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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 325 records · Page 18
All sourcesNASA NTRSDOE OSTI
NASA NTRS2001

Low Velocity Earth-Penetration Test and Analysis

Modeling and simulation of structural impacts into soil continue to challenge analysts to develop accurate material models and detailed analytical simulations to predict the soil penetration event. This paper discusses finite element modeling of a series of penetrometer drop tests into soft clay. Parametric studies are performed with penetrometers of varying diameters, masses, and impact speeds to a maximum of 45 m/s. Parameters influencing the simulation such as the contact penalty factor and the material model representing the soil are also studied. An empirical relationship between key parameters is developed and is shown to correlate experimental and analytical results quite well. The results provide preliminary design guidelines for Earth impact that may be useful for future space exploration sample return missions.

Fasanella, Edwin L.↗
NASA NTRSDate not supplied

Validating Arc-jet Condition Targets Using Inverse 1D Material Response Models

Experiments were conducted using both the Interaction Heating Facility (IHF) and Aerodynamic Heating Facility (AHF), two hypersonic arc-jet facilities at NASA Ames. These tests were run to understand the material response of ablative thermal protection system materials by exposing them to high-enthalpy flows. Using thermocouple data from the materials, test conditions were inversely determined and compared with expected results from a one-dimensional model using facility target conditions; this allowed an approximate environmental scale factor to be determined and applied to more accurately predict material response in additional tests.

material response↗
NASA NTRSDate not supplied

Experimental Calibration of Flow Rule Coefficients for LS-Dyna Mat_213

Composite materials have become a popular choice in aerospace engineering applications due to their low weight, high specific stiffness, high specific energy absorption, and economic synthesis. As use of composite materials has proliferated, the need for accurate simulation under extreme loading conditions is of increasing importance. *MAT_213 is a tabulated plasticity and damage material model in LS-DYNA designed for such use cases. To account for the nonlinear material response, a plasticity algorithm is used, which employs a non-associative flow rule with coefficients requiring experimental calibration. This work outlines an experimental methodology for calibrating these coefficients using the macroscopic stress-strain response and microscopic in-plane strain measurements from coupon scale experiments. The model material used for the development and demonstration of this methodology is a plain weave woven fabric with T300 carbon fiber tows in the warp direction and Kevlar© 49 fiber tows in the weft direction, and an Epon© 828/Epikure© 3223 thermoset epoxy matrix. Coupon-scale tensile testing performed at multiple fiber angles (carbon fibers oriented 0º, 22.5º, 45º, 67.5º, and 90º relative to the loading axis) provides data for multiple calibration processes. The measured plastic strain increments in the principal material coordinate are used to set limits for ratios between flow rule coefficients. The identified ranges are used to bound the search for a set of coefficients, leading to convergence of different coupon responses in the effective stress – effective plastic strain space. Flow rule coefficients found by this methodology are then used as (i) input for LS-DYNA simulations of uniaxial tension coupon tests at varying fiber angles, and (ii) comparison of predicted values for the plastic Poisson’s ratio in global coordinates with the experimentally measured one for all off-axis orientations. These results are quantitatively and qualitatively compared to macroscopic stress-strain curves and experimental strain components. The conformity of the experimentally measured quantities with those derived from the simulations provide a means for assessing the quality of calibrated coefficients.

Polymer Matrix Composites↗
DOE OSTI2020

AFIP6-MkII and RERTR-12 Porosity Data Collection and Analysis for Modeling and Simulation

Gathering data for the improvement of nuclear fuel modeling and simulation efforts is the primary driver for this work. Mechanistic models allow for a better understanding of the material on a micro- and macrostructural level while saving time and money over traditional experiment efforts. Historically, summarized data and correlations are the inputs for empirical material models and model validation. When improving these models for nuclear fuels with experimental results, there is a lack of reliable data readily available. Experiments - RERTR-12 and AFIP6-MkII - were conducted to understand the irradiation behavior of metallic U-10Mo monolithic fuels for use in extreme reactor environments such as research reactors like the Advanced Test Reactor (ATR) or the High Flux Isotope Reactor (HFIR). Microstructural characteristics of fission gas pores (FGP) in each experiment are collected using an automated image analysis technique developed at the University of Florida and presented here. A series of statistical tests are performed to explore the reliability of the results, as well as understand where the data is lacking and what future data collection is necessary to provide sufficient information to assist modeling efforts. The focus is on the porosity, pore size, and eccentricity of FGPs formed during irradiation in three AFIP6-MkII samples and one RERTR-12 sample. From the analysis, it is clear there are substantial impacts of fission density on the pore structure, but there also exist also underlying connections between each sample and the behavior observed in the pores. Further analyses of the pre- and post-irradiation microstructure are needed to improve the understanding of these connections. An early method for microstructural data analysis is presented within and is currently being expanded to include other microstructure data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2018

Plasticity and Damage Modeling of Stress Asymmetry and Dynamic Behavior of AFS Additive Manufactured Aluminum Alloy 2219

The Solid State Additive Manufacturing (AM) process referred as MELD that fabricated the samples in this study, provides a new path for repairing, coating, joining and additive manufacturing metals and metal matrix composites. This research will be the first application of a physics-based microstructure dependent internal state variable (ISV) plasticity and damage material model to capture the mechanical response of an AM Aluminum Alloy (AA) 2219 via the MELD process. In this research, a microstructure-based internal state variable (ISV) plasticity-damage model was used to capture the mechanical behavior of AFS 2219 aluminum alloy. Aeroprobe Corporation, creator and patent holder for the MELD process, fabricated the material by pushing a solid filler rod of AA2219-T861 material through a hollow rotating tool onto an AA2219 T851 plate substrate. As feedstock, solid or powder precursor metals are pushed through a nonconsumable rotating cylindrical tool. Herein, added layers are deposited and metallurgically bonded to substrate material or previously deposited layers by the heat generated from the rotating tool through plastic deformation of the filler material. Once a layer has been added, the tool height increases, and starts the deposition of the next layer. This process results in beneficial properties such as grain refinement, homogenization and reduced porosity (fully dense). This process will experience temperatures similar to those in the weld nugget zone (WNZ) in friction stir welding (FSW), ranging from 0.6-0.9 Tm, with Tm being the melting point of the material. MELD is highly scalable with AA deposition rates reaching over 1000 cm3/hr, which allows for MELD being used for repairs, coatings, and building components. A motivating factor driving the research for physics-based history dependent material modeling of MELD components is the ability to accurately capture the stress-state and strain rate dependence in the material caused by variations in material microstructure from the MELD processing of new or repaired components. The ISV model incorporates microstructural content and is consistent with continuum level kinematics, kinetics, and thermodynamics. These features allow the ISV model to capture large deformations at the structural scale using the kinematic and isotropic hardening, while microscale damage is obtained from the microstructural features. The benefits of the ISV model arise from the inclusion of structure-property relationships identified from microstructural characterization and experimentation. The Bauschinger effect (BE) is an important concept, vital in the accurate prediction of cyclic stress-strain response of ductile materials such as metals. The ISV model has been successfully used to capture the behavior and damage, and the BE of different aluminum alloys and steels. The ISV model uses kinematic and isotropic hardening to help capture deformations of the material at the macro scale. To understand this hardening relationship, calculating the kinematic and isotropic hardening relationship in the material is warranted for a high-fidelity model. Electron Backscattered Diffraction (EBSD) was used to characterize the as-fabricated microstructure, where a fully-dense equiaxed grain morphology with average grain size of 2.5 μm was observed. Microhardness mapping of the as-built structures, monotonic tension and compression experiments at both quasi-static (0.001/s) strain rates, tension-followed-by-compression and compression-followed-by-tension experiments were performed to obtain the set of plasticity and damage constants necessary to capture strain rate and stress state behavior of this additive material. To calibrate the plasticity-damage model, a single set of constants were determined to capture the different stress states the MELD AA2219. One set of the constants was determined from experimental true stress-strain curves for the tension and compression data. Additionally, microstructural information and data from the open literature were used as the other model constants. This research is a first of its kind for AFS AA2219, includes correlating the ISV model to the monotonic experimental results that capture the isotropic and kinematic plasticity mechanical response.

Rivera, O. G.↗
NASA NTRSDate not supplied

Simulating High Energy Dynamic Impact of IM7/PEKK Continuous Fiber Laminated Thermoplastic Composite using Open Hole Coupon Experiments

The use of advanced thermoplastic composites (TPC) for structural applications in the aerospace and automotive industries has grown increasingly popular due to their high performance, high manufactured part output, and sustainability. Enhancing verification simulations of the progressive failure in TPCs at the coupon scale is needed to better validate advanced composite material models at larger length scales, such as element level panels. MAT_213, a tabulated composite material model, has been applied to simulate high velocity dynamic impact (HEDI) and is integrated in the LS-DYNA explicit finite element (FE) software. Previous efforts using MAT_213 have calibrated HEDI simulated failures with experimental data. Traditionally simulations have relied on a structured mesh to represent quasi-isotropic panels. For this study, a continuous fiber unidirectional tape, IM7/PEKK, was analyzed through a series of verification studies of notched laminate coupons, then validation analyses of quasi-isotropic panels under HEDI were compared with experimental data. Experiments using unidirectional TPC were performed to obtain tabulated stress vs strain curves using Digital Image Correlation (DIC) for input into MAT_213. Next, notched coupon experiments were used as an intermediate step to calibrate the damage and failure behavior in MAT_213. Lastly, investigations into differences between HEDI simulations using a fiber aligned mesh were compared with experimental failure patterns and damage sizes. The use of experimentally generated material behavior along with selective mesh layout improved HEDI predictions with minimal material parameter calibration.

Polymer matrix composites↗
NASA NTRS2008

A Modeling Technique and Representation of Failure in the Analysis of Triaxial Braided Carbon Fiber Composites

Quasi-static tests have been performed on triaxially braided carbon fiber composite materials with large unit cell sizes. The effects of different fibers and matrix materials on the failure mode were investigated. Simulations of the tests have been performed using the transient dynamic finite element code, LS-DYNA. However, the wide range of failure modes observed for the triaxial braided carbon fiber composites during tests could not be simulated using composite material models currently available within LS-DYNA. A macroscopic approach has been developed that provides better simulation of the material response in these materials. This approach uses full-field optical measurement techniques to measure local failures during quasi-static testing. Information from these experiments is then used along with the current material models available in LS-DYNA to simulate the influence of the braided architecture on the failure process. This method uses two-dimensional shell elements with integration points through the thickness of the elements to represent the different layers of braid along with a new analytical method for the import of material stiffness and failure data directly. The present method is being used to examine the effect of material properties on the failure process. The experimental approaches used to obtain the required data will be described, and preliminary results of the numerical analysis will be presented.

Littell, Justin D.↗
NASA NTRS2008

A Modeling Technique and Representation of Failure in the Analysis of Triaxial Braided Carbon Fiber Composites

Quasi-static tests have been performed on triaxially braided carbon fiber composite materials with large unit cell sizes. The effects of different fibers and matrix materials on the failure mode were investigated. Simulations of the tests have been performed using the transient dynamic finite element code, LS-DYNA. However, the wide range of failure modes observed for the triaxial braided carbon fiber composites during tests could not be simulated using composite material models currently available within LS-DYNA. A macroscopic approach has been developed that provides better simulation of the material response in these materials. This approach uses full-field optical measurement techniques to measure local failures during quasi-static testing. Information from these experiments is then used along with the current material models available in LS-DYNA to simulate the influence of the braided architecture on the failure process. This method uses two-dimensional shell elements with integration points through the thickness of the elements to represent the different layers of braid along with a new analytical method for the import of material stiffness and failure data directly. The present method is being used to examine the effect of material properties on the failure process. The experimental approaches used to obtain the required data will be described, and preliminary results of the numerical analysis will be presented.

Littell, Justin D.↗
NASA NTRS2019

Quasi-Static and Dynamic Analysis of Composite Panels: Characterization and Validation

The predictive capability of a progressive damage model to simulate the quasi-static and dynamic crushing of composite specimens is evaluated in this article. The material model is commercially available within the ABAQUS finite element software package, i.e., “Damage for Fiber reinforced Composites”, and is often utilized to simulate damage progression and failure in static and dynamic failure scenarios such as crushing of a composite plate. The composite specimens used in this study consist of quasi-isotropic C-shaped and corrugated composite panels comprised of carbon fiber/epoxy braided fabric. The C-shaped panel specimen is used to calibrate the model and optimize material/model properties through comparison with experimental results. Then, using the same model parameters, the quasi-static crush response of the corrugated panel is predicted. The predictive capability of the model is further demonstrated by simulating the dynamic crushing response of both C-shaped and corrugated panels using the same material properties as in the quasi-static crush case with only minor adjustments for the dynamic elastic properties (i.e., rate dependent modulus). Results show that the in-built material model available in ABAQUS can successfully reproduce experimental results for both panels (C-shaped and corrugated) subjected to both quasi-static and dynamic loading scenarios. A small-scale parametric study on physical (experimentally measurable) and nonphysical (purely mathematical) model parameters was also conducted. It can be concluded that, achieving successful simulation results requires a more in-depth understanding of the influence of model parameter variation on the mechanical response of the composite together with the strategies and challenges of the utilized modeling methodology (e.g., FEA mesh density, etc.).

Naghipour Ghezeljeh, Paria↗
NASA NTRSDate not supplied

Establishing and Maintaining the Digital Thread of Additively Manufactured Materials and Applications

Additive Manufacturing (AM) and Integrated Computational Materials Engineering (ICME) are complementary enabling technologies for design and manufacturing of “fit-for-purpose” materials. Both technologies will impact rapid material design, reduction in cost- and time-to-market for new applications, and discovery and implementation of new materials. An ICME approach to design, however, requires experimentally validated material models at multiple length and time scales, an integrated framework that can connect analysis tools with one another to ensure the digital thread of an application is maintained, and the manufacturing (e.g., AM) capability to leverage processing-structure-property-performance (PSPP) relationships to achieve spatially varying material properties where desired. AM enables the implementation of the design of an optimized, spatially varying microstructure through careful selection of the processing parameters used during an additively manufactured build. In order to establish these PSPP relations, a large amount of data is necessary, and that data must be properly captured, analyzed and maintained in an information management system that can establish the required traceability between various aspects of the design process to ensure an application’s digital thread is maintained (from design to end of life). Such an information management system must be able to capture feedstock material pedigree, resulting microstructure from various build parameters, subsequent mechanical properties derived from testing, developed material models, and enable spatial variations in material assignment in an engineering application. Furthermore, the information management system should be easily integrated with traditionally engineered materials in a single, centralized platform to enable an ICME optimization tool to explore both types of manufacturing processes. At NASA GRC, a robust, 21st century materials information management system has been previously developed with a focus towards enabling ICME. In this work, GRC’s ICME schema is extended to accommodate additively manufactured materials, enabling storage of both traditionally and additively manufactured materials in the same construct. The methodology for properly capturing additively manufactured materials across the entire material lifecycle is presented, following the previously established database best practices, as a potential framework for establishing PSPP relationships for additively manufactured materials and applying them to engineering applications.

Data management↗
DOE OSTI2024

Calibration of Al7075 with Plate-Puncture Predictions

The following details calibration of a material model for Al7075-T6511. This aluminum alloy is commonly used across a host of engineering applications. Owing to its widespread prevalence, there is great benefit in improving simulation predictions for this alloy. In the present effort, a calibration is performed of its elastic-plastic response accounting for both rate and temperature dependence. The calibration is informed by a series of tests that include specimens of different geometries tested at different rates and temperatures. All specimens are derived from the same barstock, 3.5 inches in diameter. The fitted model itself uses an anisotropic, Hill yield surface coupled with a Johnson-Cook hardening model. Failure predictions are had by means of a modified Wilkins failure criterion. Following calibration of the material model, a validation exercise is performed against platepuncture experiments. These experiments include multiple probe shapes, probe diameters, and plate thicknesses. The puncture experiments are replicated in simulation with mesh studies performed to assess uncertainty. Key quantities of interest, notably the absorbed energy up to failure, are compared between simulation and experiment providing a means to assess the suitability of the calibration in puncture simulations.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Collaboratory on Mathematics for Mesoscopic Modeling of Materials (CM4)(Final Technical Report)

Our work on the CM4 grant focused on new mathematical and computational approaches for stochastic methods for mesoscopic systems. Our work included continuum SPDEs, molecular coarse-grained models, and hybrid particle-continuum approaches. This work was motivated by applications in soft materials, fluidic devices, and interfacial phenomena. Throughout the project we collaborated with several staff researchers, including from Pacific Northwest National Laboratories (PNNL) and Sandia National Laboratory (SNL) as well as other members of the CM4 project. Below we summarize briefly a few specific accomplishments from this work over the funding period. A full list of published papers and software releases supported by the grant are listed at the end.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1993

Process modelling for materials preparation experiments

The main goals of the research consist of the development of mathematical tools and measurement of transport properties necessary for high fidelity modeling of crystal growth from the melt and solution, in particular for the Bridgman-Stockbarger growth of mercury cadmium telluride (MCT) and the solution growth of triglycine sulphate (TGS). Of the tasks described in detail in the original proposal, two remain to be worked on: development of a spectral code for moving boundary problems, and diffusivity measurements on concentrated and supersaturated TGS solutions. During this eighth half-year period, good progress was made on these tasks.

Rosenberger, Franz↗
NASA NTRS2019

Physically-Informed Artificial Neural Networks for Atomistic Modeling of Materials

A new approach is presented for the development of classical interatomic potentials using physically-informed neural networks (PINN) combined with an analytical bond-order atomic interaction model. Due to the strong physical underpinnings, the PINN potentials demonstrate much better transferability than the existing machine-learning potentials while drastically improving the accuracy in comparison with traditional potentials. PINN potentials can be constructed for both metallic and covalent materials in a unified manner. A number of applications of PINN potentials to large-scale molecular dynamics and Monte Carlo simulations and calculation of thermal and mechanical properties of diverse materials are demonstrated. Some of the specific materials systems include silicon and aluminum, as well as alloys and compounds. Computational aspects of PINN potentials are discussed and future developments in this field are outlined.

J Hickman↗
NASA NTRS1987

The role of electronic mechanisms in surface erosion and glow phenomena

Experimental studies of desorption induced by electronic transitions (DIET) are described. Such studies are producing an increasingly complete picture of the dynamical pathways through which incident electronic energy is absorbed and rechanneled to produce macroscopic erosion and glow. These mechanistic studies can determine rate constants for erosion and glow processes in model materials and provide valuable guidance in materials selection and development. Extensive experiments with electron, photon, and heavy particle irradiation of alkali halides and other simple model materials have produced evidence showing that: (1) surface erosion, consisting primarily in the ejection or desorption of ground-state neutral atoms, occurs with large efficiencies for all irradiated species; (2) surface glow, resulting from the radiative decay of desorbed atoms, likewise occurs for all irradiating species; (3) the typical mechanism for ground-state neutral desorption is exciton formation, followed by relaxation to a permanent, mobile electronic defect which is the precursor to bond-breaking in the surface or near-surface bulk of the material; and (4) the mechanisms for excited atom formation may include curve crossing in atomic collisions, interactions with surface defect or impurity states, or defect diffusion.

Haglund, Richard F., Jr.↗
NASA NTRS2018

Determination of Ballistic Limit for IM7/8552 Using LS-DYNA MAT 261

The goal of the NASA ACC High Energy Dynamic Impact Project is to determine the state of the art of dynamic fracture simulations for high velocity impact for composite fuselage shielding applications. Using a building block approach, several computational models considered under NASA ACC are being validated against test data, starting at unconfigured panels and progressing to configured panels under combined out-of-plane and in-plane loading due to ballistic impact. The computational models being evaluated in this project include MAT 162, MAT 213, MAT 261, SPG, and Peridynamics. In this paper, the simulation results using LS-Dyna Material MAT 261 are presented. In particular, a series of blind predictions for unconfigured panels were performed to determine the ballistic limit or V50 velocity. MAT 261 employs failure approach that is generally physically-based using fracture toughness criteria. The overall material model relies on typical ply-level stiffness properties, similar to MAT 162 and other composite continuum damage material models. The fracture toughness values are based on standard tests, and thus are not subject to extensive calibration. This approach is more efficient than performing extensive optimization studies for calibration of parameters. Also, this approach of relying on physical properties reduces the uncertainty of results, as questions concerning the quality and extent of the calibration studies is no longer relevant. However, it was found that carefully controlled coupon-level tests are needed to accurately obtain the required fracture toughness values. Additionally, it should be noted that there is one significant parameter in MAT 261 that does appear to require calibration, and that is the overall failure strain. This is the strain at which the element is deleted, and is not the same as the strain at which damage begins to accumulate. This failure strain is termed EFS (Effective Failure Strain), and is the maximum effective stain for element failure. Simulations have shown that this value will significantly affect impact response and failure. The paper presents the effect of this element failure strain parameter, along with possible uncertainties in fracture toughness values. With an adjusted appropriate value for EFS, it is seen that simulation results compare well with impact test data for predicted penetration velocity.

Byar, Alan↗
NASA NTRS2015

Analytic Thermoelectric Couple Modeling: Variable Material Properties and Transient Operation

To gain a deeper understanding of the operation of a thermoelectric couple a set of analytic solutions have been derived for a variable material property couple and a transient couple. Using an analytic approach, as opposed to commonly used numerical techniques, results in a set of useful design guidelines. These guidelines can serve as useful starting conditions for further numerical studies, or can serve as design rules for lab built couples. The analytic modeling considers two cases and accounts for 1) material properties which vary with temperature and 2) transient operation of a couple. The variable material property case was handled by means of an asymptotic expansion, which allows for insight into the influence of temperature dependence on different material properties. The variable property work demonstrated the important fact that materials with identical average Figure of Merits can lead to different conversion efficiencies due to temperature dependence of the properties. The transient couple was investigated through a Greens function approach; several transient boundary conditions were investigated. The transient work introduces several new design considerations which are not captured by the classic steady state analysis. The work helps to assist in designing couples for optimal performance, and also helps assist in material selection.

Seebeck Effect↗