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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 1,351 records · Page 75
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Computational Modeling of Multi-Pass Rolling Parameters Effect on Resulting Fuel Foil Shape

A focus of the U.S. Department of Energy is to improve production yield and reduce the cost of Low Enriched Uranium (LEU)-molybdenum alloy (U-10Mo) monolithic fuel plates that will be replacing High Enriched Uranium (HEU) oxide dispersion fuels used currently in the United States High Performance Research Reactors (USHPRR). One area of improvement is lowering the high transverse waviness and longitudinal waviness currently present within rolled foils prior to cladding to produce fuel plates. Traditional rolling manufacturing techniques for other metal foils use winders to pull and straighten the foil as it is rolled back and forth to the final thickness. This approach cannot be used to roll thin U-10Mo foils (0.008-0.025” thick) because only small castings can be rolled due to nuclear criticality safety concerns. As a result, the fuel foils are too short (1 m in length) to use traditional winders. Therefore, it is crucial to identify other rolling parameters (i.e., roller friction, axial tension load, roller diameter, and roll pass reduction percent) that might reduce transverse waviness and longitudinal waviness in the rolled fuel foil and develop a high-yield, low-cost multi-pass rolling manufacturing process. This report documents a systematic finite element modeling study to investigate the effects of numerous rolling parameters to reduce resulting transverse waviness and longitudinal waviness in the fuel foil during multi-pass rolling of U-10Mo foils. The rolling of a U-10Mo plate with initial dimensions of 1”x1”x 0.048” is modeled using Abaqus CAE. This rolling is modeled to undergo eight 20% reduction roll passes to a final fuel foil thickness of 0.01”. The elastic-plastic constitutive model of the U-10Mo alloy was input to the fuel foil rolling model. The rollers were modeled as rigid bodies. A comparison of rolling friction coefficients of 0.3 and 0.7 over a wide range of applied axial tension loads were investigated in order to evaluate the effect of using a lubricant during rolling. The effect of roller diameter on the resulting transverse waviness and longitudinal waviness of the fuel foil over a wide range of axial tension loads were also investigated by modeling rollers 7/8” and 3.75” in diameter. The results of this systematic finite element method study will aid manufacturers in producing low transverse waviness and reduced longitudinal waviness in U-10Mo fuel foils.

U-10Mo, FEA, Rolling, Residual Stress, Fuel Foil↗
DOE OSTI2017

Thermal environment of the Southern Washington region of the Cascadia subduction zone

Eleven recently collected multichannel seismic (MCS) profiles from the Cascadia Open–Access Seismic Transects experiment offshore Washington State are used to characterize the distribution of bottom–simulating reflectors (BSRs) from seaward of the deformation front onto the continental shelf of the Cascadia Subduction Zone. The 11 MCS lines consisted of nine lines perpendicular and two lines parallel to the Cascadia margin covering a 100 km along–strike region of the accretionary wedge. From these MCS profiles we generated a 3–D view of the Cascadia margin thermal structure by interpreting 40,232 individual BSR picks in terms of temperature and heat flow. Overall BSR–derived heat flow values decrease from approximately 95 mW m –2 10 km east of the deformation front to approximately 60 mW m –2 located 60 km landward of the deformation front. Anomalously low heat flow values near 25 mW m –2 on a prominent midmargin terrace indicate recent sediment failure within the accretionary prism. Localized differences between BSR heat flow and numerical models reflect an estimated regional mean vertical fluid flow of +0.53 cm yr –1 for the survey area, with localized fluid flow approaching a maximum of +3.8 cm yr –1 . Distinct finite element models for the nine MCS profiles perpendicular to the deformation front reproduce BSR heat flow values, producing an overall root–mean–square misfit of 10.2 mW m –2 . In conclusion, at the deformation front, the incoming oceanic sediment/crust interface temperatures vary from 164°C to 179°C, indicating the updip limit of the Cascadia seismogenic zone.

58 GEOSCIENCES↗
NASA NTRS1980

Design, fabrication and test of graphite/polyimide composite joints and attachments for advanced aerospace vehicles

Bonded and bolted designs are presented for each of four major attachment types. Prepreg processing problems are discussed and quality control data are given for lots 2W4604, 2W4632 and 2W4643. Preliminary design allowables test results for tension tests and compression tests of laminates are included. The final small specimen test matrix is defined and the configuration of symmetric step-lap joint specimens are shown. Finite element modeling studies of a double lap joint were performed to evaluate the number of elements required through the adhesive thickness to assess effects of various joint parameters on stress distributions. Results of finite element analyses assessing the effect of an adhesive fillet on the stress distribution in a double lap joint are examined.

Skoumal, D. E.↗
NASA NTRS1987

Design modeling for shape optimization

Some important aspects of design modeling for shape optimization are discussed for both stamped sheet metal components and cast solid components. For stamped components the basis for the modeling approach is a boundary design function. Design parameters control the shape of 2-D regions. For more complex, folded plate components, the 2-D regions can be assembled using translation and rotation operations. The analysis model is automatically created using a mesh generation procedure requiring only boundary data. For less complex solid components, it was found that this approach is not suitable. For these structures, the finite element models are typically created using very sophisticated graphical modeling systems. A new approach which overlays a parameterized surface design model on an existing analysis model is described. To summarize, the future needs for solid shape design is described in terms of an extension of the previously described 2-D capability.

Botkin, M. E.↗
NASA NTRS1996

Crack Development in Cross-Ply Laminates Under Uniaxial Tension

This study addresses matrix-dominated failures in carbon fiber/polymer matrix composite laminates in a cross-ply lay-up. The events of interest are interlaminar fracture in the form of transverse cracks in the 90' plies and longitudinal splitting in the 0 deg plies and interlaminar fracture in the form of 0/90 delamination. These events were observed using various nondestructive evaluation (NDE) techniques during static tensile tests. Acoustic emission (AE) x radiography, and edge view microscopy were the principal ones utilized in a real-time environment. A comparison of the NDE results with an analytical model based on the classical linear fracture mechanics concept of strain energy release rate as a criterion for crack growth was performed. The virtual crack closure theory was incorporated with a finite element model to generate strain energy release rate curves for the analytical case. Celion carbon fiber/polyimide matrix (G30-500/PMR-15) was the material tested with cross-ply lay-ups of (0(2)/90(6))s and (0(4)/90(4))s. The test specimens contained thermally induced cracks caused by the high-temperature processing. The analytical model was updated to compensate for the initial damage and to study further accumulation by taking into account the crack interactions. By correlating the experimental and analytical data, the critical energy release rates were found for the observable events of interest.

Gyekenyesi, Andrew L.↗
NASA NTRS2008

High-Temperature Strain Sensing for Aerospace Applications

Thermal protection systems (TPS) and hot structures are utilizing advanced materials that operate at temperatures that exceed abilities to measure structural performance. Robust strain sensors that operate accurately and reliably beyond 1800 F are needed but do not exist. These shortcomings hinder the ability to validate analysis and modeling techniques and hinders the ability to optimize structural designs. This presentation examines high-temperature strain sensing for aerospace applications and, more specifically, seeks to provide strain data for validating finite element models and thermal-structural analyses. Efforts have been made to develop sensor attachment techniques for relevant structural materials at the small test specimen level and to perform laboratory tests to characterize sensor and generate corrections to apply to indicated strains. Areas highlighted in this presentation include sensors, sensor attachment techniques, laboratory evaluation/characterization of strain measurement, and sensor use in large-scale structures.

Piazza, Anthony↗
NASA NTRS2018

Automation of Structural Sizing of Aircraft Concepts Under Static Aeroelastic Constraints

This paper presents an automation process for structural sizing of subsonic and supersonic aircraft concepts under static aeroelastic constraints. The automation process starts with an OpenVSP geometry and ends with a PATRAN plot of a NASTRAN solution for static aeroelastic analysis or optimization. ModelCenter is used to integrate all analysis codes with easy-to-use interfaces. Automation tools are developed to streamline the setup process and avoid user errors. Fuel is distributed by solving an optimization problem to match the center of gravity of aircraft at a specified flight condition. Fuel weights are also automatically attached to the structural model as point masses. All other weights used in FLOPS mission analysis (excluding fuselage and wing structural weights) are automatically attached to or smeared on the structural model. For any given OpenVSP geometry and FLOPS analysis data, a static aeroelastic sizing model for NASTRAN analysis can be generated in a couple of hours. The empirical fuselage and wing structural weights from FLOPS are replaced by structural panel weights from the sized finite-element model. Three supersonic and two subsonic aircraft concepts are used to demonstrate the automation process as a physics-based weight estimation tool for aircraft conceptual design.

Li, Wu↗
NASA NTRSDate not supplied

SLS Integrated Modal Test Uncertainty Quantification using the Hybrid Parametric Variation Method

Uncertainty in structural loading during launch is a significant concern in the development of spacecraft and launch vehicles. Small variations in launch vehicle and payload mode shapes and their interaction can result in significant variation in system loads. In many cases involving large aerospace systems it is difficult, not economical, or impossible to perform a system modal test. However, it is still vital to obtain test results that can be compared with analytical predictions to validate models. Instead, the “Building Block Approach” is used in which system components are tested individually. Component models are correlated and updated to agree as best they can with test results. The Space Launch System consists of a number of components that are assembled into a launch vehicle. Finite element models of the components are developed, reduced to Hurty/Craig-Bampton models and assembled to represent different phases of flight. The only opportunity to obtain modal test data from an assembled Space Launch System will be during the Integrated Modal Test. There is always uncertainty in every model, which flows into uncertainty in predicted system results. Uncertainty Quantification is used to determine statistical bounds on prediction accuracy based on model uncertainty. For the Space Launch System, model uncertainty is at the Hurty/Craig-Bampton component level. Uncertainty in the Hurty/Craig-Bampton components is quantified using the hybrid parametric variation approach that combines parametric and nonparametric uncertainty. Uncertainty in model form is one of the biggest contributors to uncertainty in complex built-up structures. This type of uncertainty cannot be represented by variations infinite element model input parameters and thus cannot be included in a parametric approach. However, model-form uncertainty can be modeled using a nonparametric approach based on random matrix theory. The hybrid parametric variation method requires the selection of dispersion values for the Hurty/Craig-Bampton fixed-interface eigenvalues, and the Hurty/Craig-Bampton stiffness matrices. Component test/analysis frequency error is used to identify the fixed-interface eigenvalue dispersions, while test/analysis cross-orthogonality is used to identify stiffness dispersion values. The hybrid parametric variation uncertainty quantification approach is applied to the Space Launch System Integrated Modal Test configuration. Monte Carlo analysis is performed, and statistics are determined for modal correlation metrics, frequency response from Integrated Modal Test shakers to selected accelerometers, as well as other metrics for determining how well target modes are excited and identified. If the predicted uncertainty envelopes future Integrated Modal Test results, then there will be increased confidence in the utility of the component-based hybrid parametric variation uncertainty quantification approach.

Uncertainty Quantification↗
DOE OSTI2013

A micro to macro approach to polymer matrix composites damage modeling : final LDRD report.

Capabilities are developed, verified and validated to generate constitutive responses using material and geometric measurements with representative volume elements (RVE). The geometrically accurate RVEs are used for determining elastic properties and damage initiation and propagation analysis. Finite element modeling of the meso-structure over the distribution of characterizing measurements is automated and various boundary conditions are applied. Plain and harness weave composites are investigated. Continuum yarn damage, softening behavior and an elastic-plastic matrix are combined with known materials and geometries in order to estimate the macroscopic response as characterized by a set of orthotropic material parameters. Damage mechanics and coupling effects are investigated and macroscopic material models are demonstrated and discussed. Prediction of the elastic, damage, and failure behavior of woven composites will aid in macroscopic constitutive characterization for modeling and optimizing advanced composite systems.

36 MATERIALS SCIENCE↗
NASA NTRS2010

Modeling Geometry and Progressive Failure of Material Interfaces in Plain Weave Composites

A procedure combining a geometrically nonlinear, explicit-dynamics contact analysis, computer aided design techniques, and elasticity-based mesh adjustment is proposed to efficiently generate realistic finite element models for meso-mechanical analysis of progressive failure in textile composites. In the procedure, the geometry of fiber tows is obtained by imposing a fictitious expansion on the tows. Meshes resulting from the procedure are conformal with the computed tow-tow and tow-matrix interfaces but are incongruent at the interfaces. The mesh interfaces are treated as cohesive contact surfaces not only to resolve the incongruence but also to simulate progressive failure. The method is employed to simulate debonding at the material interfaces in a ceramic-matrix plain weave composite with matrix porosity and in a polymeric matrix plain weave composite without matrix porosity, both subject to uniaxial cyclic loading. The numerical results indicate progression of the interfacial damage during every loading and reverse loading event in a constant strain amplitude cyclic process. However, the composites show different patterns of damage advancement.

Hsu, Su-Yuen↗
NASA NTRS1976

A finite element-analytical method for modeling a structure in an infinite fluid

A method is described from which the interaction of an elastic structure with an infinite acoustic fluid is determined. The displacements of the structure and the pressure field of the immediate surrounding fluid are modeled by finite elements, and the remaining pressure field of the infinite fluid region is given by an analytical expression. This method yields a frequency dependent boundary condition for the outer fluid boundary when applied to the frequency response of an elastic beam in contact with an acoustic fluid. The frequency response of the beam is determined using NASTRAN, and compares favorably to the exact solution which is also presented. The effect of the fluid on the response of the structure at low and high frequencies is due to added mass and damping characteristics, respectively.

Zarda, P. R.↗
DOE OSTI2021

A microstructure-based modeling approach to predict the mechanical properties of Zr alloy with hydride precipitates

In nuclear reactors, hydrides can form in fuel cladding due to hydrogen absorption in ZIrcaloy and cause embrittlement. This work presents a microstructure-based finite element model to predict the stress-strain response of Zircaloy containing hydrides. Quantitative microstructural details extracted from scanning electron microscopy (SEM) images were used to generate heterogeneous microstructures including the morphology and spatial distribution of hydrides. The constitutive material model for zircaloy in this study is based on crystal plasticity theory which considers the hexagonal close-packed (HCP) atomic structure of Zircaloy material. The hydrides were modeled as brittle material along with a damage model. Hydride formation inside the zircoloy matrix results in residual stress. This phenomenon is also captured in this model. A parametric study has been conducted to understand the effect of volume fraction, orientation, and lamellae thickness of the hydride phase on the mechanical properties of the overall material.

Kulkarni, Shank S.↗
DOE OSTI2018

Continuation Report: Creep-fatigue Behavior and Damage Accumulation of a Candidate Structural Material for Concentrating Solar Thermal Receiver

At the start of this phase, six alloys were determined to be candidate materials for the concentrating solar power (CSP) thermal receiver: Alloys 617, 625, 740H, 230, 282 and Alloy X. From these, Alloys 740H and 282 were determined to be the most suitable, with both alloys exhibiting similar high temperature strength properties. Alloy 740H was selected due to its ease to work with (simpler heat treatments and welding procedures) and a larger database of existing data. Fatigue testing was started in this phase, with four fatigue tests having been completed, with additional fatigue testing planned, as well as tensile, creep and creep-fatigue tests starting in the next phase. Two fatigue tests performed at 850 °C and were completed in significantly fewer cycles than the two tests performed at 750 °C. Metallography was performed on the fatigued specimens to examine crack path and surrounding microstructure. These preliminary results suggest a significant drop in strength at elevated temperatures above 750 °C, however, more test results will be needed prior to setting design limits. Several potential model high temperature design methods were evaluated that could form the basis of our final recommended creep-fatigue design method for Alloy 740H. To do this we expanded on the receiver finite element model to develop a model representative of a potential Gen 3 design using KCl-MgCl2 salt coolant and operating with a salt inlet temperature of 550°C and salt outlet temperature of 720°C. Using the temperature fields from the model thermohydraulic analysis we determined the design life of the reference receiver assuming it was constructed from 740H seamless tubing and assuming high temperature design properties for 740H from literature data and, where required, naïve extrapolation. As experimental data is generated, these tentative design parameters will be updated to match the actual performance of 740H in elevated temperature service. The results of this design study are a rank ordering of potential design methods for two criteria: ease of use and design margin. The end goal of this project is to develop a creep-fatigue design method with adequate, but not over conservative, design margin that is straightforward to execute. Our receiver model is based on the preliminary design provided to DOE by Solar Reserve. Our analysis indicates a peak metal temperature of around 840° C for this design (comparable to Solar Reserve’s analysis, which shows a peak metal temperature of around 830° C). The Solar Reserve tube thickness is too thin to sustain creep-fatigue loading at this temperature. This means that the current trial design is not well-suited for evaluating different design methodologies, as we predict it will have a very short design life. We suggest that we modify our reference design with input from DOE in order to lower the maximum metal temperature to less than 800° C. We can then repeat these analyses and give a more meaningful comparison of different design methods before making a final selection.

14 SOLAR ENERGY↗
DOE OSTI2023

Probabilistic Multi-Hazard Performance Assessment of Concrete Structures in Nuclear Installations

Concrete structures in nuclear installations are subject to time-dependent degradation mechanisms that can deteriorate their physical and mechanical properties, potentially exacerbating the risk of structural failure under external forces such as a seismic event. Previous research has extensively investigated the seismic response of nuclear concrete structures and the associated risk, as well as their effect on structural components safety margins. However, substantial work is still necessary to incorporate concrete aging effects into such evaluations. In fact, most models in the literature assume pristine concrete conditions and do not account for the impact of aging on the structural components’ fragility curves. This work identifies relevant time-dependent degradation mechanisms and provides simplified models to predict the the evolution of key material properties based on data from the literature. Namely, this work focuses on the aging effects of corrosion, alkali–silica reaction (ASR), and irradiation on reinforced concrete within US Department of Energy (DOE) nuclear facilities and nuclear power plants (NPP) structures. Furthermore, degradation models based on literature data are presented that define the relationship between probabilistic material properties and the concrete’s age. In this work, sampled material properties served as input for a simplified finite element model (FEM) of a critical nuclear structural system, with the output of the FEM being the seismic response for a given ground motion. The results of the FEM were then used within a probabilistic performance assessment with a statistically significant number of samples. The research presented herein addresses the detrimental effects of hazards caused by natural phenomena on deteriorated concrete elements of nuclear installations. This work directly benefits the safety analysis performed on US DOE/ National Nuclear Security Administration (NNSA) nuclear facilities located in areas prone to seismic activity. The results presented herein could aid in the improvement of DOE-STD-1020, the DOE Standard that addresses seismic risk analysis and capacity evaluation in DOE facilities. DOE-STD-1020 refers to the requirements in American Society of Civil Engineers (ASCE) 4-98, now superseded by ASCE 4-16, that shall be met in performing dynamic response analyses and generating in-structure response spectra, provided that such requirements are consistent with the requirements of ASCE/Structural Engineering Institute (SEI) 43-05. Moreover, the results presented herein could also aid in the updating of section C3.1.1. of ASCE 4-16 to account for the effects of aging on the stiffness of reinforced elements and American Concrete Institute (ACI) 349.3R-18, “Report on Evaluation and Repair of Existing Nuclear Safety-Related Concrete Structures.” Ultimately, this work can assist the risk assessment of potential lifetime extension of the existing US commercial nuclear fleet (light water reactors) and the safety analysis of the emerging advanced nuclear reactors. The proposed proof-of-concept methodology employs open-source DOE computational tools and is transferable to commercial software commonly used by engineering firms.

42 ENGINEERING↗
NASA NTRS1992

Prediction of dislocation generation during Bridgman growth of GaAs crystals

Dislocation densities are generated in GaAs single crystals due to the excessive thermal stresses induced by temperature variations during growth. A viscoplastic material model for GaAs, which takes into account the movement and multiplication of dislocations in the plastic deformation, is developed according to Haasen's theory. The dislocation density is expressed as an internal state variable in this dynamic viscoplastic model. The deformation process is a nonlinear function of stress, strain rate, dislocation density and temperature. The dislocation density in the GaAs crystal during vertical Bridgman growth is calculated using a nonlinear finite element model. The dislocation multiplication in GaAs crystals for several temperature fields obtained from thermal modeling of both the GTE GaAs experimental data and artificially designed data are investigated.

Tsai, C. T.↗
NASA NTRS2001

Thermal/Fluid Analysis of a Composite Heat Exchanger for Use on the RLV Rocket Engine

As part of efforts to design a regeneratively cooled composite nozzle ramp for use on the reusable vehicle (RLV) rocket engine, a C-SiC composite heat exchanger concept was proposed for thermal performance evaluation. To test the feasibility of the concept, sample heat exchanger panels were made to fit the Glenn Research Center's cell 22 for testing. Operation of the heat exchanger was demonstrated in a combustion environment with high heat fluxes similar to the RLV Aerospike Ramp. Test measurements were reviewed and found to be valuable for the on-going fluid and thermal analysis of the actual RLV composite ramp. Since the cooling fluid for the heat exchanger is water while the RLV Ramp cooling fluid is LH2, fluid and therma models were constructed to correlate to the specific test set-up. The knowledge gained from this work will be helpful for analyzing the thermal response of the actual RLV Composite Ramp. The coolant thermal properties for the models are taken from test data. The heat exchanger's cooling performance was analyzed using the Generalized Fluid System Simulation Program (GFSSP). Temperatures of the heat exchanger's structure were predicted in finite element models using Patran and Sinda. Results from the analytical models and the tests show that RSC's heat exchanger satisfied the combustion environments in a series of 16 tests.

Nguyen, Dalton↗
NASA NTRS2002

Thermal/Fluid Analysis of a Composite Heat Exchanger for Use on the RLV Rocket Engine

As part of efforts to design a regeneratively cooled composite nozzle ramp for use on the reusable vehicle (RLV) rocket engine, an C-SiC composites heat exchanger concept was proposed for thermal performance evaluation. To test the feasibility of the concept, sample heat exchanger panels were made to fit the Glenn Research Center's cell 22 for testing. Operation of the heat exchanger was demonstrated in a combustion environment with high heat fluxes similar to the RLV Aerospike Ramp. Test measurements were reviewed and found to be valuable for the on going fluid and thermal analysis of the actual RLV composite ramp. Since the cooling fluid for the heat exchanger is water while the RLV Ramp cooling fluid is LH2, fluid and thermal models were constructed to correlate to the specific test set-up. The knowledge gained from this work will be helpful for analyzing the thermal response of the actual RLV Composite Ramp. The coolant thermal properties for the models are taken from test data. The heat exchanger's cooling performance was analyzed using the Generalized Fluid System Simulation Program (GFSSP). Temperatures of the heat exchanger's structure were predicted in finite element models using Patran and Sinda. Results from the analytical models and the tests show that RSC's heat exchanger satisfied the combustion environments in a series of 16 tests.

Nguyen, Dalton↗
NASA NTRSDate not supplied

Modal Propellant Gauging: High-resolution and non-invasive gauging of both settled and unsettled liquids in reduced gravity.

The modal response of a liquid-filled tank to external acoustic excitation can be used to infer with high resolutionthe mass of contained liquid, the mass flow rate of liquids into and out of the tank, and changes in tank pressure.Both contained liquid mass and internal ullage pressure affect the modal response of the tank walls through fluidmass-loading of the tank walls and pressure-induced wall stiffening, respectively. Modal Propellant Gauging refersto the technology that exploits these shifts in modal frequencies to infer the mass of propellant in a tank. MPG is anon-invasive gauging technology that has demonstrated gauging resolutions of 1% for settled propellants and 2-3%for unsettled, sloshing propellants. Extensive parabolic flight testing of the MPG system on model tanks has beenconducted to validate the technology in reduced gravity. MPG testing on a qualification tank for the Orion Program'sEuropean Service Module has also been conducted and is reported here. Finite element modeling of the OrionESM "upper" tank is discussed and compared with measurement data. Three computational approaches to massdetermination, Peak Tracking, Point Sensor, and Spectral Density methods, are described here. Use cases are definedand analyzed in the context of the Orion ESM Qualification tank data, and an implementation scheme for continuousmass gauging on the Orion ESM is discussed.Keywords: Propellant Mass Gauging, Modal Analysis, Orion ESM

Propellant Mass Gauging↗