Coupled FE-BE Multi Scale Simulation of Jointed Structures: Transient and Periodic Cases
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Linder, Hendrik [University of Stuttgart]↗
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Comparing Transient Dynamic Simulations of Jointed Structures using FEA and FE/BE Multi-scale Method
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Linder, Hendrik [University of Stuttgart]↗
Maturing Rational Design Methodologies and Industry Consensus Engineering Standards: Critical Fastened Joints - Solar PV Industry
Critical structural joints can be seen throughout a solar array and are called upon to secure modules and keep racking assembled and able to resist large demands from winds and snow loads. In the relatively new and fast-growing solar PV industry, the important role these hardware assemblies (e.g. clips, clamps, bolts, nuts, washers) play is not well understood by product designers. Failures with critical structural joints are surprisingly common and point to the need for maturing the engineering and assembly of these joints. The wide variety of design concepts (Figure 2&2) demonstrate interesting and innovative ideas but are lacking the basics of fastener engineering seen in matured industries (e.g. transportation, buildings). Complicating the maturing process for critical structural joints is that they are one component in rack supporting structures that exhibits a systems behavior; each component will affect the other and play a key role in maintaining structural integrity. When wind loads the surface of a module, the underlying racking members deflect and twist which in turn imparts forces back into the joints and into the mounted modules. Often, these supporting rack structures exhibit high deflections and low natural frequencies which amplify the demands placed into the joints even in moderate winds. Current engineering practices and associated structural conventions view solar racking support structures as they would a high mass building that exhibit more static behaviors in wind events. Solar structures are unique from high mass buildings and require the development of solar specific industry engineering consensus standards.
14 SOLAR ENERGY↗
Enabling topography-resolving structural dynamic contact simulation
Damping of structures and systems is often dominated by frictional dissipation in connections, the prediction of which remains a longstanding scientific challenge. Previous studies have shown that the actual topography of contact interfaces may have a strong effect, especially in the partial slip/liftoff regime. We recently proposed a multi-scale method, which couples finite element and boundary element modeling. The primary benefit of this approach is that it permits to analyze the effect of the actual contact topography on the dynamics of jointed structures. While this multi-scale modeling method was initially developed for quasi-static analysis, we demonstrate herein how it can be used for time step integration and Harmonic Balance analysis. We cross-verify those fully dynamic analysis methods against each other and quasi-static results, for the S4 Beam benchmark. We compare the multi-scale method against state-of-the-art full-FE analysis, in terms of numerical damping and computational performance. Some discrepancy is found to be of physical origin. Depending on the load history, it is shown that the system settles to a slightly different equilibrium. Finally, transient multi-scale simulations enable the prediction of this interesting phenomenon, for the first time, for a structure with bolted joints.
Frictional-unilateral contact↗
Probabilistic Predictions for Fastener Failure in the Sandia Mechanics Challenge Using the Discrete-Direct Uncertainty Quantification Approach
This paper documents the blind and post-blind analysis predictions for the 2023 Sandia Mechanics Challenge (SMC), which involved predicting the behavior of a threaded fastener joint structure subjected to shock loading. Utilizing repeat sets of fastener calibration data from various experimental configurations including tension, double shear, and joint tension, we developed a library of calibrated models which were propagated through the application model using the Discrete-Direct (DD) uncertainty quantification (UQ) approach. Although the initial blind predictions did not incorporate spare-sample processing to quantify fastener failure probabilities, the analyses yielded reasonable conclusions aligned with experimental results. In the post-blind analysis phase, we focused on enhancing the fidelity of the aluminum constitutive model and innovating the DD approach to obtain probabilistic predictions for fastener failure, particularly when quantities of interest (QoIs) approach their bounds. The improved aluminum model captures the behavior of the cantilever under shock loading more accurately, predicting both partial and complete cracks, although it tends to underpredict failure propagation. The enhanced DD approach facilitates probabilistic predictions that reflect the interdependent failure mechanisms of the fasteners and the cantilever, revealing that while certain fasteners are more likely to fail, the failure does not necessarily follow a progressive pattern. Overall, the post-blind analyses significantly improved the predictive capabilities of the model, providing valuable insights into the SMC application and establishing a robust foundation for informed engineering decisions. The methodology demonstrates a cost-effective and extensible approach suitable for a wide range of applications, highlighting the importance of uncertainty quantification to provide context for engineering decision making.
42 ENGINEERING↗
Multiple‐Repeated Plasma Surface Treatments for Significantly Improving Bonding Performance of Metal‐Carbon‐Fiber‐Reinforced Thermoplastic Polymer Dissimilar Adhesive Joints
This work investigates how multiple‐repeated plasma surface treatments can significantly enhance adhesively bonded metal‐carbon‐fiber‐reinforced thermoplastic polymer (CFRTP) dissimilar joints, a topic that has been rarely investigated compared to other parameters during the plasma treatment process. By conducting double cantilever beam tests on adhesively bonded AA6061‐carbon‐fiber‐reinforced polyphthalamide (CFRPPA) dissimilar joints, it is shown that the average Mode I specific fracture energy after 20 repetitions of the same plasma treatment, using processing parameters without noticeably changing surface roughness, can be improved and saturated up to almost 2000% compared to non‐treated joints and almost 240% compared to a single plasma treatment commonly used in the literature. The improvement can be attributed to the enhanced chemical bonding at the CFRPPA‐adhesive interface. This study is important for achieving strong bonding performance of CFRTP‐related structural joints using multiple plasma treatments, a simple and effective method.
36 MATERIALS SCIENCE↗
Dissimilar Material Joining via Interlocking Metasurfaces
Background The integration of dissimilar materials poses a significant challenge in engineering, necessitating innovative solutions for robust and reliable joining. Interlocking metasurfaces (ILMs) are a new joining technology comprising arrays of autogenous features patterned across two surfaces that interlock to form robust structural joints. Objective Here, this study elucidates the factors influencing the tensile performance of ILM joints formed between dissimilar materials. Methods We employed parametric optimization to identify optimal unit cell geometries for maximal yield strength based on the hypothesis that the elastic tensile properties of the materials are the primary determinants of tensile performance. Experimental validation was performed by mechanically testing the theorized optimal ILM geometry and a range of ILM geometries to capture the overall behavior trends of joints between two additively manufactured polymers, VeroPureWhite (VW) and RGDA8430-DM (8430). Results Experimental validation of optimized designs revealed that additional factors, e.g. flexural strength and localized plasticity, also strongly influenced the tensile performance of T-slot ILMs joining dissimilar materials. The proposed optimal design remained the best performer. Conclusions This study demonstrates the viability of ILMs as a joining method for dissimilar materials. ILMs can join dissimilar materials with no loss in joint yield strength compared to joints composed solely of the weaker of the two constitutive materials. ILMs demonstrated their potential as a versatile and effective joining technology in diverse engineering applications.
Elbrecht, Benjamin James [Sandia National Laborato↗
dynamics of organic-mineral interactions at the metal oxide-solution interface as studied via binding energetics (Final report)
This project focused on addressing longstanding fundamental and experimental uncertainties on how dissolved organic substances (DOS) interact with metal oxide surface under environmentally relevant conditions. By leveraging a custom-built real-time, in-tandem flow adsorption microcalorimetry-UV-Vis/fluorescence spectroscopy platform, we characterized the binding energetics, kinetics and mechanistic pathways driving DOS-metal oxide interactions at temporal resolution on the order of 1-5 seconds. We studied a diverse suite of model organic compounds/substances – including monocarboxylates (e.g. acetate and benzoate), di-carboxylates (oxalate and succinate), amino acids, amino-based nanparticles and natural organic matter – interacting at the mineral-water interface of structurally- and/or chemically distinct metal oxides (including SiO2, boehmite, ferrihydrite, and γ-Al2O3). Our results indicated that DOS-metal oxide interactions are governed by multi-step reaction pathways, often switching between distinct, resolvable enthalpy- and entropy-driven non-electrostatic or electrostatic configurations. To quantify these interactions, we developed and implemented an analytical workflow that integrates peak deconvolution and Monte-Carlo based error propagation to determine site-specific thermodynamic and kinetic parameters for individual binding/debinding events. In addition to resolving apparent first-order rate constants of each event, we were able to quantify associated apparent equilibrium constants as well as free energy, enthalpy and entropy contribution to the activation and subsequent progression of the binding/debinding process across compounds, compound class and metal oxide surfaces. The kinetic-thermodynamic data produced in this study captured how the interplay between oxide surface reactivity and DOS molecular structure jointly drives binding-debinding dynamics. Notably, that at pH below PZC of the oxide surface, neutral species were heavily involved in monocarboxylate binding, while anionic species drove dicarboxylate binding. Also, that among amino acids 1) positional isomers show distinctive binding characteristics to each other while enantiomers show no significant differences in binding characteristics, 2) molecules that bind via outer-sphere complexation show a larger entropic shift between binding and debinding with no impact on oxide surface while 3) inner-sphere interactions increased anion exchange capacity of the oxide surface. The new insights and data from this work has great potential for improving predictive modeling of carbon dynamics and specifically organic-mineral interactions in environmental and industrial systems.
54 ENVIRONMENTAL SCIENCES↗
Unified and Consistent Structure Growth Measurements from Joint ACT, SPT, and Planck CMB Lensing
We present the tightest cosmic microwave background (CMB) lensing constraints to date on the growth of structure by combining CMB lensing measurements from the Atacama Cosmology Telescope (ACT), the South Pole Telescope (SPT), and Planck. Each of these surveys individually provides lensing measurements with similarly high statistical power, achieving signal-to-noise ratios of approximately 40. The combined lensing band powers represent the most precise CMB lensing power spectrum measurement to date with a signal-to-noise ratio of 61 and an amplitude of A lens recon = 1.025 ± 0.017 with respect to the theory prediction from the best-fit CMB Planck-ACT cosmology. The band powers from all three lensing datasets, analyzed jointly, yield a 1.6% measurement of the parameter combination S 8 CMBL ≡ σ 8 ( Ω m / 0.3 ) 0.25 = 0.82 5 - 0.013 + 0.015 . Including dark energy spectroscopic instrument baryon acoustic oscillation (BAO) data improves the constraint on the amplitude of matter fluctuations to σ 8 = 0.829 ± 0.009 (a 1.1% determination). When combining with uncalibrated supernovae from Pantheon+, we present a 4% sound-horizon-independent estimate of H 0 = 66.4 ± 2.5 km s - 1 Mpc - 1 . The joint lensing constraints on structure growth and present-day Hubble rate are fully consistent with a Λ CDM model fit to the primary CMB data from Planck and ACT. While the precise upper limit is sensitive to the choice of data and underlying model assumptions, when varying the neutrino mass sum within the Λ CDM cosmological model, the combination of primary CMB, BAO, and CMB lensing drives the probable upper limit for the mass sum towards lower values, comparable to the minimum mass prior required by neutrino oscillation experiments.
79 ASTRONOMY AND ASTROPHYSICS↗
Unified and consistent structure growth measurements from joint ACT, SPT and \textit{Planck} CMB lensing
We present the tightest cosmic microwave background (CMB) lensing constraints to date on the growth of structure by combining CMB lensing measurements from the Atacama Cosmology Telescope (ACT), the South Pole Telescope (SPT) and \textit{Planck}. Each of these surveys individually provides lensing measurements with similarly high statistical power, achieving signal-to-noise ratios of approximately 40. The combined lensing bandpowers represent the most precise CMB lensing power spectrum measurement to date with a signal-to-noise ratio of 61 and an amplitude of $A_\mathrm{lens}^\mathrm{recon} = 1.025 \pm 0.017$ with respect to the theory prediction from the best-fit CMB \textit{Planck}-ACT cosmology. The bandpowers from all three lensing datasets, analyzed jointly, yield a $1.6\%$ measurement of the parameter combination $S_8^\mathrm{CMBL} \equiv σ_8\,(Ω_m/0.3)^{0.25} = 0.825^{+0.015}_{-0.013}$. Including Dark Energy Spectroscopic Instrument (DESI) Baryon Acoustic Oscillation (BAO) data improves the constraint on the amplitude of matter fluctuations to $σ_8 = 0.829 \pm 0.009$ (a $1.1\%$ determination). When combining with uncalibrated supernovae from \texttt{Pantheon+}, we present a $4\%$ sound-horizon-independent estimate of $H_0=66.4\pm2.5\,\mathrm{km\,s^{-1}\,Mpc^{-1}} $. The joint lensing constraints on structure growth and present-day Hubble rate are fully consistent with a $Λ$CDM model fit to the primary CMB data from \textit{Planck} and ACT. While the precise upper limit is sensitive to the choice of data and underlying model assumptions, when varying the neutrino mass sum within the $Λ\mathrm{CDM}$ cosmological model, the combination of primary CMB, BAO and CMB lensing drives the probable upper limit for the mass sum towards lower values, comparable to the minimum mass prior required by neutrino oscillation experiments.
Cosmology and Nongalactic Astrophysics (astro-ph.C↗
Sandia Mechanics Challenge: Predicting the Behavior of Structures with Threaded Fastener Joints in Accidents
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Kramer, Sharlotte LorraineBolyard [Sandia National↗
Sandia Mechanics Challenge: Experimental Testing for Calibration and Impact Testing of a Structure with a Thread Fastener Joint
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Ivanoff, Thomas [Sandia National Laboratories (SNL↗
Micro-structural features and material properties impact on adhesive metal joints via computational modeling and machine learning
The quality of structural bonding in practical applications depends on various factors arising from materials, pre-processing conditions, and manufacturing. Understanding how these factors influence bonding performance and determining their relative importance are of significant interest. Thus, this study evaluates the effects of microstructural features and material properties on the structural strength of adhesively-bonded metal joints at the submillimeter scale, utilizing a combination of Finite Element Modeling (FEM) and Machine Learning (ML) with Gradient Boosting Regression (GBR). The microstructural features include adhesive thickness, internal voids within the adhesive, adherend-adhesive interfacial voids, void size and volume fraction, and surface roughness. The material properties include the constitutive behavior of the adhesive, as well as the adherend-adhesive interfacial strength and fracture energy. The changes in structural strength and morphologies of the bonded metal structures with respect to different microstructural features and material properties were clarified by FEM. By further leveraging ML-GBR, the sequence of importance of these factors affecting bonding performance across various scenarios was summarized. This work provides valuable insights into the development of improved structural bonding for adhesive joints in industries such as automotive , aerospace, and beyond.
36 MATERIALS SCIENCE↗
Sensitive detection of structural dynamics using a statistical framework for comparative crystallography
Chemical and conformational changes are crucial to protein function and its pharmacological control. X-ray crystallography can reveal these changes in atomic detail, but standard analysis methods, which refine separate datasets, often overlook differences that are subtle or arise in only a subset of molecules. Direct comparison of crystallographic datasets is, in principle, more powerful, but systematic errors (“scales”) often mask changes in the crystallographic observables (“structure factors”). Machine learning algorithms that jointly estimate scales and structure factors can address this limitation. Here, we augment this approach with multivariate, structured priors derived from crystallographic theory, implemented in the variational deep learning framework Careless. Doing so strongly improves the detection of protein dynamics, element-specific anomalous signals, and the binding of drug candidates, offering a robust approach to comparative crystallography and, potentially, to detection of protein dynamics by other structure determination methods.
Hekstra, Doeke R. [Harvard Univ., Cambridge, MA (U↗
Structure of the Ecuadorian Upper Plate From a Joint Seismic‐Gravity Inversion
The Ecuadorian portion of the South American subduction zone presents an interesting case study in the structure and complex evolution of an upper plate. There are outstanding questions about its tectonic history, composition, and magmatic processes. While previous studies have employed ambient noise tomography to image the Ecuadorian upper plate, surface wave inversions alone often lack sensitivity at relevant shallow depths. This limitation can be overcome with an independent, complementary data set, such as gravity. We have jointly inverted Rayleigh wave phase velocities and Bouguer gravity anomalies to provide a more detailed seismic velocity model of the Ecuadorian upper plate. Our joint inversion has yielded several key improvements from previous models. First, we observe much shallower slow velocities beneath major basins (the Manabí, Progreso, and Gulf of Guayaquil), better aligning with expected basin structure. Second, we identify a high-velocity block beneath the entire forearc, corresponding to the Piñon Terrane, with velocities suggesting the presence of ultramafic material. Third, we highlight a new narrow swath of slow velocities beneath the Ecuadorian Andes, which closely follows the active volcanoes along the Eastern Cordillera. The extent of these slow velocities coincides with the termination of active arc volcanism and the predicted location of the subducted Carnegie Ridge. The predicted compositions for the mid to lower crust in the region preclude a purely compositional explanation for these velocities, suggesting that some level of partial melt is necessary.
Birkey, Andrew [Univ. of Delaware, Newark, DE (Uni↗
Control of Energy Transport and Transduction in Photosynthetic Down-Conversion (Final Technical Report)
The research conducted under this contract focused on three areas related to control of energy transport and transduction in natural and synthetic light harvesting systems: (1) experimental and theoretical studies exploring the use of ultrafast laser pulse shaping to manipulate the initially excited states of multi-chromophore biological light harvesting networks and influence the early time energy transfer and electronic and vibrational relaxation pathways, (2) fundamental theoretical developments aimed at computing and analyzing the dynamics of excitations of complex heterogeneous environments and nano structures, and (3) joint experimental and theoretical design studies of artificial light harvesting materials exploring the influence of incorporating different types of organic layers in low dimensional lead halide perovskite materials on their hot carrier relaxation dynamics, and theoretical studies of the design of nano structured light harvesting antenna systems. These research projects supported the training of three theoretical and computational graduate students, one experimental graduate student, and one experimental post-doctoral researcher. The research has been published in seven peer reviewed papers and presented at several international meetings and workshops.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Integrated Framework of Multisource Data Fusion for Outage Location in Looped Distribution Systems
Accurate outage location is essential for expediting post-outage power restoration, minimizing outage duration, and enhancing the resilience of distribution networks. With the advent of advanced metering infrastructure, data-driven outage location methods have significantly advanced beyond traditional approaches that rely on manual inspections. However, existing methods still face critical challenges, like reliance on single-source data, limited ability to handle partially observable systems or difficulties with loop networks. To the best of our knowledge, no single approach has comprehensively addressed all of these challenges at once. To this end, this paper proposes a comprehensive multisource data fusion framework for outage locations via probabilistic graph networks. The framework consists of three key phases. First, a novel method for reconstituting distribution networks with loops is developed, transforming looped networks into multiple radial subnetworks that retain all outage causalities of the original network. Second, Bayesian network (BN) models are established for each subnetwork, integrating multiple data sources and network structures. Finally, a joint Gibbs sampling mechanism, featuring forward and backward information flow, is designed to merge data from separate BN models and maximize the utilization of limited evidence, ensuring accurate outage location identification. In conclusion, the framework was validated on two modified public test systems, and comparative studies confirmed its effectiveness.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Advanced Composite Structures and Materials Technologies for Launch Vehicles
The NASA's Advanced Composites Technologies (ACT) Project has the potential to develop composite materials and structures technologies for the largest composite aerospace structures ever made. The objective the ACT Project of is to develop mid-technology readiness level (TRL) composite materials and structures technologies to TRL 6 for specific heavy lift Ares V launch vehicle and Altair lunar lander applications. To accomplish this objective, the ACT Project has four major technical elements: materials and manufacturing; structural concepts development and assessment of lightweight components; testing and evaluation; and highly loaded composite struts. The Project uses capabilities from across NASA to form multi-disciplinary, cross-center teams to meet the milestones of these technical elements. This presentation will describe the activities and plans for the ACT Project. Studies from the first execution year of the project will be summarized including results from materials selection and structural concept evaluation studies. Plans for continuing activities include studies for nondestructive evaluation/structural health monitoring, damage tolerance, joints, and material and structural testing, and these studies will be described. A major emphasis this fiscal year is the start of work for a manufacturing demonstration barrel. This structure will be composed of six, 5-m-diameter, 3-m-long curved panels that when assembled, result in a 10-m-diameter barrel. Activities related to the development of this structure will also be described.
Mark J Shuart↗