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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

Calibration and Validation of a Finite ELement Model of THor-K Anthropomorphic Test Device for Aerospace Safety Applications

The THOR anthropomorphic test device (ATD) has been developed and continuously improved by the National Highway Traffic Safety Administration to provide automotive manufacturers an advanced tool that can be used to assess the injury risk of vehicle occupants in crash tests. Recently, a series of modifications were completed to improve the biofidelity of THOR ATD [1]. The updated THOR Modification Kit (THOR-K) ATD was employed at Wright-Patterson Air Base in 22 impact tests in three configurations: vertical, lateral, and spinal [2]. Although a computational finite element (FE) model of the THOR had been previously developed [3], updates to the model were needed to incorporate the recent changes in the modification kit. The main goal of this study was to develop and validate a FE model of the THOR-K ATD. The CAD drawings of the THOR-K ATD were reviewed and FE models were developed for the updated parts. For example, the head-skin geometry was found to change significantly, so its model was re-meshed (Fig. 1a). A protocol was developed to calibrate each component identified as key to the kinematic and kinetic response of the THOR-K head/neck ATD FE model (Fig. 1b). The available ATD tests were divided in two groups: a) calibration tests where the unknown material parameters of deformable parts (e.g., head skin, pelvis foam) were optimized to match the data and b) validation tests where the model response was only compared with test data by calculating their score using CORrelation and Analysis (CORA) rating system. Finally, the whole ATD model was validated under horizontal-, vertical-, and lateral-loading conditions against data recorded in the Wright Patterson tests [2]. Overall, the final THOR-K ATD model developed in this study is shown to respond similarly to the ATD in all validation tests. This good performance indicates that the optimization performed during calibration by using the CORA score as objective function is not test specific. Therefore confidence is provided in the ATD model for uses in predicting response in test conditions not performed in this study such those observed in the spacecraft landing. Comparison studies with ATD and human models may also be performed to contribute to future changes in THOR ATD design in an effort to improve its biofidelity, which has been traditionally based on post-mortem human subject testing and designer experience.

Putnam, J. B.↗
NASA NTRS2013

Experimental Characterization and Simulation of Slip Transfer at Grain Boundaries and Microstructurally-Sensitive Crack Propagation

A systematic study of crack tip interaction with grain boundaries is critical for improvement of multiscale modeling of microstructurally-sensitive fatigue crack propagation and for the computationally-assisted design of more durable materials. In this study, single, bi- and large-grain multi-crystal specimens of an aluminum-copper alloy are fabricated, characterized using electron backscattered diffraction (EBSD), and deformed under tensile loading and nano-indentation. 2D image correlation (IC) in an environmental scanning electron microscope (ESEM) is used to measure displacements near crack tips, grain boundaries and within grain interiors. The role of grain boundaries on slip transfer is examined using nano-indentation in combination with high-resolution EBSD. The use of detailed IC and EBSD-based experiments are discussed as they relate to crystal-plasticity finite element (CPFE) model calibration and validation.

Gupta, Vipul↗
NASA NTRS2018

Exploring Li-Air Batteries for High Specific Energy and High Power Applications: A Simulation Study

Commercialization of lithium-air batteries face many challenges, such as electrolyte decomposition, short cycle life, low energy efficiency, low power density, etc. However, commercialization of Li-air batteries for mass sensitive applications such as electric vehicles, portable power source, and drones is more challenging due to additional constraints of safety, electrolyte evaporation, high specific energy requirements, and reliable discharge times. In this presentation, we will present our finite element simulation results comparing Li-O2 and Li-air batteries using power density, energy density, specific power, and discharge times as metrics to evaluate different electrolytes and electrode geometry to reduce total mass and maximize discharge current. We use a finite element model and a discharge product model developed in which is based on porous electrode and concentrated electrolyte theories and the discharge product is modeled using quantum tunneling; for reaction kinetics and oxygen diffusion, an improved model was used. The electrolyte properties such as ion conductivity and ion diffusion were obtained from Molecular Dynamics (MD) simulations while the other parameters for the finite element model were calibrated to match experiments at high discharge current densities (>1.5 mA/cm2). The mass densities of different electrolytes were computed using MD simulations as well. For this presentation, we examine the practical electrochemical mass of a system at different current ratings, the sensitivity of mass to the use of ambient air as compared to pure oxygen as well as the electrolyte, which affects maximum current density and the total mass associated with the electrolyte (which includes the mass of additional components), and, the optimization of battery geometry for total discharge time, average discharge voltage, maximum discharge current, and minimum electrochemical mass.

Mehta, M.↗
DOE OSTI2025

Direct sensitivity analysis on the parameterization of crystal plasticity models

Various methods for calibrating crystal plasticity finite element (CPFE) models lead to non-unique input parameter values, which subsequently introduce uncertainty in the predicted mechanical response. Sensitivity analysis (SA) conducted on crystal plasticity models is used to identify how variability in these parameters contribute to output uncertainty. Traditional SA on CPFE parameters uses simplified surrogate models to save computational time. However, the accuracy of the surrogate models depends on the quantity of training data used, and any modeling error can propagate into the SA results, potentially affecting their reliability. In this work, the elementary effects test (EET) method, a global SA technique using direct CPFE simulations was employed, and the results obtained were compared with the First Order Second Moment (FOSM) method. ExaConstit, an open-source GPU-enabled CPFE code, was used to perform the simulations and direct SA. The EET method was accurately able to capture the non-linear effects of all the input parameters on the output and is a valuable approach for reliably attributing parameter sensitivities in CPFE models. Based on the results, efficient strategies to perform future parameter calibration and SA are discussed. Additionally, the SA trends observed in different single crystal orientations closely mirrored the activity of the slip systems.

Elementary Effects Test↗
DOE OSTI2025

WHA Sphere Impacting RHA Plate: Modeling Brittle Behavior in Metal Alloys

Brittle behavior of metal alloys is often critical to modeling ballistic impact and penetration. The ALEGRA multiphysics finite element software incorporates calibrated models for the equation of state, elasticity, yield stress, plasticity and fracture, but simulations do not always capture expected metal fracture. Here we report concerted efforts to do so for one important case where experiments clearly show shear fractures: a tungsten sphere impacting a steel plate at various angles. Our best simulations show fractures that are qualitatively similar to experiments, but there are significant differences in quantitative metrics. Specifically, velocities of tracers used to quantify simulated plug parameters consistently fall short of measured plug velocities. Also, simulated plugs break apart more than expected from experimental evidence. We attribute these shortfalls to the lack of an explicit shear fracture mechanism in the material models, leading to over-estimated resistance to plug formation and movement.

36 MATERIALS SCIENCE↗
NASA NTRS1981

Experimental demonstration of static shape control

Results of a microprocessor-controlled implementation of static shape control using a specially constructed flexible beam facility are presented. The discussion covers the development of shape control algorithms, adaptation of the algorithms for use with finite element models, construction of a flexible beam, characterization and calibration of the facility, development of a finite element model for the beam, and the development of computer hardware and software. It is shown that feedback control yields better results than open-loop control, and that the use of more than two sensors in the control loop has little effect on the system performance.

Eldred, D.↗
NASA NTRS2012

Development and Calibration of a System-Integrated Rotorcraft Finite Element Model for Impact Scenarios

Two full-scale crash tests of an MD-500 helicopter were conducted in 2009 and 2010 at NASA Langley's Landing and Impact Research Facility in support of NASA s Subsonic Rotary Wing Crashworthiness Project. The first crash test was conducted to evaluate the performance of an externally mounted composite deployable energy absorber (DEA) under combined impact conditions. In the second crash test, the energy absorber was removed to establish baseline loads that are regarded as severe but survivable. The presence of this energy absorbing device reduced the peak impact acceleration levels by a factor of three. Accelerations and kinematic data collected from the crash tests were compared to a system-integrated finite element model of the test article developed in parallel with the test program. In preparation for the full-scale crash test, a series of sub-scale and MD-500 mass simulator tests were conducted to evaluate the impact performances of various components and subsystems, including new crush tubes and the DEA blocks. Parameters defined for the system-integrated finite element model were determined from these tests. Results from 19 accelerometers placed throughout the airframe were compared to finite element model responses. The model developed for the purposes of predicting acceleration responses from the first crash test was inadequate when evaluating more severe conditions seen in the second crash test. A newly developed model calibration approach that includes uncertainty estimation, parameter sensitivity, impact shape orthogonality, and numerical optimization was used to calibrate model results for the full-scale crash test without the DEA. This combination of heuristic and quantitative methods identified modeling deficiencies, evaluated parameter importance, and proposed required model changes. The multidimensional calibration techniques presented here are particularly effective in identifying model adequacy. Acceleration results for the calibrated model were compared to test results and the original model results. There was a noticeable improvement in the pilot and copilot region, a slight improvement in the occupant model response, and an over-stiffening effect in the passenger region. One lesson learned was that this approach should be adopted early on, in combination with the building-block approaches that are customarily used, for model development and pretest predictions. Complete crash simulations with validated finite element models can be used to satisfy crash certification requirements, potentially reducing overall development costs.

Annett, Martin S.↗
NASA NTRSDate not supplied

Error Localization Examples: Looking for a Needle in a Haystack

Finite element models (FEM) are routinely developed and used during fabrication of high dollar-value hardware. NASA, as part of the pre-flight certification of launch vehicles, routinely conducts vibration and static tests to calibrate models used for flight-risk assessments. During model calibration, certain areas of the model are modified, using engineering judgment and sensitivity analysis, to match the test results. Unfortunately, tools to identify problem areas in the FEM using test data directly are scarce and infrequently applied. Over the years, error localization algorithms have been proposed with very limited success. Recently, the Analytical Dynamics Model Improvement (ADMI) algorithm, which computes closed-form mass and stiffness corrections to match the test data exactly, have been shown to be an effective Error Localization Algorithm (ELA). The paper discusses three examples where ELA is used with simulated test data to locate problem areas. To gain confidence in the approach, the exact answer is shown along with ELA results. Results show that ELA is able to identify general problem areas consistent with known problem areas. In all examples, the ELA identified area is larger than the exact problem area. Nonetheless, with proper optimization tools, calibration results using the ELA identified areas provide excellent results.

model calibration↗
NASA NTRS1981

Research and development program for non-linear structural modeling with advanced time-temperature dependent constitutive relationships

Results of a 20-month research and development program for nonlinear structural modeling with advanced time-temperature constitutive relationships are reported. The program included: (1) the evaluation of a number of viscoplastic constitutive models in the published literature; (2) incorporation of three of the most appropriate constitutive models into the MARC nonlinear finite element program; (3) calibration of the three constitutive models against experimental data using Hastelloy-X material; and (4) application of the most appropriate constitutive model to a three dimensional finite element analysis of a cylindrical combustor liner louver test specimen to establish the capability of the viscoplastic model to predict component structural response.

Walker, K. P.↗
DOE OSTI2020

Comprehensive Studies on Hot Compaction and Vibration-Assisted Compaction Tests of Aluminum Powder

Abstract Aluminum powder compaction was studied using both test and simulation. Cold compaction, hot compaction, and vibration-assisted (cold) compaction tests were conducted to achieve different density ratios. First, the hot compaction test (at 300 °C, compression pressure 140 MPa) improved about 6% compared with cold compaction under the same compression pressure. Second, although the relative density ratio does not obviously improve at a vibration-assisted (cold) compaction, the strength of the specimens made under vibration loading is much better than those of cold compaction. Additionally, finite element models with well-calibrated Drucker–Prager Cap (DPC) material constitutive model were built in abaqus/standard to simulate the powder compaction process. The results of the finite element model have very good correlations with test results up to the tested range, and this finite element model further predicts the loading conditions needed to achieve the higher density ratios. Two exponential equations of the predicted density ratio were obtained by combining the test data and the simulation results. A new analytical solution was developed to predict the axial pressure versus the density ratio for the powder compaction according to DPC material model. The results between the analytical solution and the simulation model have a very good match.

Engineering↗
DOE OSTI2024

Digital image correlation and infrared thermography data for seven unique geometries of 304L stainless steel

Material Testing 2.0 (MT2.0) is a paradigm that advocates for the use of rich, full-field data, such as from digital image correlation and infrared thermography, for material identification. By employing heterogeneous, multi-axial data in conjunction with sophisticated inverse calibration techniques such as finite element model updating and the virtual fields method, MT2.0 aims to reduce the number of specimens needed for material identification and to increase confidence in the calibration results. To support continued development, improvement, and validation of such inverse methods—specifically for rate-dependent, temperature-dependent, and anisotropic metal plasticity models—we provide here a thorough experimental data set for 304L stainless steel sheet metal. The data set includes full-field displacement, strain, and temperature data for seven unique specimen geometries tested at different strain rates and in different material orientations. Commensurate extensometer strain data from tensile dog bones is provided as well for comparison. We believe this complete data set will be a valuable contribution to the experimental and computational mechanics communities, supporting continued advances in material identification methods.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Study of Microphonic Effects on the C100 Cryomodule for High Energy Electron Beam Accelerators

The Continuous Electron Beam Accelerator Facility (CEBAF) at Thomas Jefferson National Laboratory (JLab) is a particle accelerator which can accelerate an electron beam to relativistic speeds and apply the beam onto target samples. The C100 superconducting radio frequency (SRF) cavity is the primary accelerating structure of the C100 cryomodule, one of the many cryomodules which compose the CEBAF linear accelerator. SRF cavities are particularly sensitive to internal and external vibrations that can result in a phenomenon called microphonics which degrade the operational stability of a cryomodule. The purpose of this thesis is to investigate the significance of mechanical disturbances on the electromagnetic resonant frequency of a C100 SRF cavity. Knowledge of the mechanical resonance of the cavities and cryomodule sheds light into how these disturbances are most easily realized as deformation which causes radio frequency (RF) detuning. Three studies were conducted: the development and hammer test calibration of a Finite Element Analysis (FEA) model of a C100 cavity, the development and hammer test calibration of an FEA model of a C100 cavity string, and the hammer test of the C100-10R cryomodule at the Cryomodule Test Facility (CMTF). The cavity FEA model was found to accurately predict two modes found in two real cavities in a simply supported configuration. The cavity string FEA model leveraged the calibrated cavity FEA model but was not found to accurately predict the modal behavior of a real cavity string. Even so, the modal behavior of the cavity string inside the C100-10R cryomodule was captured during a hammer test while it was partially assembled. Finally, the C100-10R cryomodule was placed in the CMTF to study RF detuning. The RF detuning spectra during hammer hits and background noise was captured. The results of the hammer testing indicate two strong peaks at low frequencies (9-10 Hz and 22-23 Hz). These two frequencies were found to be nearly coincident to four instances of mechanical resonance found during the hammer testing done on the partially-assembled C100-10R. Because of this, these two modes are believed to contribute to RF detuning of the cryomodule. This test event also included the testing of the effectiveness of a configuration of BNNT canisters designed to act as dampers. While these tests show promising results, the lurking variables render these tests somewhat inconclusive.

Hull, Caleb James↗
NASA NTRSDate not supplied

Experimental Characterization of the Dimensional Stability of Deployable Composite Booms During Stowage

Thin-ply carbon fiber reinforced polymer materials offer the opportunity to create long thin-shell booms with high strength to weight ratios. These booms can be rolled up and stowed in small volumes to be later deployed. These features make them ideal for use in gossamer solar sails as well as other deployable space structures. It has been observed that stowing the booms in rolled-up configurations can cause time-dependent deformations. A comprehensive understanding of the detrimental effects of stowing the coiled booms is necessary to implement these structures in spaceflight missions. During stowage inside the spacecraft, the boom is subjected to a constant deformation/strain that causes it to relax over time, measurable by a decrease in stress. Using large deformation bending tests, the complete fold-stow-unfold-recover cycle of thin-laminate candidates for the rollable booms is characterized. Further bending and stowage testing is done at the boom level. The results from this test campaign will be used to evaluate the dimensional stability of deployable booms made from thin-ply composites that exhibit visco-elasto-plastic behavior and calibrate and validate numerical finite element models that include visco-elasto-plastic material models.

Experimental Characterization↗
DOE OSTI2021

High Temperature Sodium Submersible Flowmeter Design and Analysis

This work details the design and analysis of a permanent magnet flowmeter designed to be submerged in a pool type sodium fast reactor environment. Recently developed Samarium Cobalt rare earth magnets were utilized that have demonstrated resilience to temperature and neutron flux up to 550 °C and 10 18 n/cm 2 , respectively. This paper will discuss the theory, design, calibration and uncertainty quantification of the flowmeter. The flowmeter was calibrated over a flowrate range of 11.4 - 90.9 LPM at temperatures of 220 and 400 °C, yielding an uncertainty in calibration of 2-3.6%. Here, a finite element model was developed and validated experimentally, yielding <; 3.2% error.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Plasticity and fracture behavior of Inconel 625 manufactured by laser powder bed fusion: Comparison between as-built and stress relieved conditions

In this work, the influence of stress relief on the plasticity and fracture behavior of Inconel 625 fabricated through laser powder bed fusion additive manufacturing (AM) was investigated. The as-built versus stress relieved microstructures were compared, showing similar grain structures but the presence of ~10 vol % δ phase in the stress relieved condition, and no δ phase in the as-built condition. Mechanical tests under plane strain tension were performed on the stress relieved samples, and an anisotropic plasticity model was calibrated and validated using finite element simulations. Uniaxial and notched tension tests were performed on both as-built and stress relieved samples to probe the effect of stress relief on stress state- and direction-dependent fracture behavior. It was found that on average, the fracture strain of the stress relieved samples along the build direction was 30% higher than that along the perpendicular build direction in the stress state range studied, and the stress relief heat treatment resulted in a 45% decrease in fracture strain. The fracture strain in stress relieved samples was more strongly dependent on stress state than in as-built samples.

36 MATERIALS SCIENCE↗
NASA NTRS2006

A Theoretical Investigation of Composite Overwrapped Pressure Vessel (COPV) Mechanics Applied to NASA Full Scale Tests

A theoretical investigation of the factors controlling the stress rupture life of the National Aeronautics and Space Agency's (NASA) composite overwrapped pressure vessels (COPVs) continues. Kevlar(TradeMark) fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar(TradeMark) filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However, due to the presence of a load sharing liner, the manufacturing induced residual stresses and the complex mechanical response, the state of actual fiber stress in flight hardware and test articles is not clearly known. This paper is a companion to the experimental investigation reported in [1] and develops a theoretical framework necessary to design full-scale pathfinder experiments and accurately interpret the experimentally observed deformation and failure mechanisms leading up to static burst in COPVs. The fundamental mechanical response of COPVs is described using linear elasticity and thin shell theory and discussed in comparison to existing experimental observations. These comparisons reveal discrepancies between physical data and the current analytical results and suggest that the vessel's residual stress state and the spatial stress distribution as a function of pressure may be completely different from predictions based upon existing linear elastic analyses. The 3D elasticity of transversely isotropic spherical shells demonstrates that an overly compliant transverse stiffness relative to membrane stiffness can account for some of this by shifting a thin shell problem well into the realm of thick shell response. The use of calibration procedures are demonstrated as calibrated thin shell model results and finite element results are shown to be in good agreement with the experimental results. The successes reported here have lead to continuing work with full scale testing of larger NASA COPV hardware.

Greene, N.↗