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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Multi-scale experimental study of creep-fatigue failure initiation in a 709 Stainless Steel alloy using high resolution digital image correlation. Final report

This report discusses the efforts made towards the multi-scale study of the creep-fatigue response of stainless steel 709. Multiple experimental techniques, including digital image correlation (DIC) and electron backscatter diffraction (EBSD), were used in assessing the evolution of damage accumulation during fatigue, creep-fatigue, and thermomechanical fatigue of alloy 709. The role of microstructural features, hold times, temperature, and loading profiles were quantified and the interchangeability of temperature and time was investigated. Finally, a thermomechanical fatigue model was shown to predict well the failure of samples with varying loading profiles. Results indicate that strain accumulation in 709 steel happens primarily near grain boundaries (GBs) with the strains around GBs being inversely proportional to their measured residual burgers vector. Furthermore, hot-spots for strain accumulation were shown to be the locations of eventual microcrack nucleation. The introduction of hold times to the periodic loading cycle increases the damage accumulation rate and thus shortens the fatigue life of samples–this was true for both room temperature and high temperature. Thermomechanical cycling was shown to have little effect on the end life of samples, with the damage accumulation rate for in-phase and out-of-phase cycling being similar to isothermal fatigue. The interchangeability of time and temperature was shown to be possible within the studied load, time, and temperature ranges, since deformation mechanisms driving strain accumulation did not change with temperature (up to 650°C). The Neu-Sehitoglu thermomechanical fatigue model, with constants obtained from the literature and in part from our experimental results, was applied to predict failure of isothermal creep-fatigue samples. The main objectives of this work were to:(a) Perform high-resolution digital image correlation measurements (HiDIC) for alloy 709; (b) Quantify and assess damage accumulation at the microstructure under fatigue, TMF, and creep-fatigue conditions of 709; (c) Study of the role of hold times, i.e., adding a creep component, to: Room temperature cycling, High temperature cycling, Failure; (d) Study the mechanisms of thermomechanical fatigue in this alloy; (e) Investigate the existence of a time-temperature interchangeability criterion to aid in accelerated creep-fatigue testing; (f) Establish the validity of a combined creep-fatigue model for life prediction for 709. This report is structured with each subsequent section detailing the efforts, results, and conclusions related to each of the objectives described, mostly in chronological order.

36 MATERIALS SCIENCE↗
NASA NTRS1994

Application of an Energy-Based Life Prediction Model to Bithermal and Thermomechanical Fatigue

The inelastic hysteresis energy applied to the material in a cycle is used as the basis for predicting nonisothermal fatigue life of a wrought cobalt-base superalloy, Haynes 188, from isothermal fatigue data. Damage functions that account for hold-time effects and time-dependent environmental phenomena such as oxidation and hot corrosion are proposed in terms of the inelastic hysteresis energy per cycle. The proposed damage functions are used to predict the bithermal and thermomechanical fatigue lives of Haynes 188 between 316 and 760 C from isothermal fatigue data. Predicted fatigue lives of all but two of the nonisothermal tests are within a factor of 1.5 of the experimentally observed lives.

Radhakrishnan, V. M.↗
DOE OSTI2021

Thermomechanical and sequential stress performance of photovoltaic backsheets

Photovoltaic backsheet technology is utilized to protect the interior components of solar modules from environmental stress as well as provide electrical insulation to the module. The growing demand for solar energy and longer module service life requirements have brought backsheet performance into focus. Despite being a protective packaging material, many backsheets have exhibited failure in the field, limiting the performance and service life of entire modules. Most backsheets consist of multiple polymeric layers laminated together using adhesives. A new backsheet, with a high performance polyamide structure, has been developed as the solution to module failure. Primarily, it contains a unique polyamide-ionomer alloy targeted at improved weather resistance. In this study, several photovoltaic industry standard backsheets, and the novel polyamide compositions of multilayered backsheets fabricated from the coextrusion process, were examined using thermomechanical analysis (TMA). The coefficient of thermal expansion (CTE) for entire backsheets and their constituent layers was used to model the thermomechanical behavior of various backsheet constructions. Subsequently, thermal cycling was performed in the TMA to examine the intrinsic thermal behavior of the backsheets. Thermal cycling in the TMA indicates the resilience and dimensional stability in the coextruded structures as opposed to the laminated structures. Lastly, results from a Module Accelerated Sequential Testing (MAST), are included to show the mechanical integrity of these backsheets after sequential exposure to stressors including damp heat, ultra-violet (UV) light radiation, and thermal cycling. The laminate backsheets deteriorated extensively after sequential exposure to these stressors, while the novel coextruded structures retained their physical properties.

14 SOLAR ENERGY↗
DOE OSTI2021

Modeling the dynamic response of rock masses with multiple compliant fluid saturated joint sets - Part II: Continuum modeling

Part I of this two-part paper describes enhancements of a mesoscale model to include: many non-persistent fluid saturated joints with finite area, normal compliance with hysteresis and the weakening effects of angular deviation in the joint sets and of fluid pressure in the joints. The objective of this Part II is to use the results of the mesoscale model as simulated data to inspire functional forms in a continuum model for rock masses with multiple compliant fluid saturated joint sets which include these enhancements. Also, an algorithm is proposed for reducing the number of joint sets being modeled. Examples are presented here which show that the continuum model can predict similar anisotropic response to that observed in mesoscale simulations. In contrast with the mesoscale model, the continuum model can be used for large scale simulations of real applications, smoothly transitioning from coupled inelastic thermomechanical response near an explosive source to orthotropic elastic response far from the source.

58 GEOSCIENCES↗
DOE OSTI2021

NRC Multiphysics Analysis Capability Deployment FY21: Part 3

This report details the progress and activities of Idaho National Laboratory (INL) on the Nuclear Regulatory Commission (NRC) project “Development and Modeling Support for Advanced Non-Light Water Reactors.” The deliverables completed for this report are: Deliverable 1c: the capability to model gas mixtures was added to Pronghorn. A test problem mimicking the conditions achieved in a depressurized loss of forced cooling (DLOFC) event was solved with both RELAP-5 and Pronghorn. Pronghorn employed a finite vol ume method with the Kurganov-Tadmor discretization. The comparison between the mass fraction spatial profiles computed with RELAP-5 and Pronghorn clearly shows the presence of numerical artifacts (i.e., overly diffusive behavior at low Mach numbers). We confirmed that the problem disappears at higher Mach numbers. We recommend future work on the implementation of a low Mach finite volume formulation to better treat low Mach number problems. Deliverable 2a: we demonstrated two approaches to model the radiation/conduction/natural convection heat transfer across a stagnant gas for the PBMR-400 design using Pronghorn. The first approach is based on the net radiation method, which relies on the computation of view factors with the Multiphysics Object-Oriented Simulation Environment (MOOSE) ray tracing capability. The second method is a traditional thermal resistance approach. The test problems include both 2D and 3D geometries. In all cases, the results show very good agreement during a DLOFC transient. This confirms that the faster thermal resistance method produces solutions that are equivalent to the net radiation method for this geometry. Deliverable 3d: we demonstrated the use of the advection kernel for the delayed neutron precursor equation in Griffin with a 2D MSFR model. The results appear physical but further verification is recommended. We also recommend the addition of conjugate heat transfer to compute the temperatures and model the thermomechanic behavior of the reflectors and other structures. Significant memory and performance issues were encountered in the 3D axisymmetric model. Future work is recommended in this area. Task 8g: this task allows multidimensional MOOSE applications to be coupled to system codes (RELAP-7 and SAM). We implemented a faster multiphysics iteration coupling algorithm, which provides an overall 6× acceleration of the 3D-1D coupling of the core multidi- mensional fluid flow solver and the 1D primary and secondary loop model.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1987

Thermal Stresses in Silicon-Web Growth

Mathematical model represents thermomechanical behavior of solid web of rectangular cross section as pulled from melt of same material. Intended for application to growth of silicon webs or ribbons, model general enough to be applicable to other materials as well. Shows suitable temperature distribution results in stress-free ribbon. Conceptual ribbon of rectangular cross section pulled from melt. Simplified configuration used to calculate thermal conditions for stress-free ribbon.

Wade, Ben K.↗
NASA NTRS1992

A finite element method for the thermochemical decomposition of polymeric materials. II - Carbon phenolic composites

A previously developed formulation for modeling the thermomechanical behavior of chemically decomposing, polymeric materials is verified by simulating the response of carbon phenolic specimens during two high temperature tests: restrained thermal growth and free thermal expansion. Plane strain and plane stress models are used to simulate the specimen response, respectively. In addition, the influence of the poroelasticity constants upon the specimen response is examined through a series of parametric studies.

Sullivan, R. M.↗
NASA NTRS1990

Performance of a thermomechanical pump

This paper presents the results of a series of thermomechanical pump tests to determine the performance of a simulated transfer system. The tests compared heater power versus transfer rates with accurate temperature, pressure, flow rate and heater power data. Test data were also compared to a computer model. The thermomechanical pump performance was found to be primarily a function of supply liquid temperature and heat input near the plug.

Mills, G. L.↗
NASA NTRS1990

Status of structural analysis of 30 cm diameter ion optics

Three structural finite element programs are compared with theory, experimental data, and each other to evaluate their usefulness for modeling the thermomechanical deflection of ion engine electrodes. Two programs, NASTRAN and MARC, used a Cray XMP and the third, Algor, used an IBM compatible personal computer. The shape of the applied temperature gradient greatly affects off-axis displacement, implying that an accurate temperature distribution is required to analyze new designs. The use of bulk material constants to model the perforated electrodes was investigated. The stress and displacement predictions are shown to be sensitive to the temperature gradient and the Young's modulus, and insensitive to number of nodes, above some minimum value, and the Poisson ratio used. The models are shown to be useful tools for evaluating designs. Experimental measurement of temperatures and displacements was identified as the most critical area for further work.

Macrae, Gregory S.↗
NASA NTRS1990

Status of structural analysis of 30 cm diameter ion optics

Three structural finite element programs are compared with theory, experimental data, and each other to evaluate their usefulness for modeling the thermomechanical deflection of ion engine electrodes. Two programs, NASTRAN and MARC, used a Cray XMP and the third, Algor, used an IBM compatible personal computer. The shape of the applied temperature gradient greatly affects off-axis displacement, implying that an accurate temperature distribution is required to analyze new designs. The use of bulk material constants to model the perforated electrodes was investigated. The stress and displacement predictions are shown to be sensitive to the temperature gradient and the Young's modulus, and insensitive to number of nodes, above some minimum value, and the Poisson ratio used. The models are shown to be useful tools for evaluating designs. Experimental measurements of temperatures and displacements was identified as the most critical area.

Macrae, Gregory S.↗
NASA NTRSDate not supplied

Multiscale and Multifidelity Modeling of a 3D Woven Composite Thermal Protection System

Complex three-dimensional (3D) woven composites have been considered by multiple NASA projects in recent years as a means of offering improved mechanical and thermal performance over traditional laminated composite systems. Parallel efforts have focused on developing simulation capabilities for these systems, which have traditionally and heavily relied on experimental testing to evaluate composite performance. One system is the Heatshield for Extreme Entry Environment Technology (HEEET), which is being considered for the thermal protection system on reentry spacecraft. Optical microscopy was used to characterize the blended carbon and phenolic fiber tows. A section of HEEET insulation layer was imaged with high-resolution micro-computed tomography (microCT) and segmented to separate individual tows, porous matrix, and voids. These data were used to develop multiscale thermomechanical computational models within the NASA Multiscale Analysis Tool (NASMAT). Two NASMAT modeling approaches were considered to capture the details of the 3D woven architecture: a coarse model appropriate for inclusion in multiscale structural analyses and a high-fidelity model created by downsampling the microCT data. Both elastic and thermal properties were computed and compared. The feasibility and challenges associated with modeling complex, hybrid 3D woven composites were also addressed.

NASMAT↗
NASA NTRS2023

An Enabling Platform for Achieving Multiscale Multiphysics Analysis of Multiphase Materials

This paper will address current NASA GRC research efforts utilizing the NASA Multiscale Analysis Tool (NASMAT) which address technical gaps in three of the Vision 2040 key discipline areas. NASMAT is a versatile platform for performing computationally efficient multiscale analyses of heterogeneous materials and is available free through the NASA software catalog. It offers the user flexibility to define an arbitrary number of length scales (levels) where a variety of micromechanics theories can be implemented at each level. Micromechanics theories can be selected to balance accuracy and computational efficiency and range from analytical (Mori-Tanaka) to several semi-analytical (method of cells) formulations. The resulting anisotropic, evolving nonlinear, thermomechanical constitutive model can also be coupled with external software and used to perform multiscale analyses of more complex structures. A recent application to model a complex, three-dimensional woven composite, with a particular emphasis placed on multiscale measurements utilized to enhance the quality of the multiscale analysis will be discussed. Since typical NASMAT analyses can be completed on the order of seconds to minutes, a second example will demonstrate the ability to generate large quantities of data useful for sensitivity analysis, uncertainty quantification, or machine learning applications. Current progress on implementing NASMAT within a multiscale digital thread/digital twin framework will also be addressed. These examples will demonstrate that NASMAT is an enabling platform for achieving the goals in Vision 2040.

Multiscale↗
DOE OSTI2025

High-Fidelity Modeling of Fuel-To-Coolant Thermomechanical Transport Behaviors Under Transient Conditions

This report summarizes the work completed under NEUP project number 21-24006. The objectives of this project are to advance the high-fidelity modeling capabilities and important phenomena that is important for high-burnup UO 2 and accident tolerant fuels (ATF) during transient conditions. Accurate modeling of the time-dependent phenomena that impact material performance must be used to determine the figures of merit and safety margin. Phenomena such as fuel fragmentation, cladding oxidation, pellet-clad interaction, clad ballooning, and clad rupture are examples that pose challenges to modeling during these transients. This project focused on the development of high-fidelity tightly coupled multiphysics models that can capture the time-dependent material response and associated thermal hydraulic conditions during these events. These models can then be validated against existing separate effects tests and in-pile integral experiments and will be used to model Transient Reactor Test facility (TREAT) loss-of-coolant accidents (LOCA) experiments. To achieve the project objective, we used a combination of NEAMS and NRC codes to model various LOCA test sets for the separate effects and in-pile integral experiments. BlueCRAB tool set, which can accurately predict material response at a sub-fuel pin level, as well as modeling the entire reactor system response to these events. Fuel performance was modeled using BISON (various versions) and FAST (version 1.2.1). BISON and FAST can model on a sub-fuel pin level the fuel performance under transient conditions. Both have simplified thermal hydraulic models that are capable of providing basic coolant boundary conditions. To better capture the thermomechanical interaction between the fuel, clad, and coolant, more sophisticated thermal hydraulic models are necessary.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Analysis of contact conditions and microstructure evolution in shear assisted processing and extrusion using smoothed particle hydrodynamics method

Shear assisted processing and extrusion (ShAPE) is a solid-phase processing technique that adds an additional shear force as compared with a conventional extrusion approach. Recently, ShAPE has demonstrated the capability of extruding high-performance aluminum alloy 7075 (AA7075) tubes at speeds up to 12.2 m/min without surface tearing. However, the relationship among the ShAPE processing parameters, thermomechanical conditions, contact conditions, heat generation, and microstructure evolution remains primarily empirical because an insightful understanding of the associated physics is still lacking. To help elucidate these relationships, this work proposes a thermomechanical meshfree model for the first time for ShAPE processing of AA7075 using the smoothed particle hydrodynamics (SPH) method. The meshfree model is first validated thoroughly by experimental data in terms of material flow, die face temperature, and extrusion force with various processing parameters. The validated model is then used to analyze the steady-state contact conditions and heat generation rates during ShAPE processing. Distributions of the average grain size of AA7075 being extruded are calculated using the SPH model output. The meshfree model results reveal that extrusions conducted at lower temperatures and higher strain rates yield more refined grains and possibly higher material strength, which is also consistent with the experimental observations.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Design and Cooling Performance of Additively Manufactured Ceramic Turbine Vanes

Ceramic materials are of significant interest in aviation and power generation gas turbine engines due to their low density and ability to withstand high temperatures. Increased cycle thermal efficiency and higher specific power output is possible by incorporating ceramic components that enable high turbine inlet temperatures and lower required cooling airflow levels. However, ceramics can be difficult and costly to form into the complex shapes used in gas turbine components, often requiring specialized multi-step processes. Furthermore, ceramic components in the hottest areas of a gas turbine, such as vanes or blade shroud seals, will still likely require cooling which is challenging to implement in conventional ceramic manufacturing approaches. Therefore, this study presents a multidisciplinary approach that investigates the design, fabrication, and overall cooling effectiveness evaluation of additively manufactured (AM), polymer derived ceramic (PDC) turbine vanes. A thermo-mechanically optimized vane design was generated, ceramic additive manufacturing of the complex cooling configuration was developed, and quantification of the increase in overall cooling effectiveness was performed in a 1X scale, high-speed facility using infrared thermography. This study produced a PDC AM process, capable of printing complex internal cooling schemes in 1X scale turbine vanes. Furthermore, it was found that the optimized vane more than doubled the overall cooling effectiveness observed in the baseline design, which reasonably agreed with thermomechanical optimization model predictions. Additionally, the optimized ceramic vane outperformed an identical metal vane, in terms of area averaged cooling effectiveness, suggesting that the ceramic vane could operate at reduced coolant flowrates to achieve comparable levels of cooling performance.

Reynolds number↗
DOE OSTI2023

Design and Cooling Performance of Additively Manufactured Ceramic Turbine Vanes

Ceramic materials are of significant interest in aviation and power generation gas turbine engines due to their low density and ability to withstand high temperatures. Increased cycle thermal efficiency and higher specific power output is possible by incorporating ceramic components that enable high turbine inlet temperatures and lower required cooling airflow levels. However, ceramics can be difficult and costly to form into the complex shapes used in gas turbine components, often requiring specialized multi-step processes. Furthermore, ceramic components in the hottest areas of a gas turbine, such as vanes or blade shroud seals, will still likely require cooling which is challenging to implement in conventional ceramic manufacturing approaches. Therefore, this study presents a multidisciplinary approach that investigates the design, fabrication and overall cooling effectiveness evaluation of additively manufactured (AM), polymer derived ceramic (PDC) turbine vanes. A thermo-mechanically optimized vane design was generated, ceramic additive manufacturing of the complex cooling configuration was developed, and quantification of the increase in overall cooling effectiveness was performed in a 1X scale, high-speed facility using infrared thermography. This study produced a PDC AM process, capable of printing complex internal cooling schemes in 1X scale turbine vanes. It was found that the optimized vane more than doubled the overall cooling effectiveness observed in the baseline design, which reasonably agreed with thermomechanical optimization model predictions. Additionally, the optimized ceramic vane outperformed an identical metal vane, in terms of area averaged cooling effectiveness, suggesting that the ceramic vane could operate at reduced coolant flow rates to achieve comparable levels of cooling performance.

Fox, Andrew↗
NASA NTRS1976

Oceanic lithosphere and asthenosphere - Thermal and mechanical structure

A coupled thermomechanical subsolidus model of the oceanic lithosphere and asthenosphere is developed which includes vertical heat conduction, a temperature-dependent thermal conductivity, heat advection by a horizontal and vertical mass flow that depends on depth and age, contributions of viscous dissipation or shear heating, a linear or nonlinear deformation law relating shear stress and strain rate, as well as a temperature- and pressure-dependent viscosity. The model requires a constant horizontal velocity and temperature at the surface, but zero horizontal velocity and constant temperature at great depths. The depth- and age-dependent temperature, horizontal and vertical velocities, and viscosity structure of the lithosphere and asthenosphere are determined along with the age-dependent shear stress in those two zones. The ocean-floor topography, oceanic heat flow, and lithosphere thickness are deduced as functions of ocean-floor age; seismic velocity profiles which exhibit a marked low-velocity zone are constructed from the age-dependent geotherms and assumed values of the elastic parameters. It is found that simple boundary-layer cooling determines the thermal structure at young ages, while effects of viscous dissipation become more important at older ages.

Schubert, G.↗