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DOE OSTI2021

AFRL Additive Manufacturing Modeling Series: Challenge 4, In Situ Mechanical Test of an IN625 Sample with Concurrent High-Energy Diffraction Microscopy Characterization

In this work, we describe 3D characterization of an additively manufactured Inconel 625 nickel-base superalloy specimen conducted during a uniaxial tension test using a suite of nondestructive x-ray techniques. High-energy diffraction microscopy in both near- and far-field modalities are employed in situ to track evolution of the material orientation and stress–strain fields at six points during the mechanical test, and these data streams are registered with micro-computed tomography reconstructions which probe the material density. This data volume was matched to a multi-modal serial sectioning characterization of the specimen taken after loading, described in this article’s companion. Twenty-eight grains which were monitored throughout the experiment were selected to form the basis for AFRL AM Modeling Series Challenge 4, Microscale Structure-to-Properties.

36 MATERIALS SCIENCE↗

NASA NTRS2010

Micromechanics Modeling of Composites Subjected to Multiaxial Progressive Damage in the Constituents

The high-fidelity generalized method of cells composite micromechanics model is extended to include constituent-scale progressive damage via a proposed damage model. The damage model assumes that all material nonlinearity is due to damage in the form of reduced stiffness, and it uses six scalar damage variables (three for tension and three for compression) to track the damage. Damage strains are introduced that account for interaction among the strain components and that also allow the development of the damage evolution equations based on the constituent material uniaxial stress strain response. Local final-failure criteria are also proposed based on mode-specific strain energy release rates and total dissipated strain energy. The coupled micromechanics-damage model described herein is applied to a unidirectional E-glass/epoxy composite and a proprietary polymer matrix composite. Results illustrate the capability of the coupled model to capture the vastly different character of the monolithic (neat) resin matrix and the composite in response to far-field tension, compression, and shear loading.

Bednarcyk, Brett A.↗

DOE OSTI2024

Quantification of grain boundary effects on the geometrically necessary dislocation density evolution and strain hardening of polycrystalline Mg 4Al using in situ tensile testing in scanning electron microscope and HR-EBSD

In situ tensile testing in a scanning electron microscope (SEM) in conjunction with high-resolution electron backscatter diffraction (HR-EBSD) under load was used to characterize the evolution of geometrically necessary dislocation (GND) densities at individual grain boundaries as a function of applied strain in a polycrystalline Mg—4Al alloy. The increase in GND density was investigated at plastic strains of 0 %, 0.6 %, 2.2 %, 3.3 % from the area including 76 grains and correlated with (i) geometric compatibility between slip systems across grain boundaries, and (ii) plastic incompatibility. We develop expressions for the grain boundary GND density evolution as a function of plastic strain and plastic incompatibility, from which uniaxial tensile stress-strain response of polycrystalline Mg—4Al are computed and compared with experimental measurement. The findings in this study contribute to understanding the mechanisms governing the strain hardening response of single-phase polycrystalline alloys and more reliable prediction of mechanical behaviors in diverse microstructures.

Geometrically necessary dislocations↗

DOE OSTI2022

Study of the interplay between lower-order and higher-order energetic strain-gradient effects in polycrystal plasticity

in this report strain-gradient (SG) plasticity refers to a class of non-local theories in which gradients of plastic slip determine the storage of geometrically necessary dislocations, introducing a length-scale dependence in the mechanical behavior of crystalline materials, which is otherwise lacking in local theories. In this work, we incorporate lower-order (LO) and higher-order energetic (HOE) strain-gradient effects into a crystal plasticity fast Fourier transform (FFT)-based formulation to investigate the interplay of the length scale that each strain-gradient term introduces at the microscale, and the mechanical properties that result at the macroscale. For an applicable range of length scales, we consider two systems: a 1-D two-phase face centered cubic (FCC) laminate and a 3-D FCC polycrystal, and two uniaxial deformation modes: monotonic tension and cyclic tension–compression. We show that increases in the individual LO and HOE length scales increase the hardening rate and strength of the material, respectively. When combined, the strong LO hardening is less pronounced than the effect alone due to the lowering of the gradients due to the HOE microstress. We demonstrate that the LO and HOE hardening manifest as “isotropic” (yield surface expansion) and “kinematic” (yield surface shift) effects, respectively, consistent with their theoretical origins. We show that in cyclic loading, the Bauschinger effect emerges in both local and non-local calculations and link its origins and severity to the behavior in the strain field, slip-system rates, and the HOE microforce.

36 MATERIALS SCIENCE↗

NASA NTRS1993

Life assessment of structural components using inelastic finite element analyses

The need for enhanced and improved performance of structural components subject to severe cyclic thermal/mechanical loadings, such as in the aerospace industry, requires development of appropriate solution technologies involving time-dependent inelastic analyses. Such analyses are mandatory to predict local stress-strain response and to assess more accurately the cyclic life time of structural components. The NASA-Lewis Research Center is cognizant of this need. As a result of concerted efforts at Lewis during the last few years, several such finite element solution technologies (in conjunction with the finite element program MARC) were developed and successfully applied to numerous uniaxial and multiaxial problems. These solution technologies, although developed for use with MARC program, are general in nature and can easily be extended for adaptation with other finite element programs such as ABAQUS, ANSYS, etc. The description and results obtained from two such inelastic finite element solution technologies are presented. The first employs a classical (non-unified) creep-plasticity model. An application of this technology is presented for a hypersonic inlet cowl-lip problem. The second of these technologies uses a unified creep-plasticity model put forth by Freed. The structural component for which this finite element solution technology is illustrated, is a cylindrical rocket engine thrust chamber. The advantages of employing a viscoplastic model for nonlinear time-dependent structural analyses are demonstrated. The life analyses for cowl-lip and cylindrical thrust chambers are presented. These analyses are conducted by using the stress-strain response of these components obtained from the corresponding finite element analyses.

Arya, Vinod K.↗

DOE OSTI2026

A finite viscoelastic constitutive model for low to high strain rate response of elastomers with application of strain rate-induced glass transition

Amorphous elastomers exhibit significant rate-stiffening and unique viscous flow characteristics across a wide range of strain rates, often undergoing glass transition above a strain rate threshold. We have developed a thermodynamically-consistent and micromechanically-inspired constitutive model for soft elastomeric materials to capture the rate-dependent stress-strain behavior and hysteresis when subjected to low to high strain rates. Here, our proposed constitutive model encapsulates the viscous flow of materials through molecular motion at low strain rates and local rearrangement and alignment of the molecules trying to overcome the intermolecular resistance at high strain rates, essentially covering the glass transition. We applied our constitutive model to uniaxial compression experiments performed at low and high strain rates for polyborosiloxane (PBS) to identify the material parameters, and subsequently, performed numerical simulations of single and multi-cycle compression, stress relaxation, and small amplitude oscillatory tension-compression. Our analyses indicate that the model predicts higher total energy dissipation with increasing strain rate; however, dissipation associated with molecular relaxation decreases (forming a cusp) because, beyond a crossover strain rate, intermolecular rearrangement and alignment become dominant, which is consistent with the onset of the glass transition. For cyclic loading-unloading, we observed that dissipation over a cycle remains constant at low strain rates but decreases non-monotonically at high strain rates before becoming constant, with the peak stress over the cycle becoming higher, which can be interpreted as more loading being carried elastically by the polymer network as the intermolecular rearrangement process occurs. Additionally, our model was able to predict the qualitative nature of the storage modulus and loss modulus in the limit of small strain over a wide range of frequency sweeps.

36 MATERIALS SCIENCE↗

NASA NTRS1995

A study of elevated temperature testing techniques for the fatigue behavior of PMCS: Application to T650-35/AMB21

An experimental study was conducted to investigate the mechanical behavior of a T650-35/AMB21 eight-harness satin weave polymer composite system. Emphasis was placed on the development and refinement of techniques used in elevated temperature uniaxial PMC testing. Issues such as specimen design, gripping, strain measurement, and temperature control and measurement were addressed. Quasi-static tensile and fatigue properties (R(sub sigma) = 0.1) were examined at room and elevated temperatures. Stiffness degradation and strain accumulation during fatigue cycling were recorded to monitor damage progression and provide insight for future analytical modeling efforts. Accomplishments included an untabbed dog-bone specimen design which consistently failed in the gage section, accurate temperature control and assessment, and continuous in-situ strain measurement capability during fatigue loading at elevated temperatures. Finally, strain accumulation and stiffness degradation during fatigue cycling appeared to be good indicators of damage progression.

Gyekenyesi, Andrew L.↗

NASA NTRS1991

Stacking-sequence optimization for buckling of laminated plates by integer programming

Integer-programming formulations for the design of symmetric and balanced laminated plates under biaxial compression are presented. Both maximization of buckling load for given total thickness, and the minimization of total thickness subject to a buckling constraint are formulated. The design variables that define the stacking sequence of the laminate are zero-one integers. It is shown that the formulation results in a linear optimization problem that can be solved on readily aviable software. Constraints on the stacking sequence such as a limit on the number of contiguous plies of the same orientation and limits on in-plane stiffnesses are easily accommodated. Examples are presented for graphite-epoxy plates under uniaxial and biaxial compression using a commercial software package based on the branch-and-bound algorithm.

Haftka, Raphael T.↗

DOE OSTI2021

Thermal-Mechanical Elastic-Plastic and Ductile Failure Model Calibrations for 304L Stainless Steel Alloy

Numerical simulations of metallic structures undergoing rapid loading into the plastic range require material models that accurately represent the response. In general, the material response can be seen as having four interrelated parts: the baseline response under slow loading, the effect of strain rate, the conversion of plastic work into heat and the effect of temperature. In essence, the material behaves in a thermal-mechanical manner if the loading is fast enough so when heat is generated by plastic deformation it raises the temperature and therefore influences the mechanical response. In these cases, appropriate models that can capture the aspects listed above are necessary. The material of interest here is 304L stainless steel, and the objective of this work is to calibrate thermal-mechanical models: one for the constitutive behavior and another for failure. The work was accomplished by first designing and conducting a material test program to provide data for the calibration of the models. The test program included uniaxial tension tests conducted at room temperature, 150 and 300 C and at strain rates between 10 –4 and 10 3 1/s. It also included notched tension and shear-dominated compression hat tests specifically designed to calibrate the failure model. All test specimens were extracted from a single piece of plate to maintain consistency. The constitutive model adopted was a modular $J_2$ plasticity model with isotropic hardening that included rate and temperature dependence. A criterion for failure initiation based on a critical value of equivalent plastic strain fitted the failure data appropriately and was adopted. Possible ranges of the values of the parameters of the models were determined partially on historical data from calibrations of the same alloy from other lots and are given here. The calibration of the parameters of the models were based on finite element simulations of the various material tests using relatively ne meshes and hexahedral elements. When using the model in structural finite element calculations, however, element formulations and sizes different from those in the calibration are likely to be used. A brief investigation demonstrated that the failure initiation predictions can be particularly sensitive to the element selection and provided an initial guide to compensate for the effect of element size in a specific example.

36 MATERIALS SCIENCE↗

NASA NTRS1974

Shear-stress intensity factors for elastic sheets with cover plates

Shear stress intensity factors are calculated for three problems concerning inextensible cover plates either bonded to or embedded in an elastic sheet which is under uniaxial tension. The stress intensity factors are small when the ratio of sheet thickness to cover plate length is small and, as the ratio increase, rapidly approach their asymptotic values for infinite sheet thickness. In the problem of the embedded cover plate, the stress intensity factor also depends on the Poisson's ratio of the sheet material. The dependence on Poisson's ratio, however, is significant only when the ratio of sheet thickness to cover plate length is small. Some possible implications of the present results for debonding of reinforced sheets under cyclic loading are briefly discussed.

Fichter, W. B.↗

NASA NTRSDate not supplied

Py MILab: Capturing, Analyzing and Storing Test Data

Integrated Computational Materials Engineering (ICME) has recently received widespread attention due to its promises in reducing dependence on physical testing for engineering design by relying on simulation, reducing both time and cost to market for various applications. ICME however requires validated multiscale material models, which is heavily dependent on available test data with full material and test pedigree, including material processing, test and measurement equipment, raw data collection, and analysis methodology and results. Populating searchable information management systems with such rich data sets is often burdensome for data producers, resulting in a lack of findable data for modelers to validate and verify their models. To overcome these cultural barriers to ICME, NASA has developed of various database-integration toolsets that perform both data management activities within the organization’s best practices with additional functionality that relieves the effort of the data producer and promotes adoption of information management system. One such tool currently under development is Py MILab, an automatic framework for automatic capturing, analysis, maintenance, and storage of material test data. Py MILab uses a modular approach for capturing raw data, analyzing the data, and storing the data in a database, interfaced by neutral file structures, to promote plug-and-play capabilities for various analysis types. TMAnalysis is a Python-based tool that performs automatic data reduction and analysis of uniaxial thermomechanical test data. The TMAnalysis toolset can be implemented within the Analysis module of Py MILab, and thus requires a populated neutral file form the Raw Data Module of Py MILab and outputs a Analysis neutral file compatible with the Database Module of Py MILab. TMAnalysis is able to perform automatic segmentation of multistage tests and perform data analysis and reduction, including determination of point-wise properties in tension, compression, and shear, analysis of stress relaxation tests, creep analysis and zone identification, and combination of these stage types for tests with complex loading histories. The TMAnalysis code is accompanied with a graphical user interface (GUI) that allows users to easily analyze test data in bulk, verify the automatic, consistent analysis performed by the backend code, and edit stage segmentation if necessary before producing the output neutral files, ensuring data is properly analyzed and maintained with full traceability.

Data management↗

DOE OSTI2021

Assessing the ASME Section III, Division 5, Class A Primary Load Design Rules Against Creep Notch Effects

This report assesses the ASME Section III, Division 5, Subsection HB, Subpart B rules covering the design and construction of high temperature Class A nuclear reactor components for their robustness against creep notch effects. The creep notch effect combines the effect of multiaxial stresses on material creep deformation and damage. This report considers both effects, including the potential for creep mechanism shifts affecting the extrapolation of design data from high stress, short-time experimental data to low stress, long time operating component conditions. The report summarizes the history of and literature on multiaxial creep and surveys the current ASME design rules dealing with multiaxial effects. The report then describes the results of two dedicated numerical studies, one assessing the robustness of the ASME rules against uncertainty in extrapolating from uniaxial creep test data to multiaxial component conditions and a second study examining the potential effects of a mechanism shift from high stress, dislocation-mediated creep to diffusion-dominated creep at lower stresses. The final conclusion of the report is that the ASME rules adequately guard against multiaxial creep failure, though there are several aspects of the Code that could be optimized to provide less over-conservative design predictions or to provide a more consistent design margin as a function of temperature and stress. In a few areas, particularly the potential for mechanism shifts outside the currently-available experimental data, the Code rules should be revaluated as additional experimental data and new modeling and simulation results become available

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

3D Printing of Liquid Crystal Elastomer Foams for Enhanced Energy Dissipation Under Mechanical Insult

Polymer foams are an essential class of lightweight materials used to protect assets against mechanical insults, such as shock and vibration. Two features are important to enhance their energy absorption characteristics: the foam structure and the matrix phase mechanical behavior. This study investigates novel approaches to control both of these features to enhance the energy absorption capability of flexible lattice foams. First, we consider 3D printing via digital light processing (DLP) as a method to control the foam mesostructure across a suite of periodic unit cells. Second, we introduce an additional energy dissipation mechanism in the solid matrix phase material by 3D printing the lattice foams with polydomain liquid crystal elastomer (LCE), which undergo a mechanically induced phase transition under large strains. This phase transition is associated with LC mesogen rotation and alignment and provides a second mechanism for mechanical energy dissipation in addition to the viscoelastic relaxation of the polymer network. Here, we contrast the 3D printed LCE lattices with conventional, thermomechanically near-equivalent elastomer lattice foams to quantify the energy-absorbing enhancement the LCE matrix phase provides. Under cyclic quasi-static uniaxial compression conditions, the LCE lattices show dramatically enhanced energy dissipation in uniaxial compression compared to the non-LCE equivalent foams printed with a commercially available photocurable elastomer resin. The lattice geometry also plays a prominent role in determining the energy dissipation ratio between the LCE and non-LCE foams. We show that when increasing the lattice connectivity, the foam deformation transitions from bending-dominated to stretching-dominated deformations, which generates higher axial strains in the struts and higher energy dissipation in the lattice foam, as stretching allows greater mesogen rotation than bending. The LCE foams demonstrate superior energy absorption during the repeated dynamic loading during drop testing compared with the non-LCE equivalent foams, demonstrating the potential of LCEs to enhance physical protection systems against mechanical impact.

3D printing↗

DOE OSTI2025

Structural response reconstruction using a system-equivalent singular vector basis

Here, this paper develops a novel method for reconstructing the full-field response of structural dynamic systems using sparse measurements. The singular value decomposition is applied to a frequency response matrix relating the structural response to physical loads, base motion, or modal loads. The left singular vectors form a non-physical reduced basis that can be used for response reconstruction with far fewer sensors than existing methods. The contributions of the singular vectors to measured response are termed singular-vector loads (SVLs) and are used in a regularized Bayesian framework to generate full-field response estimates and confidence intervals. The reconstruction framework is applicable to the estimation of single data records and power spectral densities from multiple records. Reconstruction is successfully performed in configurations where the number of SVLs to identify is less than, equal to, and greater than the number of sensors used for reconstruction. In a simulation featuring a seismically excited shear structure, SVL reconstruction significantly outperforms modal FRF-based reconstruction and successfully estimates full-field responses with as few as two uniaxial accelerometers. SVL reconstruction is further verified in a simulation featuring an acoustically excited cylinder. Finally, response reconstruction and uncertainty quantification are performed on an experimental structure with three shaker inputs and 27 triaxial accelerometer outputs.

42 ENGINEERING↗

NASA NTRS1982

Equivalent damage: A critical assessment

Concepts in equivalent damage were evaluated to determine their applicability to the life prediction of hot path components of aircraft gas turbine engines. Equivalent damage was defined as being those effects which influence the crack initiation life-time beyond the damage that is measured in uniaxial, fully-reversed sinusoidal and isothermal experiments at low homologous temperatures. Three areas of equivalent damage were examined: mean stress, cumulative damage, and multiaxiality. For each area, a literature survey was conducted to aid in selecting the most appropriate theories. Where possible, data correlations were also used in the evaluation process. A set of criteria was developed for ranking the theories in each equivalent damage regime. These criteria considered aspects of engine utilization as well as the theoretical basis and correlative ability of each theory. In addition, consideration was given to the complex nature of the loading cycle at fatigue critical locations of hot path components; this loading includes non-proportional multiaxial stressing, combined temperature and strain fluctuations, and general creep-fatigue interactions. Through applications of selected equivalent damage theories to some suitable data sets it was found that there is insufficient data to allow specific recommendations of preferred theories for general applications. A series of experiments and areas of further investigations were identified.

Laflen, J. R.↗

NASA NTRS1990

Design of ceramic components with the NASA/CARES computer program

The ceramics analysis and reliability evaluation of structures (CARES) computer program is described. The primary function of the code is to calculate the fast-fracture reliability or failure probability of macro-scopically isotropic ceramic components. These components may be subjected to complex thermomechanical loadings, such as those found in heat engine applications. CARES uses results from MSC/NASTRAN or ANSYS finite-element analysis programs to evaluate how inherent surface and/or volume type flaws component reliability. CARES utilizes the Batdorf model and the two-parameter Weibull cumulative distribution function to describe the effects of multiaxial stress states on material strength. The principle of independent action (PIA) and the Weibull normal stress averaging models are also included. Weibull material strength parameters, the Batdorf crack density coefficient, and other related statistical quantities are estimated from four-point bend bar or uniform uniaxial tensile specimen fracture strength data. Parameter estimation can be performed for a single or multiple failure modes by using a least-squares analysis or a maximum likelihood method. Kolmogorov-Smirnov and Anderson-Darling goodness-to-fit-tests, 90 percent confidence intervals on the Weibull parameters, and Kanofsky-Srinivasan 90 percent confidence band values are also provided. Examples are provided to illustrate the various features of CARES.

Nemeth, Noel N.↗

NASA NTRS1990

Ceramics Analysis and Reliability Evaluation of Structures (CARES). Users and programmers manual

This manual describes how to use the Ceramics Analysis and Reliability Evaluation of Structures (CARES) computer program. The primary function of the code is to calculate the fast fracture reliability or failure probability of macroscopically isotropic ceramic components. These components may be subjected to complex thermomechanical loadings, such as those found in heat engine applications. The program uses results from MSC/NASTRAN or ANSYS finite element analysis programs to evaluate component reliability due to inherent surface and/or volume type flaws. CARES utilizes the Batdorf model and the two-parameter Weibull cumulative distribution function to describe the effect of multiaxial stress states on material strength. The principle of independent action (PIA) and the Weibull normal stress averaging models are also included. Weibull material strength parameters, the Batdorf crack density coefficient, and other related statistical quantities are estimated from four-point bend bar or unifrom uniaxial tensile specimen fracture strength data. Parameter estimation can be performed for single or multiple failure modes by using the least-square analysis or the maximum likelihood method. Kolmogorov-Smirnov and Anderson-Darling goodness-of-fit tests, ninety percent confidence intervals on the Weibull parameters, and Kanofsky-Srinivasan ninety percent confidence band values are also provided. The probabilistic fast-fracture theories used in CARES, along with the input and output for CARES, are described. Example problems to demonstrate various feature of the program are also included. This manual describes the MSC/NASTRAN version of the CARES program.

Nemeth, Noel N.↗

NASA NTRS1994

Residual strength of thin panels with cracks

The previous design philosophies involving safe life, fail-safe and damage tolerance concepts become inadequate for assuring the safety of aging aircraft structures. For example, the failure mechanism for the Aloha Airline accident involved the coalescence of undetected small cracks at the rivet holes causing a section of the fuselage to peel open during flight. Therefore, the fuselage structure should be designed to have sufficient residual strength under worst case crack configurations and in-flight load conditions. Residual strength is interpreted as the maximum load carrying capacity prior to unstable crack growth. Internal pressure and bending moment constitute the two major components of the external loads on the fuselage section during flight. Although the stiffeners in the form of stringers, frames and tear straps sustain part of the external loads, the significant portion of the load is taken up by the skin. In the presence of a large crack in the skin, the crack lips bulge out with considerable yielding; thus, the geometric and material nonlinearities must be included in the analysis for predicting residual strength. Also, these nonlinearities do not permit the decoupling of in-plane and out-of-plane bending deformations. The failure criterion combining the concepts of absorbed specific energy and strain energy density addresses the aforementioned concerns. The critical absorbed specific energy (local toughness) for the material is determined from the global specimen response and deformation geometry based on the uniaxial tensile test data and detailed finite element modeling of the specimen response. The use of the local toughness and stress-strain response at the continuum level eliminates the size effect. With this critical parameter and stress-strain response, the finite element analysis of the component by using STAGS along with the application of this failure criterion provides the stable crack growth calculations for residual strength predictions.

Madenci, Erdogan↗