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DOE OSTI2024

Evaluation of Surface Crack Formation in Photovoltaic Backsheets Using Fragmentation and Finite Element Simulations

Backsheet cracking is among the most commonly observed degradation modes of photovoltaic modules in the field. Cracks can reduce the ability of backsheets to fulfill their functions, such as protection of the modules from the environment or electrical insulation. Here, this work presents an evaluation of the degradation and cracking propensity of two backsheets during accelerated IEC TS 62788-7-2 (International Electrotechnical Commission) aging under the A3 condition with a fragmentation test using a coextruded polyamide backsheet (AAA), and a laminated multilayer backsheet with a polyethylene terephthalate core and outer layer and ethylene vinyl acetate inner layer (PPE). Results show the surface embrittlement of the AAA outer layer during exposure. A longer time of exposure causes cracks to form at lower strains during stretching and creates deeper cracks. Accordingly, Young's modulus of the outer layer increases, as measured by cross-sectional nanoindentation. PPE exhibits cracking after exposure as well. While no similar increase of modulus or crack depth can be observed, the outer layer of PPE exhibits more obvious signs of erosion during exposure, including progressive morphological changes and thickness losses. A finite element model is developed to simulate surface crack formation, based on initially zero-thickness decohesion elements. Decohesion criteria define a critical stress, at which these elements grow, and cracks can begin to form. These criteria are obtained via parameter optimization by comparison between simulation and experiment. The model is used to interpret crack formation in both backsheets.

14 SOLAR ENERGY↗

NASA NTRS1986

Application of physical parameter identification to finite element models

A time domain technique for matching response predictions of a structural dynamic model to test measurements is developed. Significance is attached to prior estimates of physical model parameters and to experimental data. The Bayesian estimation procedure allows confidence levels in predicted physical and modal parameters to be obtained. Structural optimization procedures are employed to minimize an error functional with physical model parameters describing the finite element model as design variables. The number of complete FEM analyses are reduced using approximation concepts, including the recently developed convoluted Taylor series approach. The error function is represented in closed form by converting free decay test data to a time series model using Prony' method. The technique is demonstrated on simulated response of a simple truss structure.

Bronowicki, Allen J.↗

DOE OSTI2026

An implicit-explicit time splitting strategy for the far SOL plasma fluid model with DG-FEM discretization

We consider a far scrape-off layer (SOL) plasma fluid model of ions that is governed by a Braginskiitype model: a one-dimensional, nonlinear system of advection-diffusion equations coupled with a diffusion equation for neutral particles. Our motivation for studying this system arises from the coupling between the edge plasma and radio-frequency (RF) heating, where solving a far SOL plasma fluid model provides critical insights into edge plasma dynamics. Numerical simulations of plasma fluid models require advanced computational techniques to achieve both efficiency and accuracy, especially when resolving the boundary layer in magnetically confined plasmas. In this work, we propose an implicit-explicit time operator splitting strategy that allows for an efficient solution algorithm, where the diffusive terms are treated semi-implicitly requiring only a linear solve, while the advection part is handled explicitly using a strong-stability-preserving Runge-Kutta (SSP-RK3) scheme. This leads to a fully decoupled system in which the diffusion and advection sub-problems can be solved separately, simplifying the overall solution procedure and allowing for efficient parallelization, which is particularly relevant for exploring the impact of RF heating on the SOL plasma. The main challenge of the discretization is due to the strong coupling between diffusion and advection, particularly through the boundary conditions. This makes implementation of such a scheme in an accurate and stable manner nontrivial. We discuss in detail how to split the equations and manage boundary conditions to maintain stability and well-posedness for each subsystem. We also describe a spatial discretization approach, based on the discontinuous Galerkin finite element method (DG-FEM) and present numerical results for a one-dimensional system.

Burkovska, Olena [ORNL] (ORCID:0000000163101130)↗

NASA NTRS2003

Development of a Fatigue Crack Growth Coupon for Highly Plastic Stress Conditions

This paper presents an analytical approach used to develop a novel fatigue crack growth coupon for a highly plastic 3-D stress field condition. The flight hardware investigated in this paper is a large separation bolt that fractures using pyrotechnics at the appointed time during the flight sequence. The separation bolt has a deep notch that produces a severe stress concentration and a large plastic zone when highly loaded. For this geometry, linear-elastic fracture mechanics (LEFM) techniques are not valid due to the large nonlinear stress field. Unfortunately, industry codes that are generally available for fracture mechanics analysis and fatigue crack growth (e.g. NASGRO (11) are limited to LEFM and are available for only a limited number of geometries. The results of LEFM based codes are questionable when used on geometries with significant plasticity. Therefore elastic-plastic fracture mechanics (EPFM) techniques using the finite element method (FEM) were used to analyze the bolt and test coupons. scale flight hardware is very costly in t e r n of assets, laboratory resources, and schedule. Therefore to alleviate some of these problems, a series of novel test coupons were developed to simulate the elastic-plastic stress field present in the bolt.

Allen, Phillip A.↗

NASA NTRSDate not supplied

Classical Flutter Analysis of X-57 Aircraft Mod II, III, and IV Configurations

To support airworthiness assessment of the X-57 electric propulsion demonstrator aircraft, the National Aeronautics and Space Administration (NASA) completed classical flutter analysis of the Mod II, Mod III, and Mod IV aircraft configurations. Aeroelastic analysis was primarily performed using the ZAERO analysis code developed by Zona Technology. Supplemental computational fluid dynamics (CFD) flutter analysis for the Mod III and Mod IV configurations was performed using NASA’s FUN3D software to verify the aeroelastic behavior at deployed flaps conditions. The NASTRAN finite element models (FEMs) used for aeroelastic analysis were developed by NASA. The final Mod II FEM utilized shell elements for the wing and fuselage, and beam elements for the tail and wing control surfaces. For Mod III and Mod IV aircraft models, shell element wing FEMs developed throughout the Mod III/IV wing design cycle were utilized. The fuselage and empennage FEM components were shared between the Mod II, III, and IV aircraft models. ZAERO analyses predicted flutter boundaries were >60% beyond the X-57 flight-test envelope never exceed airspeed (V NE ) for all configurations. Aeroelastic Reynolds-averaged Navier–Stokes (RANS) CFD simulations using FUN3D of the Mod III/IV configurations predicted flap mode instability did not occur until at least speeds of 60% higher than the Mod III/IV maximum flap deployment airspeed (V FE ).

Keerti K. Bhamidipati↗

NASA NTRS1990

Computational technology for flight vehicles; Proceedings of the Symposium, Washington, DC, Nov. 5-7, 1990

Recent advances in computational fluid mechanics are discussed in reviews and reports. Sections are devoted to (1) the modeling of local phenomena and edge effects in solids, (2) stochastic modeling and simulation of fracture toughness, and (3) partitioning strategy and new finite elements. Particular attention is given to global and local finite-element/spectral-boundary-element techniques for failure analysis, simulations of microfracture in metal-matrix composites, fatigue analysis of cracked anisotropic plates under stochastic loading, mathematical modeling for the analysis of nonlinear aircraft dynamics, physical and mathematical modeling of wave propagation in the Ariane 5 VEB structure, partitioning based on symmetry transformations, an FEM approach to adaptive reliability assurance, and time-domain FEMs for the large rotational dynamics of multibody systems.

Noor, Ahmed K.↗

DOE OSTI2020

Hydro-mechanical coupled modeling of hydraulic fracturing using the mesh fragmentation technique

The inclusion of special interface elements between standard finite elements is becoming a common technique to model discontinuities in porous media using the finite element method (FEM). Recently, it was proved that high aspect ratio (HAR) elements can reproduce very satisfactorily the main features of behavior observed in a single hydraulically-induced fracture. In this paper, the mesh fragmentation technique (MFT) is proposed to extend the application of HAR elements to simulate more general problems involving the formation of hydraulic fractures in rocks by introducing this type of element in-between the standard FE of a typical mesh. The proposed framework makes use of standard FE techniques. Therefore, it is relatively easy to upgrade an existing FE program for continuous porous media to deal with evolving discontinuities. The proposed approach is verified and validated against available analytical and numerical solutions. The crack patterns predicted by the MFT are also compared with the ones observed in the laboratory. The formation of multiple fractures is also analyzed. In all cases, the proposed technique was able to properly capture the main features of rock behavior subjected to hydraulic fracturing.

58 GEOSCIENCES↗

NASA NTRS1992

Probabilistic evaluation of uncertainties and risks in aerospace components

A methodology is presented for the computational simulation of primitive variable uncertainties, and attention is given to the simulation of specific aerospace components. Specific examples treated encompass a probabilistic material behavior model, as well as static, dynamic, and fatigue/damage analyses of a turbine blade in a mistuned bladed rotor in the SSME turbopumps. An account is given of the use of the NESSES probabilistic FEM analysis CFD code.

Shah, A. R.↗

NASA NTRS2011

Development and Verification of the Charring, Ablating Thermal Protection Implicit System Simulator

The development and verification of the Charring Ablating Thermal Protection Implicit System Solver (CATPISS) is presented. This work concentrates on the derivation and verification of the stationary grid terms in the equations that govern three-dimensional heat and mass transfer for charring thermal protection systems including pyrolysis gas flow through the porous char layer. The governing equations are discretized according to the Galerkin finite element method (FEM) with first and second order fully implicit time integrators. The governing equations are fully coupled and are solved in parallel via Newton s method, while the linear system is solved via the Generalized Minimum Residual method (GMRES). Verification results from exact solutions and Method of Manufactured Solutions (MMS) are presented to show spatial and temporal orders of accuracy as well as nonlinear convergence rates.

Amar, Adam J.↗

NASA NTRS1995

Parallelized modelling and solution scheme for hierarchically scaled simulations

This two-part paper presents the results of a benchmarked analytical-numerical investigation into the operational characteristics of a unified parallel processing strategy for implicit fluid mechanics formulations. This hierarchical poly tree (HPT) strategy is based on multilevel substructural decomposition. The Tree morphology is chosen to minimize memory, communications and computational effort. The methodology is general enough to apply to existing finite difference (FD), finite element (FEM), finite volume (FV) or spectral element (SE) based computer programs without an extensive rewrite of code. In addition to finding large reductions in memory, communications, and computational effort associated with a parallel computing environment, substantial reductions are generated in the sequential mode of application. Such improvements grow with increasing problem size. Along with a theoretical development of general 2-D and 3-D HPT, several techniques for expanding the problem size that the current generation of computers are capable of solving, are presented and discussed. Among these techniques are several interpolative reduction methods. It was found that by combining several of these techniques that a relatively small interpolative reduction resulted in substantial performance gains. Several other unique features/benefits are discussed in this paper. Along with Part 1's theoretical development, Part 2 presents a numerical approach to the HPT along with four prototype CFD applications. These demonstrate the potential of the HPT strategy.

Padovan, Joe↗

NASA NTRS2010

Ares I-X Flight Test Vehicle Modal Test

The first test flight of NASA's Ares I crew launch vehicle, called Ares I-X, was launched on October 28, 2009. Ares I-X used a 4-segment reusable solid rocket booster from the Space Shuttle heritage with mass simulators for the 5th segment, upper stage, crew module and launch abort system. Flight test data will provide important information on ascent loads, vehicle control, separation, and first stage reentry dynamics. As part of hardware verification, a series of modal tests were designed to verify the dynamic finite element model (FEM) used in loads assessments and flight control evaluations. Based on flight control system studies, the critical modes were the first three free-free bending mode pairs. Since a test of the free-free vehicle was not practical within project constraints, modal tests for several configurations during vehicle stacking were defined to calibrate the FEM. Test configurations included two partial stacks and the full Ares I-X flight test vehicle on the Mobile Launcher Platform. This report describes the test requirements, constraints, pre-test analysis, test execution and results for the Ares I-X flight test vehicle modal test on the Mobile Launcher Platform. Initial comparisons between pre-test predictions and test data are also presented.

Buehrle, Ralph D.↗

NASA NTRS2010

Ares I-X Launch Vehicle Modal Test Overview

The first test flight of NASA's Ares I crew launch vehicle, called Ares I-X, is scheduled for launch in 2009. Ares IX will use a 4-segment reusable solid rocket booster from the Space Shuttle heritage with mass simulators for the 5th segment, upper stage, crew module and launch abort system. Flight test data will provide important information on ascent loads, vehicle control, separation, and first stage reentry dynamics. As part of hardware verification, a series of modal tests were designed to verify the dynamic finite element model (FEM) used in loads assessments and flight control evaluations. Based on flight control system studies, the critical modes were the first three free-free bending mode pairs. Since a test of the free-free vehicle is not practical within project constraints, modal tests for several configurations in the nominal integration flow were defined to calibrate the FEM. A traceability study by Aerospace Corporation was used to identify the critical modes for the tested configurations. Test configurations included two partial stacks and the full Ares I-X launch vehicle on the Mobile Launcher Platform. This paper provides an overview for companion papers in the Ares I-X Modal Test Session. The requirements flow down, pre-test analysis, constraints and overall test planning are described.

Buehrle, Ralph D.↗

NASA NTRS2000

Ordering Unstructured Meshes for Sparse Matrix Computations on Leading Parallel Systems

The ability of computers to solve hitherto intractable problems and simulate complex processes using mathematical models makes them an indispensable part of modern science and engineering. Computer simulations of large-scale realistic applications usually require solving a set of non-linear partial differential equations (PDES) over a finite region. For example, one thrust area in the DOE Grand Challenge projects is to design future accelerators such as the SpaHation Neutron Source (SNS). Our colleagues at SLAC need to model complex RFQ cavities with large aspect ratios. Unstructured grids are currently used to resolve the small features in a large computational domain; dynamic mesh adaptation will be added in the future for additional efficiency. The PDEs for electromagnetics are discretized by the FEM method, which leads to a generalized eigenvalue problem Kx = AMx, where K and M are the stiffness and mass matrices, and are very sparse. In a typical cavity model, the number of degrees of freedom is about one million. For such large eigenproblems, direct solution techniques quickly reach the memory limits. Instead, the most widely-used methods are Krylov subspace methods, such as Lanczos or Jacobi-Davidson. In all the Krylov-based algorithms, sparse matrix-vector multiplication (SPMV) must be performed repeatedly. Therefore, the efficiency of SPMV usually determines the eigensolver speed. SPMV is also one of the most heavily used kernels in large-scale numerical simulations.

Oliker, Leonid↗

NASA NTRS1993

An explicit solution to the optimal LQG problem for flexible structures with collocated rate sensors

We present a class of compensators in explicit form (not requiring numerical computer calculations) for stabilizing flexible structures with collocated rate sensors. They are based on the explicit solution, valid for both Continuum and FEM Models, of the LQG problem for minimizing mean square rate. They are robust with respect to system stability (will not destabilize modes even with mismatch of parameters), can be instrumented in state space form suitable for digital controllers, and can be specified directly from the structure modes and mode 'signature' (displacement vectors at sensor locations). Some simulation results are presented for the NASA LaRC Phase-Zero Evolutionary Model - a modal Trust model with 86 modes - showing damping ratios attainable as a function of compensator design parameters and complexity.

Balakrishnan, A. V.↗

NASA NTRSDate not supplied

Solar Cruiser TRAC Boom Development

The TRAC boom studied is a 30 meter, high-aspect ratio and highly nonlinear structural element planned for the NASA Solar Cruiser spacecraft where it would serve as the solar sail’s skeletal system designed to deploy the packaged reflective sail membrane as well as support operational sail tension loads for flight. Key design drivers for this boom are understanding and characterizing load-deformation behavior and quantifying buckling performance–under flight conditions (zero gravity). Knowing that the full-scale solar sail system cannot be feasibly tested for flight conditions under Earth’s gravity, a building block approach is methodically followed to verify finite element analysis (FEA) predictions and to evolve the finite element model (FEM) accordingly, beginning with the lowest level complexity to match global elastic behavior to the highest level complexity to bound theoretical responses under conservative expected flight conditions. Although the testing campaign for the TRAC boom has not developed yet to produce a full-scale test data point that loads the boom to failure, the fidelity of simulations have evolved with success and warrant further interest and work on this high-aspect ratio, but highly stable, deployable structural boom.

Lee Nguyen↗

NASA NTRS1995

Simulation of thin slot spirals and dual circular patch antennas using the finite element method with mixed elements

This semi-annual report describes progress up to mid-January 1995. The report contains five sections all dealing with the modeling of spiral and patch antennas recessed in metallic platforms. Of significance is the development of decomposition schemes which separate the different regions of the antenna volume. Substantial effort was devoted to improving the feed model in the context of the finite element method (FEM). Finally, an innovative scheme for truncating finite element meshes is presented.

Gong, Jian↗

DOE OSTI2022

Forward and inverse modeling of fault transmissibility in subsurface flows

Characterizing physical properties of faults, such as their transmissibility, is crucial for performing predictive numerical simulation of subsurface flows, such as those encountered in petroleum engineering and remediation of subsurface contamination. Here, this paper provides a complete investigation of the inverse problem for fault transmissibility in subsurface flow models, under appropriate assumptions on fault structure. In particular, the following aspects are considered: 1) fault modeling and well-posedness of the forward problem; 2) finite element (FEM) discretizations of the forward problem and their rigorous a priori convergence analysis; 3) Well-posedness of the Bayesian inverse problem, FEM discretization of the infinite dimensional Bayesian inverse formulation, and its rigorous a priori analysis. Moreover, computation of the maximum a posteriori (MAP) point via fast inexact Newton-conjugate gradient optimization and a Laplace approximation of the Bayesian posterior are also presented. Numerical results illustrate the use of the proposed fault model in forward and inverse problems for subsurface flows in two dimensional domains with multiple faults.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS2018

Advanced Mirror Technology Development (AMTD) II Modal Test of A 1.5 m Glass Slumped Mirror

The Advanced Mirror Technology Development (AMTD) project is in Phase 2 of a multiyear effort initiated in Fiscal Year 2012 to mature toward the next technology readiness level critical technologies required to enable 4-m-or-larger monolithic or segmented ultraviolet, optical, and infrared (UVOIR) space telescope primary-mirror assemblies for general astrophysics and ultra-high-contrast observations of exoplanets. As part of AMTD II, a free-free modal test was performed of a light weighted slumped 1.5 m mirror made of Corning Ultra Low Expansion (ULE®) material. The test article and support structure were suspended via bungee to simulate a free-free environment. Modes were excited by roaming an instrumented modal test hammer and responses were measured. Predicted and measured frequencies are presented as well as Modal Assurance Criteria (MAC) results to compare the mode shapes. The finite element mirror model used for pre-test predictions and posttest comparisons was provided by the mirror vendor, Harris Corporation. The mirror FEM included deformations of the ribs that were a result of the slumping process. Modal test frequencies matched predictions within the 5% target with the exception of one mode and that pair differed by 5.2%. Of the seven modes measured and predicted, four had MAC values meeting the target of ≥ 0.90, one was just under and two were notably below the target.

Knight, J. Brent↗