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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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25 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Overview of Ablative TPS Modeling at NASA Ames

Over the past decade, NASA has invested in efforts to build predictive thermal protection system (TPS) material models from the micro-scale to the macro-scale. To complement the mission design cycle process and reduce the need for extensive testing, NASA is developing modeling and simulation tools that enable characterizing material properties and response to hot plasma experienced during atmospheric entry. Traditional material response and ablation modeling tools, such as the heritage code FIAT, and its multidimensional siblings, TITAN and 3dFIAT, are being complemented with newly developed software such as Icarus and PATO. Both of these programs are three-dimensional, finite-volume solvers that use unstructured meshes and 21st century programming paradigms to allow for efficient parallel simulations. FIAT and Icarus are also used for TPS sizing purposes. Today, these traditional tools are being supplemented with computational materials models at the atomistic level. The scales of interest range from computational chemistry (Density Functional Theory [DFT]), to atomistic simulations (Molecular Dynamics [MD]), to the microscale with the Porous Microstructure Analysis (PuMA) software that was recently awarded the 2022 NASA Software of the Year award. Finally, thermo-structural modeling is also of interest to the TPS Materials branch and done using commercial tools such as MSC MARC, MENTAT, NASTRAN and PATRAN. The present talk will also link the use of these computational tools to current NASA missions and projects associated with challenging and complex vehicles entries/reentries.

materials modeling↗
NASA NTRS1984

Modeling material failure with a vectorized routine

The computational aspects of modelling material failure in structural wood members are presented with particular reference to vector processing aspects. Wood members are considered to be highly orthotropic, inhomogeneous, and discontinuous due to the complex microstructure of wood material and the presence of natural growth characteristics such as knots, cracks and cross grain in wood members. The simulation of strength behavior of wood members is accomplished through the use of a special purpose finite element/fracture mechanics routine, program STARW (Strength Analysis Routine for Wood). Program STARW employs quadratic finite elements combined with singular crack tip elements in a finite element mesh. Vector processing techniques are employed in mesh generation, stiffness matrix formation, simultaneous equation solution, and material failure calculations. The paper addresses these techniques along with the time and effort requirements needed to convert existing finite element code to a vectorized version. Comparisons in execution time between vectorized and nonvectorized routines are provided.

Cramer, S. M.↗
NASA NTRSDate not supplied

Automated Probabilistic Finite Element Model Calibration Tool Based on Uncertainty Quantification and Machine Learning

Qualification and certification of safety critical parts is a hurdle to the adoption of metallic additively manufactured components for aerospace vehicle applications. Challenges include variability in part properties due to inconsistent defect distribution and microstructure. Understanding of the process through finite element modeling (FEM), and process control through in-situ monitoring, may result in significant improvements; however, solutions useful to manufacturers will require large volumes of data and automated data utilization. Toward this end, a generalizable automated FEM calibration paradigm is developed. This paradigm leverages existing and novel tools from machine learning and uncertainty quantification to enable the automatic calibration of FEMs without requiring prior knowledge of the model performance across input parameter space, including meshing and solver settings, which can require time consuming manual model probing or cause noisy and inconsistent predictions. The result is a probabilistic distribution of calibrated and validated FEM input parameters targeting measured data.

Additive manufacturing model calibration finite el↗
NASA NTRS1993

Approximating the stress field within the unit cell of a fabric reinforced composite using replacement elements

This report concerns the prediction of the elastic moduli and the internal stresses within the unit cell of a fabric reinforced composite. In the proposed analysis no restrictions or assumptions are necessary concerning yarn or tow cross-sectional shapes or paths through the unit cell but the unit cell itself must be a right hexagonal parallelepiped. All the unit cell dimensions are assumed to be small with respect to the thickness of the composite structure that it models. The finite element analysis of a unit cell is usually complicated by the mesh generation problems and the non-standard, adjacent-cell boundary conditions. This analysis avoids these problems through the use of preprogrammed boundary conditions and replacement materials (or elements). With replacement elements it is not necessary to match all the constitutional material interfaces with finite element boundaries. Simple brick-shaped elements can be used to model the unit cell structure. The analysis predicts the elastic constants and the average stresses within each constituent material of each brick element. The application and results of this analysis are demonstrated through several example problems which include a number of composite microstructures.

Foye, R. L.↗
NASA NTRS2018

Modeling Fiber Kinking at the Microscale and Mesoscale

A computational micromechanics (CMM) model is employed to interrogate the assumptions of a recently developed mesoscale continuum damage mechanics (CDM) model for fiber kinking. The CMM model considers an individually discretized three dimensional fiber and surrounding matrix accounting for nonlinearity in the fiber, matrix plasticity, fiber/matrix interface debonding, and geometric nonlinearity. Key parameters of the CMM model were measured through experiments. In particular, a novel experimental technique to characterize the in situ longitudinal compressive strength of carbon fibers through indentation of micropillars is presented. The CDM model is formulated on the basis of Budiansky's fiber kinking theory (FKT) with a constitutive deformation-decomposition approach to alleviate mesh size sensitivity. In contrast to conventional mesoscale CDM models that prescribe a constitutive response directly, the response of the proposed model is an outcome of material nonlinearity and large rotations of the fiber direction following FKT. Comparison of the predictions from the CMM and CDM models shows remarkable correlation in strength, post-peak residual stress, and fiber rotation, with less than 10% difference between the two models in most cases. Additional comparisons are made with several fiber kinking models proposed in the literature to highlight the efficacy of the two models. Finally, the CMM model is exercised in parametric studies to explore opportunities to improve the longitudinal compression strength of a ply through the use of nonconventional microstructures.

Herraez, Miguel↗
NASA NTRS2014

Three-Dimensional Imaging and Numerical Reconstruction of Graphite/Epoxy Composite Microstructure Based on Ultra-High Resolution X-Ray Computed Tomography

A combined experimental and computational study aimed at high-resolution 3D imaging, visualization, and numerical reconstruction of fiber-reinforced polymer microstructures at the fiber length scale is presented. To this end, a sample of graphite/epoxy composite was imaged at sub-micron resolution using a 3D X-ray computed tomography microscope. Next, a novel segmentation algorithm was developed, based on concepts adopted from computer vision and multi-target tracking, to detect and estimate, with high accuracy, the position of individual fibers in a volume of the imaged composite. In the current implementation, the segmentation algorithm was based on Global Nearest Neighbor data-association architecture, a Kalman filter estimator, and several novel algorithms for virtualfiber stitching, smoothing, and overlap removal. The segmentation algorithm was used on a sub-volume of the imaged composite, detecting 508 individual fibers. The segmentation data were qualitatively compared to the tomographic data, demonstrating high accuracy of the numerical reconstruction. Moreover, the data were used to quantify a) the relative distribution of individual-fiber cross sections within the imaged sub-volume, and b) the local fiber misorientation relative to the global fiber axis. Finally, the segmentation data were converted using commercially available finite element (FE) software to generate a detailed FE mesh of the composite volume. The methodology described herein demonstrates the feasibility of realizing an FE-based, virtual-testing framework for graphite/fiber composites at the constituent level.

Czabaj, M. W.↗
NASA NTRSDate not supplied

Computation of Effective Mechanical Properties and Mechanical Erosion Modeling of TPS Materials

The goal of this presentation is to provide a general overview of the multi-scale modeling formulation to determine if there is additional surface recession in Thermal Protection Systems (TPS) materials as a result of mechanical erosion due to high shear conditions during atmospheric entry. This modeling process is performed at different scales by leveraging two computational frameworks developed at NASA: the Porous Microstructure Analysis (PuMA) software, and the Porous material Analysis Toolbox based on OpenFOAM (PATO). PuMA specializes in computing effective macro-scale material properties by performing material response simulations on 3D digital micro-scale representations of porous micro-structures. The modeling of TPS materials at the micro-scale is essential to understand how they behave as part of a heat shield assembly. The first part of the presentation will detail the implementation of PuMA’s cell-centered finite volume elasticity solver, which allows the computation of macro-scale effective mechanical properties of heterogeneous and anisotropic materials such as fibrous and woven TPS composites. These homogenized mechanical properties are used by PATO’s mechanical erosion model to predict the TPS material’s recession at a larger scale. This work will also provide some examples of multi-scale analysis from the fiber level up to the unit cell. The second part of the presentation will focus on the macro-scale approach to determine if erosion at the heat shield’s surface occurs due to mechanical and thermal loads experienced during atmospheric entry. To accomplish this, a solid mechanics module was integrated within PATO enabling it to model the potential mechanical erosion in three steps: first, after obtaining the effective mechanical properties with PuMA, the implemented stress analysis solver computes the stress and the displacement fields for the TPS material using the wall shear stress tensor, computed using a CFD solver, as boundary conditions; then, regions on the surface where the stress meets the failure criteria are identified; finally, the failed material is removed and the mesh is redistributed accordingly. The outcome is a model capable of predicting the total recession in the material due to surface chemistry and mechanical erosion.

Mechanical Properties↗