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DOE OSTI2024

Tardigrade-examples V0.1.0

Tardigrade-examples is a repository of computational workflows that exercise the Tardigrade software package. The Tardigrade software package is an implementation of Eringen’s micromorphic continuum theory with capabilities to support multiscale material modeling. These capabilities include homogenization through the Micromorphic Filter, calibration of micromorphic material models, and macroscale simulation in Tardigrade-MOOSE. This repository investigates continuum upscaling of various direct numerical simulations (DNS) conducted in Abaqus finite element (FE), Ratel FE, and GEOS material point method (MPM) software. Verification of the upscaling workflow is first investigated by considering DNS of trivial stress states for homogeneous materials, results of which indicate that classical continuum behavior is recovered as expected. DNS of heterogeneous materials are then considered.

Allard, Thomas↗

DOE OSTI2013

A 3D Orthotropic Elastic Continuum Damage Material Model

A three dimensional orthotropic elastic constitutive model with continuum damage is implemented for polymer matrix composite lamina. Damage evolves based on a quadratic homogeneous function of thermodynamic forces in the orthotropic planes. A small strain formulation is used to assess damage. In order to account for large deformations, a Kirchhoff material formulation is implemented and coded for numerical simulation in Sandia’s Sierra Finite Element code suite. The theoretical formulation is described in detail. An example of material parameter determination is given and an example is presented.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Parameterization of a Cookoff Model for LX-07

A thermal decomposition model for PBX 9501 (95% HMX, 2.5% Estane® binder, 2.5% BDNPA/F nitro-plasticizer) was implemented by Dickson, et. al. The objective in this study is to estimate parameters associated with this kinetics model so it can be applied to carry out thermal ignition predictions for LX-07 (90% HMX, 10% Viton binder). LX-07 thermal ignition experiments have been carried out using the “Sandia Instrumented Thermal Ignition Apparatus”, SITI. The SITI design consists of solid cylinders (1” diameter × 1” height) of high explosive (HE) confined by a cylindrical aluminum case. An electric heater is wrapped around the outer surface of the case. This heater produces a temperature heating ramp on the outer surface of the case. Internal thermocouples measure the HE temperature rise from the center to locations close to the HE-aluminum interface. The energetic material is heated until thermal ignition occurs. A two–dimensional axisymmetric heat conduction finite element model is used to simulate these experiments. The HE thermal decomposition kinetics is coupled to a heat conduction model trough the definition of an energy source term. The parameters used to define the HE thermal decomposition model are optimized to obtain a good agreement with the experimental time to thermal ignition and temperatures. Also, heat capacity and thermal conductivity of the LX-07 mixture were estimated using temperatures measured at the center of the HE before the solid to solid HMX phase transition occurred.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2017

GeneratorSE: A Sizing Tool for Variable-Speed Wind Turbine Generators

This report documents a set of analytical models employed by the optimization algorithms within the GeneratorSE framework. The initial values and boundary conditions employed for the generation of the various designs and initial estimates for basic design dimensions, masses, and efficiency for the four different models of generators are presented and compared with empirical data collected from previous studies and some existing commercial turbines. These models include designs applicable for variable-speed, high-torque application featuring direct-drive synchronous generators and low-torque application featuring induction generators. In all of the four models presented, the main focus of optimization is electromagnetic design with the exception of permanent-magnet and wire-wound synchronous generators, wherein the structural design is also optimized. Thermal design is accommodated in GeneratorSE as a secondary attribute by limiting the winding current densities to acceptable limits. A preliminary validation of electromagnetic design was carried out by comparing the optimized magnetic loading against those predicted by numerical simulation in FEMM4.2, a finite-element software for analyzing electromagnetic and thermal physics problems for electrical machines. For direct-drive synchronous generators, the analytical models for the structural design are validated by static structural analysis in ANSYS.

17 WIND ENERGY↗

DOE OSTI2018

Center for Extended Magnetohydrodynamic Modeling

The RPI team efforts focused on providing unstructured mesh technologies to the Center for Extended Magnetohydrodynamic Modeling’s efforts on the development of the M3D-C1 plasma physics code. Specific developments included: Providing the parallel unstructured mesh infrastructure used within the M3D-C1 code; Creating a tool for the generation and subsequent adaptation of the unstructured meshes; A set of procedures to be able to initiate an M3D-C1 simulation in 2D and automatically moving the simulation to a full 3D finite element model when 3D modes begin to appear; Developing a set of physics/mesh based diagonal preconditioners; Supporting the installation of M3D-C1 on various super computer systems; Supplementing the mesh generation procedures to support a model wall region to support the application of an advanced resistive wall model; Providing M3D-C1 with tools to support PIC operations on distributed meshes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2019

Vertical Axis Wind Turbine (VAWT) with Thermoplastic Composite Blades

Rising concerns about global climate change, planet pollution and increasing use of energy have accelerated wider utilization of renewable energy sources. A recent trend in energy system development is decentralization of power generation systems. The opportunity for individuals or organizations to generate electricity locally decreases losses and part of the electricity price caused by the long-distance power transmission. Vertical axis wind turbines (VAWTs) cannot compete with traditional horizontal axis wind turbines (HAWTs) on the basis of aerodynamic performance or maximum power output generated for a given footprint. However, their ability to perform at a wide range of wind speeds, indifference to wind direction, simplicity of fabrication, transportability and maintainability make them ideal candidates for decentralized installations in urban and residential areas. The project team including Steelhead Composites (SHC), Colorado State University (CSU), National Renewable Energy Laboratory (NREL) and Arkema Inc. designed and fabricated a VAWT rotor assembly with thermoplastic composite blades using novel infusion and fabrication techniques. This full-scale VAWT rotor assembly was designed for a rated power output of 0.5-1 kW, as estimated through analytical computational fluid dynamics (CFD) methods. Those CFD simulations were combined with structural finite element analysis (FEA) to optimize the shape and composite layup of the wind blades. Much of the emphasis of this program was to characterize the recyclable thermoplastic material and composite structural design, in order to take full advantage of the material properties of such composites. Additionally, this project examined the potential of thermoplastic resin systems to transform the way VAWT rotor assemblies are joined both in the factory in in the field, by utilizing thermally welded joints to minimize field failure. The infused composite blades manufactured during this program are an excellent example of these benefits made possible by the Arkema thermoplastic resin system. This prototype blade manufacturing also provided the groundwork to inform decisions for larger scale manufacturing techniques applicable to a commercialization strategy. There is specific commercial interest for small scale VAWT’s that are competitively priced, perform to expectations, and have environmentally conscious end-of-life characteristics. Economic analysis was also conducted to compare designs and material usage, providing an estimated levelized cost of energy (LCOE) for the VAWT. The next steps for commercialization would include testing of the rotor assembly to verify predicted performance, specification of the balance of plant components (generator, inverter, etc.), and identification of a manufacturing partner with capability to scale-up production. This program has showed the potential for a commercially viable product through detailed analysis, material characterization and prototype fabrication.

17 WIND ENERGY↗

DOE OSTI2021

Failure in Confined Brazilian Tests on Sandstone

Strength of rocks in the confined tension region, where the minimum principal stress is tensile, has only infrequently been measured and is not well understood. Quasi-static confined Brazilian tests under a range of confining stresses (2.76 to 27.58 MPa) where used to determine the strength of sandstone in the confined tension region. The test results indicate that the strength in the confined tension region was a strong function of the intermediate principal stress: increasing the intermediate principal stress significantly increased the strength of the sandstone. The strength data were well fit by the Mogi–Coulomb criterion, which accounts for the intermediate principal stress. Unconfined Brazilian strength data were not well fit to the Mogi–Coulomb criterion derived from the confined Brazilian test data, consistent with a transition from tensile to shear processes dominating failure with increasing confining pressure. Observations of post-failure fracture surfaces reveal more indication of shear processes with increasing confining pressure. Numerical simulations from combined finite-discrete element method are compared to the experimental results and reflect similar conditions for failure compared to the experimental tests in the confined tension region.

42 ENGINEERING↗

NASA NTRS1979

Comparison of NASCAP predictions with experimental data

The NASA charging analyzer program (NASCAP) is a three dimensional, finite element computer code capable of simulating the electrostatic charging of an arbitrary body either in a ground test tank or in the space environment. The code incorporated surface property parameters needed to simulate insulating and conducting materials. These parameters are being updated as required to bring the NASCAP predictions into correspondence with data from ground tests. NASCAP predictions are also being compared with data from the ATS 5 spacecraft. The significance of these results is discussed.

Roche, J. C.↗

NASA NTRS1984

Applications of finite element and wave envelope element approximations to turbofan engine noise radiation including flight effects

The problem of acoustic radiation from turbofan engine inlets in flow has not lent itself fully to analysis by numerical means because of the large domains and high frequencies involved. The current work has extended the use of finite elements and wave envelope elements, elements which simulate decay and wavelike behaviour in their interpolation functions, from the no-flow case in which they have been proven, to cases incorporating mean flow. By employing an irrotational mean flow assumption, the acoustics problem has been posed in an axisymmetric formulation in terms of acoustic velocity potential, thus minimizing computer solution storage requirements. The results obtained from the numerical procedures agree well with known analytical solutions, static experimental jet engines inflow data, and also with flight test results.

Parrett, A. V.↗

NASA NTRS1984

Quasi-static solution algorithms for kinematically/materially nonlinear thermomechanical problems

This paper develops an algorithmic solution strategy which allows the handling of positive/indefinite stiffness characteristics associated with the pre- and post-buckling of structures subject to complex thermomechanical loading fields. The flexibility of the procedure is such that it can be applied to both finite difference and element-type simulations. Due to the generality of the algorithmic approach developed, both kinematic and thermal/mechanical type material nonlinearity including inelastic effects can be treated. This includes the possibility of handling completely general thermomechanical boundary conditions. To demonstrate the scheme, the results of several benchmark problems is presented.

Padovan, J.↗

NASA NTRS1988

Composite transport wing technology development

The design, fabrication, testing, and analysis of stiffened wing cover panels to assess damage tolerance criteria are discussed. The damage tolerance improvements were demonstrated in a test program using full-sized cover panel subcomponents. The panels utilized a hard skin concept with identical laminates of 44-percent 0-degree, 44-percent plus or minus 45-degree, and 12-percent 90-degree plies in the skins and stiffeners. The panel skins were impacted at midbay between the stiffeners, directly over the stiffener, and over the stiffener flange edge. The stiffener blades were impacted laterally. Impact energy levels of 100 ft-lb and 200 ft-lb were used. NASTRAN finite-element analyses were performed to simulate the nonvisible damage that was detected in the panels by nondestructive inspection. A closed-form solution for generalized loading was developed to evaluate the peel stresses in the bonded structure. Two-dimensional delamination growth analysis was developed using the principle of minimum potential energy in terms of closed-form solution for critical strain. An analysis was conducted to determine the residual compressive stress in the panels after impact damage, and the analytical predictions were verified by compression testing of the damaged panels.

Madan, Ram C.↗

NASA NTRS1988

Elevated temperature crack growth

A study was performed to examine the applicability of path-independent (P-I) integrals to crack growth problems in hot section components of gas turbine aircraft engines. Alloy 718 was used and the experimental parameters included combined temperature and strain cycling, thermal gradients, elastic-plastic strain levels, and mean strains. A literature review was conducted of proposed P-I integrals, and those capable of analyzing hot section component problems were selected and programmed into the postprocessor of a finite element code. Detailed elastic-plastic finite element analyses were conducted to simulate crack growth and crack closure of the test specimen, and to evaluate the P-I integrals. It was shown that the selected P-I integrals are very effective for predicting crack growth for isothermal conditions.

Kim, K. S.↗

NASA NTRS1990

Practical model reduction for flexible structures

The most accepted methods for developing models of flexible structures for the analysis, design and simulation of control systems are finite element methods and extraction from experimental data. Using either of these methods, models are often produced with modes that do not significantly add to the fidelity of the model. This paper presents techniques for eliminating these modes. Particular attention is paid to multiple-input, multiple-output systems. First, control system models developed for flexible structures, using finite element methods and experimental data, are briefly discussed. the shortcomings of using models with unnecessary and/or residual modes are delineated. Then, two techniques for reducing the order of models are presented; the first is applicable to single-input, single-output systems and the second for multiple-input, multiple-output systems. Finally, both are illustrated using model data from the proposed NASA Shuttle-C.

Mitchell, Jerrel R.↗

NASA NTRS1991

Interaction of the sea breeze with a river breeze in an area of complex coastal heating

The interaction of the sea-breeze circulation with a river-breeze circulation in an area of complex coastal heating (east coast of Florida) was studied using a 3D finite-element mesoscale model. The model simulations are compared with temperature and wind fields observed on a typical fall day during the Kennedy Space Center Atmospheric Boundary Layer Experiment. The results from numerical experiments designed to isolate the effect of the river breeze indicate that the convergence in the sea-breeze front is suppressed when it passes over the cooler surface of the rivers.

Zhong, Shiyuan↗

NASA NTRS1992

Fiber shape effects on metal matrix composite behavior

The effects of different fiber shapes on the behavior of a SiC/Ti-15 metal matrix composite is computationally simulated. A three-dimensional finite element model consisting of a group of nine unidirectional fibers is used in the analysis. The model is employed to represent five different fiber shapes: a circle, an ellipse, a kidney, and two different cross shapes. The distribution of microstresses and the composite material properties, such as moduli, coefficients of thermal expansion, and Poisson's ratios, are obtained from the finite element analysis for the various fiber shapes. Comparisons of these results are used to determine the sensitivity of the composite behavior to the different fiber shapes and assess their potential benefits. No clear benefits result from different fiber shapes though there are some increases/decreases in isolated properties.

Brown, H. C.↗

NASA NTRS1992

Fiber shape effects on metal matrix composite behavior

The effects of different fiber shapes on the behavior of metal matrix composites is computationally simulated. A three-dimensional finite element model consisting of a group of nine unidirectional fibers in a three by three unit cell array of a SiC/Ti-15-3 metal matrix composite is used in the analysis. The model is employed to represent five fiber shapes that include a circle, an ellipse, a kidney, and two different cross shapes. The distribution of stresses and the composite material properties, such as moduli, coefficients of thermal expansion, and Poisson's ratios, are obtained from the finite element analysis using the various fiber shapes. Comparisons of these results are used to determine the sensitivity of the composite behavior to the different fiber shapes. In general, fiber dominated properties are not affected by fiber geometry and matrix dominated properties are only moderately affected.

Brown, H. C.↗

NASA NTRS1993

State of stress, faulting, and eruption characteristics of large volcanoes on Mars

The formation of a large volcano loads the underlying lithospheric plate and can lead to lithospheric flexure and faulting. In turn, lithospheric stresses affect the stress field beneath and within the volcanic edifice and can influence magma transport. Modeling the interaction of these processes is crucial to an understanding of the history of eruption characteristics and tectonic deformation of large volcanoes. We develop models of time-dependent stress and deformation of the Tharsis volcanoes on Mars. A finite element code is used that simulates viscoelastic flow in the mantle and elastic plate flexural behavior. We calculate stresses and displacements due to a volcano-shaped load emplaced on an elastic plate. Models variously incorporate growth of the volcanic load with time and a detachment between volcano and lithosphere. The models illustrate the manner in which time-dependent stresses induced by lithospheric plate flexure beneath the volcanic load may affect eruption histories, and the derived stress fields can be related to tectonic features on and surrounding martian volcanoes.

Mcgovern, Patrick J.↗

NASA NTRS1995

Three-dimensional CTOA and constraint effects during stable tearing in a thin-sheet material

A small strain theory, three-dimensional elastic-plastic finite element analysis was used to simulate fracture in thin sheet 2024-T3 aluminum alloy in the T-L orientation. Both straight and tunneled cracks were modeled. The tunneled crack front shapes as a function of applied stress were obtained from the fracture surface of tested specimens. The stable crack growth behavior was measured at the specimen surface as a function of applied stress. The fracture simulation modeled the crack tunneling and extension as a function of applied stress. The results indicated that the global constraint factor, alpha(sub g), initially dropped during stable crack growth. After peak applied stress was achieved, alpha(sub g) began to increase slightly. The effect of crack front shape on alpha(sub g) was small, but the crack front shape did greatly influence the local constraint and through-thickness crack-tip opening angle (CTOA) behavior. The surface values of CTOA for the tunneled crack front model agreed well with experimental measurements, showing the same initial decrease from high values during the initial 3mm of crack growth at the specimen's surface. At the same time, the interior CTOA values increased from low angles. After the initial stable tearing region, the CTOA was constant through the thickness. The three-dimensional analysis appears to confirm the potential of CTOA as a two-dimensional fracture criterion.

Dawicke, D. S.↗