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NASA NTRS2004

Subsurface Stress Fields In Single Crystal (Anisotropic) Contacts

Single crystal superalloy turbine blades used in high pressure turbomachinery are subject to conditions of high temperature, triaxial steady and alternating stresses, fretting stresses in the blade attachment and damper contact locations, and exposure to high-pressure hydrogen. The blades are also subjected to extreme variations in temperature during start-up and shutdown transients. The most prevalent HCF failure modes observed in these blades during operation include crystallographic crack initiation/propagation on octahedral planes, and noncrystallographic initiation with crystallographic growth. Numerous cases of crack initiation and crack propagation at the blade leading edge tip, blade attachment regions, and damper contact locations have been documented. Understanding crack initiation/propagation under mixed-mode loading conditions is critical for establishing a systematic procedure for evaluating HCF life of single crystal turbine blades. This paper presents analytical and numerical techniques for evaluating two and three dimensional subsurface stress fields in anisotropic contacts. The subsurface stress results are required for evaluating contact fatigue life at damper contacts and dovetail attachment regions in single crystal nickel-base superalloy turbine blades. An analytical procedure is , presented, for evaluating the subsurface stresses in the elastic half-space, using a complex potential method outlined by Lekhnitskii. Numerical results are presented for cylindrical and spherical anisotropic contacts, using finite element analysis. Effects of crystal orientation on stress response and fatigue life are examined.

Arakere, Nagaraj K.↗

NASA NTRS1988

MHOST: An efficient finite element program for inelastic analysis of solids and structures

An efficient finite element program for 3-D inelastic analysis of gas turbine hot section components was constructed and validated. A novel mixed iterative solution strategy is derived from the augmented Hu-Washizu variational principle in order to nodally interpolate coordinates, displacements, deformation, strains, stresses and material properties. A series of increasingly sophisticated material models incorporated in MHOST include elasticity, secant plasticity, infinitesimal and finite deformation plasticity, creep and unified viscoplastic constitutive model proposed by Walker. A library of high performance elements is built into this computer program utilizing the concepts of selective reduced integrations and independent strain interpolations. A family of efficient solution algorithms is implemented in MHOST for linear and nonlinear equation solution including the classical Newton-Raphson, modified, quasi and secant Newton methods with optional line search and the conjugate gradient method.

Nakazawa, S.↗

NASA NTRS2004

Subsurface Stress Fields in FCC Single Crystal Anisotropic Contacts

Single crystal superalloy turbine blades used in high pressure turbomachinery are subject to conditions of high temperature, triaxial steady and alternating stresses, fretting stresses in the blade attachment and damper contact locations, and exposure to high-pressure hydrogen. The blades are also subjected to extreme variations in temperature during start-up and shutdown transients. The most prevalent high cycle fatigue (HCF) failure modes observed in these blades during operation include crystallographic crack initiation/propagation on octahedral planes, and non-crystallographic initiation with crystallographic growth. Numerous cases of crack initiation and crack propagation at the blade leading edge tip, blade attachment regions, and damper contact locations have been documented. Understanding crack initiation/propagation under mixed-mode loading conditions is critical for establishing a systematic procedure for evaluating HCF life of single crystal turbine blades. This paper presents analytical and numerical techniques for evaluating two and three dimensional subsurface stress fields in anisotropic contacts. The subsurface stress results are required for evaluating contact fatigue life at damper contacts and dovetail attachment regions in single crystal nickel-base superalloy turbine blades. An analytical procedure is presented for evaluating the subsurface stresses in the elastic half-space, based on the adaptation of a stress function method outlined by Lekhnitskii. Numerical results are presented for cylindrical and spherical anisotropic contacts, using finite element analysis (FEA). Effects of crystal orientation on stress response and fatigue life are examined. Obtaining accurate subsurface stress results for anisotropic single crystal contact problems require extremely refined three-dimensional (3-D) finite element grids, especially in the edge of contact region. Obtaining resolved shear stresses (RSS) on the principal slip planes also involves considerable post-processing work. For these reasons it is very advantageous to develop analytical solution schemes for subsurface stresses, whenever possible.

Arakere, Nagaraj K.↗

NASA NTRSDate not supplied

Impact of Thermoplastic Composites: Testing and Modeling

Thermoplastic Composites (TPCs) are being increasingly considered for aerospace applications given their faster manufacturing cycles and lower cost. The NASA High-Rate Composite Aircraft Manufacturing (HiCAM) project aims to evaluate and mature thermoplastic manufacturing technologies to achieve a 4X – 6X increase in the production rate of Next Generation Single Aisle (NGSA) commercial aircraft. Within the purview of the NASA HiCAM project, this work investigates the response of thermoplastic composites under High Energy Dynamic Impact (HEDI) conditions. HEDI tests were conducted on panels fabricated with a carbon fiber reinforced low melt semi-crystalline resin TC1225 LMPAEK T700G (T700/LMPAEK) material system. A blunt metal projectile was chosen as the impactor which impacted the T700/LMPAEK panels over a range of impact velocities imparted by a gas gun test setup. As expected, lower velocity impacts caused the projectile to rebound, whereas higher velocity impacts resulted in the projectile penetrating the test panels. For the test cases in which the projectile rebounded, the predominant damage modes recorded with Ultrasonic (UT) scans included interlaminar delaminations which exhibited a “rotating fan” like structure when viewed in the through-thickness direction. Additionally, the dynamic deflection of the center point of the back face of the test panels and the velocity of the projectile was also measured during the test. Finite element models were developed to model a test case in which the projectile rebounded. These models were developed using LS-DYNA® wherein the primary objective was to evaluate the ability of the material model MAT299 to capture the dynamic response and damage modes in the T700/LMPAEK test panels. MAT299 is a Deformation Gradient Decomposition (DGD) based Continuum Damage Mechanics (CDM) material model. The interlaminar delaminations were modeled using the cohesive contact formulation available within LS-DYNA, wherein the mixed-mode fracture is captured via the Benzegaggh-Kenane (B-K) mode-dependent fracture energy interpolation law. The above-mentioned modeling methods have mostly been applied to thermoset composites and adapting them to TPCs involves addressing challenges associated with appropriately representing material behavior. Therefore, the proposed paper would discuss the systematic approach taken to adapt thermoset composites modeling practices for applications to TPCs, while appropriately addressing material behavior. The proposed paper would show that the predicted back face center point deflection correlated reasonably well with experimental data and the peak deflection was predicted to be within 5% of the experimental measurements. The projectile rebound velocity, while predicted to be higher than the experimental measurement, was within reasonable bounds. Additionally, it will be shown that the predicted delamination shapes were in reasonable agreement with experimental data.

Composite Materials↗

NASA NTRS1994

Modeling composite and fluffy grains: The effects of porosity

Recent studies of interplanetary and interstellar dust provide evidence that cosmic dust grains are fluffy, composite objects, highlighting the need for models of the electromagnetic scattering by these grains. Effective medium theory (EMT) with Mie-type series solutions has been used to explore the effects of porosity which would be important in composite dust particles. While this indirect approach is both flexible and computationally efficient, it is not necessarily a good approximation. The need for EMT and its rather restrictive assumptions may be circumvented through a direct computation of the scattering properties via finite element methods, such as the discrete dipole approximation (DDA). Recently, the utility of the DDA method has been advanced significantly through improvements in theory, in numerical algorithms, and in computer hardware. Extensive calculations with the DDA method are used here to examine more directly the effects of porosity. A particular emphasis is placed upon developing a valid methodology. For both solid and porous targets we establish both numerical and physical convergence properties over the range of size parameter that is required for our study. DDA cross sections for grains with a range of porosity are compared to those computed by the EMT/series expansion technique to examine the applicability of several mixing rules, including two extensions of the Bruggeman rule. We show that for particles with Rayleigh vacuum inclusions, the extension proposed by Rouleau & Martin is quite successful. We also investigate the effects of larger, non-Rayleigh vacuum inclusions for various levels of porosity and find that they can be significant.

Wolff, Michael J.↗

NASA NTRS2002

Probabilistic and Possibilistic Analyses of the Strength of a Bonded Joint

The effects of uncertainties on the predicted strength of a single lap shear joint are examined. Probabilistic and possibilistic methods are used to account for uncertainties. A total of ten variables are assumed to be random, with normal distributions. Both Monte Carlo Simulation and the First Order Reliability Method are used to determine the probability of failure. Triangular membership functions with upper and lower bounds located at plus or minus three standard deviations are used to model uncertainty in the possibilistic analysis. The alpha cut (or vertex) method is used to evaluate the possibility of failure. Linear and geometrically nonlinear finite element analyses are used calculate the response of the joint; fracture in the adhesive and material strength failure in the strap are used to evaluate its strength. Although probabilistic and possibilistic analyses provide significantly more information than do conventional deterministic analyses, they are computationally expensive. A novel scaling approach is developed and used to substantially reduce the computational cost of the probabilistic and possibilistic analyses. The possibilistic approach for treating uncertainties appears to be viable during the conceptual and preliminary design stages when limited data are available and high accuracies are not needed. However, this viability is mixed with several cautions that are discussed herein.

Stroud, W. Jefferson↗

NASA NTRS2016

In Search of a Time Efficient Approach to Crack and Delamination Growth Predictions in Composites

Analysis benchmarking was used to assess the accuracy and time efficiency of algorithms suitable for automated delamination growth analysis. First, the Floating Node Method (FNM) was introduced and its combination with a simple exponential growth law (Paris Law) and Virtual Crack Closure technique (VCCT) was discussed. Implementation of the method into a user element (UEL) in Abaqus/Standard(Registered TradeMark) was also presented. For the assessment of growth prediction capabilities, an existing benchmark case based on the Double Cantilever Beam (DCB) specimen was briefly summarized. Additionally, the development of new benchmark cases based on the Mixed-Mode Bending (MMB) specimen to assess the growth prediction capabilities under mixed-mode I/II conditions was discussed in detail. A comparison was presented, in which the benchmark cases were used to assess the existing low-cycle fatigue analysis tool in Abaqus/Standard(Registered TradeMark) in comparison to the FNM-VCCT fatigue growth analysis implementation. The low-cycle fatigue analysis tool in Abaqus/Standard(Registered TradeMark) was able to yield results that were in good agreement with the DCB benchmark example. Results for the MMB benchmark cases, however, only captured the trend correctly. The user element (FNM-VCCT) always yielded results that were in excellent agreement with all benchmark cases, at a fraction of the analysis time. The ability to assess the implementation of two methods in one finite element code illustrated the value of establishing benchmark solutions.

Krueger, Ronald↗

NASA NTRS1986

Elimination sequence optimization for SPAR

SPAR is a large-scale computer program for finite element structural analysis. The program allows user specification of the order in which the joints of a structure are to be eliminated since this order can have significant influence over solution performance, in terms of both storage requirements and computer time. An efficient elimination sequence can improve performance by over 50% for some problems. Obtaining such sequences, however, requires the expertise of an experienced user and can take hours of tedious effort to affect. Thus, an automatic elimination sequence optimizer would enhance productivity by reducing the analysts' problem definition time and by lowering computer costs. Two possible methods for automating the elimination sequence specifications were examined. Several algorithms based on the graph theory representations of sparse matrices were studied with mixed results. Significant improvement in the program performance was achieved, but sequencing by an experienced user still yields substantially better results. The initial results provide encouraging evidence that the potential benefits of such an automatic sequencer would be well worth the effort.

Hogan, Harry A.↗

NASA NTRS1987

Surface flaw reliability analysis of ceramic components with the SCARE finite element postprocessor program

The SCARE (Structural Ceramics Analysis and Reliability Evaluation) computer program on statistical fast fracture reliability analysis with quadratic elements for volume distributed imperfections is enhanced to include the use of linear finite elements and the capability of designing against concurrent surface flaw induced ceramic component failure. The SCARE code is presently coupled as a postprocessor to the MSC/NASTRAN general purpose, finite element analysis program. The improved version now includes the Weibull and Batdorf statistical failure theories for both surface and volume flaw based reliability analysis. The program uses the two-parameter Weibull fracture strength cumulative failure probability distribution model with the principle of independent action for poly-axial stress states, and Batdorf's shear-sensitive as well as shear-insensitive statistical theories. The shear-sensitive surface crack configurations include the Griffith crack and Griffith notch geometries, using the total critical coplanar strain energy release rate criterion to predict mixed-mode fracture. Weibull material parameters based on both surface and volume flaw induced fracture can also be calculated from modulus of rupture bar tests, using the least squares method with known specimen geometry and grouped fracture data. The statistical fast fracture theories for surface flaw induced failure, along with selected input and output formats and options, are summarized. An example problem to demonstrate various features of the program is included.

Gyekenyesi, John P.↗

NASA NTRS1987

Surface flaw reliability analysis of ceramic components with the SCARE finite element postprocessor program

Gyekenyesi, J. P.↗

NASA NTRS1982

Studies of implicit and explicit solution techniques in transient thermal analysis of structures

Studies aimed at an increase in the efficiency of calculating transient temperature fields in complex aerospace vehicle structures are reported. The advantages and disadvantages of explicit and implicit algorithms are discussed and a promising set of implicit algorithms with variable time steps, known as GEARIB, is described. Test problems, used for evaluating and comparing various algorithms, are discussed and finite element models of the configurations are described. These problems include a coarse model of the Space Shuttle wing, an insulated frame tst article, a metallic panel for a thermal protection system, and detailed models of sections of the Space Shuttle wing. Results generally indicate a preference for implicit over explicit algorithms for transient structural heat transfer problems when the governing equations are stiff (typical of many practical problems such as insulated metal structures). The effects on algorithm performance of different models of an insulated cylinder are demonstrated. The stiffness of the problem is highly sensitive to modeling details and careful modeling can reduce the stiffness of the equations to the extent that explicit methods may become the best choice. Preliminary applications of a mixed implicit-explicit algorithm and operator splitting techniques for speeding up the solution of the algebraic equations are also described.

Adelman, H. M.↗

NASA NTRSDate not supplied

Edge Based Viscous Method for Node-Centered Formulations

This paper presents a novel, efficient, conservative, edge-based method for evaluation of mean flow viscous fluxes and turbulence-model diffusion terms of the Reynolds-averaged Navier-Stokes equations on tetrahedral grids. The new method is implemented in a practical, node-centered, finite-volume computational fluid dynamics solver. The baseline finite-volume scheme that is equivalent to a second-order accurate finite-element Galerkin approximation of viscous stresses is reformulated. The order of operations to compute the cell-based Green-Gauss gradients is changed to combine the operations by edge, which leads to an equivalent formulation on tetrahedral grids, improves efficiency, and preserves the compact discretization stencil based on the nearest neighbors. The computational results presented in this paper verify the implementation of this edge-based method by comparing its accuracy and iterative convergence with those of the well verified and validated baseline formulation. Efficiency gains for residual and Jacobian evaluations result in significant reduction of time to solution. This novel edge-based formulation on tetrahedra can be seamlessly combined with the baseline formulation on cells of other types for computing solutions on mixed-element grids.

Edge Based↗

NASA NTRSDate not supplied

NASA Langley FUN3D Analyses in Support of the 1st AIAA Stability and Control Prediction Workshop

This work summarizes the results of FUN3D analyses conducted for the 1st AIAA Stability and Control Workshop on behalf of participants from the NASA Langley Research Center. The workshop was created to establish best practices for the prediction of stability and control derivatives using computational fluid dynamics and assess the limitations of these methods when those best practices are applied. The inaugural workshop considered the ONERA version of the NASA/Boeing Common Research Model, which includes the wing, body, horizontal tail, and a vertical tail designed by ONERA. Wind tunnel data at small sideslip angles remain unpublished and served as ‘blind’ data for computational comparisons. The present research generated workshop test case data using the NASA FUN3D code, which is a parallelized, unstructured, node-based, finite-volume discretization, Reynolds-averaged Navier-Stokes flow solver. Steady- state numerical simulations were conducted for workshop test cases investigating the following: grid convergence, Mach number effect on static stability, wind tunnel sting increments, static stability-derivative calculations, and a sideslip angle sweep. Results were generated for two series of unstructured, mixed-element grids, one set provided by the workshop and another set created using the HeldenMesh grid generation software. The results provided include total- and component-level breakdowns of the force and moment coefficients, in addition to sectional pressure distributions for the wing and tail components for comparisons to wind tunnel data.

CFD↗

NASA NTRS1997

Flowfield-Dependent Mixed Explicit-Implicit (FDMEL) Algorithm for Computational Fluid Dynamics

Despite significant achievements in computational fluid dynamics, there still remain many fluid flow phenomena not well understood. For example, the prediction of temperature distributions is inaccurate when temperature gradients are high, particularly in shock wave turbulent boundary layer interactions close to the wall. Complexities of fluid flow phenomena include transition to turbulence, relaminarization separated flows, transition between viscous and inviscid incompressible and compressible flows, among others, in all speed regimes. The purpose of this paper is to introduce a new approach, called the Flowfield-Dependent Mixed Explicit-Implicit (FDMEI) method, in an attempt to resolve these difficult issues in Computational Fluid Dynamics (CFD). In this process, a total of six implicitness parameters characteristic of the current flowfield are introduced. They are calculated from the current flowfield or changes of Mach numbers, Reynolds numbers, Peclet numbers, and Damkoehler numbers (if reacting) at each nodal point and time step. This implies that every nodal point or element is provided with different or unique numerical scheme according to their current flowfield situations, whether compressible, incompressible, viscous, inviscid, laminar, turbulent, reacting, or nonreacting. In this procedure, discontinuities or fluctuations of an variables between adjacent nodal points are determined accurately. If these implicitness parameters are fixed to certain numbers instead of being calculated from the flowfield information, then practically all currently available schemes of finite differences or finite elements arise as special cases. Some benchmark problems to be presented in this paper will show the validity, accuracy, and efficiency of the proposed methodology.

Garcia, S. M.↗

NASA NTRS2008

Towards Verification of Unstructured-Grid Solvers

New methodology for verification of finite-volume computational methods using unstructured grids is presented. The discretization order properties are studied in computational windows, easily constructed within a collection of grids or a single grid. Tests are performed within each window and address a combination of problem-, solution-, and discretization/grid-related features affecting discretization error convergence. The windows can be adjusted to isolate particular elements of the computational scheme, such as the interior discretization, the boundary discretization, or singularities. Studies can use traditional grid-refinement computations within a fixed window or downscaling, a recently-introduced technique in which computations are made within windows contracting toward a focal point of interest. Grids within the windows are constrained to be consistently refined, allowing a meaningful assessment of asymptotic error convergence on unstructured grids. Demonstrations of the method are shown, including a comparative accuracy assessment of commonly-used schemes on general mixed grids and the identification of local accuracy deterioration at boundary intersections. Recommendations to enable attainment of design-order discretization errors for large-scale computational simulations are given.

Thomas, James L.↗

NASA NTRS2004

Penalty-Based Interface Technology for Prediction of Delamination Growth in Laminated Structures

An effective interface element technology has been developed for connecting and simulating crack growth between independently modeled finite element subdomains (e.g., composite plies). This method has been developed using penalty constraints and allows coupling of finite element models whose nodes do not necessarily coincide along their common interface. Additionally, the present formulation leads to a computational approach that is very efficient and completely compatible with existing commercial software. The present interface element has been implemented in the commercial finite element code ABAQUS as a User Element Subroutine (UEL), making it easy to test the approach for a wide range of problems. The interface element technology has been formulated to simulate delamination growth in composite laminates. Thanks to its special features, the interface element approach makes it possible to release portions of the interface surface whose length is smaller than that of the finite elements. In addition, the penalty parameter can vary within the interface element, allowing the damage model to be applied to a desired fraction of the interface between the two meshes. Results for double cantilever beam DCB, end-loaded split (ELS) and fixed-ratio mixed mode (FRMM) specimens are presented. These results are compared to measured data to assess the ability of the present damage model to simulate crack growth.

Averill, Ronald C.↗

NASA NTRS2016

Multiscale Static Analysis of Notched and Unnotched Laminates Using the Generalized Method of Cells

The generalized method of cells (GMC) is demonstrated to be a viable micromechanics tool for predicting the deformation and failure response of laminated composites, with and without notches, subjected to tensile and compressive static loading. Given the axial [0], transverse [90], and shear [+45/-45] response of a carbon/epoxy (IM7/977-3) system, the unnotched and notched behavior of three multidirectional layups (Layup 1: [0,45,90,-45](sub 2S), Layup 2: [0,60,0](sub 3S), and Layup 3: [30,60,90,-30, -60](sub 2S)) are predicted under both tensile and compressive static loading. Matrix nonlinearity is modeled in two ways. The first assumes all nonlinearity is due to anisotropic progressive damage of the matrix only, which is modeled, using the multiaxial mixed-mode continuum damage model (MMCDM) within GMC. The second utilizes matrix plasticity coupled with brittle final failure based on the maximum principle strain criteria to account for matrix nonlinearity and failure within the Finite Element Analysis--Micromechanics Analysis Code (FEAMAC) software multiscale framework. Both MMCDM and plasticity models incorporate brittle strain- and stress-based failure criteria for the fiber. Upon satisfaction of these criteria, the fiber properties are immediately reduced to a nominal value. The constitutive response for each constituent (fiber and matrix) is characterized using a combination of vendor data and the axial, transverse, and shear responses of unnotched laminates. Then, the capability of the multiscale methodology is assessed by performing blind predictions of the mentioned notched and unnotched composite laminates response under tensile and compressive loading. Tabulated data along with the detailed results (i.e., stress-strain curves as well as damage evolution states at various ratios of strain to failure) for all laminates are presented.

GMC↗

NASA NTRS2002

Analysis of Graphite-Reinforced Cementitious Composites

Strategically embedding graphite meshes in a compliant cementitious matrix produces a composite material with relatively high tension and compressive properties as compared to steel-reinforced structures fabricated from a standard concrete mix. Although these composite systems are somewhat similar, the methods used to analyze steel-reinforced composites often fail to characterize the behavior of their more advanced graphite-reinforced counterparts. This Technical Memorandum describes some of the analytical methods being developed to determine the deflections and stresses in graphite-reinforced cementitious composites. It is initially demonstrated that the standard transform section method fails to provide accurate results when the elastic moduli ratio exceeds 20. An alternate approach is formulated by using the rule of mixtures to determine a set of effective material properties for the composite. Tensile tests are conducted on composite samples to verify this approach. When the effective material properties are used to characterize the deflections of composite beams subjected to pure bending, an excellent agreement is obtained. Laminated composite plate theory is investigated as a means for analyzing even more complex composites, consisting of multiple graphite layers oriented in different directions. In this case, composite beams are analyzed using the laminated composite plate theory with material properties established from tensile tests. Then, finite element modeling is used to verify the results. Considering the complexity of the samples, a very good agreement is obtained.

Vaughan, R. E.↗