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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 163 records · Page 9

Benchmarking Bayesian Optimization Frameworks and Acquisition Strategies for Materials Discovery and Autonomous Laboratories

Bayesian optimization (BO) can accelerate materials discovery by guiding expensive experiments toward the most promising processing conditions. We systematically compare five BO surrogate and framework combinations (Gaussian processes in Ax, Gaussian processes and Monte-Carlo neural networks in BayBE, random forests in Lolopy, and tree-structured Parzen (TPE) estimators in Hyperopt) on three benchmarks that mimic common materials design tasks (a discrete solid-electrolyte composition space, a hybrid discrete/continuous laminate-composite design problem solved with micromechanics modeling, and the continuous Ishigami analytic function which is a standard optimization benchmark). Each BO surrogate is paired with posterior mean, probability of improvement, and expected improvement acquisition functions and run for 100 trials from randomized initial samples with uniform random search providing a control. Across five random seeds per setting, BayBE’s Gaussian-process surrogate with expected improvement consistently reached ≥95 % of the known optimum in the fewest evaluations, while Lolopy’s random forest matched or exceeded GP performance on purely categorical or mixed spaces at a higher computational cost. Posterior mean alone often stagnated at local optima, underscoring the need for exploration, whereas probability and expected improvement balanced exploration and exploitation leading to better optimization in fewer trials. Execution times ranged from milliseconds for TPE to minutes for neural-network and random-forest surrogates. These results establish baseline expectations for BO in automated materials laboratories and highlight expected improvement with Gaussian processes as a reliable first choice, with random forests offering a strong alternative when categorical variables dominate. The benchmark suite and code are released to facilitate future surrogate, acquisition, and constraint-handling research in data-driven materials optimization.

Bayesian optimization↗

Predicting Tensile Strengths of Boron/Aluminum Composites

To develop predictive theory to account for time/temperature effect of B/A1 composites, series of deformation and fracture studies was performed on commercial boron fibers over wide ranges of stress, stress application time, and temperature. By combining these single fiber results with fracture theory for metal matrix composites, design formulas were derived that describe B/A1 composite tensile and stress rupture strengths as function of time and temperature. Using derived formulas, calculated and experimental results agree to within 3 percent.

Decarlo, J. A.↗

Optimal design of a composite structure

This paper presents a design methodology for a laminated composite stiffened panel, subjected to multiple in-plane loads and bending moments. Design variables include the skin and stiffener ply orientation angles and stiffener geometry variables. Optimum designs are sought which minimize structural weight and satisfy mechanical performance requirements. Two types of mechanical performance requirements are placed on the panel, maximum strain and minimum strength. Minimum weight designs are presented which document that the choice of mechanical performance requirements cause changes in the optimum design. The effects of lay-up constraints which limit the ply angles to user specified values, such as symmetric or quasi-isotropic laminates, are also investigated.

Graesser, D. L.↗

Design of a composite wing extension for a general aviation aircraft

A composite wing extension was designed for a typical general aviation aircraft to improve lift curve slope, dihedral effect, and lift to drag ratio. Advanced composite materials were used in the design to evaluate their use as primary structural components in general aviation aircraft. Extensive wind tunnel tests were used to evaluate six extension shapes. The extension shape chosen as the best choice was 28 inches long with a total area of 17 square feet. Subsequent flight tests showed the wing extension's predicted aerodynamic improvements to be correct. The structural design of the wing extension consisted of a hybrid laminate carbon core with outer layers of Kevlar - layed up over a foam interior which acted as an internal support. The laminate skin of the wing extension was designed from strength requirements, and the foam core was included to prevent buckling. A joint lap was recommended to attach the wing extension to the main wing structure.

Adney, P. S.↗

Design of Fiber Composites for Structural Durability

Hygrothermomechanical effects analyzed by computers. Computational methodology developed and available at NASA Lewis Research Center to design and analyze fiber-composite structures subjected to complex hygrothermomechanical environments. Includes composite mechanics and advanced finited-element structural-analysis methods. Methodology applied to such problems as progressive fracture of composite material, design of composite material for cycle fatigue combined with hot and wet conditions, and general composite-laminate configurations.

Chamis, Christos C.↗

International SAMPE Symposium and Exhibition, 37th, Anaheim, CA, Mar. 9-12, 1992, Proceedings

The present conference discusses the industrial and transportation markets for advanced composites, novel NASA and military applications of advanced materials, composite space structures, sandwich structures, composite tooling and processing, advanced epoxy compositions, composites repair, commercial applications of advanced resins, metal-matrix composites, adhesive compositions, ultrahigh-temperature composites, failure analyses, testing methods for composites, and bismaleimides and polyimides. Also discussed are composite structures design, innovations in composite reinforcement, nonautoclave-processed composites, molecular composites, design and manufacture processes with thermoplastics, automation in manufacturing, technologies for large component fabrication, damage-limitation design practices, thermoplastic-matrix composites, industrial applications of composites, and process controls in composites manufacturing.

Grimes, Glenn C.↗

Options, Initial Design Requirements, Estimated Costs, Reactor Commitments, and Potential Uses of a Graphite Leadout Type Experiment Supporting Various Commercial HTR Vendors

Multiple commercial High Temperature Reactor (HTR) vendors and nuclear graphite suppliers would benefit by collaborating on a new irradiation capsule(s) that would include graphite grades not included within the AGC Experiment. This new irradiation capsule(s) would provide data to answer vendor graphite licensing issues. Rather than spending money (and especially) time in designing separate irradiation capsules for each designer, the capsule(s) would be used for multiple graphite and composite designs to maximize efficiency and promote multiple HTR designs. However, the primary motivation for assisting vendors with this new irradiation capsule(s) is lack of availability in the existing Material Test Reactors (MTRs). Cost reduction is a secondary goal. A common, collaborative, capsule design can be achieved for graphite and composites due to the similarity of different grades. Irradiation, disassembly, shipping, and PIE costs would be cost-shared by all users. It is anticipated that interest would extend across all DOE campaigns (micro-Rx, SMR, GCR, MSR, etc.) due to the similar requirements for all graphite grades.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A highly wear resistant nanostructured bainitic steel with accelerated transformation kinetics

A coupled Calculation of Phase Diagrams (CALPHAD), machine learning, and data mining approach was used to design a new, highly wear-resistant nanostructured bainitic steel. Arc melting of the designed compositions, dilatometry, and advanced microscopy indicate that the designed steel had a nanoscale dual-phase structure of ferrite and austenite (approximately 50 nm) with kinetics 7x faster for the onset of bainite and 2x faster for complete transformation. Under dry sliding conditions using the current state-of-the-art AISI 52100 bearing steel as the counter sample, the designed steel little to no wear, indicating its potential for applications in high-wear service conditions.

36 MATERIALS SCIENCE↗

Finite element analysis of a composite wheelchair wheel design

The finite element analysis of a composite wheelchair wheel design is presented. The design is the result of a technology utilization request. The designer's intent is to soften the riding feeling by incorporating a mechanism attaching the wheel rim to the spokes that would allow considerable deflection upon compressive loads. A finite element analysis was conducted to verify proper structural function. Displacement and stress results are presented and conclusions are provided.

Ortega, Rene↗

Application of Composite Mechanics to Composites Enhanced Concrete Structures

A new and effective method is described to design composites to repair damage or enhance the overload strength of concrete infrastructures. The method is based on composite mechanics which is available in computer codes. It is used to simulate structural sections made from reinforced concrete which are typical in infrastructure as well as select reinforced concrete structures. The structural sections are represented by a number of layers through the thickness where different layers are used in concrete, and for the composite. The reinforced concrete structures are represented with finite elements where the element stiffness parameters are from the structural sections which are represented by composite mechanics. The load carrying capability of the structure is determined by progressive structural fracture. Results show up to 40 percent improvements for damage and for overload enhancement with relatively small laminate thickness for the structural sections and up to three times for the composite enhanced select structures (arches and domes).

Chamis, Christos C.↗

Mechanical Characterization of Stacked Single-Crystal of Polyethylene and Monolayer MoSe 2

Polymer single crystal (SC) is a key building block of semicrystalline polymers. However, direct experimental measurement of freestanding mono-lamella polymer SC has not been demonstrated. This is, in large part, due to the difficulties associated with manipulating freestanding individual mono-lamella SC because of its extremely low rigidity and low robustness. Here, we demonstrate a new strategy to successfully suspend and test a polymer SC by using a 2D material as backing. In particular, mono-lamella polyethylene (PE) SC is stacked on monolayer MoSe 2 , and the hybrid stacks can be suspended over microholes. Nanoindentation is used to probe the suspended PE-SC/MoSe2 stacks and MoSe 2 monolayers. The results suggest the first experimentally-measured in-plane moduli of PE-SC and 2D MoSe 2 as 32 ± 3 and 237 ± 15 GPa, respectively. Such a stacked unit represents an ultrathin structure of polymer-ceramic laminate and the idea can be applied to other laminated composite systems. Therefore, this research will pave the way to accurately measure the mechanical properties of polymer SCs and their composites, as well as provide a key insight on designing composite structures.

36 MATERIALS SCIENCE↗

Computational simulation methods for composite fracture mechanics

Structural integrity, durability, and damage tolerance of advanced composites are assessed by studying damage initiation at various scales (micro, macro, and global) and accumulation and growth leading to global failure, quantitatively and qualitatively. In addition, various fracture toughness parameters associated with a typical damage and its growth must be determined. Computational structural analysis codes to aid the composite design engineer in performing these tasks were developed. CODSTRAN (COmposite Durability STRuctural ANalysis) is used to qualitatively and quantitatively assess the progressive damage occurring in composite structures due to mechanical and environmental loads. Next, methods are covered that are currently being developed and used at Lewis to predict interlaminar fracture toughness and related parameters of fiber composites given a prescribed damage. The general purpose finite element code MSC/NASTRAN was used to simulate the interlaminar fracture and the associated individual as well as mixed-mode strain energy release rates in fiber composites.

Murthy, Pappu L. N.↗

Response Surface Model Building and Multidisciplinary Optimization Using D-Optimal Designs

This paper discusses response surface methods for approximation model building and multidisciplinary design optimization. The response surface methods discussed are central composite designs, Bayesian methods and D-optimal designs. An over-determined D-optimal design is applied to a configuration design and optimization study of a wing-body, launch vehicle. Results suggest that over determined D-optimal designs may provide an efficient approach for approximation model building and for multidisciplinary design optimization.

Unal, Resit↗

Low Conductivity Thermal Barrier Coatings

Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future engine higher fuel efficiency and lower emission goals. In this presentation, thermal barrier coating development considerations and requirements will be discussed. An experimental approach is established to monitor in real time the thermal conductivity of the coating systems subjected to high-heat-flux, steady-state and cyclic temperature gradients. Advanced low conductivity thermal barrier coatings have also been developed using a multi-component defect clustering approach, and shown to have improved thermal stability. The durability and erosion resistance of low conductivity thermal barrier coatings have been improved utilizing advanced coating architecture design, composition optimization, in conjunction with more sophisticated modeling and design tools.

Zhu, Dong-Ming↗

Cost studies for commercial fuselage crown designs

Studies were conducted to evaluate the cost and weight potential of advanced composite design concepts in the crown region of a commercial transport. Two designs from each of three design families were developed using an integrated design-build team. A range of design concepts and manufacturing processes were included to allow isolation and comparison of cost centers. Detailed manufacturing/assembly plans were developed as the basis for cost estimates. Each of the six designs was found to have advantages over the 1995 aluminum benchmark in cost and weight trade studies. Large quadrant panels and cobonded frames were found to save significant assembly labor costs. Comparisons of high- and intermediate-performance fiber systems were made for skin and stringer applications. Advanced tow placement was found to be an efficient process for skin lay up. Further analysis revealed attractive processes for stringers and frames. Optimized designs were informally developed for each design family, combining the most attractive concepts and processes within that family. A single optimized design was selected as the most promising, and the potential for further optimization was estimated. Technical issues and barriers were identified.

Walker, T. H.↗

Three-Dimensional High Fidelity Progressive Failure Damage Modeling of NCF Composites

Performance prediction of off-axis laminates is of significant interest in designing composite structures for energy absorption. Phenomenological models available in most of the commercial programs, where the fiber and resin properties are smeared, are very efficient for large scale structural analysis, but lack the ability to model the complex nonlinear behavior of the resin and fail to capture the complex load transfer mechanisms between the fiber and the resin matrix. On the other hand, high fidelity mesoscale models, where the fiber tows and matrix regions are explicitly modeled, have the ability to account for the complex behavior in each of the constituents of the composite. However, creating a finite element model of a larger scale composite component could be very time consuming and computationally very expensive. In the present study, a three-dimensional mesoscale model of non-crimp composite laminates was developed for various laminate schemes. The resin material was modeled as an elastic-plastic material with nonlinear hardening. The fiber tows were modeled with an orthotropic material model with brittle failure. In parallel, new stress based failure criteria combined with several damage evolution laws for matrix stresses were proposed for a phenomenological model. The results from both the mesoscale and phenomenological models were compared with the experiments for a variety of off-axis laminates.

Aitharaju, Venkat↗

Optimal toolpath design of additive manufactured composite cylindrical structures

Structural design optimization for additive manufacturing is primarily focused on planar layer-by-layer processes and design of composite cylindrical structures does not often accommodate manufacturing constraints. In this study, we propose to optimize the toolpath trajectory of additively manufactured composite cylinders comprised of multiple thin cylindrical annuli. Additionally, our printing process is based on direct ink writing in which short carbon fibers in a thermoset resin are extruded through a moving nozzle to build up a structure. Since the fibers are primarily aligned in the flow direction of the extrudate, the printing trajectory influences the material properties of the composite structure. To accommodate this, we define the toolpaths as contours of parameterized level-set functions. This parameterization allows us to optimize the material properties and impose manufacturing constraints such as no-overlap, no-sag, minimum radius of curvature, and continuity of the toolpaths. Several examples illustrate the optimization procedure.

42 ENGINEERING↗

Design considerations for composite fuselage structure of commercial transport aircraft

The structural, manufacturing, and service and environmental considerations that could impact the design of composite fuselage structure for commercial transport aircraft application were explored. The severity of these considerations was assessed and the principal design drivers delineated. Technical issues and potential problem areas which must be resolved before sufficient confidence is established to commit to composite materials were defined. The key issues considered are: definition of composite fuselage design specifications, damage tolerance, and crashworthiness.

Davis, G. W.↗