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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Experimental data for damage mechanics simulation challenge

While there are many computational approaches for simulating damage in rock and other materials, few have been ground truth tested with either known experimental data or with blind data sets. Here, in this work, we present a bench-mark laboratory data set for a damage mechanics challenge to compare computational approaches on damage evolution in brittle-ductile materials. The samples were fabricated through additive manufacturing to produce repeatable specimens designed to fail in controlled ways. The failure was induced in the samples using a 3-point bending test to produce different Modes such as Mode I and mixed Modes including I-II, I-III and I-II-III Modes to generate a calibration data set and a blind challenge data set. Data collected included spatial and temporal measurements from traditional digital load–displacement sensors, 2D digital image correlation measurement to map surface deformations, 3D X-ray microscopy to ground-truth the crack-failure geometry, and laser profilometry to capture surface roughness. The data sets are available, on a data repository, to the community to advance computational models to improve our ability to predict damage in brittle-ductile materials.

3-point bending↗
NASA NTRS2001

Challenges Facing Design and Analysis Tools

The design and analysis of future aerospace systems will strongly rely on advanced engineering analysis tools used in combination with risk mitigation procedures. The implications of such a trend place increased demands on these tools to assess off-nominal conditions, residual strength, damage propagation, and extreme loading conditions in order to understand and quantify these effects as they affect mission success. Advances in computer hardware such as CPU processing speed, memory, secondary storage, and visualization provide significant resources for the engineer to exploit in engineering design. The challenges facing design and analysis tools fall into three primary areas. The first area involves mechanics needs such as constitutive modeling, contact and penetration simulation, crack growth prediction, damage initiation and progression prediction, transient dynamics and deployment simulations, and solution algorithms. The second area involves computational needs such as fast, robust solvers, adaptivity for model and solution strategies, control processes for concurrent, distributed computing for uncertainty assessments, and immersive technology. Traditional finite element codes still require fast direct solvers which when coupled to current CPU power enables new insight as a result of high-fidelity modeling. The third area involves decision making by the analyst. This area involves the integration and interrogation of vast amounts of information - some global in character while local details are critical and often drive the design. The proposed presentation will describe and illustrate these areas using composite structures, energy-absorbing structures, and inflatable space structures. While certain engineering approximations within the finite element model may be adequate for global response prediction, they generally are inadequate in a design setting or when local response prediction is critical. Pitfalls to be avoided and trends for emerging analysis tools will be described.

Knight, Norman F., Jr.↗
DOE OSTI2021

Numerical and experimental evaluation of mechanical performance of the multifunctional energy storage composites

This work presents numerical simulation methods to model the mechanical behavior of the multifunctional energy storage composites (MESCs), which consist of a stack of multiple thin battery layers reinforced with through-the-hole polymer rivets and embedded inside carbon fiber composite laminates. MESC has been demonstrated through earlier experiments on its exceptional behavior as a structural element as well as a battery. However, the inherent complex infrastructure of the MESC design has created significant challenges in simulation and modeling. A novel homogenization technique was adopted to characterize the multi-layer properties of battery material using physics-based constitutive equations combined with nonlinear deformation theories to handle the interface between the battery layers. Second, mechanical damage and failure modes among battery materials, polymer reinforcements, and carbon fiber-polymer interfaces were characterized through appropriate models and experiments. The model of MESCs has been implemented in a commercial finite element code in ABAQUS. A comparison of structural response and failure modes from numerical simulations and experimental tests are presented. The results of the study showed that the predictions of elastic and damage responses of MESCs at various loading conditions agreed well with the experimental data. © 2021

Materials Science↗
DOE OSTI2026

An Anisotropic Yield and Damage Material Model to Improve the Contact Pressure Analysis in a Biomass Shredding System

Size reduction systems used in biomass processing break biomass into smaller pieces by utilizing the kinetic energy from the sharp rotating blades. Abrasive and/or erosive wear caused by biomass comminution results in blade wear of the sharp edged cutters, deteriorating the process efficiency. Here, this study aims to optimize the blade design and improve the system efficiency by attempting to understand the interactions between the blades and biomass particles. Since real-time monitoring of these interactions is impractical during operation, mechanical simulations offer a viable alternative for investigating the shredding process. Yet, the irregular geometry and complex mechanical properties of biomass—such as the anisotropic nature of woodchips and their nonlinear fracture behavior—pose significant challenges for accurately simulating contact pressure. In this work an anisotropic yield material model, along with a damage initiation and evolution function, is applied to the woodchip particle to study the contact pressure on shredder blade, offering a scientific basis for improved blade design and process efficiency. This approach can be extended to other biomass processing systems with similar anisotropic feedstocks, making it a valuable tool for advancing sustainable biomass utilization.

09 - BIOMASS FUELS↗
DOE OSTI2025

Numerical Simulation Studies of Ultrasonic De-Icing for Heating, Ventilation, Air Conditioning, and Refrigeration Structures

Ice accumulation on heating, ventilation, air conditioning, and refrigeration (HVACR) structures presents significant operational challenges. These challenges include reduced efficiency, increased energy consumption, and potential damage to equipment. Traditional de-icing methods, such as chemical treatments, mechanical scraping, or heating-based techniques, are often labor-intensive, costly, and environmentally harmful. Here, this study uniquely investigates ultrasonic de-icing as an energy-efficient alternative for HVACR applications, focusing on the specific structural geometries found in these systems. A comprehensive numerical simulation framework was developed using finite element analysis to explore ultrasonic wave propagation across four distinct HVACR structures. Key parameters such as ultrasonic frequency, power levels, and the number and placement of actuators were examined for their impact on ice detachment efficiency. Results from simulations on a plate structure reveal that ultrasonic excitation can propagate effectively across large areas (at least 150 × 150 mm), enhancing the de-icing coverage. Lower frequency (e.g., 30 to 45 kHz) excitation results in greater displacement, improving de-icing performance, while increased actuator numbers with the same total power input also enhance effectiveness. Two actuators seem sufficient for the de-icing of a 300 × 300 mm plate. For tube-and-fin structures, specific high-power ultrasonic frequencies selectively excite the fin plates, demonstrating efficient ice removal when actuated on the tube. However, optimal performance requires careful design of actuator placement and vibration modes to accommodate the irregular shapes of these structures.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2016

Coupling of Mechanical Behavior of Lithium Ion Cells to Electrochemical-Thermal (ECT) Models for Battery Crush

Vehicle crashes can lead to crushing of the battery, damaging lithium ion battery cells and causing local shorts, heat generation, and thermal runaway. Simulating all the physics and geometries at the same time is challenging and takes a lot of effort; thus, simplifications are needed. We developed a material model for simultaneously modeling the mechanical-electrochemical-thermal behavior, which predicted the electrical short, voltage drop, and thermal runaway behaviors followed by a mechanical abuse-induced short. The effect of short resistance on the battery cell performance was studied.

30 DIRECT ENERGY CONVERSION↗
NASA NTRSDate not supplied

Modeling and Characterization of Crushable Composite Structures

The crushing response and the energy absorption capacity of a quasi-isotropic C-shaped composite panel is presented to simulate the progressive damage and failure mechanisms involved in the component testing. Crushable composite structures are widely used for impact applications, as because of their great high-energy absorption capability and lower weight. Simulating the crush characteristics of composite structures is challenging, as the conventional tools fail to accurately represent the failure mechanisms at the component level. Here, a cost-effective predictive tool ‘CZone’ is applied for simulating the crushing response of composite materials. CZone for Abaqus (CZA) is an add-on capability for Abaqus/Explicit and combines with the commercially available impact modeling capabilities included within the Abaqus finite element software package.

crush zone↗
DOE OSTI2024

Using Computer Simulations to Optimize Biofuel Production

The DOE strives to ensure America's security and prosperity by addressing energy challenges. NREL shares this goal and tries to achieve a clean energy world. Fossil fuels are problematic for both organizations. Using them endangers American security. Their supply is finite and burning them causes environmental damage. Biofuels are a good alternative to fossil fuels. They are renewably produced on American soil and can lower greenhouse gas emissions. Also, cars and planes need no costly mechanical adjustments to use biofuels. However, the fuels themselves are expensive. For my SULI project, I reduced the cost of biofuels by optimizing the production process through computer simulations. Existing simulations were accurate but slow. One simulation takes up to eight hours, and researchers must do hundreds. My solution reduces the computing time. I treated the biomass particles in the simulation as one-dimensional. That simplified the simulation equations, making them easier for the computer to solve. Still, biomass particles are three-dimensional. The 1D assumption was wrong and produced inaccurate results. To maintain accuracy while increasing speed, I developed a method to convert 1D simulation results into usable 3D data. I adjusted the 1D simulation until the output matched the 3D results for a specific environment. I found out how much the simulation changed when the environment changed. Machine learning algorithms defined a relationship between 1D and 3D data for all environments. This lets scientists convert fast 1D simulation results into valid 3D data.

1D↗
DOE OSTI2017

Application of NSUF Capabilities Towards Understanding the Emulation of High Dose Neutron Irradiations with Ion Beams

Development of new materials for current nuclear power plants (NPPs) or materials for new NPPs requires extensive research, development, and deployment programs. Central to these efforts, particularly for core internals, are studies on the microstructural and mechanical changes due to neutron irradiation. These radiation effects studies are typically completed using materials test reactors followed by expensive and time-consuming post-irradiation examinations (PIE). This sluggish approach has severely limited the nuclear materials field to develop new materials or verify materials for new reactor design use. It is also very difficult to achieve the high levels of damage proposed for future reactors. A logical approach to accelerating the field is the application of ion beams to simulate neutron damage, especially for high dose applications. Ion beams have been used for decades to study radiation effects but not to emulate high dose reactor irradiations. In this regard, new (or renewed) methods for ion beam irradiations, new developments in materials characterization, and greater understanding on the governing mechanisms controlling observed radiation effects have led to a need for further studies to refine the technique. A primary challenge is the ability to determine the ion irradiation conditions that produce microstructures and mechanical properties relevant to in-core neutron irradiation conditions. A large, multi-disciplinary, multi-laboratory program deemed the High Fidelity Ion Beam Simulation of High Dose Neutron Irradiation has been formed to assess and overcome the challenges associated with emulating high dose neutron irradiations using ion beams. Central to this program is the use of dual-beam ion irradiations and corresponding neutron irradiations within the BOR-60 fast reactor. These irradiations have produced hundreds of specimens for microstructural and mechanical characterization. A significant issue regarding the samples is the radioactivity of the neutron irradiated specimens as well as the need to characterize both irradiation types using the same equipment to maintain consistency and repeatability. The use of the Nuclear Science User Facilities (NSUF) has been central towards overcoming the mentioned issues and thereby enabling robust PIE in both the ion and neutron irradiated specimens of interest. In particular, the electron microscopes housed within the Low Activation Materials Development and Analysis (LAMDA) facility at Oak Ridge National Laboratory (ORNL) - an NSUF partner facility - has been instrumental in gathering high quality data for analysis. This paper will briefly highlight the PIE efforts using the NSUF capabilities within LAMDA.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Damage detection in a laboratory-scale wellbore applying Time Reversal and Nonlinear Elastic Wave Spectroscopy (TR NEWS)

We report Time Reversal and Nonlinear Elastic Wave Spectroscopy (TR-NEWS) has been used to focus acoustic energy, and make measurements correlated with damage in a variety of industrial materials. Most studies using TR-NEWS have focused on relatively small objects and may have multiple acoustic sources. In Earth, within energy extraction and carbon sequestration settings, the structure and scale of wellbores makes acoustic focusing challenging, as has been demonstrated through numerical simulations. This paper explores the feasibility of applying TR NEWS for damage detection in wellbores by constructing a laboratory-scale wellbore, and using TR to focus and make dynamic linear and nonlinear elastic measurements on it. During successive cycles of localized mechanical damage induced in the sample, the hysteretic nonlinear elastic parameter α increased with progressive mechanical damage. In addition to these strain-dependent changes in α, the width and peak amplitude of the time reversal focused energy changed near the damage site.

58 GEOSCIENCES↗
DOE OSTI2019

Experiments and Simulation of a Borehole in Salt to Understand Heat, Brine, and Vapor Migration - 19192

Disposition of heat-generating nuclear waste (HGNW) remains a continuing technical and sociopolitical challenge. Numerous concepts for HGNW management have been proposed and examined internationally, including an extensive focus on geologic disposal. One proposed geologic material is salt because of its low permeability and viscoplastic deformation that causes self-repair of damage done to the salt by waste emplacement activities. Evaluating the safety and technical challenges of storing HGNW in a salt repository is an ongoing process involving experiments and supporting numerical simulation. Currently an experiment is underway at the Waste Isolation Pilot Plant (WIPP) to explore how the presence of a heat generating source affects phenomena such as brine migration, vapor transport, and mechanical changes to the bedded salt. A sub-horizontal heated borehole test is in progress in the underground at the WIPP that includes a centrally located 10.2 cm diameter borehole with an adjustable heater surrounded with smaller diameter boreholes instrumented with thermocouples. The central borehole contains an inflatable packer, heating block, brine sampler, and constantly flowing nitrogen gas circulation system. Air-injection tests performed in the central borehole provide pressure measurements that are used to constrain permeability of the system. The steady-state temperatures, as well as the rise and fall of temperature when the heater is cycled on and off, have been measured for up to 60 days. In the borehole, dry nitrogen gas circulation evaporates water and outflows to a desiccant container where water mass is measured daily during the experiment to quantify vapor removal. Although this test is a 'shake-down' for a planned second round of fresh borehole testing, we have gathered a rich dataset. These data allow us to build simulations using the Finite Element Heat and Mass transfer code (FEHM) to evaluate the experimental results, determine field-scale parameters, and identify code improvements to reproduce important physical processes that may not be accounted for at present. A 3-D numerical mesh, built using LaGrit software (lagrit.lanl.gov; Miller et al., 2007), includes increasing resolution around the central borehole. Modeling of the experiment allows for determining the local thermal conductivity and permeability of any damaged bedded salt around the borehole, where damage from drilling may change the permeability, porosity and saturation conditions, by parameter testing and inverse methods. Additionally, assumptions about brine and vapor flow and transport are being tested by comparing measured and simulated results. The combination of experimental data and model results provide additional data to help support the safety case for safe and effective HGNW disposition in bedded salt formations. Initial results from this experiment show that water flow into the borehole is within previous experimental results. Further, we have found that the design of the heater block is restricting energy to flow into the rock salt. Thus, this test has proven useful in design of the next generation experiment where infrared heating may be used to bypass issues caused by air gaps located around the current stainless steel block heater. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Residual Stresses Affect Cell Fragment Movement

Predictive modeling tools such as the finite element method can be of tremendous help in assessing the reliability and long-term performance of photovoltaic modules. In order to obtain accurate results, the proper modeling of materials and manufacturing processes are of utmost importance. Module fabrication introduces thermo-mechanical stresses inside the module laminate, which need to be accounted for as residual stresses in finite element simulations. We found that cell fragment movement and crack opening displacements of fractured silicon cells within modules are affected by those residual stresses. Cell cracking remains a challenging topic in assessing the reliability and durability of damaged modules. Hence, accurately quantifying the separation and movement between cell fragments creates the foundation for establishing reliable lifetime and performance assessments of fractured silicon modules. Here, we present a modeling approach that uses upper and lower bounds to accurately account for the residual stresses introduced by the module lamination process. We designed a four-point flexure coupon test of a laminated, fractured silicon strip to validate our numerical results and found good agreement between our modeling methodology and the experimental data. Finally, we discuss the implications of the residual stresses on the normal crack opening and metallization wear-out of fractured silicon cells.

14 SOLAR ENERGY↗
DOE OSTI2021

Bridging microscale to macroscale mechanical property measurements and predication of performance limitation for FeCrAl alloys under extreme reactor applications

Microscale mechanical testing has greatly benefited nuclear materials studies in at least two aspects: one is its feasibility to integrate with SEM and TEM microscopes for in situ atomic scale or microscale structural characterization to reveal fundamental details, and the other is its significance in development of accelerator-based ion irradiation technique as a surrogate method to simulate neutron damage. Ion irradiation is able to reach damage creation at a level at least three orders of magnitudes higher than test reactors. However, limited ion penetration depths, which are about a few microns for MeVs heavy ions and 10s microns for MeV light ions, make microscale mechanical tests a necessity. But, there is a great challenge to bridge microscale tests to macroscale tests because a bulk specimen of irradiated nuclear materials for high dose applications cannot be obtained in laboratory.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Bridging microscale to macroscale mechanical property measurements and predication of performance limitation for FeCrAl alloys under extreme reactor applications

Microscale mechanical testing has greatly benefited nuclear materials studies in at least two aspects: one is its feasibility to integrate with SEM and TEM microscopes for in situ atomic scale or microscale structural characterization to reveal fundamental details, and the other is its significance in development of accelerator-based ion irradiation technique as a surrogate method to simulate neutron damage. Ion irradiation is able to reach damage creation at a level at least three orders of magnitudes higher than test reactors. However, limited ion penetration depths, which are about a few microns for MeVs heavy ions and 10s microns for MeV light ions, make microscale mechanical tests a necessity. But, there is a great challenge to bridge microscale tests to macroscale tests because a bulk specimen of irradiated nuclear materials for high dose applications cannot be obtained in laboratory.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Mechanics of diseased red blood cells in human spleen and consequences for hereditary blood disorders

In red blood cell (RBC) diseases, the spleen contributes to anemia by clearing the damaged RBCs, but its unique ability to mechanically challenge RBCs also poses the risk of inducing other pathogenic effects. We have analyzed RBCs in hereditary spherocytosis (HS) and hereditary elliptocytosis (HE), two typical examples of blood disorders that result in membrane protein defects in RBCs. We use a two-component protein-scale RBC model to simulate the traversal of the interendothelial slit (IES) in the human spleen, a stringent biomechanical challenge on healthy and diseased RBCs that cannot be directly observed in vivo. In HS, our results confirm that the RBC loses surface due to weakened cohesion between the lipid bilayer and the cytoskeleton and reveal that surface loss may result from vesiculation of the RBC as it crosses IES. In HE, traversing IES induces sustained elongation of the RBC with impaired elasticity and fragmentation in severe disease. Our simulations thus suggest that in inherited RBC disorders, the spleen not only filters out pathological RBCs but also directly contributes to RBC alterations. These results provide a mechanistic rationale for different clinical outcomes documented following splenectomy in HS patients with spectrin-deficient and ankyrin-deficient RBCs and offer insights into the pathogenic role of human spleen in RBC diseases.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2018

On the dynamic tensile strength of an FCC metal

The tensile response of ductile, polycrystalline metals is often accompanied by the formation of pores within the material, which coalesce and fail a plane within a metal. This large deformation process is broadly progressive, with a physical path consisting of nucleation, growth, coalescence, and failure, which occur individually over short periods of time. Thus distinct micro-mechanisms operate, each influenced by microstructure, loading path, and loading profile, which remains a significant challenge to represent and predict numerically at the macroscale. In a previous study, the influence of loading path on damage evolution in high-purity tantalum has been presented; in this paper, complimentary measurements are made on a pure, FCC copper. Samples were shock loaded to three different peak stresses using both symmetric impact, and two different composite flyer plate configurations, such that upon unloading, the three samples were subject to nearly identical tensile loading. The damage evolution in the soft-recovered copper samples was then quantified using optical metallography and electron-back-scatter diffraction. We shall compare metallurgical observations, velocimetry histories and simulations to discuss the dynamic failure mechanics observed.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2017

Runaway electrons in tokamaks

The generation of runaway electrons is a complex and important phenomenon that impacts many areas of plasma physics. Due to the decrease of electron collision frequency with increasing velocity, electrons under strong electric field can experience unlimited “runaway” acceleration. In tokamaks, runaway electrons can be produced in disruptions, due to the strong inductive electric field formed as the thermal energy of plasma gets rapidly lost. This population of runaway electrons can undergo an exponential growth, denoted the runaway electron avalanche, due to hard collisions between relativistic runaway electrons and low energy electrons. It is predicted that in a large tokamak device like the International Thermonuclear Experimental Reactor (ITER), a runway electron beam generated in a disruption event can potentially cause severe damage to the device, which poses a significant challenge for ITER to achieve its mission. It is therefore extremely important to seek an effective mitigation mechanism for runaway electrons. Experimental efforts have been made to study the properties of runaway electrons in tokamaks, including their generation, diffusion, and radiation. In order to understand these experimental results, extensive theoretical and simulation studies of runaway electron physics are required. The main topic of this thesis is to study the wave particle interaction associated with runaway electron beams in tokamaks. The runaway electrons can emit and absorb electromagnetic waves through resonances, and can be diffused in momentum space by the waves. Initially, we address the Cherenkov radiation of runaway electrons, which originates from the polarization of the plasma medium. The energy and momentum loss of the Cherenkov radiation can be modeled by adding a correction to the Coulomb logarithm in the collisional drag force. Subsequently, we address pitch angle scattering caused by normal modes in the plasma, which are driven unstable by the anisotropicity of the runaway electron beam. The fluctuating electromagnetic fields are found to act as a seed for the unstable normal modes. Numerical simulations show that the pitch angle scattering effect from the normal modes, mainly whistler waves, can be significantly larger than that from collisional pitch angle scattering. Finally, we present a synthetic diagnostic tool we developed to calculate the electron cyclotron emission (ECE) from the runaway electrons, and successfully reproduce the prompt growth of the ECE signal observed in DIII-D quiescent runaway electron (QRE) experiments. Within the thesis, we also present the application of the adjoint method to runaway electron research, and show the calculations of the runaway probability function (RPF) and the expected loss time (ELT). These calculations not only help depict the dynamics of runaway electrons in momentum space, but also can be used to efficiently calculate experimentally relevant quantities such as the critical electric field for runaway electron avalanche and the avalanche growth rate.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗