Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Modeling of Metal AM”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS2002

NASA GRC Fatigue Crack Initiation Life Prediction Models

Metal fatigue has plagued structural components for centuries, and it remains a critical durability issue in today's aerospace hardware. This is true despite vastly improved and advanced materials, increased mechanistic understanding, and development of accurate structural analysis and advanced fatigue life prediction tools. Each advance is quickly taken advantage of to produce safer, more reliable, more cost effective, and better performing products. In other words, as the envelope is expanded, components are then designed to operate just as close to the newly expanded envelope as they were to the initial one. The problem is perennial. The economic importance of addressing structural durability issues early in the design process is emphasized. Tradeoffs with performance, cost, and legislated restrictions are pointed out. Several aspects of structural durability of advanced systems, advanced materials and advanced fatigue life prediction methods are presented. Specific items include the basic elements of durability analysis, conventional designs, barriers to be overcome for advanced systems, high-temperature life prediction for both creep-fatigue and thermomechanical fatigue, mean stress effects, multiaxial stress-strain states, and cumulative fatigue damage accumulation assessment.

Arya, Vinod K.↗
NASA NTRS1990

A creep model for metallic composites based on matrix testing: Application to Kanthal composites

An anisotropic creep model is formulated for metallic composites with strong fibers and low to moderate fiber volume percent (less than 40 percent). The idealization admits no creep in the local fiber direction and assumes equal creep strength in longitudinal and transverse shear. Identification of the matrix behavior with that of the isotropic limit of the theory permits characterization of the composite through uniaxial creep tests on the matrix material. Constant and step-wise creep tests are required as a data base. The model provides an upper bound on the transverse creep strength of a composite having strong fibers embedded in a particular matrix material. Comparison of the measured transverse strength with the upper bound gives an assessment of the integrity of the composite. Application is made to a Kanthal composite, a model high-temperature composite system. Predictions are made of the creep response of fiber reinforced Kanthal tubes under interior pressure.

Binienda, W. K.↗
NASA NTRS1993

Proposed framework for thermomechanical life modeling of metal matrix composites

The framework of a mechanics of materials model is proposed for thermomechanical fatigue (TMF) life prediction of unidirectional, continuous-fiber metal matrix composites (MMC's). Axially loaded MMC test samples are analyzed as structural components whose fatigue lives are governed by local stress-strain conditions resulting from combined interactions of the matrix, interfacial layer, and fiber constituents. The metallic matrix is identified as the vehicle for tracking fatigue crack initiation and propagation. The proposed framework has three major elements. First, TMF flow and failure characteristics of in situ matrix material are approximated from tests of unreinforced matrix material, and matrix TMF life prediction equations are numerically calibrated. The macrocrack initiation fatigue life of the matrix material is divided into microcrack initiation and microcrack propagation phases. Second, the influencing factors created by the presence of fibers and interfaces are analyzed, characterized, and documented in equation form. Some of the influences act on the microcrack initiation portion of the matrix fatigue life, others on the microcrack propagation life, while some affect both. Influencing factors include coefficient of thermal expansion mismatch strains, residual (mean) stresses, multiaxial stress states, off-axis fibers, internal stress concentrations, multiple initiation sites, nonuniform fiber spacing, fiber debonding, interfacial layers and cracking, fractured fibers, fiber deflections of crack fronts, fiber bridging of matrix cracks, and internal oxidation along internal interfaces. Equations exist for some, but not all, of the currently identified influencing factors. The third element is the inclusion of overriding influences such as maximum tensile strain limits of brittle fibers that could cause local fractures and ensuing catastrophic failure of surrounding matrix material. Some experimental data exist for assessing the plausibility of the proposed framework.

Halford, Gary R.↗
NASA NTRS2009

A Method for Combining Experimentation and Molecular Dynamics Simulation to Improve Cohesive Zone Models for Metallic Microstructures

Fracture processes within a material begin at the nanometer length scale at which the formation, propagation, and interaction of fundamental damage mechanisms occur. Physics-based modeling of these atomic processes quickly becomes computationally intractable as the system size increases. Thus, a multiscale modeling method, based on the aggregation of fundamental damage processes occurring at the nanoscale within a cohesive zone model, is under development and will enable computationally feasible and physically meaningful microscale fracture simulation in polycrystalline metals. This method employs atomistic simulation to provide an optimization loop with an initial prediction of a cohesive zone model (CZM). This initial CZM is then applied at the crack front region within a finite element model. The optimization procedure iterates upon the CZM until the finite element model acceptably reproduces the near-crack-front displacement fields obtained from experimental observation. With this approach, a comparison can be made between the original CZM predicted by atomistic simulation and the converged CZM that is based on experimental observation. Comparison of the two CZMs gives insight into how atomistic simulation scales.

Hochhalter, J. D.↗
NASA NTRS2008

Nucleosynthesis Predictions for Intermediate-Mass AGB Stars: Comparison to Observations of Type I Planetary Nebulae

Type I planetary nebulae (PNe) have high He/H and N/O ratios and are thought to be descendants of stars with initial masses of approx. 3-8 Stellar Mass. These characteristics indicate that the progenitor stars experienced proton-capture nucleosynthesis at the base of the convective envelope, in addition to the slow neutron capture process operating in the He-shell (the s-process). We compare the predicted abundances of elements up to Sr from models of intermediate-mass asymptotic giant branch (AGB) stars to measured abundances in Type I PNe. In particular, we compare predictions and observations for the light trans-iron elements Se and Kr, in order to constrain convective mixing and the s-process in these stars. A partial mixing zone is included in selected models to explore the effect of a C-13 pocket on the s-process yields. The solar-metallicity models produce enrichments of [(Se, Kr)/Fe] less than or approx. 0.6, consistent with Galactic Type I PNe where the observed enhancements are typically less than or approx. 0.3 dex, while lower metallicity models predict larger enrichments of C, N, Se, and Kr. O destruction occurs in the most massive models but it is not efficient enough to account for the greater than or approx. 0.3 dex O depletions observed in some Type I PNe. It is not possible to reach firm conclusions regarding the neutron source operating in massive AGB stars from Se and Kr abundances in Type I PNe; abundances for more s-process elements may help to distinguish between the two neutron sources. We predict that only the most massive (M grester than or approx.5 Stellar Mass) models would evolve into Type I PNe, indicating that extra-mixing processes are active in lower-mass stars (3-4 Stellar Mass), if these stars are to evolve into Type I PNe.

Karakas, Amanda I.↗
NASA NTRS1984

A new analysis of charge transfer and polarization for ligand-metal bonding - Model studies of Al4CO and Al4NH3

The nature of the bonding of CO and NH3 ligands to Al is analyzed, and the intra-unit charge polarization and inter-unit donation for the interaction of ligands with metals are studied. The consequences of metal-to-ligand and ligand-to-metal charge transfer are separately considered by performing a constrained space orbital variation (CSOV) with the electrons of the metal member of the complex in the field of frozen ligand. The electrons of the metal atoms are then frozen in the relaxed distribution given by the CSOV SCF wave function and the ligand electrons are allowed to relax. Quantitative measures of the importance of inter-unit charge transfers and intra-unit polarization are obtained using results of SCF studies of Al4CO and Al4NH3 clusters chosen to simulate the adsorption of the ligands at an on-top side of the Al(111) surface. The electrostatic attraction of the effective dipole moments of the metal and ligand units makes an important contribution to the bond.

Bagus, P. S.↗
NASA NTRS1975

Velocity autocorrelation functions in model liquid metals

Starting from interatomic potentials and static radial distribution functions, a self-consistent iteration scheme has been used to calculate velocity autocorrelation functions in liquid metals. The interatomic forces are treated directly. The calculation bypasses the details of the many-body dynamics and it is not necessary to introduce any additional parameters. Several simplifications may be used without introducing appreciable deviations. The results are in good agreement with computer experiments on liquid sodium at 383 K, suggesting that the velocity autocorrelation function may be a simpler quantity than previously supposed.

Tsang, T.↗
NASA NTRS2001

Transport Modeling for Metallic Electrode: Semiconducting Nanotube Systems

Recently, current-voltage (I-V) characteristics have been reported by Collins et al. for a system with a scanning tunneling microscope (STM) tip and a carbon nanotube. The STM tip was driven forward into a film of many entangled nanotubes on a substrate, and then was retracted, so that one of nanotubes bridged the STM and the film. I-V characteristics had two different patterns for different heights. One showed large dI/ dV with V greater than 0, small dI/dV with V less than 0, and I = 0 near V = 0 (type-I), while the other showed rectification, i.e., I does not equal 0 only with V less than 0 (type-II), with the tip grounded. We propose a physical mechanism to explain the observed I-V patterns. We consider that the observed characteristics strongly reflected the nature of the tip (metal) - nanotube (semiconductor) contact. The other end of the nanotube was entangled well in the film, and simply provided a good Ohmic contact. We will argue that there are two different contact modes: vacuum gap and touching modes, depending on the presence or absence of a tiny vacuum gap d approx. 0.1 - 0.2 nm at the junction. These modes may be related to physisorption and chemisorption, respectively. Once admitting their existence, it is naturally shown that I-V characteristics are type-I in the vacuum gap mode, and type-II in the touching mode. We argue that the nanotube had to be an n-type semiconductor judging from the I-V characteristics, contrary to often observed p-type in the transistor applications, where p-type is probably due to the oxidation in air or the trapped charges in the silicon dioxide. Additional information is contained in the original extended abstract.

Yamada, Toshishige↗
NASA NTRS1982

Stationary state model for normal metal tunnel junction phenomena

A model applicable to normal metal tunnel junctions is presented. This model, referred to herein as the stationary state model, is an extension of the extended basis function theory of Kleinman and Duke (1972). Under the assumption that elastic tunneling is the dominant transport mechanism under static bias, the theory has been extended to include the case where there is an ac component of bias potential, and the fluctuation spectrum has been derived. In this approach structure eigenstates are used as the basis, allowing observables to be evaluated without recourse to the perturbation theory inherent in the transfer Hamiltonian model. Comparison is made to the appropriate results of the first order transfer Hamiltonian model, and it is found that there is close but not always exact agreement to lowest order in the tunneling exponential. The stationary state model should be accurate with large barrier transmission, as it includes all orders of the tunneling exponential. The model as presented here should be applicable to normal metal tunnel junctions, where elastic tunneling is the dominant transport mechanism (under static bias), up to infrared excitation frequencies.

Whiteley, S. R.↗
NASA NTRS2014

Computer Modeling of Direct Metal Laser Sintering

A computational approach to modeling direct metal laser sintering (DMLS) additive manufacturing process is presented. The primary application of the model is for determining the temperature history of parts fabricated using DMLS to evaluate residual stresses found in finished pieces and to assess manufacturing process strategies to reduce part slumping. The model utilizes MSC SINDA as a heat transfer solver with imbedded FORTRAN computer code to direct laser motion, apply laser heating as a boundary condition, and simulate the addition of metal powder layers during part fabrication. Model results are compared to available data collected during in situ DMLS part manufacture.

Cross, Matthew↗
NASA NTRS1984

Ultraviolet and optical observations of metal deficient red giants and chromospheric models

Three metal deficient field stars were observed in the ultraviolet and optical spectral regions: HD 165195, HD 110281, and HD 232078. High dispersion spectra near H alpha, and low dispersion, long wavelength IUE spectra were obtained. The H alpha profiles have strong asymmetric emission with absorption cores that are frequently asymmetric. The surface flux of Mg II lines is similar to that of luminous Pop I stars in spite of the lower metal abundance. Semi-empirical atmospheric models suggest that the characteristic emission in the wings of the H alpha line can arise within static chromospheres. Radial expansion gives an asymmetric, blue-shifted H alpha core accompanied by greater emission in the red line wing than the blue wing. Wind models with extended atmospheres suggest mass loss rates - 2 billion M/yr. Thus H alpha provides no evidence that steady mass loss is substantial enough to significantly affect the evolution of stars on the red giant branch of globular clusters.

Duprele, A. K.↗
NASA NTRS1987

Experimental and analytic studies of the triggered lightning environment of the F106B

The triggered lightning environment of the F106B aircraft is investigated. Scale modeling of the F106B with a metallized model was done to measure electric field enhancement factors on the aircraft and on canonically shaped conducting objects. These are then compared to numerically determined quantities. Detailed numerical modeling is done of the development of the triggered lightning channel. This is done using nonlinear air chemistry models to model a variety of physical phenomena which occur in a triggered lightning event. The effect of a triggered lightning strike on internal wires in the F106B is investigated using finite difference models and transmission line models to calculate the electromagnetic coupling of lightning currents through seams and joints of the aircraft to internal cables. Time domain waveforms are computed and compared to measured waveforms. The effect of thunderstorm particles on the initial triggering of a lightning strike is investigated. The electric field levels needed to cause air breakdown in the presence and absence of thunderstorm particles are calculated. This is done as a function of the size, shape, and density of the particles.

Rudolph, Terence↗
NASA NTRS2007

Fluorescence Visualization of Hypersonic Flow over Rapid Prototype Wind-Tunnel Models

Reentry models for use in hypersonic wind tunnel tests were fabricated using a stereolithography apparatus. These models were produced in one day or less, which is a significant time savings compared to the manufacture of ceramic or metal models. The models were tested in the NASA Langley Research Center 31-Inch Mach 10 Air Tunnel. Most of the models did not survive repeated tests in the tunnel, and several failure modes of the models were identified. Planar laser-induced fluorescence (PLIF) of nitric oxide (NO) was used to visualize the flowfields in the wakes of these models. Pure NO was either seeded through tubes plumbed into the model or via a tube attached to the strut holding the model, which provided localized addition of NO into the model s wake through a porous metal cylinder attached to the end of the tube. Models included several 2-inch diameter Inflatable Reentry Vehicle Experiment (IRVE) models and 5-inch diameter Crew Exploration Vehicle (CEV) models. Various configurations were studied including different sting placements relative to the models, different model orientations and attachment angles, and different NO seeding methods. The angle of attack of the models was also varied and the location of the laser sheet was scanned to provide three-dimensional flowfield information. Virtual Diagnostics Interface technology, developed at NASA Langley, was used to visualize the data sets in post processing. The use of calibration "dotcards" was investigated to correct for camera perspective and lens distortions in the PLIF images. Lessons learned and recommendations for future experiments are discussed.

Alderfer, D. W.↗
NASA NTRS2008

Fluorescence Imaging and Streamline Visualization of Hypersonic Flow over Rapid Prototype Wind-Tunnel Models

Reentry models for use in hypersonic wind tunnel tests were fabricated using a stereolithography apparatus. These models were produced in one day or less, which is a significant time savings compared to the manufacture of ceramic or metal models. The models were tested in the NASA Langley Research Center 31-Inch Mach 10 Air Tunnel. Only a few of the models survived repeated tests in the tunnel, and several failure modes of the models were identified. Planar laser-induced fluorescence (PLIF) of nitric oxide (NO) was used to visualize the flowfields in the wakes of these models. Pure NO was either seeded through tubes plumbed into the model or via a tube attached to the strut holding the model, which provided localized addition of NO into the model s wake through a porous metal cylinder attached to the end of the tube. Models included several 2- inch diameter Inflatable Reentry Vehicle Experiment (IRVE) models and 5-inch diameter Crew Exploration Vehicle (CEV) models. Various model configurations and NO seeding methods were used, including a new streamwise visualization method based on PLIF. Virtual Diagnostics Interface (ViDI) technology, developed at NASA Langley Research Center, was used to visualize the data sets in post processing. The use of calibration "dotcards" was investigated to correct for camera perspective and lens distortions in the PLIF images.

Danehy, Paul M.↗
NASA NTRS2016

Parallel Grand Canonical Monte Carlo (ParaGrandMC) Simulation Code

This report provides an overview of the Parallel Grand Canonical Monte Carlo (ParaGrandMC) simulation code. This is a highly scalable parallel FORTRAN code for simulating the thermodynamic evolution of metal alloy systems at the atomic level, and predicting the thermodynamic state, phase diagram, chemical composition and mechanical properties. The code is designed to simulate multi-component alloy systems, predict solid-state phase transformations such as austenite-martensite transformations, precipitate formation, recrystallization, capillary effects at interfaces, surface absorption, etc., which can aid the design of novel metallic alloys. While the software is mainly tailored for modeling metal alloys, it can also be used for other types of solid-state systems, and to some degree for liquid or gaseous systems, including multiphase systems forming solid-liquid-gas interfaces.

Vesselin I Yamakov↗