passive scientific experiments contained in trays mounted on a large cylindrically shaped structure. Special detailed finite element modeling, using the SPAR system of computer programs was required to obtain good agreement between analytical and test vibrations modes. Experimental trays contributed significantly to overall LDEF stiffnesses, and these contributions were realistically represented for each tray by the stiffness matrix of an equivalent orthotropic panel in the overall LDEF SPAR model. Orthotropic stiffnesses for this panel were obtained from finely detailed statically loaded tray SPAR models in which stiffness coupling was accounted for along with partial relative sliding allowed by the tray clamping attachments. Joint boundary conditions were also significant in the structural dynamic modeling of LDEF, and static data proved valuable in assessing modeling of local end fittings.

Edighoffer, H. H.↗

NASA NTRS1988

Improved method for stress and compatibility analysis of multicomponent rotating systems

An improved method of analyzing multicomponent rotating assemblies for the determination of operating stresses and component compatibility has been developed. In this method, a single finite element model is developed which contains all of the separate components in the rotating assembly. This is made possible by using gap elements to simulate the contact surfaces between components. The MARC finite element computer program is then used to perform the analysis. This improved method is less time consuming and more reliable than the conventional method of analyzing such systems. Results are presented for two different stress-compatibility analyses of a six-component axial flow compressor rotor. The results for the previously used flexibility analysis method are compared with those for the improved analysis method. The stresses predicted by each method compare quite well with each other. The predictions of the component compatibility, as well as the magnitude of the forces at the contact surfaces, also compare well for these two analysis procedures. It is therefore recommended that the improved analysis method be used to determine the stress-compatibility characterstics of multicomponent rotating systems.

Carek, Gerald A.↗

NASA NTRS2004

Numerical and Experimental Dynamic Characteristics of Thin-Film Membranes

Presented is a total-Lagrangian displacement-based non-linear finite-element model of thin-film membranes for static and dynamic large-displacement analyses. The membrane theory fully accounts for geometric non-linearities. Fully non-linear static analysis followed by linear modal analysis is performed for an inflated circular cylindrical Kapton membrane tube under different pressures, and for a rectangular membrane under different tension loads at four comers. Finite element results show that shell modes dominate the dynamics of the inflated tube when the inflation pressure is low, and that vibration modes localized along four edges dominate the dynamics of the rectangular membrane. Numerical dynamic characteristics of the two membrane structures were experimentally verified using a Polytec PI PSV-200 scanning laser vibrometer and an EAGLE-500 8-camera motion analysis system.

Young, Leyland G.↗

NASA NTRS1991

A rheologically layered three-dimensional model of the San Andreas fault in central and southern California

The effects of rheological parameters and the fault slip distribution on the horizontal and vertical deformation in the vicinity of the fault are investigated using 3D kinematic finite element models of the San Andreas fault in central and southern California. It is shown that fault models with different rheological stratification schemes and slip distributions predict characteristic deformation patterns. Models that do not include aseismic slip below the fault locking depth predict deformation patterns that are strongly dependent on time since the last earthquake, while models that incorporate the aseismic slip below the locking depth depend on time to a significantly lesser degree.

Williams, Charles A.↗

DOE OSTI2015

WE-AB-BRA-02: Development of Biomechanical Models to Describe Dose-Volume Response to Liver Stereotactic Body Radiation Therapy (SBRT) Patients

Purpose: Previous studies have shown that radiotherapy treatment for liver metastases causes marked liver hypertrophy in areas receiving low dose and atrophy/fibrosis in areas receiving high dose. The purpose of this work is to develop and evaluate a biomechanical model-based dose-response model to describe these liver responses to SBRT. Methods: In this retrospective study, a biomechanical model-based deformable registration algorithm, Morfeus, was expanded to include dose-based boundary conditions. Liver and tumor volumes were contoured on the planning images and CT/MR images three months post-RT and converted to finite element models. A thermal expansion-based relationship correlating the delivered dose and volume response was generated from 22 patients previously treated. This coefficient, combined with the planned dose, was applied as an additional boundary condition to describe the volumetric response of the liver of an additional cohort of metastatic liver patients treated with SBRT. The accuracy of the model was evaluated based on overall volumetric liver comparisons and the target registration error (TRE) using the average deviations in positions of identified vascular bifurcations on each set of registered images, with a target accuracy of the 2.5mm isotropic dose grid (vector dimension 4.3mm). Results: The thermal expansion coefficient models the volumetric change of the liver to within 3%. The accuracy of Morfeus with dose-expansion boundary conditions a TRE of 5.7±2.8mm compared to 11.2±3.7mm using rigid registration and 8.9±0.28mm using Morfeus with only spatial boundary conditions. Conclusion: A biomechanical model has been developed to describe the volumetric and spatial response of the liver to SBRT. This work will enable the improvement of correlating functional imaging with delivered dose, the mapping of the delivered dose from one treatment onto the planning images for a subsequent treatment, and will further provide information to assist with the biological characterization of patients’ response to radiation.

60 APPLIED LIFE SCIENCES↗