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At least 649 records · Page 36
All sourcesNASA NTRSDOE OSTI
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 NTRS1990

Mixed-Mode Bending Method for Delamination Testing

A mixed mode delamination test procedure was developed combining double cantilever beam (DCB) mode I loading and end-notch fixture (ENF) mode II loading on a split unidirectional laminate. By loading with a lever, a single applied load simultaneously produces mode I and mode II bending loads on the specimen. This mixed-mode bending (MMB) test was analyzed using both finite-element procedures and beam theory to calculate the mode I and mode II components of strain-energy release rate G(sub I) and G(sub II), respectively. A wide range of G(sub I)/G(sub II) ratios can be produced by varying the load position on the lever. As the delamination extended, the G(sub I)/G(sub II) ratios varied by less than 5%. Beam theory equations agreed closely with the finite-element results and provide a basis for selection of G(sub I)/G(sub II) test ratios and a basis for computing the mode I and mode II components of measured delamination toughness. The MMB test was demonstrated using AS4/PEEK (APC2) unidirectional laminates. The MMB test introduced in this paper is rather simple and is believed to offer several advantages over most current mixed-mode test.

Reeder, James R.↗
DOE OSTI2020

Modeling of surface mechanical behaviors of soft elastic solids: theory and examples

Surfaces of soft solids can have significant surface stress, extensional modulus and bending stiffness. Previous theoretical studies have usually examined cases in which both the surface stress and bending stiffness are constant, assuming small deformation. In this work we consider a general formulation in which the surface can support large deformation and carry both surface stresses and surface bending moments. We show that the large deformation theory can be reduced to the classical linear theory (Shuttleworth equation). We obtain exact solutions for problems of an inflated cylindrical shell and bending of a plate with a finite thickness. Our analysis illustrates the different manners in which surface stiffening and surface bending stabilize these structures. We discuss how the complex surface constitutive behaviors affect the stress field of the bulk. Our calculation provides insights into effects of strain-dependent surface stress and surface bending in the large deformation regime, and can be used as a model to implement surface finite elements to study large deformation of complex structures.

36 MATERIALS SCIENCE↗
NASA NTRS2012

Improved Displacement Transfer Functions for Structure Deformed Shape Predictions Using Discretely Distributed Surface Strains

In the formulations of earlier Displacement Transfer Functions for structure shape predictions, the surface strain distributions, along a strain-sensing line, were represented with piecewise linear functions. To improve the shape-prediction accuracies, Improved Displacement Transfer Functions were formulated using piecewise nonlinear strain representations. Through discretization of an embedded beam (depth-wise cross section of a structure along a strain-sensing line) into multiple small domains, piecewise nonlinear functions were used to describe the surface strain distributions along the discretized embedded beam. Such piecewise approach enabled the piecewise integrations of the embedded beam curvature equations to yield slope and deflection equations in recursive forms. The resulting Improved Displacement Transfer Functions, written in summation forms, were expressed in terms of beam geometrical parameters and surface strains along the strain-sensing line. By feeding the surface strains into the Improved Displacement Transfer Functions, structural deflections could be calculated at multiple points for mapping out the overall structural deformed shapes for visual display. The shape-prediction accuracies of the Improved Displacement Transfer Functions were then examined in view of finite-element-calculated deflections using different tapered cantilever tubular beams. It was found that by using the piecewise nonlinear strain representations, the shape-prediction accuracies could be greatly improved, especially for highly-tapered cantilever tubular beams.

Ko, William L.↗
NASA NTRS1980

Comparison of elastic and elastic-plastic structural analyses for cooled turbine blade airfoils

Elastic plastic stress strain states in cooled turbine blade airfoils were calculated by three methods for the initial takeoff transient of an advanced technology aircraft engine. The three analytical methods compared were a three dimensional elastic plastic, finite element analysis, a three dimensional, elastic, finite element analysis, and a one dimensional, elastic plastic, beam theory analysis. Structural analyses were performed for eight cases involving different combinations of mechanical and thermal loading on impingement cooled airfoils with and without leading edge film cooling holes. The von Mises effective total strains at maximum takeoff computed from the elastic and elastic plastic finite element analyses agreed with 9 percent for rotating airfoils and 28 percent for stationary airfoils with the elastic results on the conservative side.

Kaufman, A.↗
NASA NTRS2019

Measured Interfacial Residual Strains Produced by In-Flight Ice

The formation of ice on aircraft is a highly dynamic process during which ice will expand and contract upon freezing and undergoing changes in temperature. Finite Element Analysis (FEA) simulations were performed investigating the stress build up in a simplified case with uniform temperature changes between an idealized ice sample and acrylic substrate. These results were used to place strain gages on custom-built acrylic and aluminum specimens; these specimens were then placed in icing conditions such that ice was grown on top of the specimen. Tee rosettes were placed in two configurations adjacent to thermocouple sensors. It was hypothesized that the ice would expand on freezing and contract as the temperature of the interface returned to the equilibrium conditions. While results from the aluminum specimens matched this hypothesis, results from the acrylic specimens show a short period of contraction followed by a much larger expansion at the interface, indicating more complex ice growth thermodynamics than anticipated. Samples were observed to delaminate, and the data suggests that the residual strain is significant to the shedding of ice for in-flight applications.

residual strain↗
DOE OSTI2026

ACT University Collaboration Proposal: Role of manufacturing defects on material failure under dynamic loading for developing enhanced failure models and theories (Final Report)

Research on the tensile behavior of additively manufactured 316L stainless steel coupon specimens at increasing strain rates was conducted over the past year at Penn State. Dynamic loading rates into the 1000 1/s loading rates were performed on specimens with nearly 1.32” gage lengths. Stress-strain plots show ductile and plastic behavior well beyond 12% strain with necked specimens, having smaller effective gage lengths showing up to 56% ultimate strain. Additional tests performed on compact tension specimens helped with simulation work to understand the deformation behavior. Using finite elements, it was possible to determine the feasibility of a comprehensive experimental validation study towards an improved model for AM material failure – specifically, the Bai-Wierzbicki approach which accounts for lode angle and triaxiality. A non-significant number of tests are projected for eight specific failure nodes, with additional replicates to provide strain-rate capabilities to the existing formulation. One such correction factor is explored for quasi-static, notched specimens. Finally, stress intensity factor was explored using a set of compact-tension specimens which would also provide useful validation data for any simulation work.

36 MATERIALS SCIENCE↗
NASA NTRS1990

Finite element two-dimensional panel flutter at high supersonic speeds and elevated temperature

A consistent finite element formulation for flutter of two-dimensional panels including effects of temperature variation along panel length is presented. The von Karman nonlinear strain-displacement relation is used to account for the large-deflections, and the quasi-steady first-order piston theory is employed for aerodynamic loading in the finite-element formulation. The panel flutter under combined thermal/aerodynamic loading can be separated into solving two problems in sequence. They are: (1) postbuckling deflection, stresses and buckling stability boundary, and (2) critical dynamic pressure and linear flutter boundary. The solution procedures in solving these problems are presented in detail. Finite element results of two-dimensional panels with uniform temperature change are compared with classic analytical solutions. Influence of nonuniform temperature distributions on critical buckling temperature, flutter deflection and stresses, and flutter boundary is also given.

Xue, David Y.↗
NASA NTRS1973

Finite deformation of elasto-plastic solids

A theoretical basis is established for analysis of finite deformation of metals. The observation that finite deformation of such elastoplastic materials may be viewed as a process rather than an event leads to derivation of a complete initial and boundary value problem distinguished by its quasilinear nature. This feature of the formulation motivates adoption of an incremental approach to numerical problem solving. Numerical solution capability is established for problems of plane stress and plane strain. The validity of the theory and numerical analysis is demonstrated by consideration of a number of problems of homogeneous finite deformation for which analytic solutions are available. Subsequently the analysis is employed for the investigation of necking in flat metal tensile bars. The results of this investigation provide the first full numerical solutions for tensile necking in plane stress and plane strain. In addition a basis is provided for assessment of the validity of stress-strain relations inferred from tensile test data.

Osias, J. R.↗
NASA NTRS1986

Thermomechanical design criteria for ceramic-coated surfaces

Some early history of ceramic applications is presented. Finite element modeling of components to determine service and fabrication loads found inelastic behavior and residual stresses to be significant to component life. Inelastic behavior mitigates peak strains but enhances residual strains. Results of furnace, Mach 0.3 burner, and engine tests are discussed and categorized into design criteria (loading, geometry, fabrication, materials, analysis, and testing). These design rules and finite element analyses are brought to bear on two test cases: turboshaft engine seals, and rocket thrust chambers.

Mullen, R. L.↗
DOE OSTI2020

A continuum framework for coupled solid deformation–fluid flow through anisotropic elastoplastic porous media

We present a continuum framework for coupled solid deformation–fluid flow in anisotropic elastoplastic porous media. A thermodynamic formulation of the coupled processes gives rise to an anisotropic Biot tensor that is a function of drained elastic tangent moduli tensor of the solid skeleton and the intrinsic bulk modulus of the solid constituent. Two effective stress measures emerge from the formulation, namely, σ', which is energy-conjugate to the elastic strain, and σ'', which is energy-conjugate to the plastic strain. For the special case of transverse isotropy that is commonly encountered in natural rocks, the Biot tensor can be expressed in terms of its normal and tangential components to the bedding plane, along with a microstructure tensor. Apart from its thermodynamic consistency, an advantage of this new formulation is that standard mixed finite element formulation can be employed to discretize the domain and solve initial boundary-value problems. We conduct plane strain simulations of coupled solid deformation–fluid flow in a transversely isotropic porous medium to demonstrate the impacts of material anisotropy, stress history, and the Biot tensor on the system response.

42 ENGINEERING↗
NASA NTRS1989

Comparison of full 3-D, thin-film 3-D, and thin-film plate analyses of a postbuckled embedded delamination

Strain-energy release rates are often used to predict when delamination growth will occur in laminates under compression. Because of the inherently high computational cost of performing such analyses, less rigorous analyses such as thin-film plate analysis were used. The assumptions imposed by plate theory restrict the analysis to the calculation of total strain energy, G(sub t). The objective is to determine the accuracy of thin-film plate analysis by comparing the distribution of G(sub t) calculated using fully three dimensional (3D), thin-film 3D, and thin-film plate analyses. Thin-film 3D analysis is the same as thin-film plate analysis, except 3D analysis is used to model the sublaminate. The 3D stress analyses were performed using the finite element program NONLIN3D. The plate analysis results were obtained from published data, which used STAGS. Strain-energy release rates were calculated using variations of the virtual crack closure technique. The results demonstrate that thin-film plate analysis can predict the distribution of G(sub t) quite well, at least for the configurations considered. Also, these results verify the accuracy of the strain-energy release rate procedure for plate analysis.

Whitcomb, John D.↗
NASA NTRS1973

Finite element analysis of a composite material interface

A finite element model of a composite material interface is developed to study the influence of the interface on the thermal strain in the composite. A plane stress model is used with an axisymmetric model as a check. The interface thickness, thermal coefficient, modulus, Poisson's ratio and the percent of mineral in the composite are variables in the study. The results confirmed the usability of the finite element model in studying the polymer-mineral interface.

Murray, K. H.↗
DOE OSTI2026

Comparative analysis of plasticity-based GND density estimation methods in crystal plasticity finite element models

In crystal plasticity finite element (CPFE) simulations, accurately quantifying geometrically necessary dislocations (GNDs) is critical for capturing strain gradients in polycrystals. We compare different methods for quantifying GNDs, all of which originate from the Nye tensor, which is computed as the curl of the plastic deformation gradient. The projection technique directly decomposes the Nye tensor onto individual screw and edge dislocation components to compute GNDs. This approach requires converting a nine-component Nye tensor into densities for a larger number of dislocation systems, a fundamentally underdetermined (non-unique) process, which is resolved using L2 minimization. In contrast, when employing CPFE analysis, one could directly compute dislocation densities on each slip system using shear gradients. Projection and slip gradient methods are compared with respect to their prediction of GNDs with changing grain size, strain, and grain neighborhoods, including multigrain junctions. Although these techniques match analytical GND densities for single slip, single crystal deformation, and are consistent with anticipated overall GND trends, we find that the GND densities from projection techniques are significantly lower than those predicted from CPFE-based slip gradients in polycrystals. A suggested improvement of only using the active dislocation systems in the projection technique almost entirely resolved this mismatch.

Crystal plasticity↗
DOE OSTI2025

Machine learning-enabled multiscale modeling of mechanical deformation of aluminum and Al-SiC nanocomposites

A machine learning-enabled multiscale framework is developed for modeling the mechanical response of both pure metal and nanoparticle-reinforced metal matrix nanocomposites (MMNCs). Using aluminum–silicon carbide (Al-SiC) as an example MMNC, atomistic simulations reveal three distinct deformation mechanisms (i.e., defect-free, dislocation-based, and interface separation) governed by the interfaces between the Al matrix and SiC nanoparticles. As compared with single crystal Al, the lattice undergoes a more abrupt failure once the dislocation network becomes extensive and void nucleation initiates, whereas in Al-SiC, nanoparticle interfaces enable a more gradual progression of damage. These mechanisms are captured through a combined classification-regression neural network surrogate model that bridges atomic-scale insights with continuum-scale finite element analysis. Machine learning-enabled multiscale modeling of pure Al accurately predicted strain localization and confirmed by in-situ scanning electron microscopic tensile testing on perforated Al specimens. This study underscores the promise of integrating physics-informed machine learning with hierarchical modeling to capture the interface dominated phenomena and guide the design of advanced MMNCs.

Al-SiC↗
DOE OSTI2023

A materials data framework and dataset for elastomeric foam impact mitigating materials

The availability of materials data for impact-mitigating materials has lagged behind applications-based data. For example, data describing on-field helmeted impacts are available, whereas material behaviors for the constituent impact-mitigating materials used in helmet designs lack open datasets. Here, we describe a new FAIR (findable, accessible, interoperable, reusable) data framework with structural and mechanical response data for one example elastic impact protection foam. The continuum-scale behavior of foams emerges from the interplay of polymer properties, internal gas, and geometric structure. This behavior is rate and temperature sensitive, therefore, describing structure-property characteristics requires data collected across several types of instruments. Data included are from structure imaging via micro-computed tomography, finite deformation mechanical measurements from universal test systems with full-field displacement and strain, and visco-thermo-elastic properties from dynamic mechanical analysis. These data facilitate modeling and design efforts in foam mechanics, e.g., homogenization, direct numerical simulation, or phenomenological fitting. The data framework is implemented using data services and software from the Materials Data Facility of the Center for Hierarchical Materials Design.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Impact of Plate Thickness and Joint Geometry on Residual Stresses in 347H Stainless Steel Welds

Weldments of 347H stainless steel are potentially susceptible to stress relaxation cracking at elevated service temperatures. Mitigation of stress relaxation cracking susceptibility within a multipass weld requires a good understanding of welding practices and manufacturing techniques to control high tensile residual stresses. Here in this work, the dependence of residual stress distribution in 347H stainless steel on base plate thickness, joint geometry design, and preheating condition was systematically investigated by using three-dimensional finite element models. The finite element models were validated through good agreement between neutron diffraction measurements and calculated elastic strains. The single-V-groove welds with and without a preheating step all produced similar peak von Mises residual stresses, above 450 MPa, within both the fusion zone and heat-affected zone (HAZ). In plates thicker than 0.5 in. (12.7 mm), high tensile residual stress could be observed in a relatively large area, from the middle of the plate thickness to underneath the top surface. A double-V groove shifted the high tensile stress area to the middle thickness of the weld. A single-J-groove weld was able to confine the residual stress to a very small region near the middle thickness within the fusion zone and suppressed the von Mises residual stress within the HAZ to below 400 MPa.

14 SOLAR ENERGY↗
NASA NTRS1982

Turbine blade nonlinear structural and life analysis

The utility of advanced structural analysis and life prediction techniques was evaluated for the life assessment of a commercial air-cooled turbine blade with a history of tip cracking. Three dimensional, nonlinear finite element structural analyses were performed for the blade tip region. The computed strain-temperature history of the critical location was imposed on a uniaxial strain controlled test specimen to evaluate the validity of the structural analysis method. Experimental results indicated higher peak stresses and greater stress relaxation than the analytical predictions. Life predictions using the Strainrange Partitioning and Frequency Modified approaches predicted 1200 to 4420 cycles and 2700 cycles to crack initiation, respectively, compared to an observed life of 3000 cycles.

Mcknight, R. L.↗