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DOE OSTI2023

COUPLING SMOOTHED PARTICLE HYDRODYNAMICS WITH FINITE ELEMENT METHOD TO SIMULATE RESIDUAL STRESSES FROM FRICTION STIR PROCESSING

Friction stir processing (FSP) is a solid-state material processing technique that locally modifies the microstructure but also induces undesirable residual stresses. A robust numerical model for the FSP can help in mitigating these residual stresses. Heat source models within a finite element method (FEM) framework suffer from inaccuracies. In contrast, smoothed particle hydrodynamics (SPH) model that explicitly captures the material flow near the tool and the associated heat generation are accurate. However, the computational expense of SPH simulations can be prohibitive. In this work, we propose a coupled SPH-FEM framework. SPH is used to model the heat generation accurately near the tool and which is then inserted into to the FEM model as a heat source. To verify this proposed coupling approach, a test case is set up with typical FSP conditions and it is modeled in both SPH and SPH-FEM. The temperatures profiles were compared after the simulations have reached steady-state temperatures. The similarity of the temperature profiles from SPH-FEA and SPH validated the proposed coupling approach. This proposed approach achieves the accuracy of the SPH method while potentially retaining the low computational expense of FEM.

smoothed particle hydrodynamics, Finite Element Me↗

NASA NTRS1992

A differential CDM model for fatigue of unidirectional metal matrix composites

A multiaxial, isothermal, continuum damage mechanics (CDM) model for fatigue of a unidirectional metal matrix composite volume element is presented. The model is phenomenological, stress based, and assumes a single scalar internal damage variable, the evolution of which is anisotropic. The development of the fatigue damage model, (i.e., evolutionary law) is based on the definition of an initially transversely isotropic fatigue limit surface, a static fracture surface, and a normalized stress amplitude function. The anisotropy of these surfaces and function, and therefore the model, is defined through physically meaningful invariants reflecting the local stress and material orientation. This transversely isotropic model is shown, when taken to it's isotropic limit, to directly simplify to a previously developed and validated isotropic fatigue continuum damage model. Results of a nondimensional parametric study illustrate (1) the flexibility of the present formulation in attempting to characterize a class of composite materials, and (2) the capability of the formulation in predicting anticipated qualitative trends in the fatigue behavior of unidirectional metal matrix composites. Also, specific material parameters representing an initial characterization of the composite system SiC/Ti 15-3 and the matrix material (Ti 15-3) are reported.

Arnold, S. M.↗

NASA NTRS2004

Stressed Oxidation Life Prediction for C/SiC Composites

The residual strength and life of C/SiC is dominated by carbon interface and fiber oxidation if seal coat and matrix cracks are open to allow oxygen ingress. Crack opening is determined by the combination of thermal, mechanical and thermal expansion mismatch induced stresses. When cracks are open, life can be predicted by simple oxidation based models with reaction controlled kinetics at low temperature, and by gas phase diffusion controlled kinetics at high temperatures. Key life governing variables in these models include temperature, stress, initial strength, oxygen partial pressure, and total pressure. These models are described in this paper.

Levine, Stanley R.↗

NASA NTRS2017

Plume-Surface Interaction Modeling for a Human-Scale Mars Lander

Landing vehicles impart thermal and strain energy onto the landing site from the retrorocket exhaust. Depending on the design of the vehicle, the energy may be great enough to cause spallation at the landing site. This damage may be minor and repairable in the case of landing on a terrestrial landing pad. For missions to other planetary bodies, the spallation may cause the landing site to become uneven and unstable, as well as damage. Simulating this phenomenon in a laboratory or computationally would require a significant amount of time and other resources. These resources typically are not available during the design phase of a mission. This paper presents a computationally-efficient model for the temperature and stress distributions that arise during landing. These quantities can be used along with existing failure criteria, such as the Hoek-Brown criterion for geological materials, to quickly determine whether spallation will occur. The stress and temperature distributions at the landing site are inherently 3D; however, there is a plane of symmetry and in that plane the distributions are 2D. Both quantities are modeled using series solutions to their governing partial differential equations (PDEs). The stress is modeled using the Airy stress potential function and its governing PDE is the biharmonic equation. The temperature is governed by Fourier's law. The models assume that stress due to gravity can be neglected, the points in the plane do not accelerate, and that the material properties are constant.

Hart, Kenneth↗

DOE OSTI2024

Pretest Modeling A Spent Nuclear Fuel Seismic Shake Test

The U.S. Department of Energy Spent Fuel and Waste Science and Technology (SFWST) program is planning to conduct a series of full-scale shake table tests to simulate hypothetical earthquake conditions and record the response of surrogate spent nuclear fuel (SNF) assemblies in a dry canister storage system mockup. The shake table motions will represent a range of hypothetical earthquake conditions at hypothetical locations in the continental U.S. to generally define the range of mechanical loads that SNF can be expected to experience during extended dry storage periods. This paper describes the pretest predictions made with LS-DYNA models of the mockup storage systems. The test will use two dry storage system configurations, a mockup vertical concrete cask (VCC) and a mockup horizontal storage module (HSM). The test will use a production-quality canister and basket. Within the canister will be four instrumented fuel assemblies with fuel rods containing surrogate mass and 28 instrumented dummy assemblies that are intended to match the mass and outer dimension of a fuel assembly. The finite element models include models of the VCC and HSM on the shake table to calculate the system level dynamic responses and separate single fuel assembly models to calculate stress and strain in fuel assembly components. Both types of models include nonlinear behavior like rod-to-rod contact and the ability for VCC’s to rock and slide. This paper presents the expected response of the VCC, HSM, and fuel assemblies to the shake table testing that is planned to start in April of 2024. The earthquake conditions represent seismic hazards in the 2,000-to-20,000-year return period range. The test data is expected to confirm the expectation that fuel rod cladding will remain intact, fuel assembly structural components like guide tubes will remain intact, and no significant VCC sliding or tipping will occur in the range of conditions to be tested with the shake table.

Klymyshyn, Nicholas A.↗

NASA NTRS1991

Modeling hypersonic boundary-layer flows with second-moment closure

An ongoing research effort designed to apply the best possible second-moment-closure model to simulate complex hypersonic flows is presented. The baseline model under consideration is the Launder-Reece-Rodi Reynolds stress transport turbulence model. Two add-ons accounting for wall effects, namely, the Launder-Shima low-Reynolds-number model and the compressible wall-function technique, are tested. Results are reported for flow over a flat plate, both adiabatic-wall and cooled-wall cases. It has been found that further improvements of the existing models are necessary to achieve accurate prediction in high Mach number flow range.

Huang, P. George↗

NASA NTRS1994

Modeling of Wall-Bounded Complex Flows and Free Shear Flows

Various wall-bounded flows with complex geometries and free shear flows have been studied with a newly developed realizable Reynolds stress algebraic equation model. The model development is based on the invariant theory in continuum mechanics. This theory enables us to formulate a general constitutive relation for the Reynolds stresses. Pope was the first to introduce this kind of constitutive relation to turbulence modeling. In our study, realizability is imposed on the truncated constitutive relation to determine the coefficients so that, unlike the standard k-E eddy viscosity model, the present model will not produce negative normal stresses in any situations of rapid distortion. The calculations based on the present model have shown an encouraging success in modeling complex turbulent flows.

Shih, Tsan-Hsing↗

NASA NTRS1990

A phenomenological model of coating/substrate adhesion and interfacial bimetallic peeling stress in composite mirrors

Adhesion and interfacial stress between metal films and structural composite material substrates is discussed. A theoretical and conceptual basis for selecting coating materials for composite mirror substrates is described. A phenomenological model that interrelates cohesive tensile strength of thin film coatings and interfacial peeling stresses is presented. The model serves as a basis in determining gradiated materials response and compatibility of composite substrate and coating combinations. Parametric evaluation of material properties and geometrical factors such as coating thickness are used to determine the threshold stress levels for maintaining adhesion at the different interfaces.

Mcelroy, Paul M.↗

NASA NTRS1992

Experimental, physical and numerical modeling of lunar regolith and lunar regolith structures

An extensive series of laboratory strength and deformation experiments have been performed on a lunar regolith simulant. Results of these experiments are compared to results from experiments on real lunar regolith from the Apollo and Luna missions to illustrate the suitability of this material in capturing the engineering properties lunar regolith. In addition, these results are used to calibrate a constitutive model used to describe its stress-strain behavior. This model, in conjunction with numerical analysis techniques, is used to predict the response i.e. material parameters) of lunar simulant under 1/6-g and low confining stress conditions. These tools are also used to predict the displacement response of a lunar soil embankment structure used to cover a first generation human habitat module, which might be used to accommodate the first astronauts revisiting the moon. These predictions are compared to physical models of this structure, which are tested in a geotechnical centrifuge in order to satisfy scaling relationships between prototype and model.

Perkins, Steven W.↗

NASA NTRS2006

Second Moment Closure Near the Two-component Limit

The purpose of this paper is to explore some wider implications of the two-component limit for both single point turbulence models and spectral closure theories. Although the two-component limit arises most naturally in inhomogeneous problems like wall-bounded turbulence, the analysis will be restricted to homogeneous turbulence. But since homogeneous turbulence is the crucial case for realizability, the conclusions will nevertheless be applicable to modeling. Th essential point of our argument is that whereas the evolution of the stochastic velocity field is Markovian because it is governed by the Navier-Stokes equations, the exact stress evolution equation is not Markovian because it is unclosed. This property of moment evolution has been stressed by Kraichnan (1959). We will show that modeling stress evolution at the two-component limit with a closure that is Markovian in the stresses alone leads to basic inconsistencies in single-point modeling and, perhaps surprisingly, in spectral modes as well.

Rubinstein, Robert↗

NASA NTRS1985

A study of the second and third order closure models of turbulence for prediction of separated shear flows

The hybrid model of the Reynolds-stress turbulence closure is tested for the computation of the flows over a step and disk. Here it is attempted to improve the redistributive action of the turbulence energy among the Reynolds stresses. By evaluating the existing models for the pressure-strain correlation, better coefficients are obtained for the prediction of separating shear flows. Furthermore, the diffusion rate of the Reynolds stresses is reevaluated adopting several algebraic correlations for the triple-velocity products. The models of Cormack et al., Daly-Harlow, Hanjalic-Launder, and Shir were tested for the reattaching shear flows. It was generally observed that all these algebraic models give considerably low values of the triple-velocity products. This is attributed to the fact that none of the algebraic models can take the convective effect of the triple-velocity products into account in the separating shear flows, thus resulting in much lower diffusion rate than Reynolds stresses. In order to improve the evaluation of these quantities correction factors are introduced based on the comparison with some experimental data.

Amano, R. S.↗

NASA NTRS1990

A macro-micromechanics analysis of a notched metal matrix composite

A macro-micromechanics analysis was formulated to determine the matrix and fiber behavior near the notch tip in a center-notched metal matrix composite. Results are presented for a boron/aluminum monolayer. The macro-level analysis models the entire notched specimen using a three dimensional finite element program which uses the vanishing-fiber-diameter model to model the elastic-plastic behavior of the matrix and the elastic behavior of the fiber. The micro-behavior is analyzed using a Discrete Fiber-Matrix (DFM) model containing one fabric and the surrounding matrix. The dimensions of the DFM model were determined by the ply thickness and the fiber volume fraction and corresponded to the size of the notch-tip element in the macro-level analysis. The boundary conditions applied to the DFM model were determined from the macro-level analysis. Stress components within the DFM model were calculated and stress distributions are presented along selected planes and surfaces within the DFM model, including the fiber-matrix interface. Yielding in the matrix was examined at the notch tip in both the macro- and micro-level analyses. The DFM model predicted higher stresses (24 percent) in the fiber compared to the global analysis. In the notch-tip element, the interface stresses indicated that a multi-axial criterion may be required to predict interfacial failure. The DFM analysis predicted yielding to initiate in the notch-tip element at a stress level 28 percent lower than predicted by the global analysis.

Bigelow, C. A.↗

DOE OSTI2022

Statistics of internal stress fluctuations in dislocated crystals and relevance to density-based dislocation dynamics models

A statistical analysis of internal stress fluctuations, defined as the difference between the local mean stress and stress on dislocations, is presented for deforming crystals with 3D discrete dislocation systems. Dislocation realizations are generated using dislocation dynamics simulations and the associated stress field is computed as a superposition of a regularized stress field of dislocation lines within the domain of the solution and a complementary stress field computed via a finite-element boundary value problem. The internal stress fluctuations of interest are defined by an ensemble of the difference between the stress on dislocation lines and the local mean field stress in the crystal. The latter is established in a piecewise fashion over small voxels in the crystal thus allowing the difference between the local average stress and stress on segments to be easily estimated. The results show that the Schmid stress (resolved shear stress) and Escaig stress fluctuations on various slip systems sampled over a random set of points follow a Cauchy (Lorentz) distribution at all strain levels, with the amplitude and width of the distribution being dependent on the strain. Finally, the implications of the Schmid and Escaig internal stress fluctuations are discussed from the points of view of dislocation cross-slip and the dislocation motion in continuum dislocation dynamics.

36 MATERIALS SCIENCE↗

NASA NTRS1983

Bellows flow-induced vibrations

The bellows flow excitation mechanism and results of comprehensive test program are summarized. The analytical model for predicting bellows flow induced stress is refined. The model includes the effects of an upstream elbow, arbitrary geometry, and multiple piles. A refined computer code for predicting flow induced stress is described which allows life prediction if a material S-N diagram is available.

Tygielski, P. J.↗

DOE OSTI2025

Identification Uncertainty in Inverse Material Model Parameter Determination: A Sensitivity‐Based Decision Process for Load Path Selection

This research proposes a sensitivity-based framework for selecting the optimal prescribed loading path for a biaxial cruciform specimen. Optimality here is determined by the direction and magnitude of the prescribed displacement that minimizes the influence of random noise on the material model parameter identification. Using simulated experimental data based on finite element simulation, in this work, we identify the material model parameters of a Ludwik hardening model and plane stress implementation of the Hill-48 yield criterion using finite element model updating (FEMU). Our analysis reveals that the identification (or estimator) uncertainty of model parameters depends on the displacement boundary conditions (i.e., loading sequence) and the ground-truth value of the individual parameters. Optimal experimental design (OED) criteria based on the Fisher information matrix were investigated to mitigate indecision in the choice of optimal load path when the identification uncertainty of different material model parameters optimized at different load paths. The determinant of the Fisher information matrix was chosen here as the more useful metric due to its ability to capture uncertainty of the most influential material model parameters. The proposed framework demonstrates potential for real-time automated load step selection using scalar criteria derived prior to mechanical loading. The framework can be generalized to other geometries, boundary conditions and material models, allowing this procedure to be utilized for different experimental configurations and materials.

Fayad, Samuel S. [University of Illinois at Urbana↗

NASA NTRSDate not supplied

TPSAS-NF1676L-12973-DND

CFD methods are employing semi-empirical models used in analysis of hypersonic airbreathing engine flow paths. RANS (or Favre averaged) codes have models for turbulent stresses, mass and energy transport; turbulence chemistry interactions. LES methods have models for subgrid scale turbulence. Models depend upon experimental data for validation. Information on mean flow and statistics of the turbulent fluctuation in flow properties is useful. Data requirements: simple well defined supersonic combustion flows with well-known boundary conditions, time and spatially resolved, good instrument precision, and converged statistics. Approach: dual-pump CARS and planar laser-induced fluorescence imaging of OH radical (PLIF).

Andrew Cutler↗

NASA NTRS1979

Effect of element density on the NASTRAN calculated mechanical and thermal stresses of a spar

A NASTRAN model of a spar was examined to determine the sensitivity of calculated axial thermal stresses and bending stresses to changes in element density of the model. The thermal stresses calculated with three different element densities resulted in drastically differing values. The position of the constraint also significantly affected the value of the calculated thermal stresses. Mechanical stresses calculated from an applied loading were insensitive to element density.

Jenkins, J. M.↗

NASA NTRS2012

The Formation Environment of Jupiter's Moons

Do circumjovian disk models have conductivities consistent with the assumed accretion stresses? Broadly, YES, for both minimum-mass and gas-starved models: magnetic stresses are weak in the MM models, as needed to keep the material in place. Stresses are stronger in the gas-starved models, as assumed in deriving the flow to the planet. However, future minimum-mass modeling may need to consider the loss of dust-depleted gas from the surface layers to the planet. The gas-starved models should have stress varying in radius. Dust evolution is a key process for further study, since the recombination occurs on the grains.

planetary science↗