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DOE OSTI2013

Axisymmetric Simulations of the ITER Vertical Stability Coil

The ITER in-vessel coil system includes Vertical Stability (VS) coils and Edge Localized Mode (ELM) coils. There are two large VS ring coils, one upper and one lower. Each has four turns which are independently connected. The VS coils are needed for successful operation of ITER for most all of its operating modes. The VS coils must be highly reliable and fault tolerant. The operating environment includes normal and disruption Lorentz forces. To parametrically address all these design conditions in a tractable analysis requires a simplified model. The VS coils are predominately axisymmetric, and this suggests that an axisymmetric model can be meaningfully used to address the variations in mechanical design, loading, material properties, and time dependency. The axisymmetric finite element analysis described in this paper includes simulations of the bolted frictional connections used for the mounting details. Radiation and elastic-plastic response are modeled particularly for the extreme faulted conditions. Thermal connectivity is varied to study the effects of partial thermal connection of the actively cooled conductor to the remaining structure.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS2017

Development of a Continuum Damage Mechanics Material Model of a Graphite-Kevlar(Registered Trademark) Hybrid Fabric for Simulating the Impact Response of Energy Absorbing Kevlar(Registered Trademark) Hybrid Fabric for Simulating the Impact Response of Energy Absorbing

This paper describes the development of input properties for a continuum damage mechanics based material model, Mat 58, within LS-DYNA(Registered Trademark) to simulate the response of a graphite-Kevlar(Registered Trademark) hybrid plain weave fabric. A limited set of material characterization tests were performed on the hybrid graphite-Kevlar(Registered Trademark) fabric. Simple finite element models were executed in LS-DYNA(Registered Trademark) to simulate the material characterization tests and to verify the Mat 58 material model. Once verified, the Mat 58 model was used in finite element models of two composite energy absorbers: a conical-shaped design, designated the "conusoid," fabricated of four layers of hybrid graphite-Kevlar(Registered Trademark) fabric; and, a sinusoidal-shaped foam sandwich design, designated the "sinusoid," fabricated of the same hybrid fabric face sheets with a foam core. Dynamic crush tests were performed on components of the two energy absorbers, which were designed to limit average vertical accelerations to 25- to 40-g, to minimize peak crush loads, and to generate relatively long crush stroke values under dynamic loading conditions. Finite element models of the two energy absorbers utilized the Mat 58 model that had been verified through material characterization testing. Excellent predictions of the dynamic crushing response were obtained.

Jackson, Karen E.↗

NASA NTRS1985

Bridgman growth of semiconductors

The purpose of this study was to improve the understanding of the transport phenomena which occurs in the directional solidification of alloy semiconductors. In particular, emphasis was placed on the strong role of convection in the melt. Analytical solutions were not deemed possible for such an involved problem. Accordingly, a numerical model of the process was developed which simulated the transport. This translates into solving the partial differential equations of energy, mass, species, and momentum transfer subject to various boundary and initial conditions. A finite element method with simple elements was initially chosen. This simulation tool will enable the crystal grower to systematically identify and modify the important design factors within her control to produce better crystals.

Carlson, F. M.↗

NASA NTRS2017

Non-Linear Analysis of the NASA Super Pressure Balloons: Whole Flight Simulations

Tensys have a long-established background in the shape generation and load analysis of architectural stressed membrane structures. Founded upon their inTENS finite element analysis suite, these activities have broadened to encompass 'lighter than air' structures such as aerostats, airships, hybrid air vehicles and stratospheric balloons. Tensys have acted as consultants to the NASA Super Pressure Balloon (SPB) Program since 2004. Previous papers have focussed upon the application of inTENS to the overall structural and stability analysis of pumpkin type balloons as used in the SPB Program. Particular emphasis has been placed upon the ability to study both stress and stability at all stages of a flight. As the program has developed, increasing modelling fidelity has been introduced as design refinement has moved emphasis from the overall shape to the performance of individual details. Examples include the introduction of a contact capability into inTENS to better represent the separate cap layer of film. Localised investigations have considered the consequence of local geometric anomalies introduced during fabrication and the effects of debonding of the PBO tendon within its sleeve. Analysis to date has used a material model for the polyethylene shell film developed by Dr Rand of Winzen Engineering, supported by a program of fine resolution material tests at the Balloon Research and Development Laboratory (BRDL) at the GSFC Wallops Island Facility. Based upon work first reported by Schapery, this model has been incorporated into so-called 'snapshot' analyses within inTENS. For a given elapsed time point and temperature distribution, non-linear material properties are iteratively updated for the current stress state in each individual element until changes in those material properties are insignificant. This process has to be iterative as the film stresses and material properties are interdependent. Attempts to derive a time-stepping incremental viscoelastic capability using the Schapery Rand model encountered problems when dealing with the varying temperatures associated with balloon deployment, pressurisation and diurnal behaviour. An alternative approach has been developed by Pellegrino et al at Caltech, again with support from the NASA Balloon Program Office. This is a large strain non-linear viscoelastic model that includes film out-of-plane mechanical and thermal effects. Working from a unified base, this model can be utilised for time-stepping analyses in both a modulus or compliance mode, or a combination of both. This new capability is intended to enhance the current NASA balloon design process. This paper presents the implementation of the Caltech model into a specialist finite element suite, inTENS and its application to whole flight simulations.

Wakefield, David↗

NASA NTRS2006

Bearing-Load Modeling and Analysis Study for Mechanically Connected Structures

Bearing-load response for a pin-loaded hole is studied within the context of two-dimensional finite element analyses. Pin-loaded-hole configurations are representative of mechanically connected structures, such as a stiffener fastened to a rib of an isogrid panel, that are idealized as part of a larger structural component. Within this context, the larger structural component may be idealized as a two-dimensional shell finite element model to identify load paths and high stress regions. Finite element modeling and analysis aspects of a pin-loaded hole are considered in the present paper including the use of linear and nonlinear springs to simulate the pin-bearing contact condition. Simulating pin-connected structures within a two-dimensional finite element analysis model using nonlinear spring or gap elements provides an effective way for accurate prediction of the local effective stress state and peak forces.

Knight, Norman F., Jr.↗

DOE OSTI2014

Geometry optimization for micro-pressure sensor considering dynamic interference

Presented is the geometry optimization for piezoresistive absolute micro-pressure sensor. A figure of merit called the performance factor (PF) is defined as a quantitative index to describe the comprehensive performances of a sensor including sensitivity, resonant frequency, and acceleration interference. Three geometries are proposed through introducing islands and sensitive beams into typical flat diaphragm. The stress distributions of sensitive elements are analyzed by finite element method. Multivariate fittings based on ANSYS simulation results are performed to establish the equations about surface stress, deflection, and resonant frequency. Optimization by MATLAB is carried out to determine the dimensions of the geometries. Convex corner undercutting is evaluated. Each PF of the three geometries with the determined dimensions is calculated and compared. Silicon bulk micromachining is utilized to fabricate the prototypes of the sensors. The outputs of the sensors under both static and dynamic conditions are tested. Experimental results demonstrate the rationality of the defined performance factor and reveal that the geometry with quad islands presents the highest PF of 210.947 Hz{sup 1/4}. The favorable overall performances enable the sensor more suitable for altimetry.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

3D modeling of deep borehole electromagnetic measurements with energized casing source for fracture mapping at the Utah Frontier Observatory for Research in Geothermal Energy

Here, we present a 3D numerical modelling analysis evaluating the deployment of a borehole electromagnetic measurement tool to detect and image a stimulated zone at the Utah Frontier Observatory for Research in Geothermal Energy geothermal site. As the depth to the geothermal reservoir is several kilometres and the size of the stimulated zone is limited to several 100 m, surface-based controlled-source electromagnetic measurements lack the sensitivity for detecting changes in electrical resistivity caused by the stimulation. To overcome the limitation, the study evaluates the feasibility of using a three-component borehole magnetic receiver system at the Frontier Observatory for Research in Geothermal Energy site. To provide sufficient currents inside and around the enhanced geothermal reservoir, we use an injection well as an energized casing source. To efficiently simulate energizing the injection well in a realistic 3D resistivity model, we introduce a novel modelling workflow that leverages the strengths of both 3D cylindrical-mesh-based electromagnetic modelling code and 3D tetrahedral-mesh-based electromagnetic modelling code. The former is particularly well-suited for modelling hollow cylindrical objects like casings, whereas the latter excels at representing more complex 3D geological structures. In this workflow, our initial step involves computing current densities along a vertical steel-cased well using a 3D cylindrical electromagnetic modelling code. Subsequently, we distribute a series of equivalent current sources along the well's trajectory within a complex 3D resistivity model. We then discretize this model using a tetrahedral mesh and simulate the borehole electromagnetic responses excited by the casing source using a 3D finite-element electromagnetic code. This multi-step approach enables us to simulate 3D casing source electromagnetic responses within a complex 3D resistivity model, without the need for explicit discretization of the well using an excessive number of fine cells. We discuss the applicability and limitations of this proposed workflow within an electromagnetic modelling scenario where an energized well is deviated, such as at the Frontier Observatory for Research in Geothermal Energy site. Using the workflow, we demonstrate that the combined use of the energized casing source and the borehole electromagnetic receiver system offer measurable magnetic field amplitudes and sensitivity to the deep localized stimulated zone. The measurements can also distinguish between parallel-fracture anisotropic reservoirs and isotropic cases, providing valuable insights into the fracture system of the stimulated zone. Besides the magnetic field measurements, vertical electric field measurements in the open well sections are also highly sensitive to the stimulated zone and can be used as additional data for detecting and imaging the target. We can also acquire additional multiple-source data by grounding the surface electrode at various locations and repeating borehole electromagnetic measurements. This approach can increase the number of monitoring data by several factors, providing a more comprehensive dataset for analysing the deep-localized stimulated zone. The numerical analysis indicates that it is feasible to use the combination of the energized casing and downhole electromagnetic measurements in monitoring localized stimulated zone at large depths.

58 GEOSCIENCES↗

NASA NTRS1989

Towards real-time simulation of large space structures: Stabilization of fluid/thermal/structure interactions and implementation on high performance supercomputers

Within the Center for Space Construction, the SIMSTRUC project's objectives center around the development of simulation tools for the realistic analysis of large space structures. The word 'tools' is the broad sense; it designates mathematical models, finite element/finite difference formulations, computational algorithms, implementations on advanced computer architectures, and visualization capabilities. The results of our activities during the first year within the SIMSTRUC project are reported. On the modeling side, an alternative approach to fluid/thermal/structure interaction analysis that is a departure from the 'loosely coupled' and 'unified' approaches that are being currently practiced are described. The advantages of our approach both in terms of accuracy and computational efficiency were demonstrated. On the computational side, a software architecture for parallel/vector and massively parallel supercomputers that speeds up finite element and finite difference computations by several orders of magnitude is presented. As an example, the simulation of the deployment of a space structure that used to require over six hours of a workstation using a conventional finite element software, now runs on a multiprocessor using a parallel computation strategy in less than three seconds. In order to promote the physical understanding of the simulation behavior, a real-time visualization capability on the Connection Machine, which allows the analyst to watch the graphical animation of the results at the same time these are generated, was also developed. It is believed that by combining efficient analytical formulations with the state-of-the-art high performance computer implementations and superfast visualization capabilities, SIMSTRUC is moving fast towards the real-time simulation of large space structures. The designers as well as the researchers will certainly benefit from this technology.

Farhat, C.↗

DOE OSTI2015

SU-F-207-05: Excess Heat Corrections in a Prototype Calorimeter for Direct Realization of CT Absorbed Dose to Phantom

Purpose: To reconcile air kerma and calorimetry measurements in a prototype calorimeter for obtaining absorbed dose in diagnostic CT beams. While corrections for thermal artifacts are routine and generally small in calorimetry of radiotherapy beams, large differences in relative stopping powers of calorimeter materials at the lower energies typical of CT beams greatly magnify their effects. Work-to-date on the problem attempts to reconcile laboratory measurements with modeling output from Monte Carlo and finite-element analysis of heat transfer. Methods: Small thermistor beads were embedded in a polystyrene (PS) core element of 1 cm diameter, which was inserted into a cylindrical HDPE phantom of 30 cm diameter and subjected to radiation in a diagnostic CT x-ray imaging system. Resistance changes in the thermistors due to radiation heating were monitored via lock-in amplifier. Multiple 3-second exposures were recorded at 8 different dose-rates from the CT system, and least-squares fits to experimental data were compared to an expected thermal response obtained by finite-element analysis incorporating source terms based on semi-empirical modeling and Monte Carlo simulation. Results: Experimental waveforms exhibited large thermal artifacts with fast time constants, associated with excess heat in wires and glass, and smaller steps attributable to radiation heating of the core material. Preliminary finite-element analysis follows the transient component of the signal qualitatively, but predicts a slower decay of temperature spikes. This was supplemented by non-linear least-squares fits incorporating semi-empirical formulae for heat transfer, which were used to obtain dose-to-PS in reasonable agreement with the output of Monte Carlo calculations that converts air kerma to absorbed dose. Conclusion: Discrepancies between the finite-element analysis and our experimental data testify to the very significant heat transfer correction required for absorbed dose calorimetry of diagnostic CT beams. The results obtained here are being used to refine both simulations and design of calorimeter core components.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2014

Simulating the spectral response of quantum dot-in-well infrared photodetectors from eight band k.p method

Conduction band energy levels in quantum-dot-in-a-well structures are computed by eight band k.p method (Burt-Foreman Hamiltonian) using finite element software. Optical absorption spectrum due to intersubband transitions is simulated using Fermi golden rule. The use of contact pair boundary condition in strain calculation and criteria for choosing band mixing parameter (E{sub p}) to avoid the spurious solutions are examined in this paper. The simulated intersubband optical absorption spectrum of different structures reported in the literature is in close agreement with the experimentally measured photoconductive absorption region and shows that the method can be used as an effective modeling for quick design of the heterostructures based infrared photodetectors for various wavelengths.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2016

Thermo mechanical analysis of fully ceramic microencapsulated fuel during in-pile operation

A proposed fuel for improved performance in LWRs (Light Water Reactors) is FCM (fully encapsulated micro-ceramic) fuel concept that involves TRISO (Tri-structural-Isotropic) fuel particles embedded in a NITE (Nano Infiltrated Eutectic) silicon carbide matrix. TRISO fuel particles contain a spherical fuel kernel that will likely range from about 500 to in excess of 800 μm in diameter. The kernel and buffer layer are then typically coated with 3 isotropic layers consisting of a dense inner pyrolytic carbon (IPyC), a silicon carbide (SiC) layer, and an outer layer of dense, pyrolytic carbon (OPyC). These layers are typically around 40 μm thick, but can range from 20 to 60 μm. The TRISO particle packing fraction in the NITE-SiC matrix is expected to be 40-45 vol.%. The release of radioactivity into the coolant is dependent on the integrity of the silicon carbide layer of the TRISO particles and the NITE-SiC matrix. BISON, a code under development by Idaho National Laboratory, has been built on the Multi-physics Object Oriented Simulation Environment (MOOSE). MOOSE is a massively parallel, finite element computational system that uses a Jacobian-free, Newton-Krylov (JFNK) method to solve coupled systems and non-linear partial differential equations. A single particle comparison to fuel performance codes such as PARFUME was conducted and demonstrated that BISON is able to simulate the required physics. FCM pellets embedded with homogenous particles were simulated. It was found that the interior matrix temperature was predicted to be considerably lower than for an equivalent UO{sub 2} pellet. The swelling dependence on temperature created a compressive region around the perimeter of the pellet. However, at fluences above 6.10{sup 25} neutrons/m{sup 2}, the swelling of the pyrolytic carbon might cause significant tensile stresses and possible cracks near the surface of the pellet. This suggests that the pyrolytic carbon swelling may be an important factor in the lifetime of this fuel type.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1991

Simulation of the Space Station strut-out condition

A method is presented for reanalyzing a truss structure when one of the truss elements (struts) has failed. The method uses a modal model of the nominal structure coupled with a residual flexibility term to predict the effect of the failed strut without resolving the finite element model. By implementing the method as part of the transient simulation, it is feasible to consider a large number of potential strut failures with a minimum amount of extra effort. Preliminary application of the method to the Space Station indicates excellent agreement with results based on modifying and resolving the finite element model.

Blelloch, Paul A.↗

DOE OSTI2022

Uncertainty Quantification for Dissimilar Material Joints Under Corrosion Environment

Abstract Self-Piercing Riveting (SPR) is one of the most commonly used methods for joining dissimilar materials in the automotive industry. These joints are popular due to their adaptability, high performance and short cycle time. However, since these joints involve two dissimilar materials, they are susceptible to galvanic corrosion in the presence of an electrolyte which is driven by the difference in the equilibrium potential of the metals. This can affect the safety and resilience of these joints. In this paper, we focus on galvanic corrosion in Al-Fe SPR joints. A Machine learning (ML) based surrogate model, which is based off of FE simulations, for statistical corrosion analysis is developed. This model enables the resilience and reliability analysis of SPR joints under corrosion environment. In this study, first a physics-based finite element (FE) corrosion model has been developed to simulate the galvanic corrosion between a Fe cathode and an Al anode of a SPR joint. This model takes into account the effect of the crystal microstructure of the Al anode and the precipitation of the corrosion product. Several geometric and environmental factors including crevice gap, roughness of anode, conductivity, pH and the temperature of the electrolyte that effect corrosion are investigated. A thorough Uncertainty Quantification (UQ) analysis is conducted for the overall corrosion behavior of the Fe-Al SPR joints using a novelistic Probabilistic Confidence-Based Adaptive Sampling (PCAS) technique. PCAS is used to train the surrogate model by identifying the critical sampling points and thus reducing the overall computational costs. It is found that the electrolyte temperature has the largest effects on the material loss and needs to be managed closely for better corrosion control. By understanding the corrosion performance and resultant uncertainty impact on SPR joints, the reliability and resilience of these joints can be improved.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Nonlocal and Mixed-Locality Multiscale Finite Element Methods

In many applications the resolution of small-scale heterogeneities remains a significant hurdle to robust and reliable predictive simulations. In particular, while material variability at the mesoscale plays a fundamental role in processes such as material failure, the resolution required to capture mechanisms at this scale is often computationally intractable. Multiscale methods aim to overcome this difficulty through judicious choice of a subscale problem and a robust manner of passing information between scales. One promising approach is the multiscale finite element method, which increases the fidelity of macroscale simulations by solving lower-scale problems that produce enriched multiscale basis functions. Here, in this study, we present the first work toward application of the multiscale finite element method to the nonlocal peridynamic theory of solid mechanics. This is achieved within the context of a discontinuous Galerkin framework that facilitates the description of material discontinuities and does not assume the existence of spatial derivatives. Analysis of the resulting nonlocal multiscale finite element method is achieved using the ambulant Galerkin method, developed here with sufficient generality to allow for application to multiscale finite element methods for both local and nonlocal models that satisfy minimal assumptions. Finally, we conclude with preliminary results on a mixed-locality multiscale finite element method in which a nonlocal model is applied at the fine scale and a local model at the coarse scale.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2019

A Wave Energy Converter Design Load Case Study

This article presents an example by which design loads for a wave energy converter (WEC) might be estimated through the various stages of the WEC design process. Unlike previous studies, this study considers structural loads, for which, an accurate assessment is crucial to the optimization and survival of a WEC. Three levels of computational fidelity are considered. The first set of design load approximations are made using a potential flow frequency-domain boundary-element method with generalized body modes. The second set of design load approximations are made using a modified version of the linear-based time-domain code WEC-Sim. The final set of design load simulations are realized using computational fluid dynamics coupled with finite element analysis to evaluate the WEC’s loads in response to both regular and focused waves. This study demonstrates an efficient framework for evaluating loads through each of the design stages. In comparison with experimental and high-fidelity simulation results, the linear-based methods can roughly approximate the design loads and the sea states at which they occur. The high-fidelity simulations for regular wave responses correspond well with experimental data and appear to provide reliable design load data. The high-fidelity simulations of focused waves, however, result in highly nonlinear interactions that are not predicted by the linear-based most-likely extreme response design load method.

16 TIDAL AND WAVE POWER↗

NASA NTRS2008

The Use of a Vehicle Acceleration Exposure Limit Model and a Finite Element Crash Test Dummy Model to Evaluate the Risk of Injuries During Orion Crew Module Landings

A review of astronaut whole body impact tolerance is discussed for land or water landings of the next generation manned space capsule named Orion. LS-DYNA simulations of Orion capsule landings are performed to produce a low, moderate, and high probability of injury. The paper evaluates finite element (FE) seat and occupant simulations for assessing injury risk for the Orion crew and compares these simulations to whole body injury models commonly referred to as the Brinkley criteria. The FE seat and crash dummy models allow for varying the occupant restraint systems, cushion materials, side constraints, flailing of limbs, and detailed seat/occupant interactions to minimize landing injuries to the crew. The FE crash test dummies used in conjunction with the Brinkley criteria provides a useful set of tools for predicting potential crew injuries during vehicle landings.

Lawrence, Charles↗

DOE OSTI2014

Verification and Validation of Carbon-Fiber Laminate Low Velocity Impact Simulations.

Presented is a model verification and validation effort using low - velocity impact (LVI) of carbon fiber reinforced polymer laminate experiments. A flat cylindrical indenter impacts the laminate with enough energy to produce delamination, matrix cracks and fiber breaks. Included in the experimental efforts are ultrasonic scans of the damage for qualitative validation of the models. However, the primary quantitative metrics of validation are the force time history measured through the instrumented indenter and initial and final velocities. The simulations, whi ch are run on Sandia's Sierra finite element codes , consist of all physics and material parameters of importance as determined by a sensitivity analysis conducted on the LVI simulation. A novel orthotropic damage and failure constitutive model that is cap able of predicting progressive composite damage and failure is described in detail and material properties are measured, estimated from micromechanics or optimized through calibration. A thorough verification and calibration to the accompanying experiment s are presented. Specia l emphasis is given to the four - point bend experiment. For all simulations of interest, the mesh and material behavior is verified through extensive convergence studies. An ensemble of simulations incorporating model parameter unc ertainties is used to predict a response distribution which is then compared to experimental output. The result is a quantifiable confidence in material characterization and model physics when simulating this phenomenon in structures of interest.

English, Shawn Allen↗

DOE OSTI2018

Comparative Study of Finite Element Methods Using the Time-Accuracy-Size(TAS) Spectrum Analysis

We present a performance analysis appropriate for comparing algorithms using different numerical discretizations. By taking into account the total time-to-solution, numerical accuracy with respect to an error norm, and the computation rate, a cost-benefit analysis can be performed to determine which algorithm and discretization are particularly suited for an application. This work extends the performance spectrum model in for interpretation of hardware and algorithmic tradeoffs in numerical PDE simulation. As a proof-of-concept, popular finite element software packages are used to illustrate this analysis for Poisson’s equation.

97 MATHEMATICS AND COMPUTING↗