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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Characterization of NiC Multilayer Coating Stress for X-Ray Optic Applications

NiC multilayers have been identified as a promising coating design for hard X-ray astrophysical imaging applications enabling bandpass extension beyond the Pt K-edge of approximately 78 keV. However, these coatings are difficult to deposit with low interfacial roughness below a bilayer thickness of about 35 ˚A. Utilizing a DC magnetron sputtering system, NiC multilayer of varying d-spacings are deposited on flat Si wafers and characterized using 8.048 keV X-ray reflectometry measurements. The residual coating stress is also measured using interferometry. We investigate how deposition parameters affect both the coating quality (i.e. surface/interfacial roughness, density, etc.) and the residual coating stress. From these experimental results conducted on flat substrates, we employ FEM and ray trace simulations to determine how NiC multilayer stress could impact the figure, and therefore performance, of full shell X-ray optics.

mulitlayer↗
DOE OSTI2025

Machine-Learning-Based Multiscale Methods for 3D Modelling of Granular Materials by Incorporating History-Dependent State Variables

Over the past decades, the prevalence of machine learning (ML) methods has made the development of ML-based constitutive models for granular materials undoubtedly a popular subject. Numerous studies have been made to feature the loading path or history-dependent stress-strain response of granular media using neural networks. In this work, a novel finite element method (FEM)–ML multiscale approach was developed by incorporating internal variables to improve the simulation accuracy of 3D history-dependent granular materials for the first time. To this end, a surrogate constitutive model based on the single-step-based multi-layer perceptron (MLP) neural network was used to replace representative volume element (RVE) simulations conducted by the discrete element method (DEM) in the multiscale FEM–DEM approach. Although the prediction principle of the MLP aligns with the FEM algorithm, artificially added internal variables are required to differentiate the loading history. To address this issue, history variables associated with the Frobenius norm are proposed to be fed into the MLP coupled with the strain tensor to extract the history-dependent behaviour of granular assemblies. The developed FEM–ML approach was demonstrated in 3D conventional triaxial compression (CTC) simulations. Compared to the multiscale FEM–DEM approach, the proposed FEM–ML method exhibits a significantly improved computational efficiency.

granular materials↗
NASA NTRS1990

Development of UMARC (University of Maryland Advanced Rotorcraft Code)

The University of Maryland Advanced Rotorcraft Code (UMARC) is a user-friendly, FEM-based comprehensive helicopter rotor simulation code of high numerical robustness and computational efficiency. UMARC formulates the rotor-fuselage equations using Hamilton's principle, and are discretized using finite elements in space and time. The FEM formulation allows the code to analyze a wide variety of rotor designs. Dynamic inflow modeling is used for unsteady wake inflow computations. Predicted stability, response, and blade-load data are validated with experimental data for several configurations, including representative articulated, hingeless, and bearingless rotors.

Bir, Gunjit↗
NASA NTRSDate not supplied

Study of Aircraft Structural Response and Occupant Loading During a Ditching Event Utilizing LS-DYNA Simulation

In this study, the capability of finite element model (FEM) analysis to assess aircraft structural response and occupant injury risk during aircraft water ditching conditions was evaluated. A FEM of the Fokker F28 aircraft, previously validated against full-scale crash test data, was simulated in a realistic water impact environment utilizing recorded conditions from the ditching of US Airways Flight 1549 into the Hudson River. The FEM of the F28 aircraft, was developed from a NASTRAN loads model provided by the vehicle manufacturer, calibrated using component fuselage drop-tests, and validated through test-analysis comparisons from a full-scale crash test of the F28 onto soil. Simulation results are presented in several categories: vehicle kinematics, structural accelerations, damage, occupant responses, and injury risk predictions. Results were consistent with the general outcomes of Flight 1549, indicating that the developed vehicle FEM, validated against land impact test data, may provide an effective tool for evaluating water ditching events.

Jacob Putnam↗
NASA NTRS1999

Development of GENOA Progressive Failure Parallel Processing Software Systems

A capability consisting of software development and experimental techniques has been developed and is described. The capability is integrated into GENOA-PFA to model polymer matrix composite (PMC) structures. The capability considers the physics and mechanics of composite materials and structure by integration of a hierarchical multilevel macro-scale (lamina, laminate, and structure) and micro scale (fiber, matrix, and interface) simulation analyses. The modeling involves (1) ply layering methodology utilizing FEM elements with through-the-thickness representation, (2) simulation of effects of material defects and conditions (e.g., voids, fiber waviness, and residual stress) on global static and cyclic fatigue strengths, (3) including material nonlinearities (by updating properties periodically) and geometrical nonlinearities (by Lagrangian updating), (4) simulating crack initiation. and growth to failure under static, cyclic, creep, and impact loads. (5) progressive fracture analysis to determine durability and damage tolerance. (6) identifying the percent contribution of various possible composite failure modes involved in critical damage events. and (7) determining sensitivities of failure modes to design parameters (e.g., fiber volume fraction, ply thickness, fiber orientation. and adhesive-bond thickness). GENOA-PFA progressive failure analysis is now ready for use to investigate the effects on structural responses to PMC material degradation from damage induced by static, cyclic (fatigue). creep, and impact loading in 2D/3D PMC structures subjected to hygrothermal environments. Its use will significantly facilitate targeting design parameter changes that will be most effective in reducing the probability of a given failure mode occurring.

Abdi, Frank↗
DOE OSTI2025

Effect of sintering temperature on adhesion of spray-on piezoelectric transducers

Conventionally sol-gel spray-on transducers require a high-temperature (> 700 ◦C) sintering process; however, this process can affect the microstructure of the substrate material. For mechanical elbows and valves utilized for fluid transport in the energy sector, the components are designed to have a specific microstructure, and deviations from these specifications can create weak points in the system. For this reason it is important to investigate how the temperature of the deposition process affects the substrate. This paper investigates the effect of high-temperature and low-temperature (< 150 ◦C) processing conditions on the surface composition of the substrate. Furthermore, the resultant transducers from high- and low-temperature fabrication processes are compared to determine if a low-temperature processing method is feasible. For these studies a sol-gel spray-on process is employed to deposit piezoelectric ceramics onto a stainless-steel 316L substrate. Energy-dispersive X-ray spectroscopy is utilized to determine the composition of the substrate surface before and after transducer deposition. Results indicate that the high-temperature processing conditions may alter the surface composition of the metal due to a diffusion of the metal into the ceramic, which results in a metal surface that is bonded to the ceramic. Furthermore, it is shown that low-temperature processing of spray-on transducers is a viable method for transducer fabrication where the resultant transducers meet the industry minimum requirement of 30 dB signalto-noise ratio. In parallel simulation calculations, finite-element method (FEM) studies were performed to model the adhesive strength of the low-temperature processed transducer to the substrate surface. Comparisons between the simulations and experiments suggest that the bond strength is much greater than the commercial gel bonds and closer to hardened epoxy glue bonds. These results indicate that spray-on transducers fabricated under lowtemperature processing conditions are a viable solution for leave-in-place monitoring of structures.

M. Sinding, Kyle↗
DOE OSTI2024

Additive Manufacturing with Cellulose-Based Composites: Materials, Modeling, and Applications

Recent advances in large-scale additive manufacturing (AM) with polymer-based composites have enabled efficient production of high-performance materials. Cellulose nanomaterials (CNMs) have emerged as bio-based feedstocks due to their exceptional strength and sustainability. However, challenges such as hornification and poor dispersion in polymer matrices still limit large-scale CNM–polymer composite manufacturing, requiring novel strategies. Here, this review outlines an approach starting with atomic-level simulations to link molecular composition to key parameters like bulk density, viscosity, and modulus. These simulations provide data for finite element analysis (FEA), which informs large-scale experiments and reduces the need for extensive trials. The strategy explores how atomic interactions impact the morphology, adhesion, and mechanical properties of CNM-based composites in AM processes. The review also discusses current developments in AM, along with predictions of mechanical and thermal properties for structural applications, packaging, flexible electronics, and hydrogel scaffolds. By integrating experimental findings with molecular dynamics (MD) simulations and finite element modeling (FEM), valuable insights for material design, process optimization, and performance enhancement in CNM-based AM are provided to address ongoing challenges.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Impact of Aerodynamic Modeling Assumptions on Flutter Speeds of Vertical-Axis Wind Turbines

Theodorsen’s unsteady aerodynamic theory has been used extensively in flutter speed prediction of wind turbine blades. In this study, three key assumptions of Theodorsen theory (thin airfoil, flat wake, and small angle of attack) have been revisited, and all three assumptions have been addressed in combination to obtain new lift and moment equations that are subsequently applied in flutter calculations for full-scale vertical-axis wind turbine (VAWT) rotors, not just of an individual airfoil or blade. Furthermore, edgewise aerodynamics terms are added to the lift and moment equations to include their effects on flutter speeds. The newly obtained equations were implemented in the OWENS (Offshore Wind ENergy Simulation) toolkit, which is an FEM (Finite Element Method)-based toolkit for aeroelastic analysis of VAWTs. The effect of modifying each of these assumptions has been studied for the flutter RPM prediction of three primary modes of flutter of VAWTs: propeller, butterfly, and tower modes. For the land-based case, the most change was observed for the flutter RPM of the propeller mode, with a maximum increase of 2.62% for the two-bladed UTD 5 MW VAWT case. For the floating offshore case, the primary flutter modes (tower and platform pitch) were not significantly affected.

Engineering↗
NASA NTRS1989

Elevated temperature crack growth

Alloy 718 crack growth experiments were conducted to assess the ability of the selected path-independent (P-I) integrals to describe the elevated temperature crack growth behavior. These tests were performed on single edge notch (SEN) specimens under displacement control with multiple extensometers to monitor the specimen and crack mouth opening displacement (CMOD). The displacements in these tests were sufficiently high to induce bulk cyclic inelastic deformation of the specimen. Under these conditions, the linear elastic fracture mechanics (LEFM) parameter K does not correlate the crack growth data. The experimentally measured displacement gradients at the end of specimen gage length were used as the boundary conditions in elastic-plastic finite element method (FEM) analyses. These analyses were performed with a node release approach using CYANIDE, a GEAE FEM code, which included a gap element which is capable of efficiently simulating crack closure. Excellent correlation was obtained between the experimentally measured and predicted variation of stress and CMOD with crack length and the stress-CMOD loops for Alloy 718 tests conducted at 538 C. This confirmed the accuracy of the FEM crack growth simulation approach. The experimentally measured crack growth rate data correlated well the selected P-I integrals. These investigations have produced significant progress in developing P-I integrals as non-linear fracture mechanics parameters. The results suggest that this methodology has the potential of accurately describing elevated temperature crack growth behavior under the combined influence of thermal cycling and bulk elastic-inelastic deformation states.

Kim, K. S.↗
NASA NTRS2017

Simulation of Guided-Wave Ultrasound Propagation in Composite Laminates: Benchmark Comparisons of Numerical Codes and Experiment

Ultrasonic wave methods constitute the leading physical mechanism for nondestructive evaluation (NDE) and structural health monitoring (SHM) of solid composite materials, such as carbon fiber reinforced polymer (CFRP) laminates. Computational models of ultrasonic wave excitation, propagation, and scattering in CFRP composites can be extremely valuable in designing practicable NDE and SHM hardware, software, and methodologies that accomplish the desired accuracy, reliability, efficiency, and coverage. The development and application of ultrasonic simulation approaches for composite materials is an active area of research in the field of NDE. This paper presents comparisons of guided wave simulations for CFRP composites implemented using four different simulation codes: the commercial finite element modeling (FEM) packages ABAQUS, ANSYS, and COMSOL, and a custom code executing the Elastodynamic Finite Integration Technique (EFIT). Benchmark comparisons are made between the simulation tools and both experimental laser Doppler vibrometry data and theoretical dispersion curves. A pristine and a delamination type case (Teflon insert in the experimental specimen) is studied. A summary is given of the accuracy of simulation results and the respective computational performance of the four different simulation tools.

Composite↗
NASA NTRSDate not supplied

Modal Correlation of Complex Aerospace Joints Using Automated Variable Substitution

A critical task involved with being able to predict flight loads accurately in aerospace finite element models (FEMs) is the prior verification of the FEMs by conducting modal survey testing (MST). Experience comparing dynamic response of initial FEMs to MST data tends to demonstrate that FEMs can have unacceptable accuracy even when best modeling practices are followed. One inherent source of inaccuracy in linear dynamic FEMs is the modeling of nonlinear joints with mechanisms such as spherical bearings. These joints are usually designed to freely translate or rotate under the high levels of loading experienced in flight. Engineers who create linear FEMs conventionally model these joints without any stiffness in the mechanism degrees of freedom to meet this design intent. However, inaccuracy is observed during test validation of these FEMs, which usually relies on low-level force excitation orders of magnitude below flight load levels. This low-level modal test rarely overcomes the joint friction that is present, and thus the mechanism joints are able to react loads. This divide between the test results and the FEM creates a significant challenge to the engineer who is performing the correlation, in that the engineer has no basis for what stiffness value should be used to make the FEM match the test results. A compounding challenge is that complicated built-up aerospace structures commonly have multiple joints through a load path where each joint will “stick” and “slip” at different levels of force input. Explicitly matching the dynamics of a system containing these nonlinear mechanisms would require a nonlinear FEM, which is prohibitively costly for dynamic simulations of most aerospace systems. The objective of this paper is to present a workflow that can efficiently cycle through many iterations of a FEM, allowing a Monte Carlo style examination of the design space to identify candidate stiffness values for nonlinear mechanism joints. The outlined approach is specific to MSC Nastran and utilizes MSC Nastran’s symbolic substitution capabilities, coupled with the IMAT™ and Attune™ software packages developed by ATA Engineering, Inc. (ATA). The workflow is demonstrated with a case study from the correlation effort for The Boeing Company’s Crew Space Transportation (CST)-100 Starliner FEM. Keywords: Correlation, MSC Nastran, IMAT™, Attune™, Finite Element Model, Modal Testing

Correlation↗
NASA NTRS2011

Thermal Cycling and Isothermal Deformation Response of Polycrystalline NiTi: Simulations vs. Experiment

A recent microstructure-based FEM model that couples crystal-based plasticity, the B2<-> MB190 phase transformation and anisotropic elasticity at the grain scale is calibrated to recent data for polycrystalline NiTi (49.9 at.% Ni). Inputs include anisotropic elastic properties, texture and differential scanning calorimetry data, as well as a subset of recent isothermal deformation and load-biased thermal cycling data. The model is assessed against additional experimental data. Several experimental trends are captured - in particular, the transformation strain during thermal cycling monotonically increases and reaches a peak with increasing bias stress. This is achieved, in part, by modifying the martensite hardening matrix proposed by Patoor et al. [Patoor E, Eberhardt A, Berveiller M. J Phys IV 1996;6:277]. Some experimental trends are underestimated - in particular, the ratcheting of macrostrain during thermal cycling. This may reflect a model limitation that transformation-plasticity coupling is captured on a coarse (grain) scale but not on a fine (martensitic plate) scale.

Manchiraju, Sivom↗
NASA NTRS2015

Aeroelastic Analysis of SUGAR Truss-Braced Wing Wind-Tunnel Model Using FUN3D and a Nonlinear Structural Model

Considerable attention has been given in recent years to the design of highly flexible aircraft. The results of numerous studies demonstrate the significant performance benefits of strut-braced wing (SBW) and trussbraced wing (TBW) configurations. Critical aspects of the TBW configuration are its larger aspect ratio, wing span and thinner wings. These aspects increase the importance of considering fluid/structure and control system coupling. This paper presents high-fidelity Navier-Stokes simulations of the dynamic response of the flexible Boeing Subsonic Ultra Green Aircraft Research (SUGAR) truss-braced wing wind-tunnel model. The latest version of the SUGAR TBW finite element model (FEM), v.20, is used in the present simulations. Limit cycle oscillations (LCOs) of the TBW wing/strut/nacelle are simulated at angle-of-attack (AoA) values of -1, 0 and +1 degree. The modal data derived from nonlinear static aeroelastic MSC.Nastran solutions are used at AoAs of -1 and +1 degrees. The LCO amplitude is observed to be dependent on AoA. LCO amplitudes at -1 degree are larger than those at +1 degree. The LCO amplitude at zero degrees is larger than either -1 or +1 degrees. These results correlate well with both wind-tunnel data and the behavior observed in previous studies using linear aerodynamics. The LCO onset at zero degrees AoA has also been computed using unloaded v.20 FEM modes. While the v.20 model increases the dynamic pressure at which LCO onset is observed, it is found that the LCO onset at and above Mach 0.82 is much different than that produced by an earlier version of the FEM, v. 19.

Bartels, Robert E.↗
NASA NTRS2019

Large Male Anthropomorphic Test Device (ATD) Finite Element Model (FEM) Correlation Improvement

As part of an activity for the Commercial Crew Program (CCP), a NASA Engineering and Safety Center (NESC) team conducted tests of small female, medium male, and large male Hybrid III anthropomorphic test device (ATD) head-neck complexes. The results were compared to simulation results from ATD finite element model (FEM) predictions to determine the validity and fidelity of ATD models for use in certifying CCP vehicles. The NESC was requested to help improve the large male ATD FEM to better represent physical responses. This report contains the outcome of the NESC assessment.

Kelly, Michael J.↗
DOE OSTI2026

Enhanced accuracy through ensembling of randomly initialized auto-regressive models for dynamical systems

Computational mechanics simulations using traditional finite element methods (FEM) require prohibitively expensive computational resources for real-time engineering applications, design optimization, and digital twin implementations. While machine learning (ML) surrogate models offer significant computational speedups, autoregressive ML models for time-dependent mechanical systems suffer from error accumulation that compromises long-term prediction reliability - a critical concern for engineering applications where accuracy over extended time horizons is essential for safety and performance assessments. Here, we propose a deep ensemble framework specifically designed to address this challenge in computational mechanics applications, where multiple ML surrogate models with random weight initializations are trained in parallel and their predictions aggregated during inference. This approach leverages statistical diversity to maximize information gain from a fixed set of training data and to mitigate error propagation, while maintaining the computational efficiency that makes ML surrogates attractive for engineering practice. We validate the framework on three representative problems spanning critical areas of computational mechanics: stress field evolution in heterogeneous microstructures under complex loading (relevant to advanced materials design and composite analysis), planetary-scale shallow water dynamics (applicable to environmental and geotechnical engineering), and Gray-Scott reaction-diffusion systems (relevant to mass transport and chemical process engineering). Across all test cases, the ensemble approach demonstrates consistent error reduction of 15-33% compared to individual models. The codes for this work are available on GitHub (https://github.com/Graham-Brady-Research-Group/AutoregressiveEnsemble_SpatioTemporal_Evolution).

autoregressive prediction↗
NASA NTRS1986

A technique for the optical analysis of deformed telescope mirrors

The NASTRAN-ACCOS V programs' interface merges structural and optical analysis capabilities in order to characterize the performance of the NASA Goddard Space Flight Center's Solar Optical Telescope primary mirror, which has a large diameter/thickness ratio. The first step in the optical analysis is to use NASTRAN's FEM to model the primary mirror, simulating any distortions due to gravitation, thermal gradients, and coefficient of thermal expansion nonuniformities. NASTRAN outputs are then converted into an ACCOS V-acceptable form; ACCOS V generates the deformed optical surface on the basis of these inputs, and imaging qualities can be determined.

Bolton, John F.↗
NASA NTRS1997

Efficient Evaluation and Optimization of Structural Reliability

Use of approximations for calculating the structural failure probability under uncertainties is a necessary aspect. But efficient use of suitable approximations at different stages of reliability prediction and design makes this valuable tool practical for many large scale structures. This research addresses the modern approximation concepts and their utility in structural reliability estimation. Emphasis is placed on building higher order approximations using intervening variables to closely represent the nonlinear limit state functions. Several test problems with highly nonlinear performance functions are used to demonstrate the accuracy of the proposed method. Many of the structural problems are modeled and simulated using the finite element methods (FEM) for obtaining a detailed structural response. FEM is a computationally intensive numerical procedure with a large number of degrees of freedom. With an increase in the complexity of the structural model and the multidisciplinary nature of analyses, the number of limit states and their computation increases very significantly. The requirement of frequent repetitive analysis of the structure hinders the utility of any tool and discourages that approach from being used. One particular tool which faces this difficulty is the computation of the structural reliability under parametric uncertainties.

Grandhi, Ramana V.↗
NASA NTRS2003

Methods Developed by the Tools for Engine Diagnostics Task to Monitor and Predict Rotor Damage in Real Time

Tools for Engine Diagnostics is a major task in the Propulsion System Health Management area of the Single Aircraft Accident Prevention project under NASA s Aviation Safety Program. The major goal of the Aviation Safety Program is to reduce fatal aircraft accidents by 80 percent within 10 years and by 90 percent within 25 years. The goal of the Propulsion System Health Management area is to eliminate propulsion system malfunctions as a primary or contributing factor to the cause of aircraft accidents. The purpose of Tools for Engine Diagnostics, a 2-yr-old task, is to establish and improve tools for engine diagnostics and prognostics that measure the deformation and damage of rotating engine components at the ground level and that perform intermittent or continuous monitoring on the engine wing. In this work, nondestructive-evaluation- (NDE-) based technology is combined with model-dependent disk spin experimental simulation systems, like finite element modeling (FEM) and modal norms, to monitor and predict rotor damage in real time. Fracture mechanics time-dependent fatigue crack growth and damage-mechanics-based life estimation are being developed, and their potential use investigated. In addition, wireless eddy current and advanced acoustics are being developed for on-wing and just-in-time NDE engine inspection to provide deeper access and higher sensitivity to extend on-wing capabilities and improve inspection readiness. In the long run, these methods could establish a base for prognostic sensing while an engine is running, without any overt actions, like inspections. This damage-detection strategy includes experimentally acquired vibration-, eddy-current- and capacitance-based displacement measurements and analytically computed FEM-, modal norms-, and conventional rotordynamics-based models of well-defined damages and critical mass imbalances in rotating disks and rotors.

Baaklini, George Y.↗