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At least 271 records · Page 15

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NASA NTRS1996

Micromechanics Analysis Code (MAC). User Guide: Version 2.0

The ability to accurately predict the thermomechanical deformation response of advanced composite materials continues to play an important role in the development of these strategic materials. Analytical models that predict the effective behavior of composites are used not only by engineers performing structural analysis of large-scale composite components but also by material scientists in developing new material systems. For an analytical model to fulfill these two distinct functions it must be based on a micromechanics approach which utilizes physically based deformation and life constitutive models and allows one to generate the average (macro) response of a composite material given the properties of the individual constituents and their geometric arrangement. Here the user guide for the recently developed, computationally efficient and comprehensive micromechanics analysis code's (MAC) who's predictive capability rests entirely upon the fully analytical generalized method of cells (GMC), micromechanics model is described. MAC is a versatile form of research software that 'drives' the double or triply periodic micromechanics constitutive models based upon GMC. MAC enhances the basic capabilities of GMC by providing a modular framework wherein (1) various thermal, mechanical (stress or strain control) and thermomechanical load histories can be imposed, (2) different integration algorithms may be selected, (3) a variety of constituent constitutive models may be utilized and/or implemented, and (4) a variety of fiber and laminate architectures may be easily accessed through their corresponding representative volume elements.

Wilt, T. E.↗

NASA NTRS1999

Micromechanics Analysis Code With Generalized Method of Cells (MAC/GMC): User Guide

The ability to accurately predict the thermomechanical deformation response of advanced composite materials continues to play an important role in the development of these strategic materials. Analytical models that predict the effective behavior of composites are used not only by engineers performing structural analysis of large-scale composite components but also by material scientists in developing new material systems. For an analytical model to fulfill these two distinct functions it must be based on a micromechanics approach which utilizes physically based deformation and life constitutive models and allows one to generate the average (macro) response of a composite material given the properties of the individual constituents and their geometric arrangement. Here the user guide for the recently developed, computationally efficient and comprehensive micromechanics analysis code, MAC, who's predictive capability rests entirely upon the fully analytical generalized method of cells, GMC, micromechanics model is described. MAC/ GMC is a versatile form of research software that "drives" the double or triply periodic micromechanics constitutive models based upon GMC. MAC/GMC enhances the basic capabilities of GMC by providing a modular framework wherein 1) various thermal, mechanical (stress or strain control) and thermomechanical load histories can be imposed, 2) different integration algorithms may be selected, 3) a variety of material constitutive models (both deformation and life) may be utilized and/or implemented, and 4) a variety of fiber architectures (both unidirectional, laminate and woven) may be easily accessed through their corresponding representative volume elements contained within the supplied library of RVEs or input directly by the user, and 5) graphical post processing of the macro and/or micro field quantities is made available.

Arnold, S. M.↗

DOE OSTI2021

A constitutive model for glass–ceramic materials

Glass–ceramics have received recent attention for use in glass–ceramic to metal hermetic seals. Due to their heterogeneous microstructure, these materials exhibit a number of advantageous responses over conventional glass based seals. Key amongst them is the possibility of a controllable thermal strain response and apparent coefficient of thermal expansion which may be used to minimize thermally induced residual stresses for aforementioned seals. Furthermore, these behaviors result from an inorganic glass matrix and variety of crystalline ceramic phases including silica polymorph(s) that may undergo reversible solid-to-solid transformations with associated inelastic strain. Correspondingly, these materials exhibit complex thermomechanical responses associated with multiple inelastic mechanisms (viscoelasticity and phase transformation). While modeling these behaviors is essential for developing and analyzing the corresponding applications, no such model exists. Therefore, in this work a three-dimensional continuum constitutive model for glass–ceramic materials combining these various inelastic mechanisms is developed via an internal state variable approach. A corresponding fully implicit three dimensional numerical formulation is also proposed and implemented. The model is used to simulate existing experiments and validate the proposed formalism. As an example, the simple seal problem of a glass–ceramic seal inside a concentric metal shell is explored. Finally, the impact of the cooling rates, viscoelastic shift factors, and inelastic strain on final residual stress state are all investigated and the differing contributions highlighted.

36 MATERIALS SCIENCE↗

NASA NTRS1992

End-to-end modelling of He II flow systems

A practical computer code has been developed which uses the accepted two-fluid model to simulate He II flow in complicated systems. The full set of equations are used, retaining the coupling between the pressure, temperature and velocity fields. This permits modeling He II flow over the full range of conditions, from strongly or weakly driven flow through large pipes, narrow channels and porous media. The system may include most of the components used in modern superfluid flow systems: non-ideal thermomechanical pumps, tapered sections, constrictions, lines with heated side walls and heat exchangers. The model is validated by comparison with published experimental data. It is applied to a complex system to show some of the non-intuitive feedback effects that can occur. This code is ready to be used as a design tool for practical applications of He II. It can also be used for the design of He II experiments and as a tool for comparison of experimental data with the standard two-fluid model.

Mord, A. J.↗

NASA NTRS1990

Local stresses in metal matrix composites subjected to thermal and mechanical loading

An elasticity solution has been used to analyze matrix stresses near the fiber/matrix interface in continuous fiber-reinforced metal-matrix composites, modeling the micromechanics in question in terms of a cylindrical fiber and cylindrical matrix sheath which is embedded in an orthotropic medium representing the composite. The model's predictions for lamina thermal and mechanical properties are applied to a laminate analysis determining ply-level stresses due to thermomechanical loading. A comparison is made between these results, which assume cylindrical symmetry, and the predictions yielded by a FEM model in which the fibers are arranged in a square array.

Highsmith, Alton L.↗

NASA NTRS1984

A computer program for predicting nonlinear uniaxial material responses using viscoplastic models

A computer program was developed for predicting nonlinear uniaxial material responses using viscoplastic constitutive models. Four specific models, i.e., those due to Miller, Walker, Krieg-Swearengen-Rhode, and Robinson, are included. Any other unified model is easily implemented into the program in the form of subroutines. Analysis features include stress-strain cycling, creep response, stress relaxation, thermomechanical fatigue loop, or any combination of these responses. An outline is given on the theoretical background of uniaxial constitutive models, analysis procedure, and numerical integration methods for solving the nonlinear constitutive equations. In addition, a discussion on the computer program implementation is also given. Finally, seven numerical examples are included to demonstrate the versatility of the computer program developed.

Chang, T. Y.↗

NASA NTRS2023

Thermomechanical Real-Time Hybrid Simulation: Conceptual Framework and Control Requirements

Real-time hybrid simulation (RTHS) is an enabling technology that has transformed engineering experimentation and helped researchers expand modeling capabilities. However, breakthroughs are necessary to expand the range of hybrid simulation methods and, thus, enable experiments with loading conditions representing multiple hazards. This paper discusses the development of a new thermomechanical RTHS framework and a systematic approach to determining RTHS control requirements. First, the framework is established using a representative finite element model of a layered structural system subjected to thermal loading. A complete two-layer system model serves as the reference system, and it is then partitioned into a numerical layer and an experimental layer that share interface conditions. Next, a thermal actuator is introduced to impose dynamic thermal loading on the experimental subsystem, serving as a transfer system. Finally, control and performance metrics are defined to evaluate the realization of interface boundary conditions and map this to the RTHS execution. Through an illustrative example considering the influence of temperature on a lunar habitat, we demonstrate how to establish controller requirements for RTHS and demonstrate that this approach can be used to conduct RTHS on structures with thermomechanical loading.

Herta Montoya↗

DOE OSTI2021

Multiobjective Dynamic Optimization for Optimal Load-Following of Natural Gas Combined Cycle Power Plants under Stress Constraints

With the increasing penetration of intermittent renewable energy sources into the electric grid, there is an associated need for conventional thermal power plants that are designed to operate at base-load conditions to cycle their load rapidly and frequently and operate under low-load conditions. Fast load-following operations lead to plant efficiency loss and the reduction of equipment life. A high-fidelity dynamic model of a natural gas combined cycle power plant, with rigorous equipment level submodels, is developed to capture the plant transient performance and the thermomechanical stress evolution at the high-pressure drum is computed to assess the drum life consumption. Stress evolution is modeled for the location of the edge at the drum/downcomer junction that experiences high circumferential stress amplitude during the fast load-following operation, leading to higher fatigue damage than locations considered under existing design standards. A dynamic optimization problem is solved for optimal load-following operation. Depending on the value of the stress constraint and the desired ramp rate, satisfying the desired stress constraint may be infeasible without relaxing the ramp rate. A multiobjective dynamic optimization problem is solved using a lexicographic approach that minimizes ramp rate relaxation and maximizes efficiency while satisfying stress constraints, avoiding spraying to saturation, and maintaining main steam and reheat steam temperature within bounds. It was observed that the optimal ramp rate can be highly nonlinear as opposed to the industry-standard linear ramp rate. Nonlinear optimal ramp-rate profiles not only help to avoid stress constraints that may be unavoidable by using the linear profile but also result in higher efficiency than the linear profile. Furthermore, the study shows that there is a strong tradeoff between the relaxation in the plant ramp rate and the time-average thermal efficiency.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Machine learning prediction of glass transition temperature of conjugated polymers from chemical structure

Predicting the glass transition temperature (T g ) is of critical importance as it governs the thermomechanical performance of conjugated polymers (CPs). Here, we report a predictive modeling framework to predict T g of CPs through the integration of machine learning (ML), molecular dynamics (MD) simulations, and experiments. With 154 T g data collected, an ML model is developed by taking simplified “geometry” of six chemical building blocks as molecular features, where side-chain fraction, isolated rings, fused rings, and bridged rings features are identified as the dominant ones for T g . MD simulations further unravel the fundamental roles of those chemical building blocks in dynamical heterogeneity and local mobility of CPs at a molecular level. The developed ML model is demonstrated for its capability of predicting T g of several new high-performance solar cell materials to a good approximation. The established predictive framework facilitates the design and prediction of T g of complex CPs, paving the way for addressing device stability issues that have hampered the field from developing stable organic electronics.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1985

Creep fatigue life prediction for engine hot section materials (isotropic): Third year progress review

This program is designed to investigate fundamental damage processes, identify modeling strategies, and develop practical models which can be used to guide the early design and development of new engines and to increase the durability of existing engines. A review is given of the base program, completed in 1984, which included the comparison and evaluation of several popular high-temperature life prediction approaches as applied to continuously cycled isothermal specimen tests. The option program, of which one year is completed, is designed to develop models which can account for complex cycles and loadings, such as thermomechanical cycling, cumulative damage, multiaxial stress/strain rates, and environmental effects.

Nelson, Richard S.↗

NASA NTRS1992

Thermomechanical deformation behavior of a dynamic strain aging alloy, Hastelloy X

An experimental study was performed to identify the effects of dynamic strain aging (solute drag) and metallurgical instabilities under thermomechanical loading conditions. The study involved a series of closely controlled thermomechanical deformation tests on the solid-solution-strenghened nickel-base superalloy, Hastelloy X. This alloy exhibits a strong isothermal strain aging peak at approximately 600 C, promoted by the effects of solute drag and precipitation hardening. Macroscopic thermomechanical hardening trends are correlated with microstructural characteristics through the use of transmission electron microscopy. These observations are compared and contrasted with isothermal conditions. Thermomechanical behavior unique to the isothermal database is identified and discussed. The microstructural characteristics were shown to be dominated by effects associated with the highest temperature of the thermomechanical cycle. Results indicate that the deformation behavior of Hastelloy X is thermomechanically path dependent. In addition, guidance is given pertaining to deformation modeling in the context of macroscopic unified theory. An internal state variable is formulated to qualitatively reflect the isotropic hardening trends identified in the TMD experiments.

Castelli, Michael G.↗

DOE OSTI2024

Analyzing the impact of design factors on solar module thermomechanical durability using interpretable machine learning techniques

Solar modules in utility-scale systems are expected to maintain decades of lifetime to rival conventional energy sources. However, cyclic thermomechanical loading often degrades their long-term performance, highlighting the importance of effective design to mitigate thermal expansion mismatches between module materials. Given the complex composition of solar modules, isolating the impact of individual components on overall durability remains a challenging task. In this work, we analyze a comprehensive data set that comprises bill-of-materials (BOM) and thermal cycling power loss from 251 distinct module designs to identify the predominant design factors and their impacts on the thermomechanical durability of modules. The methodology of our analysis combines machine learning modeling (random forest) and Shapley additive explanation (SHAP) to correlate design factors with power loss and interpret the model’s decision-making. The interpretation reveals that silicon type (monocrystalline or polycrystalline), encapsulant thickness, busbar numbers, and wafer thickness predominantly influence the degradation. With lower power loss of around 0.6% on average in the SHAP analysis, monocrystalline cells present better durability than polycrystalline cells. This finding is further substantiated by statistical testing on our raw data set. The SHAP analysis also demonstrates that while thicker encapsulants lead to reduced power loss, further increasing their thickness over around 0.6 to 0.7 mm does not yield additional benefits, particularly for the front side one. In addition, other important BOM features such as the number of busbars are analyzed. This study provides a blueprint for utilizing explainable machine learning techniques in a complex material system and can potentially guide future research on optimizing the design of solar modules.

14 SOLAR ENERGY↗

DOE OSTI2025

Deconvoluting thermomechanical effects in X-ray diffraction data using machine learning

X-ray diffraction is ideal for probing the sub-surface state during complex or rapid thermomechanical loading of crystalline materials. However, challenges arise as the size of diffraction volumes increases due to spatial broadening and because of the inability to deconvolute the effects of different lattice deformation mechanisms. Here, we present a novel approach that uses combinations of physics-based modeling and machine learning to deconvolve thermal and mechanical elastic strains for diffraction data analysis. The method builds on a previous effort to extract thermal strain distribution information from diffraction data. The new approach is applied to extract the evolution of the thermomechanical state during laser melting of an Inconel 625 wall specimen which produces significant residual stress upon cooling. A combination of heat transfer and fluid flow, elasto-plasticity and X-ray diffraction simulations is used to generate training data for machine-learning (Gaussian process regression, GPR) models that map diffracted intensity distributions to underlying thermomechanical strain fields. First-principles density functional theory is used to determine accurate temperature-dependent thermal expansion and elastic stiffness used for elasto-plasticity modeling. The trained GPR models are found to be capable of deconvoluting the effects of thermal and mechanical strains, in addition to providing information about underlying strain distributions, even from complex diffraction patterns with irregularly shaped peaks.

36 MATERIALS SCIENCE↗

NASA NTRS1990

Application of thermal life prediction model to high-temperature aerospace alloys B1900+Hf and Haynes 188

The results of the application of a newly proposed thermomechanical fatigue (TMF) life prediction method to a series of laboratory TMF results on two high-temperature aerospace engine alloys are presented. The method, referred to as TMF/TS-SRP, is based on three relatively recent developments: the total strain version of the method of Strainrange Partitioning (TS-SRP), the bithermal testing technique for characterizing TMF behavior, and advanced viscoplastic constitutive models. The high-temperature data reported in a companion publication are used to evaluate the constants in the model and to provide the TMF verification data to check its accuracy. Predicted lives are in agreement with the experimental lives to within a factor of approximately 2.

Halford, Gary R.↗

NASA NTRS2006

HFGMC Enhancement of MAC/GMC

Additional information about a mathematical model denoted the high-fidelity generalized method of cells (HFGMC) and implementation of the HFGMC within version 4.0 of the MAC/GMC software has become available. MAC/GMC (Micromechanics Analysis Code With Generalized Method of Cells) was a topic of several prior NASA Tech Briefs articles, version 4.0 having been described in "Comprehensive Micromechanics-Analysis Code - Version 4.0" (LEW-17495-1), NASA Tech Briefs, Vol. 29, No. 9 (September 2005), page 54. MAC/GMC predicts elastic and inelastic thermomechanical responses of composite materials. MAC/GMC utilizes the generalized method of cells (GMC) - a model of micromechanics that predicts macroscopic responses of a composite material as functions of the properties, sizes, shapes, and responses of its constituents (e.g., matrix and fibers). The accuracy of the GMC is limited by neglect of coupling between normal and shear stresses. The HFGMC was developed by combining elements of the GMC and a related model, denoted the higher-order theory for functionally graded materials (HOTFGM), that can account for this coupling. Hence, the HFGMC enables simulation of stress and strain with greater accuracy. Some alterations of the MAC/GMC data structure were necessitated by the greater computational complexity of the HFGMC.

Arnold, Steven M.↗

NASA NTRS1992

Application of a thermal fatigue life prediction model to high-temperature aerospace alloys B1900 + Hf and Haynes 188

The results of the application of a newly proposed thermomechanical fatigue (TMF) life prediction method to a series of laboratory TMF results on two high-temperature aerospace engine alloys are presented. The method, referred to as TMF/TS-SRP, is based on three relatively recent developments: the total strain version of the method of Strain Range Partitioning (TS-SRP), the bithermal testing technique for characterizing TMF behavior, and advanced viscoplastic constitutive models. The high-temperature data reported in a companion publication are used to evaluate the constants in the model and to provide the TMF verification data to check its accuracy. Predicted lives are in agreement with the experimental lives to within a factor of approximately 2.

Halford, G. R.↗

NASA NTRS1987

Thermomechanical effects in high-speed seal rubs

The analytical effort was aimed at development of numerical model of thermal and mechanical phenomena which occur during seal rub. Finite element programs were develped for studying the temperatures that result from frictional heating during rubs, and the plastic deformation which is caused by rub forces. The experiment phase was originally intended to aid in verification of the results of the analytical model. Experimental techniques were developed for measuring surface temperatures and deformations during single pass rubs. Modifications were made to the device to permit testing at both high and cryogenic temperatures. The results from the experiments are discussed.

Kennedy, Francis E., Jr.↗

NASA NTRS1987

Constitutive modelling of single crystal and directionally solidified superalloys

Successful attempts were made to model the deformation behavior of nickel base superalloys to be used in gas turbine engines based on both a macroscopic constitutive model and a micromechanical formulation based on crystallographic slip theory. These models were programmed as FORTRAN subroutines, are currently being used to simulate thermomechanical loading predictions expected at the fatigue critical locations on a single crystal turbine blade. Such analyses form a natural precursor to the application of life prediction methods to gas turbine airfoils.

Walker, Kevin P.↗